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REFERENCE TO RELATED APPLICATION
This application is related to U.S. patent application Ser. No. 09/250,186 of John J. Milner, Joseph E. Dupuis, Richard A. Fazio, and Robert A. Aekins, filed Feb. 16, 1999, and entitled “Wiring Unit with Angled Insulation Displacement Contacts”; the subject matter of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a wire connecting unit for an electrical connector for communication and data transmission systems. The wire connecting unit has contact configurations that reduce crosstalk attenuation, propagation delay, and other electrical properties that interfere with communication and data transmission. More particularly, the present invention relates to a wire connecting unit for an electrical connector jack that terminates in eight conductors, with the eight conductors being configured to reduce electrical interference and interconnect with a plug.
BACKGROUND OF THE INVENTION
Due to significant advancements in telecommunications and data transmission speeds over unshielded twisted pair cables, the connectors (jacks, receptacles, patch panels, cross connects, etc.) have become critical factors in achieving high performance in data transmission systems, particularly at the higher frequencies. Some performance characteristics, particularly near end crosstalk, can degrade beyond acceptable levels at new, higher frequencies in the connectors unless adequate precautions are taken.
Often, wiring is pre-existing Standards define the interface geometry and pin separation for the connectors, making any changes to the wiring and to the connector interface geometry and pin separation for improving performance characteristics cost prohibitive.
The use of unshielded twisted pair wiring and the establishment of certain standards for connector interface geometry and pin separation were created prior to the need for high-speed data transmissions. Thus, while using the existing unshielded twisted pair wiring and complying with the existing standards, connectors must be developed that fulfill the performance requirements of today's higher speed communications, to maintain compatibility with the existing connectors.
Additionally, the wire connecting unit contacts are traditionally attached to a printed circuit board using solder attachments or compliant pins. Both assembly techniques have traditionally required a push foot mechanism on either side of the contact. These push foot mechanisms enable the contact to be inserted into the printed circuit board with the assembly fixturing. Since the contacts are on 0.040″ spacing and due to the annular (plated through) ring geometry requirements of a printed circuit board, contacts having a push foot on each side of each contact cannot be placed adjacent to each other in the same row. To space the contacts 0.040″ apart a single push foot would have to be utilized; however, a single push foot on one side of the contact creates a moment and can make it difficult to insert the contact into the printed circuit board.
Conventional connectors of this type are disclosed in U.S. Pat. No. 4,975,078 to Stroede, U.S. Pat. No. 5,186,647 to Denkmann et al, U.S. Pat. No. 5,228,872 to Liu, U.S. Pat. No. 5,376,018 to Davis et al, U.S. Pat. No. 5,580,270 to Pantland et al, U.S. Pat. No. 5,586,914 to Foster et al and U.S. Pat. No. 5,628,647 to Roharbaugh et al, the subject matter of each of which is hereby incorporated by reference.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a wire connecting unit for an electrical connector having a contact configuration that improves performance characteristics, but does not require changing standard connector interface geometry and contact separation.
Another object of the present invention is to provide a wire connecting unit for an electrical connector that is simple and inexpensive to manufacture and use.
A further object of the present invention is to provide a wire connecting unit for an electrical connector having contacts that connect to a printed circuit board and have only one push foot to allow adjacent contacts to be positioned in dose proximity in the same row.
The foregoing objects are basically obtained by a wire connecting unit for an electrical connector, comprising a circuit board having first and second areas, the first area having a free end and a near end. First, second, and third pairs of contacts are mounted in the first area adjacent the free end in a cantilever manner and extend upwardly and backwardly toward the near end. A fourth pair of contacts are mounted in the first area adjacent the near end in a cantilever manner and extend upwardly and forwardly toward the free end.
The foregoing objects are also obtained by a wire connecting unit for an electrical connector, comprising a circuit board having a wire termination portion and a plug connection portion. The plug connection portion has a first area and a second area, the first area having a proximal end and a distal end. A first plurality of contacts is mounted in the first area adjacent the distal end in a cantilever manner and extend generally upwardly and backwardly toward the wire termination portion. At least two of the contacts in the first plurality of contacts are adjacent to each other and have a single push foot extending therefrom A second plurality of contacts is mounted in the first area adjacent the proximal end and extend upwardly and backwardly toward the wire termination portion.
By forming the wire connecting unit for the electrical connector in as described, the connector will have improved performance characteristics, without changing the standard plug connector geometry and contact definitions. By placing the wire connecting unit's contacts in a particular configuration, maximum separation between critical contacts and positioning of other contacts adjacent each other to cancel out Gaussian fields is achieved, thereby improving electrical performance of the electrical connector. Additionally, by having only one push foot, the contacts can be placed relatively close together, increasing the contacts' ability to cancel out the Gaussian field of the adjacent contact and thereby increasing electrical performance.
Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the invention.
As used herein, terms, such as “upwardly”, “downwardly”, “forwardly” and “backwordly”, are relative directions, do not limit the connecting unit to any specific orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure:
FIG. 1 is a side elevational view in section of a wire connecting unit for an electrical connector according to the first embodiment of the present invention, prior to engagement with a plug.
FIG. 2 is a top view of the wire connecting unit for an electrical connector of FIG. 1 prior to engagement with a plug.
FIG. 3 is an end elevational view in section of the wire connecting unit taken along lines 3 — 3 of FIG. 1 .
FIG. 4 is an exploded top plan view of the wire connecting unit of FIG. 1 .
FIG. 5 is an enlarged, partial, end elevational view in section of an electrical contact for the wire connecting unit, shown in FIG. 3, having a push foot on two separate sides.
FIG. 6 is an enlarged, partial, end elevational view in section of an electrical contact for the wire connecting unit, shown in FIG. 3, having only one push foot.
FIG. 7 is a partial top perspective view of a printed circuit board for a wire connecting unit having the contact configuration of FIG. 1 .
FIG. 8 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a second embodiment of the present invention.
FIG. 9 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a third embodiment of the present invention.
FIG. 10 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a fourth embodiment of the present invention.
FIG. 11 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a fifth embodiment of the present invention.
FIG. 12 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a sixth embodiment of the present invention.
FIG. 13 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a seventh embodiment of the present invention.
FIG. 14 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a eighth embodiment of the present invention.
FIG. 15 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a ninth embodiment of the present invention.
FIG. 16 is a partial top perspective view of a printed circuit board for a wire connecting unit having a contact configuration according to a tenth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A high density jack 10 for telecommunication systems according to the present invention is schematically or diagrammatically illustrated in FIGS. 1-3. The connector comprises a connector body or housing 12 and a wire connecting unit 14 coupled to the connector body. The wiring unit comprises a printed circuit board 16 on which terminals 18 are mounted. The terminals 18 are standard 110 insulation displacement contacts (IDC), and are coupled to standard wiring as shown specifically in FIG. 2 . Through the circuit board, these terminals are electrically and mechanically coupled to resilient contacts 20 , 22 , 24 , 26 , 28 , 30 , 32 and 34 . The resilient contacts extend into the connector body in a configuration for electrical connection to a conventional or standard plug 36 , particularly an RJ plug.
if In the illustrated embodiment, connector body 12 is in a form to form a jack. However, the connector body can be of any desired form, such as a plug, cross connect or any other connector in the telecommunications or data transmission field.
Connector body 12 is generally hollow having a forwardly opening cavity 38 for receiving a conventional RJ plug. Eight parallel slots 40 extend through the connector body and open on its rear face. One of resilient contacts 20 - 34 is located in each of the slots.
Below slots 40 and remote from plug receiving cavity 38 , the connector body has a recess 42 . Recess 42 opens on the rear face of connector body 12 and is adapted to receive a portion of circuit board 16 , specifically the portion of the circuit board on which the resilient contacts 20 - 34 are mounted. A shelf 44 can extend rearwardly from the connector body below recess 42 . Shelf 44 supports circuit board 16 and facilitates the coupling between the circuit board and the connector body.
As seen in FIGS. 4 and 7 - 16 , printed circuit board 16 is divided into a relatively narrower plug connection portion or first area 46 and a relatively wider termination or second area 48 . Plug connection portion 46 is further divided into a relatively narrower nose or first area 50 having a free or distal end 52 and a proximal end 64 and into a relatively wider or second area 56 having a near end 58 .
As seen in FIGS. 3 and 5 - 7 , each resilient contact 20 - 34 comprises a proximal end 65 , a base portion 66 , a contact portion 68 , and a distal end 69 . The base portions are received and are electrically connected to the circuit paths provided on the printed circuit board and have a laterally protrusion or push foot mechanism 86 on either one side only as seen on contacts 20 - 28 or on both sides as seen on contact 30 and 32 . The contact portions are substantially parallel and extend in a cantilever manner from the base portions and are bent at an angle for receipt within slots 40 of connector body 12 . As seen in FIGS. 4-6, holes or apertures 70 , 72 , 74 , 76 , 78 , 80 , 82 , and 84 in printed circuit board 16 provide connections in the circuit board for the resilient contacts 20 - 34 either through traditional solder attachment or compliant pin. The compliant pin technique frictionally fits base portion 66 into the holes in printed circuit board 16 . Both assembly techniques require push foot 86 .
Push foot mechanism 86 enables the contacts to be inserted into the printed circuit board 16 with an assembling fixture. To comply with the contact geometry of the standard plug 36 and the annular (plated through) ring geometry requirements in a printed circuit board, the jack contacts must be spaced apart by 0.040 inch. Having a push foot on one side allows the contacts to be positioned laterally in one row on 0.040 inch spacing. By immobilizing the moment of the contact and applying pressure to the single push foot, the contact can be insert into its respective aperture in the circuit board. The closer positioning of the contacts allows greater reduction or cancellation of adjacent Gaussian fields, improving the performance of the connector.
Plug connection portion 46 comprises eight holes or apertures 70 , 72 , 74 , 76 , 78 , 80 , 82 , and 84 . Each of the holes is internally plated with an electrically conductive material, as conventionally done in this art. The holes preferably are arranged in two rows. The first row has one pair of contacts 32 and 34 mounted in the first area of the plug connection portion 46 adjacent the free or distal end 52 . The contacts generally extend perpendicularly to the circuit board and then extend generally upwardly and backwardly toward the wire termination portion 48 at angle of about 60-70 degrees relative to the printed circuit board 16 , as seen in FIGS. 4 and 7. The second row has 3 pairs of contacts 20 , 22 , 24 , 26 , 28 , and 30 mounted in the first area 50 of the plug connection portion 46 adjacent the proximal end 64 and extending upwardly and backwardly toward said wire termination portion 56 at angle of about 60-70 degrees relative to the printed circuit board 16 . The contacts in the second row (i.e. 20 and 22 , 24 and 26 , and 28 and 30 ) each has a single push foot 86 extending laterally and outwardly from the proximal end 65 of its respective contact, away from the other contact in its respective pair of contacts, as seen specifically in FIG. 6 . The two contacts in the first row have push feet or push foot mechanisms extending from both sides of their proximal ends, as seen specifically in FIG. 5 . In this configuration, the physical separation of contacts 30 and 32 enhances the near end cross talk performance.
Particularly, contacts 24 and 26 form a first pair and contacts 34 and 36 form a second pair. These first and second pairs, because of their positions, pose the greatest crosstalk problem. The increased separation between these two pair reduces crosstalk problems.
Embodiment of FIG. 8
As seen in FIG. 8, the contacts can be arranged in two rows of four each, which rows are laterally offset from one another. Specifically, in this configuration, the pairs of contacts are equally split with contacts 120 , 126 , 128 and 132 forming a first row of contacts mounted in the first area 50 of the plug connection portion 46 adjacent the free or distal end 52 . Initially, the contacts generally extend substantially perpendicularly to the printed circuit board and then extend generally upwardly and backwardly toward the wire termination portion 48 . Contacts 122 , 124 , 130 and 134 form a second row of contacts mounted in the first area 50 of the plug connection portion 46 adjacent the proximal end 64 and extend upwardly and backwardly toward said wire termination portion 48 . Each contact in the first row of contacts is substantially the same distance from free end 52 as each other contact in the first row. Each contact in the second row of contacts is substantially the same distance from the proximal end 64 as each other contact in the second row. The contacts in this configuration have a similarity of neutral axis length or length measured from the printed circuit board to the point in which the contact mates with the plug. A similarity in neutral axis length optimizes the skew performance of the connectors.
The FIG. 8 configuration maximizes the spacing of the contacts in the row and the two contacts of each pair. The spacing in each row facilitates the use of two push feet on each contact.
Embodiment of FIG. 9
In the embodiment of FIG. 9, the contacts are arranged in a similar dual row configuration as that of the embodiment shown in FIG. 8 . However, in this embodiment, the first row of contacts (i.e. contacts 220 , 226 , 228 and 232 ) each extend substantially vertically from the printed circuit board, curve toward the free end 52 , then curve back toward the proximal end 64 , creating a protrusion 288 , before extending back toward the near end 58 of the printed circuit board. Additionally, the second row of contacts (i.e. contacts 222 , 224 , 230 and 234 ) each extend substantially vertically from the printed circuit board 16 then curve toward the free end 52 before extending back toward the near end 58 of the printed circuit board. This design creates greater separation between the two rows and increases the neutral axis length or the distance of the contact from the surface of the printed circuit board to the mating point with plug 36 . By lengthening the neutral axis length the contacts can be more accurately tuned, therefore making the electromagnetic interference equal and opposite between pairs of the contacts. However, increasing the neutral axis length increases the compensation created by the electromagnetic field, and therefore the electromagnetic interference induced across the interface is greater than similar configurations.
Embodiment of FIG. 10
In the embodiment of FIG. 10, the contacts are arranged in a dual row configuration The first row has 3 pairs of contacts 320 , 322 , 324 , 326 , 328 , and 330 mounted in the first area 50 of the plug connection portion 46 adjacent the distal end 52 . Initially, the contacts extend substantially perpendicularly to the printed circuit board and then extend upwardly and backwardly toward said wire termination portion 48 . The second row has one pair of contacts 332 and 334 mounted in the first area 50 of the plug connection portion 46 adjacent the proximal end 64 and extend generally upwardly and backwardly toward the wire termination portion 48 . Each contact of the pairs of contacts in the first row (i.e. 320 and 322 , 324 and 326 , and 328 and 330 ) has a single push foot 86 extending laterally and outwardly from its proximal end 65 , remote from the other contact in its respective pair of contacts. The contacts in the second row have a push foot mechanism extending from each side of their proximal ends 65 . This configuration of contacts provides increase separation between of the pair of contacts 332 and 334 , particularly, relative to the pair of contacts 324 and 326 , reducing unwanted electromagnetic coupling between these two contacts.
Embodiment of FIG. 11
In the embodiment of FIG. 11, the contacts are arranged in three rows. The first row comprises contacts 422 , 424 , 426 , and 428 mounted in the first area 50 of the plug connection portion 46 adjacent the distal end 52 . Initially, the contacts extend substantially perpendicularly to the printed circuit board and then extend upwardly and backwardly toward wire termination portion 48 . The second row has two contacts 420 and 430 mounted in the first area 50 of the plug connection portion 46 adjacent the free or distal end 52 , but further from the distal end then the first row of contacts, and extending generally upwardly and backwardly toward the wire termination portion 48 . The third row has one pair of contacts 432 and 434 mounted in the first area 50 of the plug connection portion 46 adjacent the proximal end 64 and extending generally upwardly and backwardly toward the wire termination portion 48 . The contacts of the inside pair 424 and 426 , in the first row, each has a single push foot 86 extending laterally and outwardly from its proximal end 65 , remote from the other contact of that pair of contacts. The contacts in the second and third rows have push foots extending from each side of their proximal ends 65 . By forming a contact configuration in this manner, performance is similar to the embodiment in FIG. 10, and electromagnetic coupling between contacts 432 and 434 is reduced due to the separation of these two contacts.
Embodiment of FIG. 12
The embodiment of FIG. 12 also uses a three row configuration. However, in this configuration, the first row comprises contacts 520 , 526 , and 528 mounted in the first area 50 of the plug connection portion 46 adjacent the distal end 52 . Initially, the contacts extend substantially perpendicularly to the printed circuit board and then extend upwardly and backwardly toward wire termination portion 48 . The second row comprises contacts 522 , 524 and 532 mounted in the first area 50 of the plug connection portion 46 adjacent the proximal end 64 , but further from the proximal end then the third row of contacts, and extend generally upwardly and backwardly toward wire termination portion 48 . The third row comprises the pair of contacts 532 and 534 mounted in the first area 50 of the plug connection portion adjacent the proximal end 64 and extend generally upwardly and backwardly toward the wire termination portion. This configuration performs similarly to the embodiments of FIGS. 10 and 11.
Embodiment of FIG. 13
In FIG. 13, the contact configuration has a first pair of contacts 620 and 622 , a second pair of contacts 624 and 626 , and third pair of contacts 628 and 630 mounted in a cantilever manner in first area 50 of plug connection portion 46 adjacent free end 52 . Initially, these six contacts extend substantially perpendicularly to the printed circuit board and then extend upwardly and backwardly toward the near end of the plug termination portion. A fourth pair of contacts 632 and 634 is mounted in the second area 56 of the plug termination portion 46 adjacent the near end 58 in a cantilever manner. Contacts 632 and 634 extend upwardly and forwardly toward free end 52 . The first, second and third pairs of contacts extend in a row in which each contact is substantially equidistant from the free end. Each contact in the first, second, and third pairs of contacts has a single push foot 86 extending laterally and outwardly from its proximal end 65 , remote from the other contact in its respective pair of contacts. The contacts in the fourth pair are aligned so that each contact is substantially equidistant from the near end.
Contacts 620 , 622 , 624 , 626 , 628 , and 630 extend at angle of about 60-70 degrees relative to the printed circuit board, in a similar configuration as described above. Contacts 632 and 634 , however, initially extend substantially vertically relative to the printed circuit board and then curve toward the free end at an angle preferably less than 60 degrees. Contacts 632 and 634 then curve downwardly toward the surface of the printed circuit board, forming a protrusion 688 . The protrusion allows the plug to easily mate with contacts 632 and 634 without contacting the distal end of the contacts.
This configuration of contacts provides maximum separation between contacts 632 and 634 and the other contacts, reducing unwanted electromagnetic coupling therebetween The physical lay out of contacts 620 and 632 produce a electromagnetic field that is equal and opposite to the field produced by contacts 634 and 630 so each field is canceled out, enabling the electromagnetic coupling to be induced. This configuration also induces backward wave coupling, since the electromagnetic wave is traveling in opposite directions through adjacent contacts. Additionally, return loss is improved due to the fact that each contact in first through third pair of contacts are immediately adjacent its respective pair.
Embodiment of FIG. 14
The FIG. 14 configuration is similar to the embodiment of FIG. 13, however, contacts 722 , 724 , 726 and 728 form an additional row that is adjacent the proximal end 64 of the first area 52 of the plug connection portion 46 . Contacts 720 , 730 , 732 and 734 are in the same configuration as that of the embodiment in FIG. 13 . This configuration of contacts provides maximum separation between contacts 732 and 734 , reducing unwanted electromagnetic coupling between these two contacts. The physical lay out of contacts 720 and 732 produce a electromagnetic field that is equal and opposite to the field produced by contacts 734 and 730 so each field is canceled out, enabling the electromagnetic coupling to be induced. This configuration also induces backward wave coupling, since the electromagnetic wave is traveling in opposite directions through adjacent contacts. However, since all the pairs of contacts are not immediately adjacent one another the return loss is not as preferable as the embodiment of FIG. 13 .
Embodiment of FIG. 15
The embodiment of FIG. 15 is similar to the embodiment of FIG. 14 . Contacts 820 , 822 , 824 , 830 , 832 , and 834 are placed in a substantially similar configuration as the corresponding contacts of the embodiment of FIG. 14; however, contacts 826 and 828 are positioned closer to the proximal end 64 of the first area 50 of the plug connection portion 46 than contacts 822 and 824 , thus, creating a fourth row of contacts. This configuration performs similarly to the embodiment of FIG. 14 . However, since there is less separation between the contacts at the near end and the contacts at the proximal end 64 , performance is reduced.
Embodiment of FIG. 16
The FIG. 16 embodiment is similar in configuration to the embodiment of FIG. 12, in that it has three rows. The first row comprises contacts 920 , 926 , and 928 mounted in the first area 50 of the plug connection portion 46 adjacent the distal end 52 and extending upwardly and backwardly toward wire termination portion 48 . The second row comprises contacts 922 , 924 and 932 mounted in the first area 50 of the plug connection portion 46 adjacent the proximal end 64 , but further from the proximal end 64 then the third row of contacts and extending generally upwardly and backwardly toward the wire termination portion 48 . The third row comprises contacts 932 and 934 mounted in the first area 50 of the plug connection portion 46 adjacent the proximal end 64 and extend substantially perpendicularly from the printed circuit board 16 . Contacts 932 and 934 then curve forward toward the free 52 end before curving generally upwardly and backwardly toward the wire termination portion 48 . This configuration performs similarly to the configuration of the embodiments of FIG. 14 and 15, since there is separation between contacts 932 and 934 . However, in this configuration, the contacts extend in a substantially similar direction (i.e. upwardly and backwardly) and therefore, there is no backward wave coupling.
Even though some of the configurations do not have the same enhanced performance as other configurations mentioned above, some configurations having shorter contacts, for example, the configurations shown in FIGS. 11, 12 , and 15 , and may be more desirable, since the mechanical layout may improve their performance when deflected to the deflection limits.
The features of the contact configurations of the embodiments shown in FIGS. 8-16, which are substantially similar to the embodiment shown in FIGS. 1-7 are identified with like reference numbers. The same description of those similar features is applicable to the embodiments shown in FIGS. 8-16. Additionally, the description of other elements of the wiring unit, such as the printed circuit board, housing, and all other aspects of the wiring unit, apply to the embodiments in FIGS. 8-16.
While specific embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. | A wire connecting unit for an electrical connector for communication and data transmission systems includes a circuit board with a free and a near end and having four pairs of contacts mounted in a cantilever manner. The wire connecting unit has specific contact configurations that reduce crosstalk, attenuation, propagation delay, and other electrical and magnetic properties that interfere with communication and data transmission. In one embodiment, a first row of contacts extends generally upwardly and backwardly from the free end of the printed circuit board toward the near end, and a second row of contacts placed further from the free end of the printed circuit board than the first row of contacts extends generally upwardly and backwardly from the free end toward the near end. Each adjacent contact can have only a single push foot that extends laterally and outwardly from its proximal end, remote from the other contact in the respective pair, allowing the contacts to be placed relatively close together to further reduce the electrical and magnetic properties that interfere with communication and data transmission. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application Ser. No. 61/277,542, filed on Sep. 25, 2009 by the present inventors, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to apparatus and methods for heat treating semiconductor wafers and more particularly to apparatus and methods for uniformly heating semiconductor wafers using microwave energy.
2. Description of Related Art
Single frequency microwaves have been explored for annealing ion implanted semiconductor wafers in the past. Heating semiconductors with microwave energy is very effective, leading to the interest of annealing wafers. However, as the size of the wafers has grown to 300 mm, used routinely today, uniform heating of the entire wafer is a challenge with fixed frequency microwaves. It will get even more difficult as the industry moves to 450 mm wafers. Furthermore, when it comes to placing metal components, circuits as well as metal coated wafers in a fixed frequency microwave cavity, the challenges are escalated: the arcing of metals tends to damage the circuits, and this becomes a major barrier to using this approach for the production of semiconductor devices.
One important heat treatment application involves annealing wafers to form metal silicides, which have been widely applied to IC fabrication because of their high melting points and low resistance. Use of fixed-frequency microwaves for this application has generally been unsuccessful. It should be noted that although single or fixed frequencies can in theory be used for microwave heating of semiconductors, they generally produce non-uniform heating, and when metal films are involved arcing with these films becomes a serious issue. However, pulsed microwave beam as described in U.S. Pat. No. 6,316,123, by Lee et al. has been used to locally heat and convert the metal to silicides. The pulse duration was of the order 0.02 to 0.15 seconds. This approach is similar to the laser spot annealing used on semiconductor wafers.
Metal silicides have been widely applied to IC fabrication. As the critical dimensions for contact area and source/drain regions become progressively smaller, nickel silicide is emerging to be the choice of material over cobalt and titanium silicide. However, the nickel silicide system has various phases and undergoes phase transformation during the heating cycle. Among all the phases, the lowest resistivity NiSi is the desired silicide phase for contacts to a semiconductor device. Thus there is the need to make sure that there is no temperature variation on the wafer so that the same phase is formed over the entire surface. Higher or lower temperature will alter the phase formation and hence the resistivity of the silicides.
Another important application involves the annealing or activation of dopant species in the silicon wafer following ion implantation, used for fabricating UltraShallow Junctions (USJ) and devices. The annealing process repairs the implantation damage and activation provides good conductivity. The key elements in forming USJ are junction depth and sheet resistance, and process manufacturability and repeatability. These shallow junctions demand low thermal budgets, requiring processing at a high ramp rate with a minimum of peak temperature overshoot. In a high-volume production environment it is critical to measure and control temperature for any thermal process. Lamp-based RTP spike-anneal has enabled recent production while laser spike-anneal (LSA) is emerging and even being claimed as the process of record for current high performance semiconductor device manufacturing. Generally, these are very short duration processes and there are challenges in measuring and controlling peak temperatures in spike-anneal process. The high temperature spikes may also lead to wafer warpage and strain in the device structure.
OBJECTS AND ADVANTAGES
Objects of the present invention include the following: providing an apparatus for heating semiconductor wafers using microwave energy; providing a microwave heating system having improved temperature control; providing a microwave heating system adapted to heat large semiconductor wafers uniformly; providing a method to anneal metal-coated semiconductor wafers to form metal silicides thereon; and, providing a method for microwave treatment of ion implanted semiconductor wafers. These and other objects and advantages of the invention will become apparent from consideration of the following specification, read in conjunction with the drawings.
SUMMARY OF THE INVENTION
According to one aspect of the invention, an apparatus for processing semiconductor wafers comprises:
a microwave applicator cavity;
a microwave power supply configured to deliver power to the applicator cavity;
a dielectric support configured to support a semiconductor wafer having a selected diameter;
a dielectric gas manifold configured to supply a controlled flow of inert gas proximate to the periphery of the semiconductor wafer to provide differential cooling to the wafer edge relative to the wafer center; and
a first temperature measuring device configured to measure the temperature near the center of the wafer and a second temperature measuring device configured to measure the temperature near the edge of the wafer.
According to another aspect of the invention, a method for processing semiconductor wafers comprises the steps of:
supporting a semiconductor wafer to be processed on a dielectric supporting member within a microwave applicator cavity;
introducing microwave energy into the cavity;
measuring the temperature of the wafer at a first point near its center and at a second point near its periphery; and,
supplying a controlled flow of gas proximate to the periphery of the wafer sufficient to provide differential cooling to the wafer edge relative to the wafer center.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings accompanying and forming part of this specification are included to depict certain aspects of the invention. A clearer conception of the invention, and of the components and operation of systems provided with the invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting embodiments illustrated in the drawing figures, wherein like numerals (if they occur in more than one view) designate the same elements. The features in the drawings are not necessarily drawn to scale.
FIG. 1 illustrates the use of a quartz fixture allowing gas flow adjacent to the edge of a wafer undergoing microwave processing according to one aspect of the invention.
FIG. 2 illustrates the result of RBS measurements on ion-implanted Si processed according to one example of the present invention.
FIG. 3 illustrates a portion of the RBS spectrum presented in FIG. 2 , emphasizing the annealing of near-surface implantation damage.
FIG. 4 illustrates another portion of the RBS spectrum presented in FIG. 2 , emphasizing the annealing of implanted As ions, causing them to adopt substitutional positions on the Si lattice.
FIG. 5 illustrates sheet resistance versus time for ion implanted Si annealed in accordance with one aspect of the invention.
FIG. 6 shows the secondary ion mass spectroscopy (SIMS) plot of concentration of dopant versus the depth in silicon for as-implanted dopant as well as the annealed specimens.
DETAILED DESCRIPTION OF THE INVENTION
Variable Frequency Microwave (VFM) is well suited for processing semiconductor materials. The basic VFM approach is well-known and taught in at least the following U.S. patents, each of which is incorporated herein by reference in its entirety: U.S. Pat. Nos. 5,321,222; 5,721,286; 5,961,871; 5,521,360; 5,648,038; and 5,738,915. In particular, the continuous sweeping of frequencies over the available bandwidth, as taught in the aforementioned references, reduces the potential for arcing and subsequent damage. Frequency sweeping is often carried out by selecting a center frequency and then rapidly sweeping the frequency in a substantially continuous way over some range (typically +/−5% of the center frequency, although this range can vary depending on such factors as the type of microwave source, and the overall size of the cavity compared to the microwave wavelength). Numerous kinds of wafers with integrated circuits have been exposed to VFM and it has been demonstrated that there is no damage to the circuits or their functionality. The use of VFM provides more rapid processing as compared to conventional annealing furnaces.
Thus VFM process provides the means of using microwave energy as a continuous wave (CW in contrast to pulse) to anneal wafers with coatings of cobalt, titanium or nickel to form their respective silicides. The uniformity of heating with VFM further offers the potential to scale up from 300 mm to 450 mm wafers.
As noted earlier, one objective of the invention is to provide uniform and rapid microwave annealing of large semiconductor wafers, especially the wafers with metallizations that cannot be easily processed with single frequency microwave because of the potential for damaging arc formation. Exemplary processes include fabrication of a metal silicides as well as dopant activation and oxidation of silicon.
It is instructive to review briefly the general thermal behavior of a large thin wafer of the type used in semiconductor manufacturing. When a heated wafer is pulled out of an oven the edges of the wafer (having higher surface/volume ratio) are the first to cool on the entire wafer. The same applies (instantaneously) when the wafer is placed in a convection oven where the hot air around the wafer tries to heat the wafer. After a transient period in which the wafer edge is hotter than the center, the wafer eventually reaches equilibrium with the environment and is uniformly hot. Similarly, in rapid VFM heating the edges of the wafer will heat more during the temperature ramp up and eventually as the high temperature is achieved and the soak stage starts, the gradient between the center and edge of the wafer will diminish. One of the objectives of the invention, in addition to the uniform VFM heating of metalized wafers, is to control the temperature gradient between the center and edge of the wafer, even during the temperature ramp up.
For the annealing processes of silicidation and dopant activation, nitrogen is generally used to minimize oxidation of silicon. The flow of nitrogen can be instrumental to minimizing the temperature gradient between the edge and center of the wafer. It will be appreciated that other gases may be used for particular applications.
The experimental set up for this approach is shown schematically in FIG. 1 . A quartz fixture is placed in a microwave cavity. (One particularly suitable cavity is the MicroCure® 2100, made by Lambda Technologies, Inc., Morrisville, N.C.) The quartz, being microwave transparent, will allow microwave energy to travel in the chamber without any restriction. Quartz boats are standard carriers for wafers in the semiconductor industry. Nitrogen flow is plumbed from the bottom of the cavity. A single-wafer quartz boat can be modified to include a thin-walled quartz cylinder and a thin top quartz plate (with perforation only on the edges) attached to the cylinder. As nitrogen is allowed into this quartz containment the only path for nitrogen to flow is through these tiny perforations, which act as nozzles to blow cool nitrogen on the edges of the wafer. The wafer is placed in a slot on the boat above the perforated quartz plate. It will be appreciated that other configurations of the gas manifold may be substituted for the configuration shown in FIG. 1 . For example, quartz tubing may be formed into a ring approximately the same diameter as the wafer and holes drilled at various points along the tube, thereby achieving the same effect of discharging a controlled flow of gas around the periphery of the wafer
Silicon is transparent at optical (IR) wavelengths longer than 1.1 μm and this is known to make IR temperature monitoring with longer wavelengths more difficult. Thus the temperature monitoring for this arrangement is performed using the small wavelength (0.9 μm) devices. One of the advantages of using such a device is that the temperature can be monitored through a quartz window, or in this case the quartz plate disposed between the wafer and temperature monitoring device. It will be understood that there will be some transmission losses through quartz; this can easily be corrected by using the Radiance Multiplier to calibrate it for viewing through quartz. Making the measurement from the underside of the wafer eliminates the effect of surface composition changes (silicon, metals, dielectric) from run to run or from process to process.
EXAMPLE
A setup with two temperature monitoring devices, one in the center of the wafer and another one toward the edge of the wafer, is shown generally in FIG. 1 . During the ramp up when the edge temperature T E is higher than the center temperature T C , the nitrogen flow must be increased to compensate. As the soak temperature is approached, the VFM power requirement goes down and T E is no longer leading, the nitrogen flow can be reduced so that the condition T E ≈T C is maintained during the ramp as well as the soak stage. The nitrogen flow can be controlled to be proportional to the temperature differential T E −T C , thus providing an automatic control mechanism to enable the wafer temperature to be uniform over the entire process.
It will be appreciated that in many cases the gas flow may be dynamically controlled in a real-time feedback loop that is directly related to the output of the two temperature sensors. However, in other cases it may be adequate to use a recipe-driven control system, wherein the setup is initially calibrated in one or more test runs for a semiconductor wafer with a particular set of properties, and when the best process cycle is determined, it is simply stored and repeated whenever a wafer of that type is processed.
It is well known that steep thermal profiles give the best junction characteristics by limiting dopant diffusion. The primary challenge is the ability to deliver consistent process uniformity for production worthiness, measured by within-wafer uniformity and wafer-to-wafer repeatability, to get product yield from the wafer edge especially as device geometries shrink, where an even shallower junction must be ensured. The successful integration of any type of anneal requires control on low thermal budget history to ensure limited dopant diffusion and least deformation and process-induced stresses.
The present invention provides a method for low thermal budget and low stress process by achieving activation through uniform heating in the temperature range up to about 600° C. using Variable Frequency Microwaves. With conventional heating at higher temperatures the silicon expands according to its coefficient of thermal expansion. With current heating methods, it is around a 1000° C. that the lattice structure allows the arsenic dopant ion to occupy the lattice position of silicon and impart conductivity to the semiconductor, when annealing and activation occurs. Depending on the particular dopant and the resistivity of the semiconductor wafer, the optimal temperature might be as low as 300° C.
With VFM heating the expansion of the lattice at any given temperature will be the same as with any heating method. However, one needs to consider the different mechanism of heating with VFM. For heating polar liquids like water, the polar molecule is set into rotation by the alternating electromagnetic field. The mobility of the water molecule is higher as compared to heating with conventional means. The microwave enhancement in chemical synthesis (where applicable—when polar molecules are present), is a result of the higher mobility and hence the higher probability of the reactants to combine and form the reaction product.
In solids, the free rotation of dipoles is not practical. However, the microwave interaction mechanism with the material does not simply disappear. The tendency for a rotational movement will be there. For example, a single bond is more likely to respond to microwaves as compared to a double bond and obviously a triple bond will have the most restrictive movement if any. There would be more heat generation in the single bond situation versus the double bond and the least in the triple bond.
Considering the material of our interest, silicon, although the detailed and exact heating mechanism remains somewhat conjectural, what is very clear is that doped silicon wafers heat very well with VFM. Thus, there is VFM interaction with silicon and the dopant ions that impart the conductivity to silicon. As the temperature increases lattice expansion will occur no matter what the heating mechanism. The VFM interaction with the dielectric and charge carriers will allow the dopant ions to drift into the lattice (substituting for silicon) position at a temperature lower than those used for conventional heating methods. The apparent VFM induced enhanced mobility within the lattice also allows repair of the damage cause by the implant process. Thus the annealing and activation of As-implanted wafers can be performed at lower temperature, around 550° C. or so. The lower temperature VFM activation ensures that there will be limited dopant diffusion and will not influence the performance and reliability of the semiconductor devices.
EXAMPLE
Annealing tests were done using samples of silicon consisting of p-type boron doped (100) orientated Si. These wafers have been implanted at room temperature with 30 keV As + ions with doses 5×10 15 As + cm −2 . The projected range (R P ) and straggle (ΔR P ) are 26 and 9 nm, respectively. Post implantation anneals were performed using Lambda Technologies' Variable Frequency Microwave (VFM) system equipped with a 1600 Watt output amplifier. The key component for this tool was the Traveling Wave Tube (TWT) amplifier with frequency sweep from 5.85-6.65 GHz. The swept frequency provided a more uniform microwave field and temperature uniformity as compared to fixed frequency microwave and allows processing of electronic components without causing any damage. The temperature of the silicon samples was monitored as a function of time within the reactor by the use of Photrix IR device manufactured by Luxtron Corporation (now LumaSense Technologies). For all samples, the anneal temperature range was 500-540° C.
Samples were characterized prior to and after microwave annealing. The implant damage was quantified by ion channeling and conventional Rutherford backscattering spectrometry (RBS) using a 2.0 MeV He + analyzing beam. During ion channeling analysis, samples were analyzed in random and in the aligned [001] channeled orientation. He + ions were collected using a solid state detector, positioned 13° from the incident beam. Layer thicknesses were estimated from RBS data.
Detailed characterization results are presented as Appendix A, “Variable Frequency Microwave Activation and Solid Phase Regrowth of Arsenic Ion-Implanted Silicon at Temperatures below 550° C.,” in Applicants' aforementioned Provisional Application 61/277,542. The characterization results may be summarized as follows:
FIGS. 2-4 display the results of ion channeling analysis of silicon samples implanted with 30 keV, 5×10 15 As + cm −2 prior to and after microwave annealing for times up to 9 minutes. FIG. 2 shows spectrum corresponding to the randomly oriented RBS spectrum for as-implanted silicon. Note the As signal has been increased by a factor of ten for clarity. In addition the figure shows the aligned spectra corresponding to ion channeling analysis with As + implanted samples oriented in a [001] channeled direction, and [001] channeled spectrum for un-implanted silicon. The as-implanted spectrum demonstrates that a highly damaged silicon layer exists near the surface of the silicon. Comparison of the yield from the aligned and random spectra demonstrates that the as-implanted sample contains a layer of disorder, but with the degree of disorder being less than that in amorphous silicon.
The spectra from the annealed samples demonstrate that samples processed for times greater than 6 minutes showed a significant reduction in the lattice damage incurred during high dose ion implantation. Comparison of the normalized yield spectrum with that of un-implanted silicon demonstrates that VFM processing results in almost complete repair of ion implantation damage. Normalized yield comparisons (i.e., χ min , the ratio of channeled yield to random yield) of silicon spectra results in a χ min of 0.3 whereas χ min of the un-implanted silicon was 0.28. In all samples annealed for times greater than 6 minutes, the ion channeled spectra approximated those of spectrum virgin silicon. These results would imply complete solid phase epitaxial regrowth.
Inspection of the As signals in FIG. 4 shows that increased annealing times results in reduced As signal. This implies that the As atom are sitting substitutionally on Si matrix site (i.e. dopant is activated). Ion channeling analysis also provides a means to quantify the fraction of As atoms residing substitutionally on Si (host-atom) sites and it is calculated from the measured χ Si and χ As using the following expression,
% As on Si sites=(1−χ As )/(1−χ Si )
where χ As and χ Si are the chi minimum (the ratio of the yield from the aligned spectrum to the random spectrum) from the As and Si signals, respectively. The values of % As on Si sites are tabulated in Table 1.
Although FIGS. 2-4 demonstrate that dopant activation occurs during microwave processing, they do not determine the extent of dopant activation. To demonstrate the increase in resultant carrier concentrations, and to qualify the extent of dopant activation, Hall effect results are shown in Table 1. For comparison with similar dopant activation methods, arsenic implanted samples which were microwave processed experienced near complete electrical activation in medium and high dose samples.
In order to monitor electrical activation of arsenic during microwave processing, sheet resistance readings were taken as a function of microwave process time. FIG. 5 demonstrates the change in sheet resistance and resistivity for arsenic implanted and microwave annealed silicon, as a function of microwave processing time. As can be seen in FIG. 5 , samples VFM annealed realized a decrease in R s and ρ with time. Of special note in FIG. 5 , the R s nearly saturates for all microwave processing after 6 min. The improved resistivity between the 6 and 9 minute anneals correlates with the improved crystalline structure of the higher temperature anneal. Note that the open triangles display the sheet resistance R s as a function of VFM treatment time for Si implanted with 5×10 15 As + cm −2 . At 6 minutes the sheet resistance is lower than the filled triangle obtained from a 900° C., 30 s RTP anneal.
Secondary ion mass spectroscopy results are shown in FIG. 6 . The results show that diffusion even after 9 minutes of annealing in VFM is less than diffusion after 900° C. 30 seconds of rapid thermal anneal. Results from the 6 min VFM plot has an even smaller extent of diffusion when compared to the 9 min VFM anneal. These findings confirm inference from sheet resistance measurements that VFM anneal is comparable to a 900° C., 30 seconds RTP anneal, however with less diffusion.
Additional results are presented in Appendix B, “Variable Frequency Microwave Induced Low Temperature Dopant Activation in Ion Implanted Silicon,” in Applicants' aforementioned Provisional Application 61/277,542.
The foregoing results demonstrate the usefulness of the present invention for performing rapid annealing of doped semiconductor wafers. Although the specific tests used a particular concentration of As ions in silicon, it will be appreciated by those skilled in the art that other dopants may be used to achieve desired properties and these may be either n-type or p-type materials as are well known in semiconductor fabrication. It will likewise be appreciated that the starting wafer may be any desired form of Si, including intrinsic, p-type, n-type, Si on sapphire, or amorphous Si, or the starting wafer may be another semiconductor such as GaAs, GaN, SiGe, etc. as are familiar in the art.
The invention may also be used for annealing metallized layers to form metal silicides, in conjunction with the methods described in Applicants' U.S. Provisional Pat. App. Ser. No. 61/207,901, filed on Feb. 18, 2009 and entitled, “Method and Apparatus for Controlled Thermal Processing,” the entire disclosure of which is incorporated herein by reference.
Other applications of the invention are discussed in the following examples.
TABLE 1
Bulk
Sheet
% As
Time
concentration
Resistivity
resistance
on
(min)
(10 18 /cm 3 )
(10 −4 Ω-cm)
(Ω/square)
χSi
χAs
Si
0
9.3
22
3.038E+08
15.8
84.1
19
1
49
23
179
9.3
81.6
20
6
113
12
77
3.3
11.7
91
9
275
8
87
2.8
8.5
94
EXAMPLE
Crystallization of amorphous layers: During the fabrication of integrated circuits it is common to prepare the substrate and form an amorphous silicon (or other semiconductor) layer on the substrate. This film subsequently has to be heated to be crystallized. In some cases crystallization is metal (e.g. aluminum, silver, nickel, palladium) induced and occurs near the eutectic temperatures, which happens to be lower than without introducing any metal. Another method of low temperature crystallization is by annealing in the presence of atomic hydrogen.
The present invention provides a method for a low thermal budget and low stress process by achieving crystallization through uniform heating in the desired temperature range using Variable Frequency Microwaves (VFM). The internal heating and penetrating microwaves can uniformly initiate the nucleation and ensure crystal growth in the film.
EXAMPLE
Densification of dielectric films: This invention also provides a method for low thermal budget and low stress process densification of dielectric layer through volumetric and uniform heating using Variable Frequency Microwaves at temperature usually lower than other heat treatments.
In some cases reported in the literature a silicon dioxide dielectric layer is formed on a substrate surface by a sequential deposition. The deposited layer thickness may be insufficient to prevent substantially complete penetration of annealing process agents into the layer, so the dielectric layer is then annealed to remove water and followed by full densification of the film. The deposition and anneal processes are then repeated until a desired dielectric film thickness is achieved.
For features and trenches during IC fabrication the dielectric film needs to be conformal so that the liquid-like flow properties will allow the high aspect ratio narrow width gaps to fill more efficiently without trapping any voids or seams. When it comes to annealing and densification of these films most surface heating techniques including IR and lasers, have line of sight concerns and will not penetrate deeper. That is where the higher penetration with VFM can achieve uniform densification even deep in the trenches. VFM has been successfully used for anneal and densification of these dielectric films in the temperature range of 350-400° C.
In general any thermal process performed on semiconductor wafer can be performed by volumetric VFM heating which will usually be more efficient than most surface heating techniques.
EXAMPLE
Annealing of single crystal photovoltaic cells: Lately the use of silicon for solar application has exceeded that of the semiconductor market. Thus the same processes of forming p-n junction, annealing to enhance the circuit voltage, drying and firing of the metalized current carrying contacts, need thermal treatment where the VFM enhanced processes will work very well. Some of the specific advantages that apply here are:
1. Rapid, internal and uniform heating 2. Enhanced diffusion with microwave heating 3. Better densification (of films) has been achieved with microwaves 4. Finer and uniform grain structures have been achieved 5. VFM has been used to dry and heat treat metal pastes
EXAMPLE
Annealing of polycrystalline/amorphous silicon photovoltaic cells: Fabrication of single crystal solar cells is expensive and energy extensive. One approach to reduce the cost of these solar cells is to use polycrystalline or amorphous silicon to form the p-n junction. The cost of single crystal growth is eliminated but the efficiencies of the alternatives are lower. Nevertheless, the same thermal treatment necessary for fabrication of single crystal solar cell apply to polycrystalline and amorphous silicon solar cells.
This invention also provides a method for low thermal budget process for the heat treatment and/or anneal at various steps using Variable Frequency Microwaves usually for shorter times or at lower temperature than other heat treatment techniques. With most heat treatments the entire chamber is heated and hence the energy consumption is much higher. With VFM since only the semiconductor is heated and in many cases to a lower temperature, it provides means to lower the thermal budget of what is otherwise an energy extensive process.
EXAMPLE
Heat treatment of thin film photovoltaic cells: To lower the cost of solar cells even further, thin films solar cells have gained substantial momentum. Various semiconductor films (GaAs, CuInSe 2 , CuGaSe 2 , CdTe and InP) are deposited on low cost glass or polymeric substrates. Some of the coatings can actually be screen printed or inkjet printed onto flexible substrates. To improve the properties of these coated films have to heat treated. The p-n junctions formed by these films have to be annealed to enhance the open circuit voltage. The key advantages of VFM listed under annealing of single crystal silicon solar cell apply to these films too.
Another film which could be used for the crystalline solar cell but is discussed here in the thin film section is the Transparent Conductive Oxide (TCO). Indium Tin Oxide (ITO) is becoming very popular for this purpose although there are others (AZO and IZO) also being considered. These films act as a top electrode and window to allow sunlight into the junction.
ITO films have unique optical and electrical properties of high transmittance in the visible region and strong reflectance in the infrared (IR) region as well as excellent conductivity. Thus ITO films play an important role in various optoelectronic devices. The electrical and optical properties of ITO films are found to be strongly dependent on the growth conditions and deposition methods. The crystalline structure, grain size, optical transmittance and conductivity all are influenced by the anneal temperatures, therefore, choosing an appropriate annealing process is important for making high quality ITO films. VFM has been demonstrated to work for annealing, densification and influencing the grain structure.
Therefore this invention also provides a method for low thermal budget process for the heat treatment and/or anneal of ITO and other TCOs using Variable Frequency Microwaves usually for shorter times or lower temperature than other heat treatment techniques.
ITO coatings are also useful on substrates for optoelectronic materials and liquid crystal displays. Phosphor-coated ITO substrates are also used in flat panel displays. Various manufacturers now offer indium tin oxide coated float glass, aluminosilicate glass, and PET coated substrates.
EXAMPLE
Flat panel displays: The use and processing of ITO leads to another example, viz., Flat Panel Displays (FPD) that encompass a growing number of technologies enabling video displays that are much lighter and thinner than traditional television and video displays that use cathode ray tubes. FPD can be divided into two general categories:
1. Volatile displays require that the pixels be periodically refreshed to retain their state, even when displaying a static image. This refresh typically occurs many times a second. These include: Plasma displays; Liquid crystal displays (LCDs); Organic light-emitting diode displays (OLEDs); Light-emitting diode displays (LED); Electro-luminescent displays (ELDs); Surface-conduction electron-emitter displays (SEDs); and Field emission displays (FEDs), also called Nano-emissive displays (NEDs). 2. Static flat panel displays rely on materials where the color states are bistable. No energy is required to maintain the image instead energy is required to change to the next stable state. This results in a much more energy-efficient display, but has a tendency of having slow refresh rates which are not desirable in interactive displays. Bistable flat panel displays are beginning deployment in limited applications (e.g. in outdoor advertising).
The displays briefly described above are diodes (p-n junctions) and generally have the structure of a glass substrate, coated with a TCO which acts as the window and an electrode, then there is a layer of conducting polymer (e.g., an organic light-emitting diode, OLED), the next layer is an emissive coating, and finally the metal electrode.
Various materials and processes used in the manufacturing of these display are the same or similar to those used in the semiconductor manufacturing, which include but are not limited to, spin coating of polyimide (PI), sol-gel approach for nano-hybrids with silica other metal oxide precursors, deposition of low-k materials and films of nanoparticle biodegradable polymer (or nano-composites).
After the above processes there are numerous heat treatments which include but are not limited to:
1. Thermal process required for removing volatile solvents. 2. Thermal treatment of ITO substrates for improvement of OLED performance. 3. Thermal treatment of spin-coated layers on substrate. 4. Thermal treatment of the flexible plastic to increase the optical transparency of substrate. 5. Thermal annealing improves the performance of organic light-emitting diodes containing BCP/LiF/Al. 6. Low Temperature Poly-Silicon (LTPS) annealing is the preferred approach for producing the critical poly-silicon layer during active matrix OLED Flat Panel Display fabrication. 7. Turn-on voltages, luminance, and driving current of the flexible organic light emitting devices (OLEDs) are strongly affected by the thermal history of the flexible substrate. 8. Thermal annealing of fluorescent one-layered organic light-emitting devices (OLEDs) doped with organic salts shows homogeneous and enhanced electroluminescence.
VFM processing has been successfully been applied to curing of polyimide and other polymeric coatings on wafers and annealing in semiconductor manufacturing. Some specific advantages for flat panel displays cells include:
1. Rapid, internal and uniform heating of the coatings 2. Enhanced diffusion with microwave heating 3. VFM can rapidly cure nano-particle polymeric films and nano-composites 4. Better densification (of films) can be achieved with microwaves 5. Finer and uniform grain structure can be achieved 6. VFM can dry and heat treat metal pastes used as electrodes
It will be appreciated that, although some of the foregoing examples were directed particularly to VFM systems, the invention may also be used to improve uniformity in fixed-frequency heating systems. Such systems may employ microwave generators using magnetrons, klystrons, gyrotrons, or other microwave power generating devices as are well known in the art. The applicator cavity may be single-mode or multimode as are well known in the art.
It will be appreciated that many suitable noncontacting thermal measurement devices are available from various manufacturers; devices include one-color pyrometers, two-color pyrometers, and fiber optic temperature monitors. All of these devices are familiar to those skilled in the art. | A microwave heating system comprises a microwave applicator cavity; a microwave power supply to deliver power to the applicator cavity; a dielectric support to support a generally planar workpiece; a dielectric gas manifold to supply a controlled flow of inert gas proximate to the periphery of the workpiece to provide differential cooling to the edge relative to the center; a first temperature measuring device configured to measure the temperature near the center of the workpiece; and, a second temperature measuring device configured to measure the temperature near the edge of the workpiece. The gas flow is controlled to minimize the temperature difference from center to edge, and may be recipe driven or controlled in real time, based on the two temperature measurements. The method is particularly useful for monolithic semiconductor wafers, various semiconducting films on substrates, and dielectric films on semiconducting wafers. | 7 |
BACKGROUND OF THE INVENTION
The invention relates generally to apparatus for manufacturing, filling and closing shipping containers made of synthetic plastic material. More particularly, the invention relates to a method for removing undesired residue of a filling liquid which is inserted by means of a filling mandrel into the shipping container as well as to an apparatus suitable for implementing the method.
In known methods for the continuous manufacture of filled, closed hollow containers of thermoplastic material, a tube or hose made of synthetic plastic material which is extruded while still in a plastic state is enclosed within the forming molds for the container which move at the same velocity as the hose. The hose is inflated into the formed shape in this manner by an increased internal pressure, with the resulting container being filled while a connection with the formed container base is maintained, with a subsequent separating and closing operation being performed by welding after which the container is detached. In addition to this generally known process, further improvements have been developed which consist, however, basically only in a supplement and further development of these known techniques. In all prior art proposals thus far, a filling mandrel is basically used which is insertable through an opening in the head of the mold forming the container, or which is already in position within the mold during the shaping or molding process. When, for example, highly viscous fluids are to be used in the filling operation, difficulties occur due to the fact that as a result of increased adhesive forces, residue of the filling liquid tends to adhere to the surface of the filling mandrel thereby causing difficulties in succeeding molding or forming operations of the container causing unwanted separation of portions of the liquid or other materials. This disadvantage is avoided by presently known state-of-the art techniques by removing the filling mandrel from the container during different stages of the process in accordance with the constantly rising fluid level. Thus, only a small part of the filling mandrel is wetted with the liquid. However, such an approach results in a considerable increase in the cost requirements of the apparatus particularly due to the additional control elements which are necessitated by the requirement for introduction and removal of the filling mandrel. A further disadvantage arises in that a considerable delay can occur in a machine which is required to operate continuously because the insertion and removal of the filling mandrel is time consuming and hence causes a reduction in the output of the machine or in its operating efficiency.
The present invention is intended to avoid these disadvantages while at the same time insuring that in a process of the aforementioned type, despite the rigid connection of the filling mandrel, any filling liquid which remains thereon as a residue will not operate to disturb or unduly influence the succeeding molding or shaping operations.
SUMMARY OF THE INVENTION
In accordance with the present invention, the aforementioned disadvantages are overcome, by a procedure which effects automatic stripping of the residue of the filling material remaining on the outer surface of the filling mandrel during the separation of the filling mandrel from the container with the stripped residue being supplied to the interior of the container which is then made accessible by removal of the mandrel therefrom.
By means of the process of the present invention, a generally trouble-free, continuous molding or shaping process of the container is enabled while avoiding problems which may be caused accumulation of filling material residue which may adhere to the filling mandrel and drop off into the region or zone of the following section of the hose, thereby leaving undesirable and uncontrolled hardening locations.
Accordingly, as a result of the present invention, measures such as the introduction and removal of the filling mandrel during the molding operation, which usually must be performed in known machines, can thereby be avoided.
The apparatus according to the present invention comprises a blow mold which is preferably movable in approximately vertical directions with an extruded hose segment which is formed by an extrusion nozzle supplying the hose section with a filling mandrel being movable to within the blow mold forming the container. The invention is particularly characterized by the fact that the blow mold is formed, preferably in the region above its filling level, with a constriction, the inner surface of the constriction forming with the outer surface of a part of the filling mandrel coming into contact with the filling material an annular or circular gap which corresponds approximately to the wallthickness of the shaped or molded section of the container.
It has proved advantageous in order to enable the annular gap to be adapted to prevailing conditions to provide means for varying the size of the gap. Within the concept of the present invention it is further proposed that the constriction formed in the blow mold be made of an exchangeable or replaceable portion of the mold. In order to implement the molding or shaping of the hose section prior to the stripping off process and in order to accomplish the required ventilation and aeration of the device, it is proposed that in implementing the invention the filling mandrel be formed with a tapered configuration above the maximum filling level with respect to the lower part thereof which forms the annular gap with the inner surface of the constriction.
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 use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
IN THE DRAWINGS:
FIG. 1 is a sectional view of the apparatus according to the present invention; and
FIG. 2 is an enlarged sectional view of the upper region of the mold.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, the apparatus for implementing the process of the present invention is shown as comprising an extrusion head 1 connected to an extrusion nozzle 2 and supplied therefrom with thermoplastic material. The thermoplastic material is discharged from a nozzle 3 in a tubular or hose-shaped configuration in a vertical direction. The thermoplastic tubular section from which the container is formed is represented at 20.
A mold 5 shaped as a hollow body consists of a pair of oppositely movable mold parts 6 and 7 and abuts the lower face 4 of the extrusion head 1. A second molding device 8 corresponding with the mold 5 alternates with the mold 5 and encloses and abuts in an alternating manner the extruded hose segment.
The molds 5 and 8 alternatively open and close, in a manner known to those skilled in the art, to clamp the hose 20 during the blow molding process. For example, the mold parts 6,7 separate and are brought together during the molding operation to release a formed container and to clamp a next succeeding hose segment during the molding operation.
Coaxially with the discharge nozzle 3 of the extrusion head 1, there is formed an air blast channel 9 having a filling mandrel 10 centered therein. The channel 9 which provides air to effect the blow-molding operation, is suitable for supplying an air blast as well as for the supply of supporting air required for the abutment of a non-enclosed segment of the hose. The channel 9 may, upon appropriate rerouting, also be used for ventilation or rinsing of the shaped or molded hollow space of the hollow body.
An additional air blast channel 11 is disposed within the filling mandrel 10. The inner channel 11 is also suitable for draining the discharge pressure by appropriate rerouting of valves (not shown) within the space communicating therewith. For this purpose there is formed in a bottom wall 12 of the hollow mold 5 an opening 13. The bottom wall 5 is formed, in accordance with the embodiment illustrated in FIG. 1, with a slightly conical configuration tapering upwardly and inwardly of the mold 5 which serves simultaneously as a sealing seat, as well as for the abutment of the filling mandrel 10 which is movable in an axial direction slightly upwardly and downwardly.
The bottom wall 12 is also provided with a fillet 14 which is directed towards the interior of the hollow body and within which there are formed guided lateral welding elements 15 and 16 extending perpendicularly to the axis of the hollow body. These elements can be displaced by means of a piston 17 within a cylindrical space 18 for the purpose of welding, and if necessary also for separation, of two hollow bodies adhering to each other. The bottom wall 12 of the hollow body molding device 5 receives, for example, a part of a head region 21 to be shaped or molded. At this point, the upper front side of the container to be formed, as well as the lateral welding elements, are disposed within the bottom wall of the upper container, thereby resulting in the potentiality of a waste-free separation of the hollow bodies.
According to the more detailed view of the embodiment of the present invention shown in FIG. 2, a constriction 22 is formed in the upper region of the blow molds 5 and 8. An inner coating 23 on the constriction 22 forms with the outer surface of a part 24 of the filling mandrel 10 which comes in contact with the filling liquid, an annular gap 25 which is shown in dot-dash form. The annular gap 25 corresponds approximately to the thickness of the molded container segment, so that the molded container surface thereof facing the filling mandrel 10 fits approximately thereagainst and strips off the residue of filling liquid adhering thereto during the downward movement of the blow mold. Thus, the filling mandrel is stripped from any residue thereby avoiding disadvantages which could be caused by such residue during subsequent molding operations.
Above the constriction 22 there is formed a circular recess 26 which serves to receive any surplus material which may result from subsequent sagging or slippage of the discharged segment of the hose. In FIG. 2 there is illustrated the initial position of the blow mold disposed under the extrusion head 1. In this position the constriction 22 is not yet in contact with the part 24 of the filling mandrel 10, which is surrounded upon completion of the filling process with liquid and which contains residues thereof during the withdrawing process.
The filling mandrel 10 is provided above the part 24 with a tapered or conical shape. The region which is still in a thermoplastic condition at the height of the constriction is therefore free, on the one hand, from the disturbing influences of interior or inner parts, and, on the other hand, an opening is formed which permits aerating and ventilation of the container space disposed thereunder. Only upon completion of the filling process and of the hardening stage resulting therefrom is the container disposed in the upper mold with drawn from the extrusion head. At this time the inner coating of the already molded container comes into contact with the slightly thicker lower part 24 of the coating or surface of the filling mandrel 10 at the height of the constriction 22 and therefore all of the filling liquid residue from the container is stripped off.
The freely suspended segment of hose 20 supported by the supply of the supporting air from the channel 9 assumes a shape approximating that indicated by the dash-dot shape shown upon joining of both halves of the molds 6 and 7 of the upper hollow-body molding device 5. Thereby, there remains within the bottom wall 12 a through-opening 13', which is closed upon the first formation of a hollow body by the transverse welding elements 15 and 16 so that a forming or shaping of the hose segment abutting against the walls of the molding halves 6 and 7 is accomplished. The front side of the filling mandrel 10 is disposed at the beginning of this process approximately at the height of the illustrated dash-dot line at 30 in order to enable movement thereof upon molding of the hollow body into the conically shaped bottom wall region. It is also possible to allow the filling mandrel to remain in its lower position. Upon unloading of the hollow space, the filling operation can commence and upon completion thereof the first hollow body molding device is moved in a closed state downwardly into the position of the molding device 8, which has, in the meantime, opened and which has assumed the upper position immediately below the extrusion head 1. Concurrently with downward movement of the molding device 5, the segment of the hose required for the next manufacturing process is extruded. At this time, the constriction 22 with the hose material adhering thereto also performs a stripping operation of the filling liquid residue adhering to the filling mandrel 10.
As soon as the molding devices 7 and 6 have reached their lower position, the molding halves of the molding device 8 may be moved toward one another. The hose segment 20 is surrounded thereby to be appropriately molded while still leaving an opening communicating with the head region 21 of the already filled hollow body. The consequently arising blasting pressure propagates through the openings 13, 13' up to the head region 21 of the already molded and filled container. Immediately thereafter, the filling mandrel 10, upon setting thereof on the centering surface of the bottom wall 12, insures a tight sealing engagement with respect to the opening 13 so that independently of the upper hollow body, a higher pressure may thereby be exerted or an unloading of the head region of the already filled hollow body may also be undertaken. At this time, the second hollow body is already molded and is being filled by the introduction of the filling liquid. As soon as an appropriate molding or shaping of the head region of the already filled container has been accomplished the transverse welding elements 15 and 16 move against the hose segment forming the opening 13 and close the latter so that the container may now be removed in a closed state from the mold. In the meantime the second container has also been filled, so that the filling mandrel moves back to its initial position. At this time, the molding halves of the lower molding device are opened and moved upwardly toward the hose head 1, while the second molding device is moved downwardly while it is still in a closed state. The hose segment, which is now surrounded or enclosed, as well as the head region of the already filled second hollow body are formed in the same manner and are subsequently closed.
While the specific embodiment of the invention has been shown and described in detail to illustrate the application of the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles. | In a machine for the manufacture, filling and closure of plastic containers, undesired residue of the filling material is removed from a filling mandrel which extends into the container to be manufactured by provision of a constriction in the blow molding equipment within which the container is formed. The filling mandrel comprises an enlarged end upon which undesired residue tends to accumulate. The blow mold is formed with a constriction through which the mandrel is withdrawn and by forming a gap between the mandrel and the constriction, which gap is approximately equivalent to the thickness of the container, unwanted residue is automatically stripped from the mandrel as it is withdrawn. | 1 |
RELATED APPLICATION DATA
[0001] This application claims priority of U.S. Provisional Application No. 60/606,008 filed on Aug. 31, 2004, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a method for optimizing the interpretation of analog image signals or sequences of image signals output by medical image recording devices.
BACKGROUND OF THE INVENTION
[0003] In the field of x-ray image-assisted, image-guided surgery a physician works with the aid of a navigation system that provides information on the inner body structure of a patient with the aid of intraoperatively produced x-ray images. In such image guided surgery, it is important to precisely identify the moment at which a new image is recorded by the x-ray apparatus. The navigation system has to “know” the moment when the x-ray apparatus recorded a particular x-ray image in order to correctly assign said x-ray image information to corresponding patient position/location data detected by the navigation system.
[0004] When using analog x-ray apparatus and/or C-arc x-ray apparatus, the time the image was produced conventionally is detected with the aid of certain hardware components. For example, an x-ray detector can be attached to the image intensifier of a C-arc x-ray apparatus. Whenever an image is acquired, the detector is exposed to x-ray radiation and the corresponding time can be detected. In other conventional systems, a light detector can be attached to the control lamp of the C-arm, and the light detector is activated when an image is acquired. Both methods are hardware-assisted methods that require additional detectors to be attached to the x-ray apparatus. This increases susceptibility to errors and also increases the apparatus hardware.
SUMMARY OF THE INVENTION
[0005] The present invention provides a method for optimizing the interpretation of analog image signals or sequences of image signals output by medical image recording devices, such as x-ray apparatus, that overcomes one or more of the disadvantages discussed above. In particular, the invention enables one to ascertain the moment when a new image signal is detected without additional or dedicated hardware. Further, the invention enables the type and properties of new images to be interpreted.
[0006] The advantages that may be achieved in accordance with the invention are based on performing a method for optimizing the interpretation of analog image signals or sequences of image signals output by medical image recording devices, such as an x-ray apparatus. The method comprises the steps of testing the correlation of consecutively recorded image signals; establishing that the image signal depict the same image if the correlation is not less than a particular threshold value; establishing that the image signals possibly depict different images if the correlation is less than a particular threshold value; and dynamically adjusting the threshold value if the correlation has changed (the threshold can be adjusted based on the current signal-to-noise ratio, for example).
[0007] In other words, the present invention enables one to move away from using hardware to detect the moment a new image is produced. More specifically, the present invention can interpret the image signal and deduce from the contents of the image signal or sequence of image signals whether a new image has been produced. This is advantageous in that less hardware is required to operate the system. Further, in interpreting the detected image signals, additional information can be obtained that can be used during surgery.
[0008] As will be discussed below, the threshold value preferably is dynamically adjusted. If the threshold value were not adjusted, instances could arise where a new recorded image that does not change over a certain period of time, constantly lies below the threshold value due to an increased proportion of noise, thus affecting the correlation of the image data and the position data. A system that does not adapt the threshold value would constantly output a signal indicating new images are being detected. By adapting the threshold value, this source of error can be eliminated.
[0009] In a preferred embodiment, the threshold value can be set higher as the signal-to-noise ratio is increased and lower as the signal-to-noise ratio is decreased. In this case, or also in general terms, the threshold value can be set such that a correlation gap between the image signal and the threshold value is kept constant.
[0010] As already mentioned above, constantly analyzing the image contents allows more than just establishing whether a new image is pending at the image receiver of an analog x-ray apparatus. It also enables the identification of whether or not only particular recording parameters have changed or whether the end of a long-term x-ray recording has been reached.
[0011] Based on this knowledge, the present invention provides a method in which a certain number of consecutive image signals below the threshold value are evaluated when different images are depicted, and the standard deviation of these signals can be determined and compared with a pre-set value, whereupon:
c1a) if the number of changed image signals in succession is at least equal to a predetermined sample number and the standard deviation is lower than the pre-set value, it can be established that the correlation deviation has been caused by changes in the manner of recording the same image, in particular by changes in contrast or brightness; and c1b) the threshold value is re-set lower; or c2a) if the number of changed image signals in succession is at least equal to a predetermined sample number and the standard deviation is higher than the pre-set value, it can be established that the correlation deviation has been caused by continuously detecting images from different and changing recording situations, in particular by continuously recording during a relative movement between the recording apparatus and the recorded object; c2b) the threshold value is not re-set; or c3) if the number of changed image signals in succession is less than a predetermined sample number, an image signal from the consecutive image signals can be classified as a new image.
[0017] In accordance with the invention, all possible situations may be detected or interpreted from the acquired image signals, and navigation then can be performed proceeding from and based on a correct image interpretation.
[0018] In one embodiment, when image signals are classified as a new image, the time the new image was produced can be detected. This time can be relayed to a further processing system, in particular a medical navigation system, which can process the image information, assign it to current patient location data, and output the information for image-assisted medical treatment.
[0019] In accordance with another embodiment, an additional threshold value can be determined which lies between the correlation value of the signal and the threshold value, and image signals between the threshold value and the additional threshold value can be classified as outliers and not taken into account when dynamically setting the threshold value.
[0020] The invention further relates to a program which, when it is running on a computer or is loaded onto a computer, causes the computer to perform a method as described above. The invention further relates to a computer program storage medium comprising a program as defined above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a flow diagram for carrying out a method in accordance with the present invention.
[0022] FIG. 2 is a block diagram of a computer system that can be used to implement the method of the present invention.
DETAILED DESCRIPTION
[0023] The invention will now be described with reference to the drawings. It is noted that the features of the invention can be implemented individually or in any combination. Further, the invention can be used with various medical image recording devices, including, for example, computer or nuclear spin tomographs or the like. As used herein, the term “adjust(ing) the threshold value” refers to setting, resetting, adapting, changing, etc., the threshold value based on certain criteria.
[0024] In general terms, the invention can be classified as an evaluation of an auto-correlation value for a medical imaging system (e.g., a C-arc x-ray apparatus) video output signal. More specifically, the auto-correlation value or correlation is calculated by comparing sequential frames of the video signal, wherein the correlation range is less than or equal to 1.0 (perfect correlation, no changes between sequential frames) and greater than or equal to −1.0 (no correlation between sequential frames). Due to signal noise, the correlation generally will be at a value less than −1.0, which shall be referred to in the following as n.
[0025] When an individual new image is acquired, the correlation value drops from n to a smaller value, which is referred to in the following as s, and then rises again, for example, back to n. In order to detect this acquisition of an individual image, a threshold value is set which is referred to in the following as T lower . This threshold value lies between n and s. When the correlation value falls below the threshold T lower , a new image is detected. In addition, the gap between n and T lower is kept constant.
[0026] This enables the threshold value T lower to be dynamically adjusted in order to take into account long-term changes in the noise level which can arise due to changes in the video signal quality or the contrast of the C-arc image. This also enables changes in contrast and long-term image detection to be distinguished, as long as the noise level of an image having a changed contrast does not fall below the threshold value T lower . In order to take this instance into account, the number of consecutive frames below the threshold value T lower is counted. When a predetermined number of consecutive frames are below the threshold, the standard deviation “sigma” of the correlation value in each case is calculated and compared with a pre-set value or limit value c. This limit value or pre-set value c serves to distinguish between a change in contrast (with a low standard deviation of the correlation values) and constant or long-term image detection (with a high standard deviation of the correlation values). If sigma is less than c, the change in the noise level is regarded as a change in the contrast of the image. The threshold value T lower then is adjusted to the current correlation value, wherein the gap between the image signal and a correlation of 1.0 (perfect correlation) is multiplied by a constant factor greater than 1, and the result is used as an adjusted gap for the new threshold. If sigma is greater than c, the change in the noise level is regarded as a result of long-term recording and the threshold value T lower is not adjusted.
[0027] Furthermore, a second threshold value T upper also can be introduced, which lies between T lower and n. This threshold value T upper serves to distinguish outliers in the correlation values, which are generated by momentary disruptions in the video signal, from actual image detection signals. All values between T lower and T upper are qualified as outliers and are not taken into account when dynamically setting the threshold value T lower .
[0028] In the following, the procedure is explained again more precisely on the basis of the enclosed flow diagram in FIG. 1 . The following abbreviations are used in this diagram:
[0029] k: correlation values (k=1.0 signifies identical images)
[0030] T lower : lower threshold value, determines a new image
[0031] T upper : upper threshold value, determines outliers
[0032] sigma: standard deviation of sequential correlation values
[0033] c: limit/pre-set value for sigma
[0034] The flow diagram represents the situation during the acquisition of new images. The explanation begins with step 10 wherein a new image (e.g., from the image intensifier of a C-arc x-ray apparatus) is retrieved from the frame grabber. Next at step 12 , a determination is made as to whether a previous image is available. If a previous image is not available, then the procedure moves back to step 10 and a new image again is retrieved from the frame grabber. If, however, a previous image is available, then at step 14 the correlation between the old image and the new image is calculated and stored in an archive. At step 16 , a test is performed to determine whether the image has changed. If the image has not changed, the procedure moves back to step 10 and a new image again is retrieved from the frame grabber. If the image has changed, then a report or notification is generated that can be relayed to a further processing system, such as a medical navigation system or the like, which processes the image information, assigns the image information to current patient location data, and outputs the image information for image-assisted medical treatment.
[0035] The test performed at step 16 is shown in steps 20 - 38 of FIG. 1 . Beginning at step 20 , it is determined whether the current correlation value k is less than the threshold value T lower . If k is less than T lower , the number of changed images in succession is compared with a pre-set sample number. If this pre-set sample number has not yet been reached, it may be assumed that no extraordinary circumstances have occurred and that the image has simply changed and the procedure moves to step 24 . At step 24 , the number of changed images in succession is increased, and at step 26 the value k for the detected correlation is ignored for the purposes of the noise archive. The method returns to the step which tests whether the image has changed (step 16 ), wherein this question is answered with a ‘yes’.
[0036] If at step 22 the question as to whether the sample number has been reached is to be answered with a ‘yes’, then at step 28 the standard deviation sigma of the samples is determined and compared with a pre-set value c. If the standard deviation is lower than c, then at step 30 it may be assumed that it is not a new image but rather that there has merely been a change in the type of image detection, e.g., a change in contrast. The archive is reset, and the method switches to the outlier test at step 32 described below.
[0037] If, however, it is established that the standard deviation is greater than the pre-set value c, it may be assumed that it is an image from a number of images produced during a long-term transillumination. It is then established at step 24 that the image has changed and the number of changed images in succession is increased. At step 26 the value k is ignored for the purposes of the noise archive, and the test as to whether the image has changed (step 16 ) is given the answer ‘yes’.
[0038] If k is not less than T lower , it is assumed that this is the normal case having a certain noise level, and the procedure moves to step 32 , which establishes whether an outlier is present in the signal. The test at step 32 establishes whether the correlation value k is less than the threshold value T upper . If k is not less than T upper , then at step 34 the value for k is not an outlier and is entered in the noise archive. At step 38 the number of changed images in succession is zeroed, and the question as to whether the image has changed (step 16 ) is answered with a ‘no’. If the value for k is less than T upper , then at step 36 the value for k is qualified as an outlier and is entered in the noise archive. At step 38 the number of changed images in succession is zeroed, and the question as to whether the image has changed (step 16 ) is answered with a ‘no’. The method then returns again to the step in which a new image is retrieved from the frame grabber.
[0039] Moving to FIG. 2 , a computer system 50 for executing a computer program in accordance with the present invention is illustrated. The computer system 50 includes a computer 52 for processing data, and a display 54 (e.g., a Cathode Ray Tube, Liquid Crystal Display, or the like) for viewing system information. A keyboard 56 and pointing device 58 may be used for data entry, data display, screen navigation, etc. The keyboard 56 and pointing device 58 may be separate from the computer 52 or they may be integral to it. A computer mouse or other device that points to or otherwise identifies a location, action, etc., e.g., by a point and click method or some other method, are examples of a pointing device. Alternatively, a touch screen (not shown) may be used in place of the keyboard 56 and pointing device 58 . Touch screens may be beneficial when the available space for a keyboard 56 and/or a pointing device 58 is limited.
[0040] Included in the computer 52 is a storage medium 60 for storing information, such as application data, screen information, programs, etc. The storage medium 60 may be a hard drive, an optical drive, or the like. A processor 62 , such as an AMD Athion 64™ processor or an Intel Pentium IV®, processor, combined with a memory 64 and the storage medium 60 execute programs to perform various functions, such as data entry, numerical calculations, screen display, system setup, etc. A network interface card (NIC) 66 allows the computer 52 to communicate with devices external to the computer system 50 .
[0041] The actual code for performing the functions described herein can be readily programmed by a person having ordinary skill in the art of computer programming in any of a number of conventional programming languages based on the disclosure herein. Consequently, further detail as to the particular code itself has been omitted for sake of brevity.
[0042] Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application. | A method for optimizing the interpretation of analog image signals or sequences of image signals output by medical image recording devices. The correlation of consecutively recorded image signals is tested and, based on the test, the image signals are identified as depicting the same or different images. More specifically, if the correlation is not less than a particular threshold value, it is established that the image signals depict the same image. If the correlation is less than a particular threshold value, it is established that the image signals possibly depict different images. Further, the threshold value is dynamically adjusted if the correlation has changed. | 6 |
This invention relates to enterprise-wide data storage systems, and in particular, to methods and systems for selectively correcting errors in data stored in such a system.
BACKGROUND
When we store data on a disk, we often take it for granted that we will one day be able to recover that identical data from the disk. In reality, there are many errors made in storing data on a disk. Fortunately, modem data storage systems provide error-management utilities for largely eliminating the undesirable effects of these data errors. These error-management utilities include both scanning utilities that periodically scan the disk for data errors, and error-correction utilities that repair errors identified by the scanning utilities.
The error-management utilities operate unobtrusively in the background. Periodically, the scanning utility scans the entire disk for data errors. When the scanning utility identifies a data error, it writes information descriptive of that data error to an output device, such as the printer or a monitor. This information takes the form of an unstructured stream of text.
It is not the case that every data error identified by the scanning utility will be repaired by an error-correction utility. In some cases, a data error is so severe that it cannot be repaired at all. In other cases, repair of a particular data error can result in other, more serious errors. Thus, an error-correction utility generally does not blindly repair all disk errors identified by a scanning utility. Instead, there is typically a filtering step in which the error-correction utility is made to repair only selected data errors. This filtering step is performed by a human operator who monitors the data errors as they are listed at the output device and compiles a list of those data errors that are to be repaired.
Once the scan is complete, the human operator executes the error-correction utility. For each data error on the list of data errors to be repaired, the operator executes the error-correction utility. In doing so, the operator provides the error-correction utility with an argument list that causes the error-correction utility to repair that particular error.
The foregoing method is practicable when the number of errors is relatively small. However, as data storage systems have become progressively larger, the number of data errors encountered during a disk scan has likewise become proportionately larger. As a result, it has become increasingly difficult for a human operator to digest a list of data errors and to prepare instructions for an error-correction utility within the time constraints required for reliable operation of the data storage system.
As data storage systems continue to grow in their storage capacity, it is foreseeable that a human operator will no longer be able to even complete execution of the error-correction utility for a particular scan before it is time to begin the next scan.
SUMMARY
The invention provides a method of scanning a mass-storage device in a manner that makes information obtained during that scan directly available to an error-correction utility. This enables the error-correction utility to directly determine, with a minimum of human intervention, whether to repair particular data errors.
In a system incorporating the invention, a system scan buffer is allocated in a global memory in data communication with a mass-storage device. The mass-storage device is then scanned by a scanning utility. As the scanning utility performs the scan, it detects data errors in the mass-storage device. When it does so, it writes information descriptive of those data errors to the scan buffer. This information is thus available for later access by an error-correction utility or by a human operator.
The information written to the scan buffer can include an error code indicative of a type of data error. This is useful because it enables an error-correction utility to automatically determine whether or not the data error is of the type that it ought to repair.
The information written to the scan buffer can also include a status flag indicative of whether the data error has been repaired or a repair flag indicative of whether the data error is to be repaired. The status flag enables the data error to remain in the scan buffer even though it may have already been repaired. The repair flag provides a mechanism for allowing a human operator to override decisions made by an error-correction utility.
Because certain error-correction utilities are only capable of repairing data errors identified by particular scanning utilities, each entry in the scan buffer can also include a signature identifying the scanning utility that detected the data error.
An error-correction utility functions more effectively when it knows where the data error occurred. To provide this information, each entry in the scan buffer can also include an address code indicative of a logical location of the data error in the mass storage medium.
In some data storage systems, a plurality of mass-storage devices is in communication with the global memory. For such systems, information from the various mass-storage devices can be interleaved in the scan buffer. In this case, the scan buffer includes information descriptive of a data error includes information identifying the mass-storage device in which the data error occurred.
The invention also encompasses a method of repairing a data error in a mass storage system having a global memory in communication with at least one mass-storage device. In this method, an error-correction utility retrieves information descriptive of the data error from a scan buffer in global memory. On the basis of this information, the error-correction utility determines whether the data error is to be repaired. If the data error is to be repaired, the error-correction utility attends to the repair. Otherwise, the error-correction utility proceeds to obtain information about other data errors, if any, in the mass-storage device.
The error-correction utility can implement a programmed rule for deciding, on the basis of the information descriptive of the data error, whether the data error is to be repaired. Such information is preferably embodied in the form of a flag. Alternatively, the information descriptive of the data error can be displayed to a system operator. The system operator then makes a manual determination of whether or not that data error is to be repaired. If it is, the system operator alters the entry corresponding to that data error so that the error-correction utility will recognize that that data error is to be repaired.
The invention also includes within its scope a data storage system having a mass-storage device and a global memory in data communication with the mass-storage device. The global memory contains a scan buffer containing information descriptive of data errors in the mass-storage device. Typically, the information is organized in the scan buffer into a sequence of error entries, each one of which corresponds to a data error. The individual error entries are divided into fields that contain information used by an error-correction utility for deciding whether or not the particular data error associated with that error entry is to be repaired.
The error entry is structured to contain one or more fields containing particular types of information. These fields can include an error-class field containing information indicative of a type of data error, a status-flag field containing information indicative of whether the data error has been repaired, a repair-flag field containing information indicative of whether the data error is to be repaired, a signature field containing information identifying the scanning utility that detected the data error, a time-stamp field containing information indicative of when the data error was recorded in the buffer, and an address field containing a logical location of the data error in the mass storage medium.
These and other features of the invention will be apparent from the following detailed description and the accompanying figures, in which:
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic illustration of a data storage system incorporating the principles of the invention;
FIG. 2 is a schematic illustration of the architecture of the global memory shown in FIG. 1;
FIG. 3 is a representative data structure of the scan buffer of FIG. 2;
FIG. 4 shows the architecture of the global memory in FIG. 2 with several matching pairs of scanning utilities and error-correction utilities;
FIG. 5 is a flowchart showing the method for creating error entries in the scan buffer of FIG. 1;
FIG. 6 is a flowchart showing the method by which error entries are used by the error-correction utility.
DETAILED DESCRIPTION
FIG. 1 shows a disk storage system 10 for practice of a disk scanning method according to the invention. The disk storage system 10 includes a global memory 12 having a front-end 14 and a back end 16 . At its back end 16 , the global memory 12 is in data communication with a plurality of device controllers 18 ( 1 )- 18 ( n ), each of which controls a plurality of storage devices 20 ( 1 )- 20 ( m ). At its front end 14 , the global memory 12 is in data communication with a plurality of host adaptors 22 ( 1 )- 22 ( i ), each of which is in data communication with a plurality of hosts 24 ( 1 )- 24 ( j ).
The host adaptors 22 ( 1 )- 22 ( i ) generate instructions for communicating data between the global memory 12 and the individual hosts 24 ( 1 )- 24 ( j ). Similarly, the device controllers 18 ( 1 )- 18 ( n ) generate instructions for communicating data between the global memory 12 and the individual storage devices 20 ( 1 )- 20 ( m ). Both the host adaptors 22 ( 1 ) 22 ( i ) and the device controllers 18 ( 1 )- 18 ( n ) are fully described in commonly owned U.S. Pat. No. 5,335,352 entitled “Reconfigurable Multi-Function Disk Controller,” which is hereby incorporated by reference.
The storage devices 20 ( 1 )- 20 ( m ) are typically disk storage devices that include arrays of magnetic disk drives. However, depending on the requirements of the system's users, other mass-storage devices such as tape drives or optical disks can be used in place of some or all of the disk storage devices.
The global memory 12 is typically a high-speed semiconductor memory for temporary storage of data that has been read from, or will ultimately be written to, at least one of the storage devices 20 ( 1 )- 20 ( m ). The transfer of data into and out of the global memory 12 , and the allocation of global memory 12 among the storage devices 20 ( 1 )- 20 ( m ), is under the control of a cache manager 26 . Although shown in FIG. 1 as being resident in global memory 12 , the cache manager 26 is a virtual entity that can be resident elsewhere in the data storage system 10 or distributed among various components of the data storage system 10 .
The interposition of a global memory 12 between the storage devices 20 ( 1 )- 20 ( m ) and a host 24 ( 1 ) improves system throughput by largely eliminating the host's lengthy wait for disk access. From the host's point of view, the global memory 12 appears as a single logical disk with extremely low latency. In reality, the latency has still occurred, but it is borne by the cache manager 26 rather than by the host 24 ( 1 ). The fact that the cache manager 26 later relays data from the global memory 12 to one or more storage devices 20 ( 1 )- 20 ( m ), or that the cache manager 26 pre-fetches data from those storage devices, is invisible to the host 24 ( 1 ).
As shown in FIG. 2, global memory 12 includes a data storage section 28 and a control section 30 . The data storage section 28 in turn is divided into a plurality of cache slots 32 ( 1 )- 32 ( n ), with each cache slot corresponding to one of the device controllers 18 ( 1 )- 18 ( n ) and representing a track accessible to that device controller. A particular device controller 18 ( 1 ) accesses only its own corresponding cache slot 32 ( 1 ) and not the cache slots 32 ( 2 )- 32 ( n ) associated with other device controllers 18 ( 2 )- 18 ( n ).
In a data storage system 10 as shown in FIGS. 1 and 2, occasional data errors can occur in the storage of data on a storage device 20 ( 1 ). These data errors are associated with specific locations 34 ( 1 )-( n ) on the device 20 ( 1 ). Therefore, as part of routine system maintenance, it is important to periodically scan the entire storage device 20 ( 1 ) to identify and classify any errors that may exist. This function is performed by a scanning utility 36 that examines each record on a storage device 20 ( 1 ) to determine whether data associated with that record is consistent with entries in an ID_table 38 stored in the control section 30 of the global memory 12 . An example of such a scanning utility 36 is described in connection with a U.S. Patent Application entitled “Error Detection in Disk-Storage Systems,” filed on Jul. 20, 2000 and identified by U.S. application Ser. No. 09/620,013, the contents of which are herein incorporated by reference.
The control section 30 also includes a scan buffer 40 for holding information describing any data errors identified by the scanning utility 36 . The scan buffer 40 includes error entries 42 ( 1 )-( 4 ) corresponding to each of the errors 34 ( 1 )-( 4 ) in the storage device 20 ( 1 ). The scan buffer can be partitioned so that each storage device 20 ( 1 )- 20 ( m ) has its own section of the scan buffer 40 . Alternatively, error entries corresponding to different devices can be interleaved within the scan buffer 40 . In such a case, the error entries 42 ( 1 )-( 4 ) can include, as part of each entry, information identifying the storage device associated with that entry.
When the scanning utility 36 encounters a data error, it adds an error entry 42 to the scan buffer 40 . As shown in FIG. 3, this error entry 42 , which corresponds to the error encountered by the scanning utility 36 , includes an address field 42 a that contains logical coordinates identifying the location of the error. When the storage device is a disk drive, for example, the logical coordinates include the head and cylinder associated with an erroneous track on a disk within the drive. In addition, the scanning utility 36 notes the date and time the data error was identified. This information is saved in a time-stamp field 42 b that forms a part of the error entry 42 .
The scanning utility 36 also identifies the nature of the data error and includes that information in an error-class field 42 c that forms part of the error entry 42 . The error-class field 42 c is useful because certain types of data error may not be easily repairable by known error correction algorithms without jeopardizing the integrity of other system components. In addition, the statistical distribution of error types can be useful in identifying specific system components that may be prone to failure.
The error entry 42 also includes a status flag 42 d that indicates whether or not the data error corresponding to that error entry 42 has been repaired. This status flag 42 d is initially set by the scanning utility 36 to indicate that the data error has not been repaired.
As shown in FIG. 4, there may be a plurality of scanning utilities 36 a-c available for scanning the storage device 20 ( 1 ), with each of the scanning utilities 36 a-c being optimized for a particular purpose. When this is the case, the scanning utilities 36 a-c have matching error-correction utilities 44 a-c . An error-correction utility 44 a can repair data errors identified by its matching scanning utility 36 a but generally not data errors found by a different scanning utility 36 b . As a result, the error entry 42 preferably includes a signature field 42 e to identify the particular scanning utility that created the error entry 42 .
Following the completion of at least a portion of the disk scan by the scanning utility 36 , an error-correction utility 44 inspects the scan buffer 40 to identify which errors to correct. In one embodiment, the error-correction utility 44 inspects each error entry 42 for which: (1) the status-flag field 42 d indicates that the data error has not been repaired; and (2) the signature field 42 e indicates that the data error was identified by a scan utility matched with the error-correction utility 44 . On the basis of other information contained in the error entry 42 , the error-correction utility 44 automatically decides whether to repair that error.
For example, the error-correction utility 44 can be programmed to repair only specific types of errors. In this case, the error-correction utility 44 inspects the error-class field 42 c and decides, on the basis of information in the error-class field 42 c , whether to repair the data error.
Alternatively, the error-correction utility 44 can be programmed to repair only errors made between specified dates and times. In this case, the error-correction utility 44 inspects the time-stamp field 42 b and, on the basis of information contained in the time-stamp field 42 b , decides whether to repair the data error.
An error-correction utility 44 can also be programmed to repair only data errors made by a particular storage device 20 ( 1 ) or data errors associated with specified logical locations on a particular storage device 20 ( 1 ). In such a case, the error-correction utility 44 inspects the address field 42 a and, on the basis of information in the address field 42 a , decides whether to repair the data error.
Finally, an error-correction utility 44 can also be programmed to repair only errors identified by Boolean combinations of the foregoing fields. For example, the error-correction utility 44 can be instructed to repair only data errors on a particular storage device between specified dates and having specified error types.
In another embodiment, a human operator examines the contents of the scan buffer 40 to determine which of the data errors is to be repaired. In this case, the error entry 42 also includes a repair flag 42 f whose value is set by the human operator. The error-correction utility 44 then repairs only those data errors designated by the repair flag 42 f.
The first and second embodiments can also be integrated together by having the error-correction utility 44 follow programmed rules for repairing disk errors unless the repair flag 42 f indicates that the programmed rules are to be overridden by human intervention.
FIGS. 5 and 6 summarize the scanning method and error-correction methods in a flowchart. As shown in FIG. 5, the scanning method is preceded by the allocation 46 of a scan buffer in the global memory. This step is typically executed as part of initializing the disk storage system. A counter is then initialized 48 and a track identified by that counter is scanned 50 . The scanning utility then determines if a data error exists on that track 52 . If a data error exists, the scanning utility creates an entry in the scan buffer with information descriptive of that error 54 . Otherwise, the scanning utility checks to see if that track is the last track to be checked 56 . If it is, the scanning utility ends the scan 58 . Otherwise, the scanning utility increments the counter 60 and begins another iteration of the loop.
FIG. 6 shows the error-correction method that begins with the error-correction utility initializing 62 a counter and reading 64 the corresponding error entry from the scan buffer. The error-correction utility then determines 66 , from information in the error entry, whether it is to repair the data error. If the error entry indicates that the data error is marked for repair, the error-correction utility repairs 68 , or attempts to repair, the data error.
In either case, the error-correction utility determines 70 whether there are additional error entries in the scan buffer. If there are none, the error-correction utility terminates 72 . Otherwise, the error-correction utility increments 74 the counter and proceeds to read the next error entry in the scan buffer.
The foregoing description sets forth one particular embodiment of a system that incorporates the principles of the invention. However, the invention is not limited to the specific embodiment set forth above. Instead, the scope of the invention is to be determined by the appended claims. | A method for scanning a mass-storage device in communication with a global memory includes allocating a scan buffer in the global memory for placement of information descriptive of any errors found during the scan. When a scanning utility identifies a data error on the mass-storage device, it writes structured information descriptive of the error to the scan buffer. This information is available to an error-correction utility. The error-correction utility uses this information to determine, with a minimum of human intervention, which data errors to repair and which to ignore. | 6 |
BACKGROUND OF THE INVENTION
Pressure infusion devices are known for infusing fluid under pressure such as whole or component stored human blood or intravenous fluid into a patient. Time can be very important when it is necessary to infuse a fluid under pressure into a patient. One of these devices is in the form of a bladder to which is secured netting. A fluid-filled plastic bag is positioned between the bladder and the netting and a bulb connected to the bladder is squeezed repeatedly until the required pressure of about 300 millimeters of mercury is reached whereupon the fluid in the plastic bag is infused under pressure into the patient. This device has certain drawbacks among which are:
THE PLASTIC FLUID BAG IS NOT EASILY POSITIONED BETWEEN THE BLADDER AND NETTING, THE BLADDER APPLIES PRESSURE AGAINST ONLY ONE SIDE OF THE PLASTIC BAG, THE NETTING IS NOT A SUBSTANTIALLY RIGID SURFACE AGAINST WHICH THE OTHER SURFACE OF THE PLASTIC BAG ENGAGES, IT TAKES ABOUT THIRTY TO THIRTY FIVE SQUEEZES ON THE BULB TO RAISE THE PRESSURE IN THE BLADDER TO THE REQUIRED LEVEL, AND THESE DEVICES ARE DIFFICULT TO SANITIZE.
Another pressure infusion device has a zipper to connect ends of a rectangular piece of material together to form a cuff. A bladder is encased in an enclosure member which is snapped into position on the piece of material. The liquid-filled plastic bag is placed on the bladder-contained enclosure member, the ends of the material are zipped together and the bladder is pumped with air to the desired pressure level. The drawbacks of this pressure infusion device are the same as those above.
A further pressure infusion device is disclosed in U.S. Pat. No. 3,565,292 which is mechanically operated by the controlled action of a piston applying pressure to the liquid-filled plastic bag. A crank is used to spring load the piston in order to provide the necessary pressure. The drawbacks of this pressure infusion device are:
IT TAKES CONSIDERABLE TIME TO CRANK THE PRESSURE TO THE REQUIRED LEVEL, IT IS MECHANICAL AND IT DOES NOT HAVE A PRESSURE GAUGE TO INDICATE THE PRESSURE BEING APPLIED ONTO THE LIQUID-FILLED PLASTIC BAG.
SUMMARY OF THE PRESENT INVENTION
The present invention relates to infusion devices and more particularly to pressure infusion devices.
The present invention overcomes the drawbacks of the afore-mentioned pressure infusion devices by providing a clear plastic laminated structure wherein the middle two thirds defines a bladder which applies pressure to about eightly per cent of the periphery of the liquid-filled plastic bag when it is encased therewithin. The inside surfaces of the ends of the laminated structure are provided with respective sections of a Velcro fastening device so that the plastic laminated structure can be secured in the form of a pressure cuff very rapidly. Netting material is secured between the inner and outer sheets of the laminated plastic material to provide stiffness to the structure. The inner and outer sheets of material are made of transparent plastic material so that the level or volume of the fluid in the plastic bag is visible in all directions of viewing. The bladder is pumped to the required pressure level in about 10-15 squeezes. The infusion device is readily cleaned and will not stain.
An object of the present invention is to provide a pressure infusion device that has a bladder which will engage about eightly per cent of the periphery of a liquid-filled plastic bag when encased therein.
Another object of the present invention is the provision of a pressure infusion device that enables a liquid-filled plastic bag to be rapidly secured in position therein.
A further object of the present invention is to provide a pressure infusion device that is made from clear material to enable viewing the volume of the liquid-filled plastic bag encased therein.
An additional object of the present invention is the provision of a pressure infusion device that is economical to manufacture by heat sealing or welding two materials together, easy and fast to operate, easy to clean and it enables ready visibility of the condition of the liquid-filled plastic bag encased therein.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention will appear more fully from the following description and the accompanying drawings illustrating a preferred embodiment of the invention. It is to be understood that changes may be made from the exact details shown and described without departing from the principles of the invention.
FIG. 1 is a perspective view of the pressure infusion device in its open position with a liquid-filled plastic bag in position thereon;
FIG. 2 is a view similar to FIG. 1 but with the pressure infusion device in a closed position in the form of a pressure cuff around the liquid-filled plastic bag; and
FIG. 3 is a cross-sectional view taken along lines 3--3 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, a pressure infusion device 10 includes a bladder section 12 and end sections 14 and 16. Bladder section 12 also includes a planar projection 18 in which a hole 20 is provided to enable the pressure infusion device 10 to be mounted on a hook 22 on a post 24. A metal grommet is preferably secured in hole 20 to enforce it. A tubular projection 26 is provided by bladder section 12 in which is secured an end of flexible tubing 28. The other end of tubing 28 is positioned onto one end of a T-shaped member 30. A pressure gauge 32 is connected to another end of member 30 and a flexible bulb 34 preferably having a one-way value 36 therein is connected via flexible tubing 38 to a further end of member 30. A valve 40 is provided by bulb 34 to maintain or release the pressure that bulb 34 has applied to bladder section 12. The pressure gauge 32 is always in a position for viewing due to its location immediately adjacent bulb 34.
The pressure infusion device 10 is formed of inner and outer sheets 42 and 44 of transparent or clear plastic material such as, for example, polyvinyl chloride. 0 A sheet of netting material 46, which is preferably made of polyester material, is disposed between the inner and outer sheets 42 and 44 to form a laminated structure. The edges of inner and outer sheets 42 and 44 and netting 46 are secured together in accordance with a conventional electronic heat applying technique and the ends of bladder section 12 are heat sealed together along lines 48 and 50 in the same manner so that bladder section 12 is completely sealed and leakproof. Sections 52 and 54 of a Velcro fastening device are secured along the inside and outside surfaces respectively of end sections 14 and 16. Also, sections 56 and 58 of a Velcro fastening device are secured onto the inner sheet 44 just below hole 20. Sections 52 and 58 comprise closed-spaced projections all over them and sections 54 and 56 define loosely-packed material.
A conventional liquid-filled plastic bag 60, which can contain either whole or component stored human blood or intravenous fluid, is provided with a hole 62 and filter 64. Tubing 66 is connected to filter 64 and it is connected to a needle (not shown) which is inserted into a patient's body. Section 58 is passed through hole 62 and engaged with section 56 to maintain bag 60 in position on bladder section 12. End 16 is moved into engagement with bag 60 and end 14 is moved into engagement with end 16 so that sections 52 and 54 latch ends 14 and 16 together so that a pressure cuff is now formed around bag 60.
Valve 40 is closed and bulb 34 is squeezed repeatedly causing air to be pumped into bladder section 12 and the pumping is continued until the desired pressure level as indicated by gauge 32 is reached. The pressure on bag 60 as exerted thereon by bladder section is being exerted over about eighty per cent of the bag as shown in FIG. 3 so that the liquid in bag 60 can now be infused into the patient by operation of valve 68 in a rapid and uniform manner. The fact that device 10 is made of clear plastic will enable visual inspection of bag 60. Also, device 10 is able to be readily cleaned many times for extended use. The Velcro fastening devices enables rapid positioning of bag 60 in position on bladder section 10 and securing ends 14 and 16 together to form the pressure cuff. The ends 14 and 16 when in a latched position form a semirigid section.
As can be discerned, a pressure infusion device has been disclosed within which is mounted a liquid-filled plastic gab and which includes a bladder section that will engage about eighty per cent of the plastic bag when the bladder is pumped up to the desired pressure level in order to infuse the liquid in the plastic bag under pressure into a patient in a fast and uniform manner. The pressure infusion device is made of clear plastic material so that the condition of the plastic bag can readily be discerned and so that it can be easily cleaned and sanitized. The fastening devices provided on the pressure infusion device enables quick mounting of the liquid-filled plastic bag in position and to replace a used plastic bag with a filled plastic bag. Although the invention has been explained with reference to a particular embodiment, it is to be appreciated that various adaptations and modifications may be made without departing from the appended claims. | A pressure infusion device includes a bladder as part of the cuff in which a fluid filled plastic bag is encased wherein the bladder surrounds at least eighty per cent of the plastic bag, and, upon fluid being pumped into the bladder, the fluid in the plastic bag is infused under pressure to a patient. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for continuously producing a pitch-based carbon fiber felt excellent in uniformity of the unit weight and physical properties. The term "carbon fiber felt" as used herein includes activated carbon fiber felt as well.
Specifically, the pitch-based carbon fiber felt which is produced by the process of the present invention is excellent in uniformity of the unit weight and physical properties and provides high-performance thermal insulator, cushioning thermal insulator, filter media, adsorbent and the like. In particular, the pitch-based carbon fiber felt which is produced from optically anisotropic pitch as the raw meterial can be used in carbon-carbon composite, electrodes of an electric cell, nuclear fusion reactor walls, etc. Moreover, the activated carbon fiber felt can be efficiently utilized in water purification, solvent recovery and the like.
2. Description of Related Art
A pitch-based carbon fiber felt has heretofore been produced by the process comprising the step of collecting the pitch fibers that have been spun out by centrifugal spinning system, vortical spinning system or spun-bond spinning system in the form of tow or sheet on a perforated belt; the step of stabilizing treatment in an oxidative atmosphere; the step of carbonizing treatment in an atmosphere of an inert gas, the step of direct activating treatment in an atmosphere of an activating gas, or the steps of carbonizing treatment in an atmosphere of an inert gas and subsequent activating treatment of the carbonized fibers; the step of webbing the pitch-based carbon fiber precursor in the form of tow or sheet obtained through the foregoing steps via independent carding treatment; the step of laminating the webbed precursor; and the step of fixing the fibers by entangling the fibers by needle punching, water jet and the like, or by bonding the fibers with an adhesive.
In the above-mentioned process, the fiber precursor in the form of tow or sheet brings about generally a shrinkage of about 5 to 20% in carbonizing treatment and about 10 to 50% in the activating treatment due to an intrinsic shrinkage caused by weight loss thereof and flexure of the fibers in the carbonizing and activating treatment.
The remarkable shrinkage of the fibers gives rise to ununiform shrinkage thereof in a carbonization or activation furnace which will lead to ununiform unit weight of the tow or sheet obtained therethrough, and in the extreme case, to breakage of the tow or sheet. Particularly in the case of activated carbon fiber, the above-mentioned shrinkage leads to ununiform specific surface area.
Also the above-mentioned process involves the problems of a lower process yield and impossibility of enhancing its strength because of the fiber precursor in the form of tow or sheet being hackled in the course of carding treatment. Particularly, in the case of low elongation fibers such as optically anisotropic pitch-based carbon fiber or particularly low-strength fibers such as activated carbon fiber, the above-mentioned process makes it difficult to produce a felt containing 100% of pitch-based carbon fiber and having a uniform unit weight, sufficient handleability and high strength.
On the other hand, melt-blow spinning system has the advantage of favorable productivity and capability of producing fine fibers having a fiber diameter of about 10 μm or smaller. However, in the case where the pitch-based fibers obtained by melt-blow spinning system having a finite length, especially the fine fibers having an average fiber diameter of about 10 μm or smaller are applied to the process for producing the pitch-based carbon fiber felt, there are caused more frequently the aforesaid shrinkage and/or breakage of the tow or sheet during the carbonizing treatment or activating treatment and the breakage of the fibers in the carding treatment, showing the tendency of increased ununiformity of the physical properties of the obtained felt such as the unit weight and specific surface area.
Conclusively, it was impossible by any of the conventional processes to produce a felt excellent in uniformity of physical properties in a high yield from pitch-based carbon fiber or activated carbon fiber. As a result of intensive investigation made by the present inventors on the above-mentioned problems, it was found by them to be effective to carry out the carbonizing treatment or activating treatment of the carbon fiber precursor which brings about a remarkable shrinkage under the condition enabling free shrinkage of the web. The present invention has been accomplished on the basis of the aforestated finding and information.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to eliminate the problem of inferior uniformity of unit weight and physical properties of the conventional pitch-based carbon fiber felt.
It is another object of the present invention to provide a process for continuously producing a pitch-based carbon fiber felt excellent in uniformity and handleability comprising the fibers made by melt-blow spinning system which could never been felted by any of the conventional processes by reason of the remarkable shrinkage at the time of carbonization or activation.
Other objects of the present invention will become apparent from the detailed description to follow taken in conjunction with appended claims.
For the above-mentioned objects, the present invention provides a process for continuously producing a pitch-based carbon fiber felt which comprises the steps of spinning a pitch by melt-blow spinning system; accumulating the spun fibers as a pitch fiber web preferably on a perforated belt; continuously cross lapping the web; subsequently stabilizing the cross lapped web; carbonizing and/or activating the stabilized web; and then felting the resultant web. A preferred embodiment of the present invention is particularly characterized in that when the stabilized pitch fiber web is carbonized and/or activated, an inert gas or an activating gas is allowed to flow from the underside of the stabilized pitch fiber web to the upside thereof at a flow rate of 0.2 to 2.5 m/sec.
The present invention also provides a pitch-based carbon fiber felt having an average fiber diameter of 10 μm or smaller, a unit weight of 150 to 1000 g/m 2 and a variance of the unit weight in both the lengthwise and widthwise directions expressed in terms of coefficient of variation (CV) of 5% or less.
The process according to the present invention exerts a particularly excellent effect in the case of producing a felt having uniform unit weight and advanced physical properties from an activated carbon fiber web which undergoes a large shrinkage at the time of activating treatment.
DESCRIPTION OF PREFERRED EMBODIMENT
(1) Pitch and Pitch Fiber Web
The type of pitch to be employed in the present invention is not limited to petroleum-base nor coal tar-base, but is roughly divided into optically anisotropic type and optically isotropic type.
An optically anisotropic pitch is the pitch which comprises an anisotropic pitch as the principal component, from which is obtained carbon fibers having high tensile strength, high tensile modulus of elasticity, excellent chemical resistance and excellent resistance to oxidation at elevated temperatures.
In view of the physical properties of the carbon fiber to be obtained, a pitch having an optically anisotropic component of 70% or more is preferable.
On the other hand, an optically isotropic pitch is rich in aqueous gas reactivity and therefore, is preferably used as the raw material for activated carbon fiber.
The pitch-based short fibers obtained by melt-blow spinning system have usually a fiber diameter of 5 to 30 μm and a fiber length of several centimeters to several meters.
The pitch fiber web to be employed in the present invention has a unit weight of desirably 15 to 100 g/m 2 . A unit weight thereof of less than 15 g/m 2 undesirably lowers the web strength and causes such problems as insufficient stability in releasing from the collecting belt, web breakage at the time of the web traverse in the cross lapping step, etc., whereas a unit weight exceeding 100 g/m 2 makes it difficult to evacuate the draw gas flow generated at the time of spinning through the accumulated pitch fiber web, thus undesirably causing rope-like mottles on the web surface and further, ununiform unit weight in producing a felt by cross lapping of the web.
Accordingly, it is advantageous to thinly accumulate the pitch fiber web and widely cross-lap the web (for example, 1 to 3 m in width) from the viewpoint of the equipment construction cost and the successive treatment in the process. Thus, the pitch fiber web has a unit weight of more disirably 20 to 90 g/m 2 , most desirably 20 to 50 g/m 2 .
As the spinning system to be employed in the process of the present invention, melt-blow spinning system is adopted to produce the fibers since it enables to optionally regulate the fiber diameter in the range of 5 to 30 μm, approximately, has several advantages such as a high output per unit time per one piece of spinning nozzle and excellent productivity and besides permits stable spinning, especially for the fine-diameter fibers. The fibers thus spun is preferably accumulated on a perforated belt while the draw gas flow is sucked from the rear side of the fibers. The flow rate of the gas sucked from suction holes is desirably 5 to 100 m/sec, more desirably 12 to 50 m/sec.
A flow rate of the gas lower than 5 m/sec undesirably causes floating of the pitch fiber in a spinning chamber, bulkiness of the obtained web and poor handleability thereof, whereas that exceeding 100 m/sec unfavorably brings about breakage and/or deterioration of the fibers.
(2) Cross-Lapping Treatment of Pitch Fiber Web
The accumulated pitch fiber web is introduced in a cross lapper without being cut off, continuously cross lapped to form multilayer, for example, generally lapping at least 8 layers or sheets to form multilayer (hereinafter, cross lapped web in the form of multilayer is referred to as "cross lapped web"), placed on a perforated belt and continuously fed in a stabilizing furnace.
The number of the laminated layers is appropriately selected taking into consideration the diameter of pitch fiber to be used, the successive processing, the aimed unit weight of the product to be obtained, the purpose of use of the final felt product and so forth. In order to assure the uniformity of the cross lapped web unit weight, desirably at least 8, more desirably 12 to 30 sheet should be laminated.
As a cross lapper to be used for producing cross lapped web, there may be optionally used a cross lapper which is publicly known in itself and used for laminating nonwoven fabrics, etc. However, taking into consideration the brittleness of the pitch fiber web, a horizontal type cross lapper is preferably used from the operational standpoint. In addition, from the viewpoint of antistatic property, the belt on which the cross lapped web is placed is preferably the one with electrical conductivity.
The unit weight of the cross lapped web varies depending upon the thread diameter and the unit weight of the aimed final product, but is desirably 200 to 1200 g/m 2 , more desirably 300 to 1000 g/m 2 .
It is possible in the cross lapping step in the process of the present invention to laminate the pitch fiber that can not be uniformly and stably accumulated at a unit weight of 100 g/m 2 or more in the spinning step so as to match the successive steps, thereby efficiently balancing the spinning step with the stabilizing step and successive steps. Specifically, the cross lapping prior to the stabilizing step has made it possible to thinly spin pitch fiber web, cross lap the web according to the unit weight of the final felt product, proceed with successive steps and thereby continuously carry out the whole steps. The process in which the stabilizing step is followed by cross lapping step makes it difficult to always balance the treatment capacity of the spinning step with that of the stabilizing step and leads to the disadvantage that continuous operation is impossible and the productivity is poor.
Moreover, the cross lapping treatment exhibits an extremely great effect against shrinkage which takes place at the time of carbonization or activation.
Specifically, the shrinkage takes place simultaneously in the progressing direction of the cross lapped web and in the direction of width in an amount of 5 to 20% in carbonization, and 10 to 50% in activation. The above shrinkage can be absorbed uniformly by the shift between the laminated surfaces of the web that has been laminated in multilayer.
According to the conventional processes, the shrinkage is concentrated on the place where the strength of the precursor web is minimized, the unit weight of the carbon fiber web coming out of a carbonizing or activating furnace is made ununiform and in the extreme case, the web is cut off.
Such ununiform shrinkage brings about ununiform streams of inert gas or activating gas and especially in the case of activated carbon fiber felt, the shrinkage is accompanied with such problems as ununiformity of specific surface area and micropore distribution. The phenomenon is remarkable in the longitudinal(flow) direction in the case of continuously treating the webs.
In the process of the present invention, the interlaminar adhesive strength is lower than the strength of the web itself owing to the multilayered lamination and, when shrinkage takes place in the laminate placed in a carbonizing furnace or an activating furnace, the shift due to the shrinkage is uniformly generated in the interlaminar section of the web having the lowest bonding stregth. Hence, despite the totally decreased unit weight, the product thus obtained makes itself a carbon fiber web excellent in uniformity of the unit weight and physical properties including specific surface area, etc.
(3) Stabilization of Cross Lapped Web
The cross lapped web can be stabilized continuously in liquid phase or gas phase by the use of a conventional process, but is preferably stabilized in an oxidative atmosphere containing air, oxygen, nitrogen dioxide or the like at a temperature from 200° to 400° C. and at an average temperature rise rate of 1° to 15° C./min, particularly 3° to 12° C./min.
(4) Carbonization and Activation
The cross lapped pitch fiber web after the stabilization is carbonized at a temperature from usually 500° to 1500° C., preferably 600° to 1200° C. in an atmosphere of an inert gas such as nitrogen or activated at a temperature from usually 500° to 1500° C., preferably 800° to 1200° C. in the presence of an activating gas such as steam or carbon dioxide and then entangled by needle punching or the like to form the objective pitch-based carbon fiber felt.
A carbonizing temperature lower than 500° C. results in a low strength of the carbon fiber to be obtained, a high friction coefficient and likelihood of damage to the fiber at the time of entangling treatment by needle punching or the like, while the temperature above 1500° C. will lead to an undesirably low elongation, especially with an optically anisotropic pitch-based fiber and likelihood of damage to the fiber such as cutoff and powdering, thereby remarkably decreasing the process yield. An activating temperature lower than 500° C. uneconomically lowers aqueous gas reactivity to an extreme extent, whereas the temperature exceeding 1500° C. undesirably causes deterioration of furnace materials.
In order to further uniformalize web shrinkage in a carbonizing furnace or an activating furnace, it is particularly effective to forcedly pass an inert gas or an activating gas from underside of the cross lapped web to upside thereof at a flow rate of preferably 0.2 to 2.5 m/sec, that is, to effect carbonization or activation under the floating condition (the weight of the cross lapped web itself is negligible) of the cross lapped web at an optimum flow rate which varies depending on the fiber diameter, unit weight, etc. but is usually in the range of 0.2 to 2.5 m/sec, thereby minimizing the contact resistance with the belt. A flow rate less than 0.2 m/sec results in failure to substantially float the cross lapped web with scarcely any effect, while that more than 2.5 m/sec is undesirable from the viewpoint of production stability since it causes the cross lapped web to scatter as the case may be.
As the effective means for generating the gas flow, there is available a method in which an inert gas or an activating gas is spouted from the underside of the perforated belt. It is also effective in the present invention to devise the shape of belt so as to minimize the contact resistance in enhancing free shrinkage of the cross lapped web.
In the process of the present invention, it is possible to effectively carry out the carbonization and activation of the stabilized cross lapped web in the same furnace by alternately switching over the atmospheric gas, but in the case where carbonization needs to be followed by activation, there may be installed a carbonizing furnace and an activating furnace in series in the downstream side of a stabilizing furnace to carry out continuous operation.
(5) Felting of Cross Lapped Web
In the process of the present invention, as the method of felting there are available entangling means such as needle punching treatment and water-jet treatment, an adhesion means in which fibers are fixed with an adhesive and the like, among which is preferable the needle punching treatment, which can dispense with effluent water treatment and simplify the operation.
In the case of needle punching for felting in the present invention, the needle punching density is preferably 3 to 120 punches/cm 2 . A needle punching density less than 3 punches/cm 2 results in deterioration of felt stregth, dimensional stability and handleability, whereas the density exceeding 120 punches/cm 2 enhances felting treatment but undesirably increases damage to the fibers, conversely decreasing felt stregth.
It is possible in felting treatment by needle punching or the like to laminate a nonwoven fabric or cloth of other fiber having other properties such as high elongation on one side or both the sides of cross lapped web.
According to the present invention, it is possible to regulate the unit weight of the final product to 500 to 1000 g/m 2 in the case of a carbon fiber felt and to 150 to 500 g/m 2 in the case of an activated carbon fiber felt and also to suppress the variance of the unit weight in both the widthwise and lengthwise directions to 5% or less expressed in terms of coefficient of variation (CV).
The samples for measuring the variance of the unit weight are obtained by collecting 5 cm squares at every 20 cm distance in both the widthwise and lengthwise directions making a total of 10 pieces in each direction.
The fiber diameter of the final product is desirably 10 μm or smaller, more desirably in the range of 5 to 10 μm taking into consideration the thermal insulation properties at elevated temperatures in the case of a carbon fiber felt and the enlargeable surface area in the case of an activated carbon fiber felt.
In order to produce a felt having random fiber orientation and uniform unit weight, a method in which a card web is laminated and thereafter felted with a needle punch has heretofore been employed. However, in the case of the fibers with low elongation such as carbon fiber, especially optically anisotropic pitch-based carbon fiber or the fibers with extremely low strengh and brittleness such as activated carbon fiber, the fibers are cut off or powdered in the carding step, whereby the felt strength is markedly decreased, variance of the unit weight is increased and process yield is lowered.
A carbon fiber felt made from phenol, rayon or PAN is usually produced by a method wherein a felt is at first made by conventional carding treatment and thereafter the felt thus obtained is carbonized, graphitized or activated. In the above-mentioned method, however, the overall process yield through carbonization, graphitization or activation is 20 to 50% by weight based on the starting fiber material. Accordingly, the processing cost becomes 2 to 5 times when converted from the yield of the final product in spite of a high process yield in the carding step or the like, thus leading to an extremely high processing cost. Furthermore, the ununiform shrinkage in the carbonization step or activation step results in the production of the final product having only ununiform unit weight and physical properties.
The present invention solves the above-mentioned problems. Specifically, in the process of the present invention a pitch fiber web is accumulated in the spinning step; the pitch fiber web is continuously cross lapped; subsequently the cross-lapped web is stabilized; the stabilized web is carbonized and/or activated; and the resultant web is felted directly with needle punching or the like not by way of carding treatment.
More specifically the present invention provides a process which comprises accumulating in a thin state a pitch fiber web preferably having a unit weight of 15 to 100 g/m 2 consisting of the aggregate of short length fibers that have been spun by melt-blow spinning system; cross lapping the pitch fiber web; then stabilizing the cross lapped web; carbonizing and/or activating the stabilized web preferably in the forced stream of a gas flowing from the underside of the stabilized web towards the upside thereof; and finally felting the resultant web thus treated. By reason of uniform shrinkage occurring in the above-mentioned steps as well as unnecessary carding treatment, the process of the present invention is capable of continuously and inexpensively producing a pitch-based carbon fiber felt having excellent uniformity of the unit weight which could never been embodied by any of the conventional processes and having prominent physical properties such as high strength. In particular, the felt having an average fiber diameter of 10 μm or smaller is produced at a high process yield with high efficiency at a low cost.
In the following the present invention will be described in more detail with reference to the examples but it shall not be limited thereto.
EXAMPLE 1
A pitch fiber web was produced by melting a petroleum-base optically isotropic pitch having a softening point of 260° C. as the starting raw material, and drawing the molten pitch by the use of a spinneret having 1500 holes of 0.2 mm in diameter in a row in a slit of 3 mm in width and by spouting heated air through the slit under the conditions including a pitch discharge rate of 1500 g/min, pitch temperature of 325° C., heated air temperature of 330° C. and heated air pressure of 0.2 kg/cm 2 G. The spun out fibers were accumulated on a belt made of stainless steel wire mesh with 20 mesh by suction from the rear side of the belt under an air flow rate of 32 m/sec to obtain a pitch fiber web having a unit weight of 25 g/m 2 , an average fiber diameter of 7 μm, and an average fiber length of about 10 cm. The pitch fiber web was continuously cross lapped with a horizontal cross lapper so as to attain a unit weight of 600 g/m 2 and then stabilized in an air atmosphere by raising the temperature from room temperature to 300° C. at an average heat-up rate of 6° C./min. Subsequently the stabilized web was activated in an atmosphere of an activating gas comprising 40% steam fraction at 950° C. for 20 min. by passing the activating gas from the underside of the belt to the upside thereof at a flow rate of 1.2 m/sec and then was subjected to needle punching at a punching density of 10 punches/cm 2 and selvage cutoff at both ends to obtain an activated carbon fiber felt having a unit weight of 300 g/m 2 , and an average fiber diameter of 6 μm. The series of steps from the above-mentioned spinning through the needle punching were continuously carried out. The felt was cut into 5 cm square samples at every 20 cm distance in both the widthwise and lengthwise directions making a total of 10 samples, respectively, and measured for the variance of the unit weight in both the widthwise and lengthwise directions in terms of coefficient of variation(CV). The results obtained (CV) were 2.8% and 3.1%, respectively, showing sufficiently small values and uniform unit weight. Measurement was made also of the iodine adsorption of the samples used for measuring the unit weight. The result obtained was 1760 mg/g in average with CV value of 3.4%, also showing uniform values.
COMPARATIVE EXAMPLE 1
Following the procedure in Example 1, a pitch fiber web having a unit weight of 250 g/m 2 was accumulated and activated except that cross lapping and forcedly passing the gas stream during the activation step were omitted. The activated carbon fiber web discharged from the activating furnace was cut off at an interval of about 2 m, causing about 50 cm clearances among the cut off pieces. The iodine adsorption was measured in the same manner as in Example 1. The result obtained gave smaller values in the central part of the web with CV value of 12.6%, thus showing large variances.
EXAMPLE 2
A pitch fiber web was produced by melting a petroleum-base optically anisotropic pitch having an anisotropic proportion of 98% and a softening point of 285° C. as the starting raw material, and drawing the molten pitch by the use of a spinneret having 1500 holes of 0.15 mm in diameter in a row in a slit of 3 mm width and by spouting heated air through the slit under the conditions including a pitch discharge rate of 1500 g/min, pitch temperature of 345° C, heated air temperature of 360° C. and heated air pressure of 0.5 kg/cm 2 G. The spun out fibers were accumulated on a belt made of stainless steel wire mesh with 20 mesh by suction from the rear side of the belt under an air flow rate of 32 m/sec to obtain a pitch fiber web having a unit weight of 50 g/m 2 , an average fiber diameter of 10 μm and an average fiber length of about 15 cm. The pitch fiber web was continuously cross lapped with a horizontal cross lapper so as to attain a unit weight of 600 g/m 2 without being treated in a cutoff step and then stabilized in an air atmosphere by raising the temperature from room temperature to 320° C. at an average heat-up rate of 4° C./min. Subsequently the stabilized web was carbonized by passing nitrogen from the underside of the belt to the upside thereof at a velocity of 1.0 m/sec and elevating a temperature up to 1000° C., and then was subjected to needle punching at a punching density of 10 punches/cm 2 and selvage cutoff at both ends to obtain a carbon fiber felt having a unit weight of 550 g/m 2 , and an average fiber diameter of 9 μm. The series of steps from the above-mentioned spinning through the needle punching were continuously carried out. The felt was cut into 5 cm square samples at every 20 cm distance in both the widthwise and lengthwise directions making a total of 10 samples, respectively, and measured for the average variance of the unit weight in both the widthwise and lengthwise directions in terms of coefficient of variation (CV). The results obtained (CV) were 2.6% and 3.0%, respectively, showing sufficiently small values and uniform unit weight. The felt having a strength of 1353 g/5 cm width was obtained in an overall process yield of 78% by weight from the spinning step to the final felting step.
COMPARATIVE EXAMPLE 2
Following the procedure in Example 2, a pitch fiber web having a unit weight of 250 g/m 2 was accumulated and carbonized at 1000° C. except that cross lapping and forcedly passing the nitrogen stream during the carbonization step were omitted.
The pitch fiber web thus obtained was subjected to carding treatment by the conventional process and needle punching to obtain a carbon fiber felt having a unit weight of 550 g/m 2 . Following the procedure in Example 2, measurement was made of the variance (CV) of the unit weight in both the widthwise and lengthwise directions. The results obtained (CV) were 7.2% and 8.9%, respectively, revealing large values and ununiform unit weight. In addition, the felt as the final product gave a low strength, i.e. 530 g/5 cm width. The overall process yield from the spinning step to the final felting step was 47% by weight, that is, extremely low as compared with the process yield obtained in Example 2. | There is disclosed a process for continuously producing a pitch-based carbon fiber felt which comprises the steps of spinning a pitch by melt blow spinning system; accumulating the spun fibers as a pitch fiber web composed of the aggregate of short fibers; continuously cross lapping the web; subsequently stabilizing the cross lapped web; carbonizing and/or activating the stabilized web; and then felting the resultant web. The above-mentioned process is capable of efficiently producing a pitch-based carbon fiber felt having uniform unit weight and excellent physical properties and well suited for use in high-performance thermal insulator, cushioning thermal insulator, filter media and adsorbent for water purification and solvent recovery, etc. | 3 |
FIELD OF THE INVENTION
This invention relates to the methods of construction assembly for greenhouses, sun rooms, solariums and other glazed structures and the laminated materials used therein for support and structural beams.
BACKGROUND OF THE PRIOR ART
Construction of glazed structures can involve the use of a wide variety of materials and methods, representing each builder's particular variations in procedures and preference. Most such variations reflect obvious choices of alternatives which exist in the prior art of constructing such structures. Common to most such structures is a skeletal framework of parallel support beams forming the outline of the portion to be glazed with additional beams spaced according to the integrity desired. Glazing is then attached to the supporting beam members thereby enclosing the structure.
Problems occurring in the art include the cost of materials used in the structures which in turn make the total cost of the structure prohibitive to many potential purchasers. Another problem is the ability to construct the structure in a way which satisfies both the integrity requirements of local building codes and the aesthetic characteristics desired. Support beams comprising aluminum are often used allowing the beams to be small in width and depth, but lacking the attractive appearance of wood. Wood and wood laminates are also used, but to achieve the integrity necessary for the structure, support beams of wood and laminates are usually too bulky to achieve the most pleasing appearance. Also regarding appearance, problems exist in the art with the development and inclusion of designs and methods of construction resulting in desired features of the structures, such as a knee wall, which satisfy local building codes and have an attractive appearance.
OBJECTS OF THE INVENTION
It is a principal object of this invention to provide glazed structures which are more attractive and of sufficient integrity by using materials of a laminate composition which are of greater strength in the necessary dimensions than those laminate materials previously used in the construction of glazed structures, thereby allowing the attractive appearance of wood through the use of support beams with a width and depth small enough to create the most desirable appearance.
It is also an object of the invention to provide glazed structures which include desirable design features while retaining the integrity of the structure required by the local building codes.
It is also an object of the invention to use a laminate material which, while superior to laminates previously used in the art, is less expensive and can, therefore, reduce the cost of materials needed to construct a glazed structure.
BRIEF DESCRIPTION OF DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a glazed structure showing the skeletal structure of the laminate material and the glass used to enclose the structure.
FIG. 2 is a side cross-sectional view of a glazed structure showing the interconnection of the sections of glazing, the connection to the supporting building, the connection of the vertical and horizontal support beams, and the continuity of the horizontal support beam when a knee wall is incorporated.
FIG. 3 is a perspective view of the laminate material showing the multiple unfinished lamina and the layer of finished lamina on two sides and one edge.
FIGS. 4(a), 4(b) and 4(c) are three cross-sectional views of the connection of the glazing to the supporting building, between the horizontal and vertical support beams and the knee wall assembly, each showing the dovetail channel connector.
FIG. 5 is a cross-sectional view of a support beam showing the dovetail channel connector.
DESCRIPTION OF PREFERRED EMBODIMENT
A building system for the on-site assembly of a glazed structure including a support member for the structure comprising a rectangular laminated wood beam consisting of a plurality of longitudinally extending relatively thin wood lamina extending the length of the beam, said beam having at least three finished surfaces in which a decorative laminate is applied to both sides of the beam and to one edge thereof, the other edge of said beam being disposed facing outward from the structure, said beam being the support member for an adjacent glazing plane whereby the three finished surfaces of the beam face inwardly in the structure and present a decorative appearance thereto and the longitudinally extending lamina are oriented perpendicularly to the glazing surface.
The system described above in which the beam is the approximate size of a standard construction grade beam member and comprises through its thickness approximately 20 lamina, each having an individual thickness of approximately 0.10 inches.
The system described above in which the direction of the grain of the wood of each of the lamina in the beam is parallel to the direction of the grain of the wood in all the other lamina.
The system described above in which the support members are used in the construction in such an orientation that the planes formed by the lamina are perpendicular to the planes formed by the glazing.
In a glazed structure assembly, the improvement comprising a building system for the on-site assembly of a glazed structure including a support member for the structure comprising a rectangular laminated wood beam consisting of a plurality of longitudinally extending relatively thin wood lamina extending the length of the beam, said beam having at least three finished surfaces in which a decorative laminate is applied to both sides of the beam to one edge thereof, the other edge of said beam being disposed facing outward from the structure, said beam being the support member for an adjacent glazing pane whereby the three finished surfaces of the beam face inwardly in the structure and present a decorative appearance thereto and the longitudinally extending lamina are oriented perpendicularly to the glazing surface.
The assembly described above in which the glazing member is supported with a single or, preferably, double glazed glass windowpane mounted in an extruded member supported by the beam.
The assembly described above in which the extruded member is mounted in a groove in the unfinished side edge of the beam.
The assembly described above in which the groove includes a dovetail shaped female channel adapted to receive a corresponding male shaped formed in the extruded member.
The assembly described above in which the beams are a side wall column support and a roof rafter support.
The assembly described above in which the side wall column support beam is an intrinsic element of a knee wall in which the beam extends from the floor to the extending end of the rafter.
Referring to FIG. 1, the present invention includes a building system and a glazed structure formed from the skeletal structural beams 1, the horizontal and vertical support beams 2a and 2c, and crossbeams 2b and the glazing 3. All of the structural beams 1 and support beams 2a and 2c comprise the laminate material described in FIG. 3. The glazing 3 comprises any glass or other transparent or semi-transparent material satisfying the integrity requirements necessary under the local building codes.
Referring to FIG. 2, the supporting building 8 is connected to the glazed structure by means of a header plate 9 and a universal spacer 4a. Extending outward from the supporting building 8, primarily horizontally with a downward inclination, the support beams 2a extend the full depth of the glazed structure and connect to the vertical support beams 2c by means of a spline plate 10. The vertical support beams 2c connect to a wood bottom plate 5 which in turn connects to the floor or foundation. A knee wall having a finished interior is shown at 6, and on the exterior a brick wall 7 is shown. The glazing 3 is attached to the exterior of the horizontal and vertical support beams 2a and 2c and to the crossbeams 2b, and is held in place by vinyl connector units 11. The number of cross beams 2b and support beams 2a and 2c may vary depending upon factors such as the size of glazed structure, the integrity required and the glazed structure's appearance.
Referring to FIG. 3, the drawing shows a perspective view of the laminate material of the invention used for the structural beams 1, and the support beams 2a and 2c. The laminate material for a standard inch and three-quarters construction laminated structural member comprises approximately twenty lamina 12, made of thin layers of unfinished wood and adhesives. Dissimilar to other laminate and plywood materials, each of the lamina 12 of the laminate material used in the invention is joined with the grain of the wood in each layer running the same direction, that direction being parallel with the length of the laminated structural member and perpendicular to the direction of the stacking of the layers. The unidirectional grain of the wood gives the laminated structural member greater strength in the direction of the planes formed by each of the lamina 12. The laminate material is used in the construction of the glazed structures with the planes formed by the lamina 12 perpendicular to the planes formed by the glazing 3, thereby utilizing the increased strength of the unidirectional lamina 12 and allowing the use of such structural and support beams 1, 2a and 2c to achieve the mose desirable appearance with the required integrity. A preferred commercial laminate from which the laminated structural members of the invention are made is sold as "Micro:Lam"™ by Trus Joist Corporation.
To achieve the desirable appearance, layers of finished decorative laminate 13a and 13b are connected to the two sides 13a and one edge 13b of the laminated structural members. The three finished sides face inward and can be seen in the final structure. The unfinished side 14 faces the glazing and cannot be seen from the interior of the finished structure.
Referring to FIG. 4(a), the cross-sectional view of the connection between the supporting building 8 and the glazed structure shows the connection between the glazing 3 and the header plate 9 which is accomplished through the use of the vinyl connector units 11 comprising a vinyl connector 11a, a bar cap 11b, and neoprene glazing pads 11c. The vinyl connector is joined to an wood crossbeam 2b by means of a dovetail female channel running the length of the crossbeam 2b and a dovetail male formation at one end of the vinyl connector 11a. The glazing 3 and universal spacer 4a are then placed on the sides of the vinyl connector 11a, with the glazing 3 being separated from the wood crossbeams 2b with a neoprene glazing pad 11c. The unit is then sealed with a bar cap 11b having a male lock-clasp protruding member which is inserted into the female lock-clasp cavity on the edge of the vinyl connector 11a opposite the male dovetail formation. The glazng 3, universal spacer 4a and the bar cap 11b are similarly separated by neoprene glazing pads.
A flashing 15a is connected to the supporting building 8 and extends over and covers the bar cap 11b and empties onto the glazing 3.
The wood crossbeam 2b is connected to the support beams 2a which are in turn connected to the header plate 9. In the interior of the glazed structure the header plate 9 and the end of the support beams 2a and crossbeams 2b are covered with decorative wood trim 19.
Referring to FIG. 4(b), the cross-section shows the assembly of the connection between the vertical and horizontal sides of the glazed structure. Similar to FIG. 4(a) the glazing 3 is connected to the crossbeam 2b by means of the vinyl connector unit 1. The vertical and horizontal vinyl connector units 11 are connected to a common treated wood blocking 16 which is angled to accommodate both vinyl connector units 11. The wood blocking 16 is covered with a knee flashing 15b. The glazed assembly is connected to the horizontal and vertical support beams 2a and 2c, said beams being connected to each other with a spline plate 7.
Referring to FIG. 4(c), the cross-section shows the connection between the glazed portion of the structure and an optional knee wall 6. The glazing 3 is connected to a vinyl connector unit 11 which is connected on its opposite side to a square aluminum tube 18. As in FIG. 4(a) and FIG. 4(b), the vinyl connector unit 11 is connected to a crossbeam 2b by means of a dovetail connector track. The aluminum tube 18 is connected to a sill plate insert 20 which is covered on the exterior by a sill flashing 15c and on the interior by decorative wood trim 19. The glazed assembly is attached to the vertical support beam 2c which is attached to the crossbeam 2b and the sill plate insert 20.
Referring to FIG. 5, the cross-section shows the connection of the two sections of glazing 3 to the support beams 2a and 2c. As with the connections in FIG. 4, the connection of the glazing 3 to the support beams 2a and 2c employs a vinyl connector unit 11. The female dovetail channel 25 in the laminated structural and support beams 1, 2a, and 2c extends the length of the beams for receipt of the protruding male dovetail member 11a of the vinyl connector unit 11. The unfinished surface of the beams 14 faces the glazing, and the two sides and the opposite edge of the support beams 13a and 13b are a finished decorative laminate and face the interior of the glazed structure. The lamina 12 of the beams, having a unidirectional grain of the wood layers, provide additional strength along the plane formed by the lamina 12 and allow the support beams to be of small enough width and depth to achieve the most desirable appearance. | A building system and a structural improvement to the construction of glazed structures such as sun rooms, solariums and greenhouses which use laminated structural beams made of thin unfinished lamina layers of wood and surfaced on three sides with decorative finished lamina for appearance. The laminate material is made with the grain of the wood in the lamina all running parallel with the length of the beams, thereby increasing the strength of the beams and allowing the use of beams smaller in width and depth. The gazed structure includes methods of connection between the beams and the glazing and methods of incorporation of design features such as a knee wall. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to processes and apparatus for the application of fluids, being more particularly concerned with fluid distribution mechanisms for coating materials on surfaces being hereinafter generically referred to as "sheets" or "sheet means" or the like, for such purposes as, for example, hot melt adhesive, solvent type pressure-sensitive adhesive, resins, plastic, or other fluid materials.
Fluid distribution mechanisms for depositing fluid coatings in predetermined patterns (including intermittent configurations) upon surfaces such as sheets and the like, have been employed through the years in a wide variety of applications. In the illustrative example of adhesive coatings and the like, dispensers involving shuttered openings and nozzles have been employed as described, for example, in U.S. Pat. No. 3,174,689, issued Mar. 23, 1965 to the applicant D. B. McIntyre herein. Such fluid distribution systems have sometimes employed hot melt dispenser apparatus, for example, where the adhesive material and the like is converted from solid to molten form and continuously distributed along predetermined patterns, with or without a bumper spot, for such uses as the adhesive coating of papers and other materials. Apparatus of this nature may, for example, be of the form described in U.S. Pat. No. 3,323,510, issued June 6, 1967 to said D. B. McIntyre.
The philosophy underlying such and related techniques has principally resided in the forcing of the adhesive or other fluid out of nozzle structures and upon moving sheets and the like at controlled instants of time and for controlled intermittent periods of time with the aid of metered units such as, for example, the Type 1BUP2 marketed by Acumeter Laboratories, Inc., Newton Lower Falls, Massachusetts, or other well-known types of fluid metering mechanism. A further example of such an intermittent expanded-nozzle construction and system for the intermittent application of such coatings and deposits upon moving sheets or articles is described in U.S. Pat. No. 3,595,204, issued Jul. 27, 1971 to said D. B. McIntyre and F. S. McIntyre. Clearly, however, other types of fluid application and distribution apparatus may be and have been employed for related purposes.
There are occasions, however, where either the fineness of the dots, lines, or other patterns of this fluid coating to be deposited, or the rate of high speed of the sheet or other material, imposes too stringent conditions upon metered distribution nozzles and the like. For example, with a web or sheet moving at an approximately 1000 feet per minute rate or 16 feet per second, the estimated time for an application of adhesive one-eighth inch long in the direction of web travel, would require an on-time of three-fourth of one millisecond. The fastest practical electrical devices, such as solenoid valves, however, are capable of cycling at rates of the order of a cycle in about 30 milliseconds, more or less, making the use of such techniques for applying adhesive and the like thus unfeasible for the purposes of the present invention.
BRIEF DESCRIPTION OF THE INVENTION
An object of the invention, accordingly, is to provide a new and improved process and apparatus for fluid application that is particularly, though not exclusively, adapted for adhesive coatings and the like, and which is well suited for the high-speed and fine-dimensioned coating applications before discussed that cannot be practically mechanically shuttered from fluid application systems.
A further object is to provide a novel fluid applicator apparatus and system of more general use, as well. A further illustration of possible usage of the invention, indeed, resides in applying a solution across a moving web to penetrate the fibers of the substrate and facilitate the softening of these fibers so that subsequent folding of the web at the softened location will ultimately overcome the cracking of the fibers. Other applications will also immediately suggest themselves to those skilled in this art.
In summary, however, from one of its broader aspects, the invention contemplates a process of fluid application that comprises moving a sheet under tension at a predetermined speed longitudinally past a predetermined line transverse to the longitudinal movement of the sheet; periodically rotationally forcing a projection against one side of the sheet in the vicinity of said transverse line to deflect the sheet thereat; producing on the opposite side of the sheet along said transverse line globules of fluid to be deposited on the sheet as coatings; timing such globule production to occur at the time of and between the periodic deflection of the sheet; and adjusting the size of the globules to be sufficient to contact the sheet on the said opposite side along said transverse line when the sheet is deflected in order to cause the deflected sheet to wipe off the globules as coatings thereupon. Preferred adjustment and constructional details, together with other objects of the invention, are more particularly delineated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings, FIG. 1 of which is an isometric view of an adhesive coating application of the invention, in preferred form;
FIG. 2 is a side elevation upon an enlarged scale, with parts broken away to show the fluid application mechanism of FIG. 1; and
FIGS. 3 to 5 are fragmentary longitudinal sections illustrating various adhesives or other fluid application details suitable for the system of FIGS. 1 and 2.
DETAILED DESCRIPTION OF THE INVENTION
It is believed most conducive to operational explanation of the method and apparatus underlying the invention, to consider first the principles of fluid application illustrated in FIGS. 3-5 before discussing their embodiment in the practical system of FIGS. 1 and 2.
Referring to FIG. 3, a paper sheet or other web 1 is shown entering from the left, moving horizontally in the form shown, over an adjustable idler roll 3, and passing longitudinally along a predetermined substantially straight path (indicated by the dash line) over a transverse extrusion nozzle 5, as of the types previously described and as described in said Letters Patent, and under a bumper roll mechanism 7, rotating counter-clockwise about a horizontal rotational axis, and thence proceeding under tension through draw rolls 9, to the right. The nozzle defines a stationary line transverse to the longitudinal movement of the sheet and spaced from the predetermined path of the sheet. The bumper roll 7 is driven synchronously with the web, as later explained, and mounts one or more transverse projections or blades 11 on its surface, being driven at the same effective speed as the web 1 or faster than web speed and causing the projections 11 periodically to deflect the web 1 from the predetermined path and towards the nozzle 5, the orifice 5' of which is disposed preferably off-center at an angle A to the vertical axis of the bumper roll 7, shown to the left in FIG. 3. Globules of adhesive or other fluid are thus periodically transferred to the web in the shape of a transverse line or dash. The adhesive metering will, of course, be synchronous to web speed and proportional to bumping frequency.
In preferred operation, irrespective of the diameter of bumper roll 7, the position of the nozzle 5 will be relatively located at the bottom side of the web at substantially the same angle A, such that the relative dimensional positions change proportionately with bumper roll diameter. In most applications with adhesive applications on paper and similar webs, this angle of position A of the nozzle is preferably approximately 15°. This angle is substantially the same as the deflection angle the deflected web 1 makes with the horizontal axis of the idler roll 3.
As an example, if it be assumed that the bumper roll 7 is of six-inch circumference, the position of the nozzle 5 may be located approximately one-eighth to three-sixteenth inch off the center line of the bumper roll. For a larger circumference bumper roll 7, say 22 inches in circumference, the position of the nozzle 5 may be approximately five-eighth to nine-sixteenth inch to the side of the vertical center axis of the bumper roll. The time of contact with the nozzle orifice 5' can be varied, moreover, with variation of the angle A, including even to an equivalent angle on the other side of said vertical axis for reverse effects. It has been found, for the applications above mentioned, however, that there is an optimum position for momentary contact of the web and relatively stationary nozzle orifice, with sharp lift-off following bumper roll projection contact with the upper side of the web; namely, substantially the before mentioned angle of about 15° of nozzle displacement from the vertical axis of the bumper roll 7 and of web deflection from the horizontal axis of the idler roll 3.
In the modification of FIG. 5, the nozzle 5 is provided with a curved segment 5" on the aft portion substantially concentric with or corresponding approximately to the curvature of the bumper roll 7. This construction enables the attainment of a slurred pattern of adhesive application, indicated in dotted lines, in the direction of the web travel, as for such purposes as remoistenable adhesive layers for subsequent finishing into envelopes or the like. The transverse bumper projection or blade 11 is shown in the form of a tapered blade for producing the desired wipe pattern. The metering is controlled, as described in said Letters Patent, for example, but is timed to produce adhesive globules at substantially the time of and between periodic deflections at the web.
In the embodiment of FIG. 4, on the other hand, the wiping surface of the nozzle 5 is concavely constructed at 5'", again substantially paralleling the curvature of the bumper roll 7, but this time with the orifice 5' substantially alined with the vertical axis of the bumper roll 7. By rotating the bumper roll 7 oppositely to the direction of web travel, this construction can create a longer dwell time and consequently a longer slur wiping pattern than in the embodiment of FIG. 5, and better defined start and stop edges.
As before stated in connection with the relative speeds of the bumper roll rotation and of the moving web, it has been found that if the speed of the bumper roll mechanism (taking into account the number of bumper projections) is made substantially equal to or faster than the effective web speed, the definition of adhesive application across the web is sharp and well defined; whereas if the speed of the bumper roll mechanism is adjusted effectively to be less than web speed, a slurring action occurs, causing the adhesive or other application to be less well-defined. For instance, in an envelope application, the relative speeds experienced to date by the system of the present invention, vary up to a thousand feet a minute, wherein the bumper roll, of 23 9/16 inch circumference, itself is travelling at the same speed as the web and contains four bumper uniformly spaced projections, 90° apart, per roll. This enabled pasting four times per press repeat, enabling four envelopes per press repeat to be adhesive coated at 1000 feet a minute per one-up installation.
In practical equipment adapted for use with existing press equipment, a plurality of successive bumper rolls 7 may be used as in FIGS. 1 and 2. Three such bumper rolls 7 are there shown, each roll having a total circumference of 23 9/16 inch and positions for from one to four bumper projections or blades 11, to bump-wipe the incoming web 1 from one to four times per press repeat of the 23 9/16 inches. This capability provides the envelope-making line to produce one to four envelopes per press cut-off, being adaptable for not only one-up operation, but also a two-up and other multiple operation, as well. This can be effected because of the changing length of rolls that are capable of bringing in as much as a 20 inch wide web which, when converted into two 10 inch webs, can each be cross-pasted simultaneously and then subsequently plowed over on top of each other to create two simultaneously two-up envelope streams as an output of the press.
In order to registrate the cross-pasted positions from the first to the second and third bumper rolls 7, slotted flanged drive adjustments 7' are provided so that, when the press is shut down, the bolts may be loosened to advance or retard the relative positions with respect to each other in order to achieve the desired registration point, with such slotted and mating flange units providing this adjustment for phase generation. A phase variator 23, as of the endless chain loop type manufactured by Candy Manufacturing Company of Chicago, Illinois, permits advancing or retarding the relative registration printing of the adhesive application to desired positions, at will, during running, by advancing or retarding the output sprocket drive 23' to the cross-pasted bumper system; other types of known adjustment devices may also be used, such as a helical differential drive unit with a worm and worm gear assembly, for achieving the same end result, though the chain loop system is less expensive for the loads and the speeds intended in many applications of the invention.
In many applications, adhesive will not properly slur or grab or adhere to a moving web because of lack of compatibility of wetting properties of the adhesive and the paper, film, foil or other web substrate. It has been found that to create more attractiveness for a fluid, such as hot-melt adhesive such as pvc or polyethelene films or the materials discussed in said Letters Patent, to a moving web, and to enable application in a very low film thickness, such as one-thousandth of an inch, the web should be pre-heated and the metering adjusted to provide globule production that adheres in the periods of bumper projection contact and/or immediately thereafter, adjacent to or just after its entering the idler roll 3, as schematically shown by the arrow H, FIG. 3. The heating system may be of conventional types, such as hot air, radiant heaters, or even a hot iron placed on the moving web.
It is desired to contrast the approach of the invention with other available adhesive-application techniques and thus illustrate the marked improvement and flexibility attainable with the invention. As before stated, the bumper roll 7 can rotate at the same surface speed as the web or rotate faster than web speed. For example, a multiple print repeat printing press having repeat capability of 17, 22, 23 3/4, 23 9/16, 26 1/4 inches, would require a bumper system containing bumper rolls of 26 1/4 inch circumference. Since the press line shaft always rotates the same number of times per print repeat, the bumper roll would be running at surface speeds greater than web speeds; i.e. on one day, the set up might be for a 26 1/4 inch press repeat, whereas, the next job might require a 17-inch press repeat. The bumper roll 7 will pass 26 1/4 inches of travel for 17 inches of web. Therefore, the bumper roll does not "know" at what speed it is running, so long as its speed is equal to or faster than web speed. This is totally different from the conventional printing of adhesives on webs where the web speed and printing cylinder speeds have to be matched to obtain application repeat. It can thus be seen that prior-art changing of cylinders for different repeats is not required for the bumper approach of the present invention.
While the invention has been described with reference to envelope adhesive applications, it is clear that it can also be applied to other uses, including on presses that are producing magazine tabloids and signatures coming off the end of the printing press and subsequently passed into a bindery operation and then saddle-stitched or perfect-bound in book form. Other modifications will also occur to those skilled in this art, and all such are considered to fall within the spirit and scope of the invention as defined in the appended claims. | Novel fluid application processes and apparatus wherein fluid extruded through a nozzle is wiped off the nozzle at various angles of attack by periodically forcing a moving sheet, web, or other article against the nozzle in a controlled manner as the same moves past the nozzle, thus to produce predetermined coatings upon the sheet, web, or other article, ranging from an array of dots and lines to an array of bands or elongated continuous bands of coating fluid. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel and improved support for growing plants in the ground or in potted plants.
2. Prior Art
Horticulturists and gardeners have traditionally used a garden stake to provide support for many types of plants, particularly vines, which are planted in the ground and in containers. One disadvantage of conventional garden stakes is that they do not provide adequate support for the plant because the stake itself is not rigidly fixed in the ground or container so that the conventional garden stake often begins to lean over and is difficult to maintain in an upright position. The conventional garden stakes are particularly likely to lean over from the upright position as the plant grows larger. When the stake leans over from its upright, vertical position in a potted plant, the gardener may attempt to solve the problem by replanting and reinserting the stake.
With the present invention, the novel design of the garden stake provides substantially improved anchor fixing of the garden stake in the soil so that the stake will remain upright even as the plant grows. The garden stake of the present invention provides an improved support so that the garden stake will remain upright and vertical eliminating the need to replant and reinsert the stake. Eliminating the necessity to replant is particularly important when it is aesthetically or physically impractical to replant. If replanting is necessary, the present invention facilitates the removal of the plant by simply pulling out the garden stake. As the root ball is intertwined with the anchor, the plant will be removed with the stake.
SUMMARY OF THE INVENTION
The principal object of the invention has been to provide a versatile, rigid plant support which is simple in design, inexpensive to manufacture, easy to install and easy to use.
Another object of the invention is to provide a rigid attachment to the upright support, improving stability without major disturbance to the surrounding plant life or root system. The radially-expanding feet provide improved mechanical support for the stake or support so that garden stake will remain in an upright position.
Another objective of this invention is to provide a garden stake which may be of varying heights, is simple to use and which requires a minimum of tools to assemble and install.
Another objective of this invention is to provide a device which does not adversely effect or detract from the beauty of the plant being supported.
Another objective of this invention is to provide a device containing no outwardly projecting elements to cause injury or to catch clothing and the like.
By using either metals, plastics or wood products in its construction, the invention satisfies another objective of this invention by using materials which are inert and will not adversely effect plant growth on chemical reaction with the soil.
The garden stake of the present invention includes a support, which may be a cylindrical tube. The support is maintained in an upright vertical position by an anchor. The anchor has legs which expand radially when the anchor is inserted into the ground.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the present invention;
FIG. 2 is a partial axial view of the present invention;
FIG. 3 is a cross-sectional view of the retaining ring of the present invention taken along the line 3--3 shown in FIG. 2;
FIG. 4 is a partial cross-section view of one embodiment of the present invention showing its insertion into the ground;
FIG. 5 is a partial cross-sectional view of another embodiment of the present invention showing its configuration when used to support a potted plant;
FIG. 6 is a partial cross-sectional view of another embodiment of the present invention showing its use with plants growing in the ground;
FIG. 7 is a cross-sectional view of a portion taken along the line 7--7 of FIG. 6;
FIG. 8 is a partial axial view of the present invention;
FIG. 9 is a partial exploded view of the present invention;
FIG. 10 is a cross-sectional axial view Of an embodiment of the present invention;
FIG. 11 is a partial cross-sectional view of an embodiment of the present invention taken along line 11--11 of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1 of the drawings, one preferred embodiment of the garden stake 1 of the present invention is shown. The garden stake includes the support 3 which is connected to the anchor 4. The anchor 4 has legs, 5, 7 and 9 which expand radially outward. The legs are formed with feet 11, 13 and 15. The garden stake 1 is inserted into the ground by exerting downward force on the support 3 which places a downward force on the anchor 4, urging the anchor into the soil. Upon insertion, the legs are flared outward into the soil, serving as an anchor securing the support 3 in an upright position in the soil.
In a preferred embodiment, the feet have pointed ends 12, as shown in FIG. 1, to aid in soil and root penetration. Rounded or blunt-ended feet may also be used.
The anchor 4 may be affixed to the support 3 in a number of different ways. A cylindrical plug 25 is inserted on one end in the bottom 26 of the support 3 and on the other end is connected to the anchor as seen in FIG. 3. In one embodiment shown in FIGS. 1 and 3, the fastener 17 is inserted into plug 25 through the cap 19 and the opening 21 located at the top of the anchor 4 and into the plug 25. The plug 25 may be tapered at both ends to facilitate the assembly of the support 3. Multiple sections of the support may be connected to each other to achieve the various heights of the stake. Referring to FIG. 8, another section 28 is connected to support 3 to increase the height.
The garden stake of the present invention has two separate configurations, one for use with potted plants and a second configuration for use with plants growing in the ground. It has been found that in many instances the bottom of the pot provides sufficient resistance to force the legs outward with the application of a downward force. When downward vertical force is placed on support 3 through the guide 27, the legs 11, 13 and 15 expand radially when they make contact with the bottom of the container 43 in which the plant is growing, as shown in FIG. 5.
When the garden stake of the present invention is inserted into the ground as shown in FIG. 4 for use with plants growing in ground soil, another method is used to cause the feet of anchor 4 to radially expand upon insertion into the ground. Referring to FIG. 6, an elongated fastener or screw 35 and an expansion ring 39 placed inside the legs are utilized to radially expand the feet. The expansion ring 39 forces the legs outward when the apparatus is inserted into the soil to the desired depth. The threads of the screw 35 are received by the of plug 25. As the user pushes down on the support 3 through the guide 27 applying downward vertical force on threaded plug 25, the screw 35 is tightened into the plug 25 thereby causing the ring 39 to move toward the support.
The guide 27 is used to assist in the penetration of the soil by the anchor and to frustrate premature expansion of the legs. The guide 27 is placed around the combination of the support 3 and the anchor 4 prior to insertion into the soil. The guide 27 is placed to constrain the motion of the feet as shown in FIG. 2. The guide 27 is held with one hand while the support 3 is rotated clockwise and pushed downward as shown in FIG. 4. The clockwise motion of support 3 tightens the elongated screw 35 in the plug 25, thereby causing the expansion ring 39 to move toward the support. The expansion ring has an outer diameter greater than that of the anchor such that when the support 3 is rotated, the legs 5, 7, and 9 expand outwardly in a plane substantially perpendicular to the axis of the support 3. Downward force and rotation on the anchor 4 and the elongated screw 35 causes the expansion ring 39 to move upward urging the legs to spread outward, as shown in FIG. 6. When the insertion of the anchor in the soil is completed, the guide 25 is withdrawn upward as the feet expand.
The guide 27 is also used to hold the anchor in place while the support 3 is being turned, tightening the elongated screw 35. The interior portion of the guide 27 is formed with a groove or a track (not shown). In the preferred embodiment, the anchor 4 is formed of a single piece of sheet metal which is rolled into the substantially cylindrical shape shown in FIG. 1. When the sheet metal is rolled, a seam 40 is formed with a small gap between the ends of the sheet metal. The seam 40 is engaged by the track, thereby retaining the anchor while the support is being turned.
The expansion ring 39 is generally circular in shape and may be formed with One Or more tabs 41, 42, and 43 extending outward from its perimeter. The inner surface of the anchor 4 may be serrated as shown in FIG. 7. The tabs engage the grooves 47 to retain the expansion ring in place against the legs of the anchor and to facilitate the desired expansion of the legs. The outer diameter of the expansion plate is approximately equal to or slightly greater than the outer dimension of the anchor. Experimentation indicates these tabs are not necessary if care is exercised in the insertion of the anchor, but the tabs and the grooves do provide improved performance.
After the stake is installed in the soil, the plant may be tied to the support by means of a string, tie-wrap, cord, or other means. Perforations to aid in tying the plant to the stake may be provided in the support 3, as shown in FIG. 1 and as shown in FIG. 8, to hold string and the like.
The anchor 4 may advantageously be integrally formed with the plug 25 as shown in FIGS. 10 and 11, or alternatively, bonded or otherwise affixed to the end 26 of the support. When screw 17 is used to Connect the anchor to the support through the plug 25, the plug may have threaded to engage the threads of the screw 17 or the screw 17 may be self-tapping. When the plug 25 is integrally formed with anchor 4, the plug includes slots for receiving the legs of the anchor as shown in FIG. 11.
The support 3 may also use wire or other stiffening elements to permit the use of such materials which normally return to their initial configuration, such as nylon and plastics. The grooves 47 provide resistance between the legs and the expansion ring 39 which permits the use of flexible materials for the anchor, such as thin metal, plastic, nylon, wood, bamboo, or other materials. Experimentation with bamboo or other wood products, have demonstrated an ability to provide the geometrical and structural needs of this invention could be used. Such materials provide a biodegradable alternative to the plastics and metal embodiments. While the preferred embodiment employs metal stamping or molding, the garden stake of the present invention may also be machined from solid stock.
The support 3 may advantageously be hollow and made from extruded plastic. The support 3 may be a variety of different shapes, including a cylindrical tube as shown in FIG. 1 or hexagonal in cross-section as shown in FIG. 9. | An inexpensive garden stake to provide physical and structural support to growing plant life is disclosed. The invention provides an improved device for providing an anchoring base to the supporting stake which increases the useful life of a garden stake. The anchor has legs which expand upon implantation. The increased support provided by the anchor reduces the need for replanting or disturbing the plant in a significant manner. | 0 |
FIELD OF THE INVENTION
The present invention relates to an implantable apparatus for use treating gastroesophageal acid reflux and particularly to an artificial sphincter for the lower esophageal sphincter.
BACKGROUND OF THE INVENTION
Gastroesophageal reflux disease (GERD) is one of the most common medical illnesses in today's western society. Gastroesophageal reflux occurs when the contents of the stomach, including acids and digestive fluids, leak back past the lower esophageal sphincter into the esophagus. This produces the sensation commonly referred to as “heartburn”. Over prolonged periods, this condition can seriously compromise a person's health. Studies indicate that the incidence of gastroesophageal reflux is on the rise. For example, health care providers use Common Procedural Terminology (“CPT”) codes to report treatment of certain conditions. In 1999, the CPT code for GERD was the most commonly used code from gastroenterologists' offices in the United States, indicating the prevalence of the condition. Incidence of this disease is similarly common in all parts of Europe and probably in any affluent society.
Currently, there are four options available for treatment of gastroesophageal reflux disease. These options are life-style modification, medication, surgery, and endoscopic fundoplication. Life-style modification comprises dietary changes and positioning of body so that, with the help of gravity, upward reflux of food and acid from the stomach is prevented. This treatment is seldom effective alone.
Medication is the most common treatment. Depending upon the degree of severity, a physician may prescribe medications ranging from less potent acid-blockers like Ranitidine (the so-called “Histamine 2 receptor blocker”) to strong acid-production blockers like Prilosec (the Proton pump inhibitors—PPI). The results from treatment by medication are quite satisfactory in the majority of the cases. The problems are the need to take medication for the remainder of the patient's life with its enormous cost, the inconvenience of constantly keeping medicine with the patient, and the long-term concern about strong acid inhibition as a side effect of the medication. There is some data suggesting that atrophic gastritis may develop in some patients as a result of longterm therapy by medication. There is also a phenomenon called acid-rebound after discontinuation of medication. Finally, although medical therapy is effective against acid reflux conditions, it is not effective in controlling so-called “alkaline” or “bile” reflux.
Surgical therapy is currently recommended for the patients whose symptoms are not controlled by medication or for the patients who do not want to take long-term medication. Both traditional surgical procedures and laparoscopic approaches have been tried. Recent literature suggests that there may be significant long-term concerns with regard to the laparoscopic approach. Of course, the patient has to be physically fit to undergo such a procedure. In spite of cost, the difficulty of patient selection and the invasiveness involved, approximately 80,000 of these procedures were performed in the United States in 1999.
Endoscopic fundoplication is a very recent procedure done by the gastroenterologists. It consists of securing a suture in a purse-string-like configuration to the part lower part of the esophagus or upper part of the stomach, which basically creates an additional mechanical barrier to the contents of reflux from the stomach to esophagus. The data is very preliminary on this procedure and very few gastroenterologists are trained to perform it. Even in the best case, there are significant limitations to the procedure and some patients with large hiatus hernia will not qualify for this.
SUMMARY OF THE INVENTION
Despite multiple treatment options, treatment of GERD still needs improvement in long-term, low-cost treatment. Therefore, there is room for improvement in this area. I plan to accomplish this by an implantable esophageal sphincter apparatus, described below.
The apparatus comprises an adjustable band or sphincter body to be placed at the lower part of esophagus, most of the time over or around the Lower Esophageal Sphincter (LES) or around the very first part of stomach adjoining the esophagus. The internal inflation of the band can be increased or decreased to some extent, which in turn will adjust the tightness of the device. This will meet the need for some patients who might find it easier to swallow with a loose band and subsequently make it tighter to prevent reflux. The device will be of human-grade implantable material. The device will enhance the normal tone or pressure of the LES that naturally exists in the competent LES. In many cases, this natural tone is lost or these patients have more frequent LES relaxation than normal. This leads to chronic GERD. Placement of the esophageal band will prevent these phenomena from occurring and thereby prevent GERD. In short, this will mimic the normal human physiology by a mechanical means. This will promote the natural pressure barrier between the esophagus and stomach that naturally exists in normal physiologic state. The end result will be prevention of reflux and thereby GERD.
The apparatus will be implanted in a single surgical procedure. Most of the time, it could be placed by laparoscopic methods, which will minimize the invasiveness of the surgery and will lessen the duration of hospitalization. In some situations, a traditional open surgical method may be required. After gaining access in the abdominal or thoracic cavity either by laparoscopic or open surgical technique, the surgeon will isolate the area of the lower esophageal sphincter and the esophago-gastric junction (EGJ). During this procedure, an endoscope or a bougie of a satisfactory diameter placed per orally will give both guidance to the degree of tightness and protection to the esophagus. An inflatable sphincter body may be wrapped around the esophagus and may be connected to an inflation device with a fluid reservoir. The inflation device and reservoir may be implanted underneath the skin of the anterior chest wall or of the abdominal wall during the same surgical procedure with the sphincter body. The inflation device may have a pump mechanism that will respond to external control to increase or decrease the inflation of the sphincter body that, in turn, will either increase or decrease the tightness of the area upon which the sphincter body is placed (usually at the lower esophageal sphincter). The sphincter body may be held in place at the area of implantation by sutures and by fenestration mechanisms, which will allow ingrowths of tissue or fibrous elements of the body around the sphincter body or into porous materials on the sphincter body. After placement of the full device, the physician or surgeon will activate the pump mechanism and test the response of the mechanism before final closure.
The apparatus may also include a circumferential shield on a distal side of the sphincter body. The shield is adapted to fit against the distal or lower side of the patient's diaphragm and inhibits the development or re-occurrence of a hiatus hernia, that is, a protrusion of the stomach past the diaphragm through the passage for the esophagus. The apparatus, therefore, also provides a treatment for hiatus hernias.
A patient would undergo normal pre-surgical evaluation to determine suitability as a surgical candidate. Both gastroenterologists and surgeons with appropriate interests and competency in reflux treatment procedures should usually be consulted. Tests may include upper gastrointestinal endoscopy, and 24-hour pH and motility testing. These tests would provide objective evidence of GERD in the patient involved, including evidence of severity of damage, anatomic integrity of the organs involved, associated co-existing diseases that can effect patient's outcome and the extent and severity of reflux itself. In addition, certain radiological testing to image the upper gastrointestinal organs may also be an integral part of this evaluation.
After implantation of the apparatus, a physical examination of the patient may be conducted to reevaluate signs and symptoms as they pertain to the patient's pre-surgical and post-surgical outcome. If appropriate, endoscopy, 24-hour pH and motility studies may also be included in the post-surgical testing. Certain radiological testing, such as a CT scan, or upper gastrointestinal radiology, may be included.
It is an object of my invention, therefore, to provide an apparatus for the treatment of gastroesophageal reflux disease. Another object of my invention is to provide an apparatus having a prosthetic sphincter body for placement at or near the lower esophageal sphincter.
Yet another object of my invention is to provide a sphincter body that is inflatable to predetermined size.
Another object of my invention is to provide an artificial sphincter body that cannot be closed beyond a predetermined minimum orifice size. A further object of my invention is to provide control mechanisms for controlling the size of the sphincter body.
Another object of my invention is to provide an artificial sphincter body for the esophagus with a gap or opening to allow the sphincter body to be placed around the esophagus.
It is also an object of my invention to provide an implantable prosthetic sphincter having a shield to prevent development or re-occurrence of hiatus hernias of the stomach through the diaphragm.
These and other features and advantages of the present invention will be apparent to one skilled in the art from the following detailed description, connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representation of a patient with a prosthetic sphincter apparatus according to my invention implanted near the lower esophageal sphincter of the patient.
FIG. 2 is a perspective view of an implantable prosthetic sphincter apparatus according to the present invention.
FIG. 3 is a top plan view of the prosthetic sphincter apparatus of FIG. 2 .
FIG. 4 is a block diagram of a control mechanism for use with the apparatus of the present invention.
FIG. 5 is a perspective view of a manual pump for use with the present invention.
FIG. 6 is a through section view of the manual pump of FIG. 5 .
FIG. 7 is a perspective view of an implantable esophageal sphincter body with diaphragm shield.
DETAILED DESCRIPTION
I will now describe my invention with reference to the accompanying drawings, wherein like numerals are used to describe like parts in the various views. FIG. 1 illustrates an implantable esophageal sphincter apparatus 10 in a patient 12 . The apparatus 10 comprises a toroidal sphincter body 14 that is placed around the esophagus 16 of the patient 12 adjacent the lower esophageal sphincter 18 . The sphincter body 14 would usually be implanted above the patient's stomach 20 and preferably immediately above the diaphragm 22 . The diaphragm is a domed, muscular layer of tissue separating the abdomen and the thorax. A tube 24 connects the sphincter body 14 to a control apparatus 26 that regulates the size of the sphincter body 14 , as explained hereafter.
The sphincter body 14 comprises a generally toroidal inflatable bladder 28 having an inner wall 30 and an outer wall 32 . Preferably, the bladder 28 also has a first end 34 and a second end 36 forming a gap 38 . Viewed from above, as in FIG. 3, the sphincter body forms a “C”, a structure that allows the sphincter body 14 to be placed around the esophagus 16 by passing the esophagus through the gap 38 . A clasp 40 on the outer wall 32 near the first end 34 connects to an anchor 42 on the outer wall 32 near the second end 36 , allowing the two ends to be tied together after the sphincter body 14 has been placed around the patient's esophagus. The clasp and anchor may take any suitable form. For example, the clasp 40 may be a pre-threaded suture 44 with attached needle 46 having a distal end permanently attached to the sphincter body, as illustrated in FIG. 2, and the anchor 42 may be a sewing tab 48 . Alternatively, sewing tabs could be provided on both the first and second ends and an ordinary prethreaded suture could be threaded through both tabs to hold the ends together. Another type of clasp 40 is shown in FIG. 3 . The clasp 40 may comprise a strip 50 of hook-and-eye fastener, and the anchor 42 may be a mating piece 52 of hook-and-eye material. A third embodiment of a clasp 40 , as shown in FIG. 7, may comprise an elastomeric filament 54 having teeth along one side. The filament 54 engages a receptacle 56 having an opening 58 with a spring latch for connecting with the teeth, in the manner of a cable tie. After the gap is closed, excess length of the male filament could be trimmed away. Other specific forms for the clasp and anchor will suggest themselves to one of skill in the art.
When the sphincter body 14 has been placed around the esophagus, it is desirable to control the size of a central opening 60 through the sphincter body 14 . The inflatable bladder tends to expand radially when filled with fluid. An inextensible outer surface 62 adjacent the outer wall 32 of the bladder 28 constrains the bladder so that the central opening 60 becomes smaller rather than larger as the bladder is filled. The surface 62 may be an inextensible polymeric substance such as polyamide. It may also be a rigid structure of, for example, titanium, Elgiloy (trademark) steel, or other implantable material.
The lower esophageal sphincter allows food to pass from the esophagus into the stomach, but prevents acidic stomach contents from entering and damaging the esophagus. This can be accomplished without completely closing the sphincter. Thus, if the sphincter body 14 can restore some of the effectiveness of the sphincter by partially closing the sphincter. Food can still pass into the stomach, but either acid or bilious reflux is minimized or eliminated, without continually adjusting the sphincter body. It is important, therefore, that the sphincter body close only to a predetermined minimum diameter. A relatively inextensible, flexible skin 64 adjacent the inner wall of the bladder 28 and connected to the inextensible outer surface, prevents the sphincter body from closing completely, and preferably from completely closing the lower esophageal sphincter within the sphincter body 28 . Preferably, the minimum inside diameter of the esophagus should be not less than about 45 French (15 mm), and more preferably not less than about 54 French (18 mm). Such an opening will allow food to be swallowed, yet inhibit either acid or bilious reflux. The wall of the esophagus is usually between 2 mm or 3 mm thick. The central opening 60 of the sphincter body should be not less than about 57 French (19 mm), or more preferably not less than about 66 French (22 mm). In some patients, the benefits may be obtained with a larger central opening, allowing larger portions of food to be swallowed comfortably. Less inflation of the bladder produces a larger central opening.
The control apparatus 26 regulates the amount of a fluid, such as normal saline solution, that fills the sphincter body 14 . Although the control apparatus 26 may adjoin the sphincter body 14 , it is preferable that the control apparatus be spaced away from the sphincter body in a more accessible area of the body. A tube 24 with at least one lumen for carrying fluid to and from the sphincter body 14 connects the sphincter body and the control apparatus. A control apparatus illustrated in FIG. 2 comprises an implantable chamber 66 having a fluid container 68 with a pierceable septum 70 . The tube 24 communicates with the fluid container 68 through a nipple 72 . The chamber 66 is implanted beneath the patient's skin and is accessible by a needle inserted through the skin and septum 70 . Fluid can be inserted into or withdrawn from the chamber 66 with a syringe. The fluid will, in turn, inflate or deflate the bladder in the sphincter body, thereby enlarging or decreasing the size of the central opening 60 .
The control apparatus 26 may also be an implantable electrically controlled pump 74 , illustrated in block diagram in FIG. 4 . The electrically controlled pump 74 comprises a bi-directional fluid pump 76 connected to a battery power supply 78 , a fluid reservoir 80 , and the tube 24 leading to the sphincter body. A receiver-controller 82 receives instructions transmitted from an external control device 84 and causes the pump 76 to move fluid into or out of the sphincter body. An electrical conductor 86 connects the controller 82 to a sensor 88 , such as a strain gauge or a pressure sensor, mounted on the sphincter body 14 (FIG. 3 ). In response to detected changes, the electrically controlled pump 74 may decrease or increase the central opening 60 . The sensors 88 could also detect whether the increased pressure is on the upper (or esophageal) side of the sphincter body or on the lower (or stomach) side, and respond accordingly. For example, increased pressure on the upper side may indicate that the patient is attempting to swallow, and the central opening may need to be enlarged. Increased pressure on the lower side may indicate an increased chance for either acid or bilious reflux, and the central opening may need to be reduced. The receiver 82 , fluid reservoir 80 , pump 76 and battery 78 should all be enclosed in a case 90 which is impervious to body fluids. Suitable titanium cases are well known from other types of implantable medical devices, for example, implantable pacemakers.
A third example of a control apparatus 26 is shown in FIGS. 5 and 6. The apparatus is a manually controlled pump 92 . The manually controlled pump 92 has a case 94 with a deflectable diaphragm 96 and a reversible valve 98 . The reversible valve 98 communicates with the tube 24 . As seen best in FIG. 6, the manually controlled pump 92 has a chamber 100 inside the case 94 . A collapsible bag 102 in the chamber contains a supply of fluid. The bag communicates with a pumping chamber 104 under the deflectable diaphragm 96 through a one-way valve 106 in a partition 108 . The partition 108 separates the chamber 100 and collapsible bag 102 from the pumping chamber 104 . The manually controlled pump 92 is implanted beneath the skin of the patient so that the patient can press on the diaphragm 96 and force fluid through a second one-way valve 110 into the tube connected to the sphincter body. This action will fill and expand the sphincter body, decreasing the size of the central opening, and closing the esophagus. To reverse the flow and open the sphincter body, the patient would place a magnet over the manually controlled pump 92 . The magnet displaces a metallic dam 112 from a normal position covering a third one-way valve 114 to a temporary position blocking the second one-way valve 110 . A small leaf spring 116 holds the metallic dam 112 in its normal position, but it is not strong enough to resist the magnetic attraction applied to the metallic dam 112 . With the third valve 114 exposed, fluid flows back into the bag 102 , driven by the elastic bladder in the sphincter body. The patient is thereby able to adjust the opening in the sphincter body within the limits imposed by the inextensible outer surface 62 and the inextensible, flexible skin 64 .
The esophagus passes through a “hiatus”, or opening, in the diaphragm before reaching the stomach. As a consequence either of the physical debilities attending acid reflux disease or of the surgery recommended to treat the disease, the esophageal hiatus may become enlarged and a hiatus hernia may develop. A hiatus hernia is a protrusion of the stomach upward into the mediastinal cavity through the esophageal hiatus of the diaphragm. To correct or to avoid the development of this condition, a shield 118 may be provided on the sphincter body 14 . The shield 118 comprises a generally circular sheet 120 of biologically compatible material attached to a distal side 122 of the sphincter body 14 . Suitable materials may be knitted or woven Dacron (trademark) cloth or Gore-Tex (trademark) material. The sheet 120 has an opening 124 corresponding to the central opening 60 of the sphincter body 14 . A slot 126 extends through the sheet 120 from the gap 38 in the sphincter body 14 to an outer edge 128 of the sheet 120 . Additional slots may be provided to allow the sheet to conform to the concave underside of the diaphragm, or the sheet may be shaped to approximate the expected shape of the diaphragm.
An interior region 130 of the sheet adjacent the sphincter body 14 and extending a selected distance radially outward from the sphincter body 14 is relatively stiff and provides a barrier at the esophageal hiatus. An outer region 132 between the inner region 130 and the outer edge 128 is more flexible and may be adapted to encourage tissue growth into the material of the outer region. This would tend to anchor the shield 118 to the diaphragm. The shield may also the sutured to the diaphragm, particularly posteriorly near the crura of the diaphragm, that is, to the tissues connecting the diaphragm to the back. A notch 134 may be provided in the right anterior part of the outer region 130 so that the shield would not be in contact with the lower vena cava. Similarly a second notch 136 at the anterior side of the shield so that the shield would not be in contact with the descending aorta. The tube 24 should be connected to the distal side 122 of the sphincter body 14 and extend through the shield 118 . To implant the apparatus, the sphincter body 14 would preferably be pushed through the diaphragm like a plug, thereby bringing the shield 118 to rest adjacent the distal, or bottom, side of the diaphragm. The tube 14 and control apparatus 26 would be implanted in the abdominal cavity.
Although I have now described my invention in connection with my preferred embodiment, those skilled in the art will recognize that my invention may take other forms without departing from the spirit or teachings thereof. The foregoing description is intended, therefore, to be illustrative and not restrictive, and the scope of my invention is to be defined by the following claims . | An implantable esophageal sphincter apparatus with an adjustable band to be placed at the lower part of the esophagus. The inflation of the band, or sphincter body, can be increased or decreased to adjust the tightness of the device. The inflatable sphincter body may be wrapped around the esophagus and may be connected to an inflation device with a fluid reservoir. The inflation device may have a pump mechanism that will respond to external control to increase or decrease the inflation of the sphincter body. The sphincter apparatus will be held in place at the area of implantation by sutures and by fenestration mechanisms, which will allow ingrowths of tissue or fibrous elements of the body around the sphincter apparatus or into porous materials on the sphincter apparatus. The apparatus may also include a circumferential shield on a distal side of the sphincter apparatus. The shield is adapted to fit against the distal or lower side of the patient's diaphragm and inhibits the development of a hiatus hernia, that is, a protrusion of the stomach past the diaphragm through the passage for the esophagus. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of processes for the synthesis of steroids, and in particular to a process for the preparation of drospirenone on an industrial scale.
STATE OF THE ART
[0002] The compound of formula (I) below, the chemical name of which is 6β,7β; 15β,16β-dimethylene-3-oxo-17α-pregn-4-ene-21,17-carbolactone, is commonly indicated by the name drospirenone:
[0000]
[0003] Drospirenone is a synthetic steroid with progestogenic, antimineralocorticoid and antiandrogenic action; thanks to these characteristics, it has been used for some time in the preparation of pharmaceutical compositions with contraceptive action for oral administration.
[0004] Various processes for the preparation of drospirenone are known in literature. The process described in European patent EP 075189 B1 obtains the end product drospirenone by hot oxidation of 17α-(3-hydroxypropyl)-6β,7β; 15β,16β-dimethylene-5β-androstane-3β,5,17β-triol with the mixture pyridine/water/chromic anhydride. This step constitutes a substantial drawback of the process: indeed, chromic anhydride, like all Cr(VI) compounds, is a proven carcinogen, the use of which is subject to legislative restrictions such that the precautions required during its use and disposal make it virtually unusable.
[0005] Another process for the preparation of drospirenone is described in European patent EP 918791 B8; in the process of this document the drospirenone is obtained, again starting from 17α-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5β-androstane-3β,5,17β-triol, in two distinct phases and employing an oxidant such as for example potassium bromate in the presence of ruthenium salts as catalysts, which necessarily must then be completely eliminated from the product. European patent EP 1828222 B1 describes a further process, wherein the oxidation step is accomplished by using calcium hypochlorite as oxidant in the presence of 2,2,6,6-tetramethylpiperidine-1-oxyl radical or a derivative thereof as a catalyst; in the process of this patent the oxidant is added in portions until completion of the reaction. This process overcomes the disadvantages of the prior art since the calcium hypochlorite is not a carcinogenic reagent, nor is 2,2,6,6-tetramethylpiperidine-1-oxyl radical a metal catalyst that imposes a purification of the end product; however, the need for subsequent additions of reagent and the analytical controls in the course of reaction, however simple, are a hindrance to a standardized production that must proceed continuously or nearly so. Consequently, the method of this patent too has process drawbacks from the point of view of an industrial production.
[0006] There is therefore still a need to have a simple process that allows the drawbacks of the prior art to be overcome.
[0007] Object of the present invention is thus to provide an industrial process that allows the preparation of drospirenone while avoiding the use of reagents that are hazardous or the use of which is in any case restricted by industry regulations, and minimizing operator interventions during the process itself.
SUMMARY OF THE INVENTION
[0008] This object is achieved with the present invention, which relates to a process for the production of drospirenone comprising the reaction of the compound 17α-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5β-androstane-3β,5,17β-triol with gaseous oxygen in the presence of catalytic amounts of 2,2,6,6-tetramethylpiperidine-1-oxyl radical (or a derivative thereof), a ferric salt and sodium chloride, in a solvent consisting of acetic acid or a mixture of an acid and at least one organic solvent, at a temperature of between 30 and 50° C. The definition “catalytic amounts” means a molar non-stoichiometric amount of reagent, i.e. below the theoretical stoichiometric amount needed if the compound were the primary oxidant of the reaction.
[0009] In the reaction, the compound 17α-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5β-androstane-3β,5,17β-triol, having the formula (II) below, can be in a mixture with one or both its lactols, as described in example 6 of the cited patent EP 1828222 B1. The reaction scheme (reaction scheme 1) is as follows, wherein the lactols are shown in parentheses to indicate that they may or may not be present, and the symbol in the lactols formula indicates that the —OH group can be located either above or below the plane of the molecule (thus, respectively, in β or α configuration):
[0000]
[0010] The solvent consists of pure acetic acid, or of acetic acid or another acid in a mixture with one or more organic solvents.
[0011] Said reaction allows drospirenone to be obtained directly, in a single process step, thus eliminating the need for subsequent additions of other reagents such as for example a protic acid or a base in intermediate reaction steps to complete the conversion.
[0012] Characteristics and advantages of the present process are illustrated in detail in the following description.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The Applicant has developed a new, extremely simple process, which allows drospirenone to be obtained using oxygen in the presence of a catalytic system consisting of 2,2,6,6-tetramethylpiperidine-1-oxyl radical or a derivative thereof, a ferric salt (i.e. in which iron is in the oxidation state (III)) and sodium chloride, and in a solvent consisting of, or comprising, an acid.
[0014] The compound 2,2,6,6-tetramethylpiperidine-1-oxyl radical is known in the field with the abbreviation TEMPO, which will be used hereinafter
[0015] The oxidation of alcohols with TEMPO, ferric nitrate and sodium chloride was recently described in the article “Development of a general and practical iron nitrate/TEMPO-catalysed aerobic oxidation of alcohols to aldehydes/ketones: catalysis with table salt” published in Adv. Synth. Catal. 2011, 353, 1005-1017. From reading this article, however, an expert in steroid chemistry would not have been directed to apply what is described in the reaction of the present invention. In the article abstract, the authors clearly state that the oxidations of simple alcohols (alkyl- and phenyl-carbinols and allyl alcohols) with oxygen are well known while the object of the article is to provide an oxidation method for allenols and propargyl alcohols.
[0016] No reference is made to complex molecules such as steroids or to the possibility of obtaining transformations other than an oxidation from alcohol into aldehyde or ketone.
[0017] The described oxidation, in 1,2-dichloroethane as preferred solvent, serves for selectively obtaining ketones and/or aldehydes from alcohols. No example is described for the obtaining of an acid from an alcohol or of a lactone from a lactol, transformations which on the other hand are necessary for obtaining drospirenone. 1,2-dichloroethane, used at room temperature, is the preferred solvent indicated in the article, as clearly stated on page 1011, paragraph “Typical procedures for the synthesis of aldehydes or ketones” of the article.
[0018] From reading the article, a person skilled in the art would not have learned the indication of using an acid as reaction solvent, alone or in combination with an organic solvent, at a temperature of between 30 and 50° C.
[0019] The reactions involved in the transformation from (II) (and possibly lactols) into (I) of scheme 1 are manifold and comprise the formation of a double bond by elimination of water and the ex-novo formation of a lactone ring; in particular, oxidation, cyclization and dehydration reactions are necessary in said , transformation; these reactions are illustrated in the diagram below, in the top two lines of which there are indicated the transformations taking place at the carbon in position 17 of the steroid skeleton (in case the reagent is a lactol, the transformation consists only of the last step indicated in the top line), while in the bottom line there are indicated the transformations taking place at the ring A (as per IUPAC nomenclature) of the steroid skeleton:
[0000]
[0020] In contrast to what is described in European patent EP 1828222 B1 and in EP 918791 B8, in the present invention all the reagents are loaded into the reaction vessel in a single addition, without the need for further interventions in the course of the reaction, and all the above-indicated reactions occur in the course of a single process step.
[0021] The oxidation substrate of the present process, i.e. 17α-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5f3-androstane-3β,5,17β(3-triol (or a mixture thereof with the corresponding lactols) can be obtained starting from commercial products by means of procedures known to a person skilled in the art. Preferably, said compound is obtained according to the procedure described in steps a) to f) of patent EP 1828222 B1.
[0022] Gaseous oxygen can be supplied into the reaction vessel as pure oxygen, air, or a synthetic mixture of oxygen with an inert gas (for example, the so-called synthetic air, widely used in the medical field); oxygen, in any one of these forms, can be used in static conditions, i.e. in a closed vessel containing a gaseous atmosphere consisting of or containing oxygen, or in conditions of slight flow of the same gaseous atmosphere.
[0023] As mentioned, as first component of the catalytic system it is possible to use the compound known as TEMPO or derivatives thereof; the TEMPO derivatives of possible use are 4-hydroxy-2,2,6,6-tetramethylpiperidine-1-oxyl radical, 4-methoxy-2,2,6 ,6-tetramethyl piperidine-1-oxyl radical, 4-(benzoyloxy)-2,2,6,6-tetramethylpiperidine-1-oxyl radical, 4-acetamido-2,2,6,6-tetramethylpiperidine-1-oxyl radical and 4-amino-2,2,6,6-tetramethylpiperidine-1-oxyl radical. This component is used in an amount of between 15 and 25% in moles, preferably 20% in moles, with respect to the reaction substrate.
[0024] The TEMPO catalyst or the derivatives thereof are added in a single portion at the start of the reaction and are not affected by the acid reaction environment. The second component of the catalytic system is a ferric salt such as, for example, ferric nitrate nonahydrate Fe(NO 3 ) 3 .9H 2 O, which is added as fine powder in an amount of between 15 and 25% in moles, preferably 20% in moles, with respect to the reaction substrate.
[0025] The third component of the catalytic system is sodium chloride, which is added as fine powder in an amount of between 15 and 25% in moles, preferably 20% in moles, with respect to the substrate to be oxidized.
[0026] Acetic acid can be used as solvent for the reaction, either alone or in a mixture with an organic solvent; the solvent must clearly be inert under the reaction conditions, and can be selected from ethyl ether, diisopropyl ether, methyl t-butyl ether, tetrahydrofuran, methyltetrahydrofuran, ethyl acetate, isopropyl acetate, butyl acetate, heptane, hexane, cyclohexane, toluene, xylene, methylene chloride, 1,1-dichioroethane, 1,1,2-trichloroethane, acetone, methyl ethyl ketone, methyl isobutyl ketone, acetonitrile, dimethylformamide, dimethylacetamide, dimethylsulphoxide, chlorobenzene or mixtures thereof.
[0027] Alternatively, in the case in which acetic acid is not used, the reaction solvent consists of one of the above-mentioned organic solvents, or a mixture thereof, to which there is added an acid selected from oxalic acid, citric acid, para toluene sulphonic acid, formic acid, sulphuric acid, perchloric acid, hydrochloric acid, phosphoric acid, nitric acid, hydrobromic acid, fumaric acid, maleic acid, xinafoic acid (1-hydroxy-2-naphthoic acid), benzoic acid and substitution derivatives thereof on the aromatic ring, or bisulfites of alkali metals or alkaline-earth metals. The protic acids mentioned can be used in anhydrous form or in any known hydrated forms (for example, in the case of oxalic and para toluene sulphonic acids, commonly available commercially in the form of the monohydrates thereof), or in the form of aqueous solutions (for example in the case of hydrochloric acid, commonly available commercially as an aqueous solution at the maximum stable concentration, of about 37% by weight, or at a concentration equal to about 18% by weight, or nitric acid).
[0028] Preferred solvents for the reaction are pure acetic acid (known in chemistry as “glacial”) and mixtures of one or more of the above-mentioned organic solvents and an acid selected from acetic acid, citric acid or potassium bisulfite monohydrate.
[0029] The oxidation reaction can be carried out at a temperature of between 30 and 50° C., and preferably of between 30 and 40° C., for a time of between 2 and 24 hours, preferably of between 6 and 20 hours.
[0030] The crude drospirenone obtained with the present process is purifiable with techniques known to persons skilled in the art and described in publications and patents; for example, purification can be achieved by crystallization from isopropyl acetate, as described in patent EP 1828222 B1. The inventors have found that the yields of drospirenone the process vary between about 60 and 85%.
[0031] The invention will be further illustrated by the following examples, which are provided by way of an illustrative and non-limiting example of the present invention. The reagents used in the examples are commonly available commercially and are used without the need for preventive purifications. All concentrations are expressed as weight percentages unless otherwise specified.
EXAMPLE 1
[0032] Into a 100 ml flask is loaded 1 g of 17α-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5β-androstane-3β,5,17β-triol (II) into 3 ml of glacial acetic acid. 200 mg of ferric nitrate nonahydrate, 78 mg of TEMPO and 29 mg of sodium chloride are added.
[0033] The reagent mixture is stirred at 35° C. for 16 hours in an atmosphere of pure oxygen. The progress of the reaction is monitored by TLC from which there is found the disappearance of the starting product (II) and the formation of drospirenone (I) (by comparison against samples of the pure compounds obtained by methods known in the field).
[0034] At the end of the reaction the reaction mixture is poured into 12 ml of water, it is extracted with ethyl acetate thus obtaining, after evaporation of the solvent, 1.05 g of residue.
[0035] By means of HPLC analysis (European Ph method) the previous TLC findings are confirmed: intermediate (II) absent, drospirenone (I) present. The crude product, crystallized from isopropyl acetate as per a method known in literature, provides a product of pharmaceutical quality.
EXAMPLE 2
[0036] In a 100 ml flask are loaded 5 g of 17α-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5β-androstane-3β,5,17βp-triol (II) into 30 ml of methylene chloride. 1 g of ferric nitrate nonahydrate, 400 mg of TEMPO and 150 mg of sodium chloride and 250 mg of citric acid are added.
[0037] The reagent mixture is stirred at 35° C. for 20 hours in an atmosphere of pure oxygen. The progress of the reaction is monitored by TLC from which there is found the disappearance of the starting product (II) and the formation of drospirenone (I) (by comparison against samples of the pure compounds obtained by methods known in the field).
[0038] At the end of the reaction the reaction mixture is poured into 30 ml of water, the phases are separated and the organic phase is washed with basic solution (NaHCO 3 ).
[0039] After evaporation of the solvent 5.2 g of raw product are obtained.
[0040] By means of HPLC analysis (European Ph method) the previous TLC findings are confirmed: intermediate (II) absent, drospirenone (I) present. The crude product, crystallized from isopropyl acetate as per a method known in literature, provides a product of pharmaceutical quality.
EXAMPLE 3
[0041] Into a 2 litre flask are loaded 23.3 g of ferric nitrate nonahydrate, 12.2 g of TEMPO, 4.5 g of sodium chloride, 750 ml of isopropyl acetate, 7.5 g of citric acid and 150 g of 170c-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5β-androstane-3β,5,17β-triol (II).
[0042] The mixture is stirred at 35° C. in an atmosphere of pure oxygen. The progress of the reaction is monitored after 18 hours by TLC from which there is found the disappearance of the starting product (II) and the formation of drospirenone (I) as main stain (comparison against an authentic sample).
[0043] The reaction mixture is washed with 250 ml of basic aqueous solution (NaHCO 3 ) and then with 250 ml of water.
[0044] The solvent is eliminated under reduced pressure thus obtaining 170 g of residue. After crystallization with isopropyl acetate and dessication of the filtrate solid, there are obtained 104 g of drospirenone (I) of pharmaceutical quality.
EXAMPLE 4
[0045] Into a 100 ml flask are loaded 5 g of 17a-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5β-androstane-3β,5,17β-triol (II) in 25 ml of butyl acetate. 775 mg of ferric nitrate nonahydrate, 400 mg of TEMPO, 150 mg of sodium chloride and 250 mg of citric acid are added.
[0046] The reagent mixture is stirred at 35° C. for 20 hours in an atmosphere of pure oxygen. The progress of the reaction is monitored by TLC from which there is found the disappearance of the starting product (II) and the formation of drospirenone (I) (by comparison against samples of the pure compounds obtained by methods known in the field).
[0047] At the end of the reaction the reaction mixture is poured into 30 ml of water, the phases are separated and the organic phase is washed with basic solution (NaHCO 3 ).
[0048] After evaporation of the solvent 5.12 g of raw product are obtained.
[0049] By means of HPLC analysis (European Ph method) the previous TLC findings are confirmed: intermediate (II) absent, drospirenone (I) present. The crude product, crystallized from isopropyl acetate as per a method known in literature, provides a product of pharmaceutical quality.
EXAMPLE 5
[0050] Into a 100 ml flask are loaded 5 g of 17α-(3-hydroxypropyl)-6β,7β;15β,16β-dimethylene-5β-androstane-3β,5,17β-triol (II) into 25 ml of chlorobenzene-isopropyl acetate 80/20.
[0051] There are added 770 g of ferric nitrate nonahydrate, 400 mg of TEMPO, 150 mg of sodium chloride and 250 mg of citric acid.
[0052] The reagent mixture is stirred while bringing the temperature from the initial value of 30° C. to 45° C. over a period of 20 hours in pure oxygen atmosphere.
[0053] The progress of the reaction is monitored by TLC from which there is found the disappearance of the starting product (II) and the formation of drospirenone (I) (by comparison against samples of the pure compounds obtained by methods known in the field).
[0054] At the end of the reaction the reaction mixture is poured into 30 ml of water, the phases are separated and the organic phase is washed with basic solution (NaHCO 3 ) and then with water.
[0055] After evaporation of the solvent 5.05 g of raw product are obtained.
[0056] By means of HPLC analysis (European Ph method) the previous TLC findings are confirmed: intermediate (II) absent, drospirenone (I) present. The crude product, crystallized from isopropyl acetate as per a method known in literature, provides a product of pharmaceutical quality. | A process is described wherein, by employing 17α-(3-hydroxypropyl) -63,7β3;15β,16β-dimethylene-5β-androstane-3β,5,17β-triol (II) as starting product, in a single stage reaction there is obtained drospirenone, (I), whereby the reaction is achieved using gaseous oxygen as the stoichiometric oxidant in the presence of a catalytic system containing (i) TEMPO or a derivative thereof (ii) a ferric salt (Fe3+) and (iii) NaCl. The product drospirenone is a known synthetic steroid with progestogenic, antimineralocorticoid and antiandrogenic action, that is useful for preparing pharmaceutical compositions with contraceptive action. | 2 |
BACKGROUND OF THE INVENTION
This invention generally relates to front end loaders and especially to mounting systems by which front end loaders are secured to tractors or other suitable equipment. More particularly, the invention relates to front end loaders of the type which are designed to be mounted well into the length the tractor or other motive equipment. These are so-called mid-mount front end loaders, which typically mount at a location to the rear of the front wheels of the equipment. The front end loader has a latch assembly which mates with a mounting bracket assembly secured to the tractor, motive equipment or the like. Securement components are provided which attach the latch assembly and thus the front end loader to the mounting bracket assembly and thus the tractor and the like. Certain of the securement components are assigned respective storage positions when the front end loader is not in use and not secured to the tractor or the like. These attachment components quickly and easily are reoriented and used to securely attach the front end loader to the tractor or the like. This can be accomplished without requiring separate tools to work the transformation between the storage position and the working position of the loader.
Agricultural tractors and other motive type equipment are at times used to perform so-called front end loading tasks which typically involve moving or lifting bulk, heavy and/or oddly shaped items, as well as tasks such as clearing access areas, roads and the like of debris, snow or other obstacles. Typically, it is preferred to avoid having to dedicate a tractor and the like to only front end loader uses. When used herein, the terms tractor or tractor and the like are used to denote equipment which will accept and provide mobility and operability to a front end loader.
It is accordingly important that loader attachments be rapidly and readily connected and disconnected to the tractor which is to provide the operational power and transport capabilities to the front end loader. In this way, the tractor can be used for functions other than front end loading during a portion of the day (or other time period) and for front end loading tasks at other times. It is therefore beneficial for a front end loader to be easily attached and detached from the tractor, vehicle or other suitable equipment.
Loaders with quick or rapid coupling features are generally known. These devices are not always capable of withstanding heavy use and rough handling. Another disadvantage which is encountered for some of these units is the need to use separate tools during the assembly and disassembly operations, which tools are not a part of the loader system. For some prior loader systems, all components are not readily stored on the units themselves when not attached to the tractor and the like.
Front end loaders come in various different sizes and styles, often necessitating quick attachment assemblies which are especially designed in order to accommodate a particular loader make and model. This requires the manufacturing of a variety of assemblies intended for the same purpose but having different size or shape requirements. Such necessitates the manufacture of different assemblies for performing the same function but for different loader makes and models, creating inefficiencies in the use of manufacturing facilities, time, labor and materials.
Accordingly, there is a need for a front end loader mounting system which allows for a mid-mount front end loader to be attached and detached in a matter of minutes. Such an assembly should also be self-contained, very durable, and not require specific tools to effect the attachment and detachment of the loader. It also would be advantageous to have this type of loader attachment system require a minimum of parts which are specifically designed and made for a particular loader type, size or model.
SUMMARY OF THE INVENTION
In accordance with the present invention, a mounting system is provided for a mid-mount front end loader. The system includes a universal mounting bracket assembly for securing to a mid-mount location of a tractor or other piece of motive equipment, which universal mounting bracket assembly accepts a latch assembly of any number of a variety of front end loader models and sizes. When attached, pedestal pins from the latch assembly rest within respective pedestals of the mounting bracket assembly, and a clamp component secures the latch assembly and thus the front end loader to the universal mounting bracket assembly and thus the motive equipment. Securement components lock the clamp in place in order to maintain its clamping function so that the latch assembly and mounting bracket assembly remain firmly secured together, even during rugged operation of the front end loader.
It is accordingly a general object of the present invention to provide an improved mounting system for front end loaders, front end loaders employing such a system, and a procedure for rapidly and easily engaging and disengaging the front end loader from a motive piece of equipment such as a tractor.
Another object of this invention is to provide an improved mounting system for mid-mount front end loaders, as well as procedures for attaching and detaching the front end loaders from motive equipment, which system and procedures incorporate a universal mounting bracket assembly to thereby reduce the number of components which must be manufactured, assembled and warehoused.
Another object of the present invention is to provide an improved front end loader mounting system and procedure which allow for mounting and dismounting easily within reasonable manufacturing tolerances without sacrificing versatility and durability.
Another object of this invention is to provide improved mid-mount front end loader mounting system apparatus and procedure wherein a plurality of securement components are safely and securely stored on the front end loader when unattached to a tractor and are easily and conveniently transformed into working positions at which attachment is accomplished, this being achieved without requiring any devices or tools separate from the apparatus itself.
These and other objects, features and advantages of the present invention will be apparent from and clearly understood through a consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In the course of this description, reference will be made to the attached drawings, wherein:
FIG. 1 is a perspective view showing a mid-mount loader secured to a tractor;
FIG. 2 is a side elevational view of a front end loader and the mounting system in accordance with the invention, shown in a parked orientation, with a tractor being shown schematically moving toward the parked loader;
FIG. 3 is a view similar to FIG. 2, with the lift cylinder retracted for alignment of the loader latch assembly with the mounting bracket assembly on the tractor;
FIG. 4 is a side elevational view along the lines of FIG. 2, showing the loader fully installed and parking stands in their storage position;
FIG. 4A is a plan view of a detail of a preferred component of the latch assembly;
FIG. 5 is an enlarged, detail view of the assembled attachment components as generally shown in FIG. 4;
FIG. 6 is a perspective view of a preferred embodiment of the universal mounting bracket assembly according to the invention;
FIG. 7 is an exploded perspective view showing the universal mounting bracket assembly of FIG. 6 in association with mounting kit components by which the universal mounting bracket assembly is secured to a tractor;
FIG. 8 is a perspective view illustrating a typical relationship of two as-mounted universal mounting bracket assembles in association with tractor securement brackets;
FIGS. 9 a , 9 b , 9 c and 9 d are side elevational views providing examples of tractor mounting kits for different types of tractors;
FIG. 10 is a perspective view, somewhat exploded, of a mid-mount loader frame having latch assemblies according to the invention;
FIG. 11 is a perspective view, partially exploded, particularly illustrating a preferred clamp assembly;
FIG. 12 is an enlarged, detail side elevational view showing a preferred combination of securement components mounted in storage position onto the illustrated latch assembly;
FIG. 13 is a side elevational view similar to FIG. 12 and illustrating positions of various components intermediate of the storage and working positions; and
FIG. 14 is a perspective view showing the embodiment of FIGS. 12 and 13, with the various components being in their respective working positions for full attachment of the loader onto the tractor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is generally illustrated in FIG. 1, which shows a front end loader generally designed as 21 . Also shown is a front portion of a tractor as an illustration of a suitable piece of motive equipment. A mounting system is generally shown at 23 . Loader 21 is a mid-mount front end loader having a frame assembly 24 , attachment control cylinders 25 , a bucket 26 , a bucket control cylinder 27 and parking stands 28 . It will be noted that the mounting system 23 is rearward of tractor wheels 29 .
FIG. 2 shows the front end loader 21 in its parked condition, the parking stands 28 and the bucket 26 resting upon generally level ground. An embodiment of the latch assembly is generally designated at 31 . A mounting bracket assembly is generally designated at 32 . It will be appreciated that in FIG. 2, the tractor is signified by wheel 29 . Included is a pedestal 33 . A second pedestal 34 also is shown. Each pedestal is positioned, sized and shaped to receive, in generally nesting fashion, pedestal pins 35 and 36 , respectively.
In FIG. 3, attachment control cylinder or lift cylinder 25 is shown retracted until the respective pedestal pins 35 , 36 are positioned in general horizontal and lateral alignment with and for entry into respective pedestals 33 , 34 . In this regard, a guide projection 37 is provided to facilitate proper seating of the pedestal pins within the pedestals. More particularly, the operator will move the motive equipment into the parked front end loader 21 generally and raise lower pedestal pin 35 by adjusting the bucket control cylinder FIG. 1) until pedestal pin 35 is engaged by the guide projection 37 . At that stage, minor adjustment of the lift cylinder 25 can be carried out, if necessary, in order to complete the nesting function.
Mounting bracket assembly 32 includes a universal mounting bracket assembly 38 , together with a tractor mounting bracket 39 . Assembly 32 can be considered to be a mounting kit which can be substantially permanently secured to a tractor or other piece of motive equipment. Even if the tractor mounting bracket 39 is specifically designed for a particular tractor, for example, the universal mounting bracket assembly 38 itself need not be modified to accommodate that particular tractor.
After the nesting of the pedestal pins into the pedestals is completed, a clamp assembly 41 is secured as described in greater detail herein. During movement of the mounting bracket assembly 32 into the latch assembly 31 , further alignment guidance is preferably provided by an internal guide plate 42 having tapered access ramps 43 opening into a receptor slot 44 , as generally shown in FIG. 4 A.
Greater detail of the latch assembly 31 and mounting bracket assembly 32 , as secured together, are found in FIG. 5. A first securement component 45 and a second securement component 46 are shown in place so as to lock down the latch assembly 31 onto the mounting bracket assembly 32 . The primary function of these securement components is to maintain proper placement of the clamp assembly 41 in a manner which will remain secure even during rough use typically associated with equipment and implements of this general type. For ease of operation and convenience, it is preferred that these securement components are easily stored on the front end loader itself when the front end loader is not attached to motive equipment such as a tractor. A particular embodiment is primarily shown herein, but it will understood that other specific structures are possible.
In this illustrated embodiment, the first securement component 45 is in the form of an elongated pin which is generally horizontally extending. Illustrated second securement component 46 is generally T-shaped. A generally transverse portion 47 of securement component 46 is shown to be generally parallel to the pin securement component 45 . A longitudinal portion 48 of the securement component 46 connects the transverse portion 47 to clamp member 49 when the loader is attached to the tractor.
Further details of the mounting bracket assembly 32 are provided in FIGS. 6, 7 , 8 , 9 a , 9 b , 9 c and 9 d . For example, in FIG. 7, assembly components of a typical tractor mounting bracket assembly are shown. The illustrated assembly includes a mounting rail 51 , as well as a front member 52 , a rear member 53 , a bottom member 54 and a top cap 55 . These members provide rigid, stable and secure upwardly extending mounting of the universal bracket assembly 38 , which structure is enhanced by the plurality of gussets such as those shown at 56 , 57 and 58 . FIG. 8 shows completed construction of a pair of mounting bracket assemblies 32 , 32 a . It will be appreciated that, in each of the mounting bracket assemblies 32 and 32 a , the universal mounting bracket assembly 38 is identical, irrespective of whether same is positioned on the left or the right. Accordingly, during manufacture of the mounting bracket assembly, identical universal mounting bracket assemblies 38 are manufactured and assembled into any one of a number of attachment assemblies 59 , 59 a (FIG. 8 ), 61 (FIG. 9 a ), 62 (FIG. 9 b ), 63 (FIG. 9 c ) or 64 (FIG. 9 d ).
Additional details of the latch assemblies 31 and of the loader frame 24 are shown in FIG. 10 . Each latch assembly 31 is rotatably mounted to frame assembly 24 by any suitable structure, included the illustrated rod 65 received within sleeve 66 . A similar pivotal mount can be provided for the lift cylinder 25 , this mounting being generally represented in FIG. 10 by the sleeve 67 . Certain aspects of a preferred embodiment of the first securement component 45 also are shown in FIG. 10 . Included is a so-called quick pin having a shaft 68 and a handle 69 . Also shown in this view as a component of the mounting bracket assembly is a handle wrench 71 , fashioned for reception within projecting shelf member 72 of the latch assembly. Shelf member can take the form of generally parallel projections as shown in FIG. 10 or as a single projection, such as one which is generally C-shaped.
FIG. 11 provides specific details of a preferred embodiment of the second securement component, this being particularly efficient and cost effective to manufacture. In this illustrated embodiment, a clamp member or assembly 73 is provided with an internal or engaging surface 74 which is configured and sized so as to engage one of the pedestal pins, with the objective of clamping same between the latch assembly 31 and the mounting bracket assembly 32 . In this illustrated embodiment, clamp 73 clamps lower pedestal pin 36 up against lower pedestal 34 . By virtue of its being securely attached to both the latch assembly 31 and to the mounting bracket assembly 32 , clamp 73 secures together each of latch assembly 31 , mounting bracket assembly 32 and pedestal pin 36 .
Turning now to the specific clamp securing arrangements which are shown in this embodiment, the first securement component 45 takes the form of a so-called quick pin, composed of shaft 68 and handle 69 (FIG. 10 ). When the system is in its attached or working position, shaft 68 rests within openings 75 through each support plate 76 and 77 . Shaft 68 also passes through hole 78 of the clamp 73 , two such holes being shown in FIG. 11 . As is perhaps best seen in FIG. 14, the handle 69 of this illustrated quick pin is positioned for engagement with one of the support plates 76 , thereby preventing passage of the shaft 68 through opening 75 . Prevention of any substantial movement of the shaft 68 out of opening 75 is preferably prevented by another component of the assembly, as discussed elsewhere herein.
Securement of the clamp 73 to the mounting bracket assembly 32 takes the form, in the embodiment illustrated in FIG. 11, of a generally T-shaped securement component. This overall configuration allows for the longitudinal portion 48 of this securement component to remain permanently attached to the mounting bracket assembly 32 . In FIG. 11, this takes the form of a simple hex bolt 79 , which is secured in place in any customary or suitable manner, such as by the illustrated hex nut 81 and washer 82 .
The longitudinal portion is permanently secured to the transverse portion in any suitable or customary manner. In the embodiment which is illustrated in FIG. 11, the manner by which the longitudinal portion is secured to the transverse portion is an arrangement which can provide for some limited rotation of the longitudinal portion with respect to the transverse portion, to the extent such might be necessary to facilitate attachment and disattachment action. In FIG. 11, an eye bolt 83 is a primary component of the longitudinal portion of the second securement component 46 . Bolt 79 passes through its eye 84 , which effectively secures this longitudinal portion of the T-shaped assembly to its transverse portion. Continuing further with the embodiment illustrated in FIG. 11, an extension nut 85 , in combination with lock washer 86 , secures the clamp 73 to the mounting bracket assembly 32 .
Further details regarding the operation of the specific embodiment that is illustrated in FIG. 10 and FIG. 11 are found in FIGS. 12, 13 and 14 . These figures illustrate generally the sequence of operations by which the respective locations of various components are transformed or used to move from a storage position as shown in FIG. 12 through a working position as shown in FIG. 14 . At the storage positions shown in FIG. 12, the extension nut 85 and the lock washer 86 are positioned along the handle wrench 71 which is stowed on a projecting shelf 72 . The storage position of illustrated quick pin 87 is within storage openings 88 , 89 (FIG. 14 ). T-shaped securement component comprising transverse bolt 79 and longitudinal eye bolt 83 are shown at rest on the universal mounting bracket assembly 38 , which is not as yet secured to the latch assembly 31 . Clamp 73 is shown still in its storage position on the latch assembly 31 .
Reorientation of the various members from this storage position to the working position begins with removal steps. Each of the handle wrench 71 , the quick attach nut or extension nut 85 , and the lock washer 86 are removed from the projecting shelf 72 . In addition, the quick pin 87 and the clamp 73 are removed from their storage positions as shown in FIG. 12 to their working positions as shown in FIG. 13 . More specifically, quick pin 87 is passed through opening 91 at shelf member 72 and through a clamp mounting hole 92 (FIG. 11) of the universal mounting bracket assembly 38 (after same had been moved into general alignment with opening 91 ), thereby permitting continued passage of quick pin 87 through and into an opening (not shown) through the other plate of the latch assembly 31 , this opening being generally similar to opening 91 . This working position of the quick pin 87 is one in which quick pin handle 69 prevents further passage of the quick pin through the opening 91 . With this alignment completed, the clamp 73 readily swings over eye bolt 83 , which passes through hole 93 of the clamp 73 .
Next, as generally visible in FIG. 13, the lock washer 86 and extension nut 85 are installed over the eye bolt 83 . This installation is easily facilitated by use of the handle wrench 71 which readily fits through slots 94 of the extension nut, as is generally illustrated in FIG. 13 . Spacing of these holes and slots 94 along the periphery of the extension nut 85 allows the handle wrench to be inserted at multiple locations so that the operator's hand can easily clear surrounding components when loosening or tightening the extension nut 85 .
Thereafter, as evident in FIG. 14, the handle wrench 71 is returned to its storage position. At this location, the handle wrench 71 prevents any substantial outward movement of the quick pin 87 out of the opening 91 . If desired, appropriate measures may be taken to secure handle wrench 71 in its FIG. 14 position, such as by having force fit engagement between the shaft of the handle wrench 71 and the installed quick pin 87 . Alternatively or additionally, threading of one or more components can be provided.
It will be appreciated that an important advantage of the present invention is that the front end loader and the latch assembly depending therefrom are not directly attached to the frame of the motive equipment or tractor. Instead, the attachment is to the mounting bracket assembly 32 . When the assembly components are clamped together, a clearance hole permits one to get the quick pin in and out. When it is desired to take the quick pin out and remove the lock, this is readily accomplished. The quick pin is, in effect, a secondary latch. One needs to pull the pin out of its working position before it is possible to have the front end loader removed from the tractor or the like.
It will be understand that the embodiments of the present invention which have been described are illustrative of some of the applications of the principles of the present invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention. | A mounting system is provided by which front end loaders of the mid-mount type are rapidly attached and detached from a tractor or other piece of motive equipment. A procedure for latching and unlatching is also provided, as well as mid-mount front end loaders having a quick attach and quick detach mounting system. A universal mounting bracket assembly is included which can be used on either the right side or the left side and can be used with a variety of front end loader models. A clamp secures together a support, a pedestal pin of the support, and the universal mounting bracket assembly in order to achieve the quick connect of the mid-mount loader onto the tractor. | 4 |
BACKGROUND OF THE INVENTION
The present invention is directed to bicycle computers and, more particularly, to a bicycle computer that has diagnostic modes.
Display devices for displaying various types of data for bicycles, such as the bicycle speed, distance traveled and transmission gear, are frequently attached to bicycles. Display devices capable of displaying such a variety of parameters are equipped with switches for switching the type of parameter displayed and indicating the start and stop of measurement. The display device is also often detachably attached to the bicycle, with the switches often being integrally provided with the display device. It is known that the bicycle computer is easier to operate when these switches are disposed on lever brackets, such as brackets for fixing brake levers to the handle bar as shown in U.S. Pat. No. 4,071,892.
In the past, to determine whether such display devices were functioning properly, the display device had to be attached to the bicycle, signal lines had to be connected to the various sensors and manually operated switches, and the bicycle had to be operated while the shifter or the like was operated. When the display device was not operating properly, it was no easy feat to determine the cause of the trouble, which could have been caused by malfunctioning of the display means of the display device (liquid crystal display panel, light-emitting diode display panel, and the like), malfunctioning of the data processing means such as the CPU or the like inside the display device, or malfunctioning of the various sensors or the various signal lines from the sensors.
SUMMARY OF THE INVENTION
The present invention is directed to a bicycle computer wherein troubleshooting diagnostics may be carried out easily using the existing computer display and which allows the source of the malfunctions to be easily identified. In one embodiment of the present invention, a bicycle display device includes a display having a plurality of display elements, an input circuit for inputting a plurality of sensor signals from a plurality of sensors, and a display control circuit for processing the plurality of sensor signals and for displaying information processed from the plurality of sensor signals on the display. An operating mode switch is provided for switching the display control circuit among a plurality of operating modes, wherein the plurality of operating modes comprises a normal operating mode, a display diagnostic mode, and an input diagnostic mode. A display mode switch is also provided for switching the type of data displayed on the display control circuit.
In a more specific embodiment, when the display control circuit is in the display diagnostic mode, the display displays information indicating whether the plurality of display elements are functioning properly. For example, a numerical sequence may be displayed on numerical display elements and/or all display elements may be flashed at the same time. When the display control circuit is in the input diagnostic mode, the display displays information indicating whether the plurality of sensor signals are being received. For example, the display may flash a display element or display a numeral corresponding to the sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a particular embodiment of a front face of a bicycle display device according to the present invention;
FIG. 2 show a particular embodiment of a back face of a bicycle display device according to the present invention;
FIG. 3 shows a particular embodiment of the display elements contained on the front face of the bicycle display device shown in FIG. 2;
FIG. 4 shows a lever bracket/switch assembly that may be used with the bicycle computer shown in FIG. 1; and
FIG. 5 is a block diagram showing a particular embodiment of electronic circuitry used in the bicycle computer according to the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a particular embodiment of a front face of a bicycle display device according to the present invention. As shown in FIG. 1, the display device frame 1 is constructed of a nearly square plate-shaped body with rounded corners. A liquid crystal panel 51 is attached as the display means to the front face of the display device frame 1 . Several display elements are incorporated in the liquid crystal display panel 51 , allowing various types of data such as speed, distance traveled, the shifter gear, time, etc. to be displayed as described below. Display panels based on light-emitting diodes and the like can also be used instead of liquid crystal display panels as the display means.
As shown in FIG. 2, an attaching component 13 is formed on the back face of the display device frame 1 so that the frame 1 can be readily attached and detached with a clip (not shown in figure) fixed to the bicycle handle bar. A battery lid 14 can be removed with a coin or the like when the battery serving as the power source for the display device is replaced. An A switch 21 and B switch 22 for switching the operating mode of the display device are provided on the back face of the display device frame 1 . An AC switch 23 for initializing data stored in the display device to factory settings and for resetting the display device is similarly provided on the back face.
FIG. 3 shows a particular embodiment of the display elements contained on the front face of the bicycle display device shown in FIG. 2 . As shown in FIG. 3, the bicycle speed, time, and other such data are displayed numerically in a main numerical display 52 and auxiliary numerical display 53 . A content display 54 is a display showing the display contents of the main numerical display 52 and the auxiliary numerical display 53 . For example, “VEL” indicates traveling speed, “DST” displays the distance traveled or the cumulative distance, “CLK” displays the time, “TIM” displays the traveling time, and “GEA” displays what gear the shifter is in. The speed units can be switched between kilometer per hour and miles per hour, and the units of distance can be switched between kilometers and miles. When the units of distance are set at the initial settings of the display panel, the unit display of the liquid crystal display panel 51 also displays the set units.
The rear sprocket speed step display 55 displays the sprocket speed step of the rear derailleur. The rear sprocket speed step display 55 consists of a display of disc shapes lined up according to size from left to right in descending order. This arrangement corresponds to the effective radius of the gears of the actual derailleur. At the initial settings of the display device, the speed steps of the front and rear derailleurs can be set so as to match the actual speed steps of the bicycle. For example, when the rear sprocket is in fifth gear, the rear sprocket speed step display 55 shows the five disc-shaped displays from the left and not the four on the right.
The front sprocket speed step display 56 displays the sprocket speed step of the front derailleur. The front sprocket speed step display 56 consists of a display of disc shapes lined up according to size from left to right in ascending order. When, in the initial settings, the front sprocket is in the second speed step, the front sprocket speed step display 56 shows the two disc-shaped displays from the left and not the one on the right. The rear and front sprocket speed step displays 55 and 56 , respectively, are thus arranged so that the disc-shaped displays corresponding to the gear array of the actual derailleurs of the bicycle are in descending order. The speed step can thus be seen intuitively at a glance.
The positional relation between the group of figures in the front sprocket speed step display 56 and the group of figures in the rear sprocket speed step display 55 is such that the front sprocket speed step display 56 is set up in front or above, intuitively corresponding to the lay out of the actual derailleurs. When a signal (indicating the gear position) from the gear sensor located at the derailleur operating lever is detected, the disc-shaped displays corresponding to the current gear of the front and rear sprocket speed step displays 56 and 55 begin to blink, and the new gear is displayed. The gear can thus be known at a glance. The overall status of the sprocket speed step can also be promptly grasped.
In this embodiment, the start/stop switch 24 and the display mode switch 25 (see FIG. 5) are located apart from the display device frame 1 of the display device. The start/stop switch 24 is a switch for indicating the start and stop of measurement on the display device when the distance traveled, the lap time, or the like is displayed on the display device. The display mode switch 25 is a switch for switching the type of data displayed on the display device. These switches must be operated frequently by the operator while riding the bicycle and are therefore located near the usual grip position for right-handed riders. A lever bracket is a suitable location for these switches.
FIG. 4 depicts a lever bracket on the right side where the start-stop switch 24 and display mode switch 25 are located. The lever bracket is a bracket to which is attached an operating lever 3 allowing the brakes to be operated and the shifter to be operated. It is fixed to the bicycle handle bar 15 by a fixing band 16 . The right side operating lever 3 allows the front brakes to be operated and the rear derailleur to be shifted. The entire outer surface of the lever bracket is covered with a synthetic resin bracket cover 17 . An R gear sensor 32 (FIG. 5) for sensing the gear of the rear derailleur is located at the shift control (not shown in figures) inside the lever bracket, and it is connected by a signal cable to the input terminal 134 of the display device. Two push buttons 18 protrude from the bracket cover 17 . The start/stop switch 24 and the display mode switch 25 of the display device are located inside the push button protrusions 18 .
When the push buttons 18 are pressed, the bracket cover 17 is elastically deformed, allowing the switches to be operated. The height of the two push buttons 18 , the shapes of the protrusions, the configuration of the textured pattern at the apex of the protrusions, and the like are different so as to allow them to be distinguished by touch. Since the protrusions can be distinguished by touch, the rider can tell which button is which and avoid pressing the wrong button without having to look at the buttons.
The push buttons 18 are conveniently located where they will be readily touched by the thumb when the operator grips the operating lever 3 to operate the brakes. More specifically, the push buttons 18 are located in a different place than is customary for the finger position on the inside of the grip component so as to prevent the switches from being inadvertently operated.
FIG. 5 is a block diagram showing a particular embodiment of electronic circuitry used in the bicycle computer according to the invention. A CPU 10 for data processing is located in the display device. ROM 11 and RAM 12 are connected as memory means by a bus to the CPU 10 . A program and data are stored in the ROM 11 and RAM 12 to operate the CPU 10 . That is, various types of data processing of the sensor signals from the sensors and the like take place in the ROM 11 , and a display control program 111 for controlling the display of the liquid crystal display panel 51 of the display device is also stored there. The outer peripheral length of the tires, the speed steps of the front and rear derailleurs set to the initial settings in the display device, and the like are stored in the set value memory 121 in the RAM 12 .
The liquid crystal display panel 51 is connected by a bus and interface circuit to the CPU 10 , and the display of the liquid crystal display panel 51 is controlled by the CPU 10 and the display control program 111 . The A switch 21 , B switch 22 , start/stop switch 24 , and display mode switch 25 are also connected by the bus and interface circuit to the CPU 10 . The CPU 10 senses when the switches are on and off. The start/stop switch 24 and display mode switch 25 are located apart from the display device and the like, and are thus connected by the signal cable to the input terminals 131 and 132 . The AC switch 23 initializes the display device. When the AC switch 23 is pressed, the CPU 10 is reset, and the data stored in the set value memory 121 is initialized to the factory settings.
Various sensors such as the F gear sensor 31 for sensing the gear of the front derailleur, the R gear sensor 32 for sensing the gear of the rear derailleur, and the rotation sensor 33 for sensing the rotation of the tires are also connected by the bus and interface circuit to the CPU 10 , and the output from these sensors is processed by the CPU 10 . The signal cables from the various sensors are connected to the input terminals 133 , 134 , and 135 of the display device.
The display device described above is operated in the following manner. First, when the battery is set up in the display device, the main numerical display 52 and auxiliary numerical display 53 are set up to display the traveling speed and time. The display mode switch 25 can be pressed several times to switch display on the main numerical display 52 between distance traveled, gear numerical value display, maximum speed, average speed, and so forth. In the display mode showing the distance traveled on the main numerical display 52 and the lap time on the auxiliary numerical display 53 , the start/stop switch 24 can be pressed to start and stop measurement.
The operating mode for thus displaying these various types of bicycle data is the normal mode for the display device. The operating mode of the display device is the display mode of the display control program 111 and the CPU 10 (the display control means). In addition to the normal mode, the operating modes of the display device include a display diagnostic mode for ascertaining whether or not the various display elements of the liquid crystal display panel 51 are operating properly, and an input diagnostic mode for ascertaining whether or not the sensor signals from the sensors and the switches are operating properly. A program for switching between these operating modes is included in the display control program 111 . The operating modes are switched by the A switch 21 and the B switch 22 . That is, the A switch 21 and B switch 22 function as operating mode switches for switching the operating mode of the display device.
The operating mode of the display device is in normal mode immediately after the battery of the display device has been replaced, or when the AC switch 23 is pressed to reset the display device. When the A switch 21 is continuously pressed for a first prescribed period of time in normal mode, the operating mode of the display device is switched to display diagnostic mode. A period of about 10 seconds, for example, can be set as the first prescribed period of time. In display diagnostic mode, the displays on the main numerical display 52 and auxiliary numerical display 53 of the liquid crystal display panel 51 switch between 0, 1, 2, and so forth at fixed intervals. When the display reaches 7, all the display elements then blink for a certain period of time, and the display again begins to switch between 0, 1, 2, and so forth. The display diagnostic mode makes it possible to ascertain whether or not the various display elements of the liquid crystal panel 51 are operating properly.
When the B switch 22 is continuously pressed for a second prescribed period of time in display diagnostic mode, the operating mode of the display device switches to input diagnostic mode. A period of about 2 seconds, for example, can be set as the second prescribed period of time. Input diagnostic mode makes it possible to ascertain whether or not the various sensors and switches are operating properly. The various sensors and remote switches are connected to the display device, and the display device is put into input diagnostic mode. In this embodiment, the “rpm” display element in the liquid crystal display panel 51 blinks when the rotation sensor 33 is operating properly as the tires are rotated. If it does not blink, the cause may be a malfunction of the rotation sensor 33 , broken wires in the signal cables, defective connections in the terminal connections, or the like. The location of the malfunction can be readily determined.
When the operating lever 3 is operated to control shifting in input diagnostic mode, the gear display corresponding to the gear of the front and rear sprocket speed step displays 56 and 55 in the liquid crystal display panel 51 flash according to the current sensor signals from the F gear sensor 31 and R shift gear sensor 32 . The switches are pressed to ascertain the operation of the switches. When the A switch 21 is pressed, the main numerical display 52 displays a 1. Similarly, when the B switch 22 is pressed, the main numerical display 52 displays a 2. When the display mode switch 25 is pressed, the main numerical display 52 displays a 3. When the start/stop switch 24 is pressed, the main numerical display 52 displays a 4.
When the B switch 22 is continuously pressed for the second prescribed period of time in input diagnostic mode, the operating mode of the display device returns to normal mode. The operating mode of the display device can thus be switched to display diagnostic mode and input diagnostic mode in addition to normal mode. As such, the operation of the display can be readily ascertained, and the source of trouble during malfunctions can be readily determined.
In display diagnostic mode, the operations can be checked with a single unit, even when the various sensors or remote switches are not connected. Display diagnostic mode also makes it possible to ascertain whether or not the display elements as well as the CPU 10 , ROM 11 , and RAM 12 are operating properly. That is, when the displays of the main and auxiliary numerical displays 52 and 53 are switched at fixed time intervals between 0, 1, 2, and so forth, this indicates that the CPU 10 is properly operating the display control program 111 , and that the circuits are normal.
Similarly, input diagnostic mode makes it possible to check the operation of each sensor and switch, thus making it easy to determine the source of trouble and allowing malfunctions to be promptly repaired. That is, in the absence of displays confirming the operation of the sensors and switches, defects can be determined in a sensor itself, a signal cable, a connecting terminal, or the like.
While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. For example, the size, shape, location or orientation of the various components may be changed as desired. The functions of one element may be performed by two, and vice versa. In the aforementioned embodiments, the start/stop switch and display mode switch were located on the right side lever bracket, but they can also be located at the left lever bracket for left-handed riders. When the display device is in input diagnostic mode, the operation of the sensors and switches was checked by the display on the liquid crystal display panel, but audio signals verifying operation may also be output from speakers at the same time that operations are checked by display on the liquid crystal display panel. In such cases, the audio signal frequency, pulse number output in the form of a pulse, time interval, or the like may be varied according to the type of switch or sensor.
Thus, the scope of the invention should not be limited by the specific structures disclosed. Instead, the true scope of the invention should be determined by the following claims. | A bicycle display device includes a display having a plurality of display elements, an input circuit for inputting a plurality of sensor signals from a plurality of sensors, and a display control circuit for processing the plurality of sensor signals and for displaying information processed from the plurality of sensor signals on the display. An operating mode switch is provided for switching the display control circuit among a plurality of operating modes, wherein the plurality of operating modes comprises a normal operating mode, a display diagnostic mode, and an input diagnostic mode. A display mode switch is also provided for switching the type of data displayed on the display control circuit. | 1 |
[0001] This application is a divisional of U.S. application Ser. No. 13/855,440, filed Apr. 2, 2013 which is currently pending and which claims priority to U.S. provisional application Ser. No. 61/623,916, filed Apr. 13, 2012.
FIELD OF THE INVENTION
[0002] This disclosure relates generally to the recovery of bitumen from oil sands by means of light solvents.
BACKGROUND OF THE INVENTION
[0003] The Athabasca oil sands in north east part of the province of Alberta now comprise one of the largest remaining oil reserves in the world. The oil bearing geological formation is shallow near the Alberta-Saskatchewan border and is located a few tens of meters below the surface there. The formation slopes to the west such that, in 10-20 km, it is more than 300 m below the surface. As a result, there are two methods being used to extract the oil from the ground. Mining is economically viable where the formation is less than 70 m below the surface. “In Situ” processes, where horizontal oil wells are drilled, are used when the formation is deeper than is economically minable. Mining has a higher recovery ratio since the entire ore body is accessible.
[0004] Oil sand is comprised of three main components: solids, oil and water. The solids can be sub-classed into sands and silt/clay particles. The sand particles are larger than the silt/clay particles, ranging from stones and pebbles down to fines near 1 μm diameter. Silts and clays are finer particles and tend to be between 100 and 0.1 μm in size. FIG. 1 shows the solids particle size distribution for a number of types of ore bodies in the Athabasca region. Curves 1 , 2 and 3 correspond to ore bodies with higher sand content. Curves 4 and 5 correspond to ore body with higher silt and clay content since more than 60 wt % of the particles are smaller than 100 μm. There are ore bodies with even higher silt/clay content. As a broad rule, the bitumen content of the ore varies inversely with the concentration of fines. The term “fines” is applied to particles smaller than 44 μm. Vertical line A represents this boundary on FIG. 1 . Generally, the wt % passing of fines is less than 30% for ore bodies bearing more than 7% bitumen. 7% bitumen is considered near the lower limit of economic recoverability for current technology. Curves 4 and 5 would not be representative of economically viable ore bodies since the fines contents are 38% and 43% respectively.
[0005] The oil can be sub-classed into bitumen and asphaltenes. Bitumen is the desired component because it can be readily upgraded into synthetic crude oil. Asphaltenes are components with high carbon content. They also contain sulfur, metals and aromatic molecule groups. The molecules are large but also form solid crystalline conglomerations of molecules. The asphaltene particles range from nanometer to micrometer scales and they form 17-18 wt % of the oil mixture. While they are solid they are considered to be part of the oil component. They are undesirable because they increase the viscosity of the bitumen mixture and, more importantly, because they disrupt the upgrading process. Asphaltenes tend to “coke” the upgrading vessels and equipment, requiring expensive maintenance and down time.
[0006] The water component of the oil sand is important. Solid particles are hydrophilic and tend to be within the water component of the ore. The sand particles are “wetted” with a fine layer of water, approximately 10 nm in thickness. Where the sand grains touch, a pendular ring of water forms by surface tension. Oil is hydrophobic and coats the sand grains outside of the water layer. This is an important factor. It means that when the ore is immersed in solvents, the bitumen is accessible to the solvent without disturbing the water layer. The remainder of the interstitial space between the oil coated sand grains is filled with water. This interstitial water component contains a large part of the fines content of the oil sand because the fines are hydrophilic. Nevertheless, there are still fines incorporated into oil phase of the ore and these become the most difficult solids to separate from the bitumen.
[0007] The mass fraction ranges for the various components in commercially viable oil sand are listed in Table 1.
[0000]
TABLE 1
Oil Sand Ore Component Mass Fractions
Component
Wt %
sand
81-88
silt/clay
water
3-6
bitumen
5-13
asphaltenes
1-3
[0008] It is important to emphasize that the separation of the solids from the bitumen must be nearly complete for commercial processing. For a low grade ore of 7% bitumen, 99.94% of the solids must be removed from the bitumen stream to meet the pipeline specification of less than 0.5 wt % solids and water.
Bitumen and Solvent Properties
[0009] Bitumen is highly viscous. To separate the bitumen from the solids, the viscosity of the bitumen must be reduced so that it will flow away from the sand. The two main methods of reducing the bitumen viscosity involve increasing the bitumen temperature, or diluting the bitumen with a solvent.
[0010] FIG. 2 shows an exponential decrease in viscosity with temperature. The viscosity of pure bitumen (0% solvent) drops three orders of magnitude with a temperature increase of 60° C. For this reason, all of the processes used in the current art involve some amount of heating. However, this viscosity decrease is insufficient to allow the solids to be separated from the bitumen. At a temperature of 80° C., pure bitumen has a viscosity of 1000 mPa-s, which is similar to that of thick syrup. Further viscosity reduction is required, and is accomplished by means of solvents. FIG. 2 shows that propane solvent, mixed in a 50% mass fraction reduces the viscosity of the bitumen by more than six orders of magnitude. Therefore, the addition of propane solvent offers a substantial advantage over any known heating methods.
[0011] There are two broad classes of solvents: Paraffinic solvents and aromatic solvents. Paraffinic solvents are non-ring hydrocarbon chain molecules ranging from propane, with three carbon atoms, to very long chains. Methane and ethane (one and two carbon atoms) have triple points lower than atmospheric temperature and pressure and therefore cannot be liquids at the temperatures and pressures normally encountered in these applications. Therefore, methane and ethane cannot be used as solvents. Shorter chain paraffins make better solvents because of their lower density and viscosity and also because they do not dissolve asphaltenes well. The disadvantage of these solvents is that they are either vapors at atmospheric pressure and 20-80° C., or they have very high vapor pressures and thus tend to evaporate even if they are liquids.
[0012] Table 2 shows that the boiling temperature of the solvents increases with higher molecular weight. Propane, butane, pentane or hexane cannot be used as solvents at atmospheric pressure and 80° C. because they would all boil away. Heptane would experience significant losses to the atmosphere because it would evaporate quickly.
[0000]
TABLE 2
Solvent Properties
Solvent Properties (1)
Molecular
Weight
Boiling
Vapor
Dynamic
kg/kg-
Temp. (2)
Pressure
Density
Viscosity
Solvent
mole
° C.
MPa (abs)
kg/m 3
mPa-s
Propane
44.0956
−42.12
3.264
365
0.047
Butane
58.1222
−0.50
1.062
497
0.093
Pentane
72.1488
36.06
0.392
559
0.137
Hexane
86.1754
68.72
0.153
599
0.175
Heptane
100.2019
98.38
0.061
629
0.223
Naphtha
(3)
30-200
(3)
600-850
0.980
(1) At 82.2° C. and at the vapor pressure noted.
(2) At atmospheric pressure, 101.325 kPa.
(3) Naphtha is a mixture of solvents, containing paraffins from C5-C12 as well as aromatic solvents. All values in this row are approximate and depend on the particular grade of naphtha.
[0013] As the molecular weight of a paraffinic solvent increases, its behavior becomes more like aromatic solvents in its ability to dissolve asphaltenes.
[0014] Aromatic solvents have heavier molecular weights and are liquids at atmospheric pressure and temperature. Naphtha, a mixture of paraffinic and aromatic elements, is a commonly used solvent.
Clark Hot Water Extraction Process
[0015] The current state of the art is the Clark hot water extraction process. This process is described in a number of Canadian patents by Karl Adolf Clark, including 289,058 and 448,231. Numerous improvement patents for this process also exist. The Clark process requires substantial physical equipment. Ore is mined, crushed and mixed with hot water and caustic in large atmospheric pump boxes. The slurry mixture is pumped from the pump boxes in large hydrotransport pipelines to an extraction plant. The hydrotransport pipeline serves two purposes; to transport the ore and to ensure that the oil, water and sand are thoroughly mixed. When the slurry reaches the extraction plant it flows into large primary separation cells where, with recirculation pumps, an oily froth is created and most of the sand is separated from the oil. Water and solids are sent to the tailings ponds while the remaining solid fines and froth are sent to the froth treatment plant. The froth is mixed with solvents to lower the bitumen viscosity and to allow the final separation of the bitumen from the water and solids. The water extraction process understandably uses a large amount of water. The water usage varies from 5 to 9 m 3 of water per m 3 bitumen depending on the quality of the ore. A significant portion of this water is recycled back from the tailings ponds where the solids have settled out. Nevertheless, about 3 to 5 m 3 of water per m 3 bitumen is made up from fresh water sources. Energy use varies from 3 to 5 GJ/m 3 of bitumen; much of this energy is spent on heating and moving water about. A significant amount of heat is lost when the hot water is sent to the tailings ponds. This loss varies from 1 to 2 GJ/m 3 of bitumen with an average of 1.7 GJ/m 3 . An important disadvantage of this system is that the fines, which are concentrated in the interstitial water within the ore, are mixed with large volumes of water, diluting them. The interstitial water/fines mixture is a difficult separation by-product to re-concentrate and to dispose of Fines do not settle out of the water easily, even after decades. The mixed fines and water build up over time, requiring ever larger settling ponds, called tailings ponds, to be constructed. These ponds have attracted much adverse attention because flocks of migrating wildfowl have been trapped and killed in the oily tailings. The government of Alberta has directed that the current system is unsustainable. The current tailings ponds must be cleaned up and future facilities must include some, as yet undefined, improved technology to reduce pond size or eliminate them entirely.
Solvent Based or Solvent Assisted Mining Extraction
[0016] Numerous patents disclose the use of solvents for bitumen extraction in mining applications. Most of these utilize a single heavy solvent that remains as a liquid at atmospheric pressure and temperature in a continuous fashion. The continuous nature of these methods and machines require that the oil sand and solvent be mixed at atmospheric pressure. These methods and machines do well in separating the bitumen from the oil sand but have difficulty with the fines that are carried away with the solvent bitumen mixture. Because the solvent-bitumen mixture still has a relatively high viscosity, the fines are not easily separated. If lighter solvents are used, they tend to evaporate and are lost to the atmosphere.
[0017] A number of patents overcome this disadvantage by using a two solvent system. The first solvent is a heavy solvent, such as naphtha, which acts to separate the bitumen from the coarse sand and also as a slurrying agent to allow the mixture to be transported to pressurized containers. The second solvent, such as propane, butane or hexane, is used to wash the first solvent, lowering its viscosity and allowing complete separation of the fines. Recent examples of such patents include Canadian patent 2,582,078 by Willem Duyvesteyn, et al., Canadian patent application 2,724,806 by Olusola Adeyinka, et al., and Canadian patent 2,520,943 by Vining Wolff, et al.
[0018] U.S. Pat. No. 7,384,557 (the '557 patent) describes the use of a single solvent, including paraffinic solvents with both batch and continuous embodiments. This technique uses a series of screws or solids piston pumps to move the ore to several pressurized extraction chambers. The batch embodiment utilizes a complex system and involves multiple filters and a liquid-liquid separation unit.
Improvements of the Proposed Method and Machine Over Hot Water Processes
[0019] The proposed method and machine constitutes an improvement over the hot water extraction process because it accomplishes the majority of the work done by the hot water separation systems in one vessel. It radically reduces the amount of water and solids being physically moved, heated, stored and recycled. The four main areas of improvement are:
1. Decreased Capital Costs
[0020] Less equipment will be required by this proposed invention, and the required equipment will be smaller. The water supply and preheating and storage systems will be much smaller than the current system in capacity. No slurry preparation or hydrotransport or primary extraction systems will be required. They are replaced by the batch separation machines. The froth treatment systems will be replaced by water wash systems of modest size since they are handling concentrated mixtures, not low density froth streams.
2. Lower Heat Energy Use
[0021] As noted above, the Clark process uses 3-5 GJ/m 3 of bitumen produced, with heat losses to tailings ponds averaging 1.7 GJ/m 3 . The proposed system is expected to have three main heat loads, as described in Table 3:
[0000]
TABLE 3
Single light Solvent Method Energy Use
FIG. 1
Solvent recovery
Ore heating
Water heating
Total
Curve #
GJ/m 3 of bitumen
1
0.41
0.53
0.28
1.22
2
0.41
0.63
0.36
1.40
3
0.41
0.79
0.44
1.64
[0022] It can be clearly seen that the total heat usage is less than the Clark water heating losses alone.
3. Diminished Water Use
[0023] As noted above the Clark process uses 5 to 9 m 3 of water per m 3 of bitumen produced. The net usage of water by the Clark process is 3 to 5 m 3 of water per m 3 of bitumen produced. This is compared to a range of 1 to 2 m 3 water per of bitumen for this proposed method and machine.
4. Tailings Ponds Reduced or Eliminated
[0024] The quantity of water being used in the applicant's method to separate the fines from the solvent-bitumen mixture for average and high grade ore ( FIG. 1 , curves 1 , 2 and 3 ) is such that it can be returned to the mine pit without creating any tailings ponds. Low grade ores with high fines contents (>25% by wt %) may require tailings ponds. It is expected that these ponds would be very much smaller than those currently required.
Improvements Over Solvent Extraction Methods
[0025] Solvents which are liquids at atmospheric pressure and moderate temperatures have viscosities that are too high to permit efficient separation of fines from the solvent-bitumen mixture. Therefore, these prior art patents are not economically viable unless large settling tanks are used to hold the solvent-bitumen mixture for long periods of time to allow settling, or large numbers of centrifuges are used to accelerate the separation. The applicant's proposed method and machine constitute an improvement over single heavy solvent methods and machines because of its ability to separate a large proportion of the fines in the machine itself, leaving the remainder in a low viscosity fluid that allows further separation with relative ease. The recovery of light paraffin solvents requires much less energy use than that for heavy solvents that are conventionally used.
[0026] The applicant's method and machine constitute an improvement over dual solvent methods because the same result is accomplished with substantially less equipment, since only a single solvent recovery system is required. The light solvent is used to maximum advantage in the first separation, causing more than 80% of the solids to be removed in that first step. It is expected to use less energy since only one solvent needs to be recovered and because the recovery of light paraffin solvents requires less heat. Such light solvents flash to vapor using the heat stored in the bitumen, and they may immediately be recovered by condensation.
Improvements Over the Single Paraffinic Solvent System
[0027] The system described in U.S. Pat. No. 7,384,557 has a number of characteristics that are not required or are opposite to the applicant's proposed method and machine, as described below.
[0000] i) augers and paddles are required to move and mix the material.
[0028] The applicant's method requires no mechanical machinery for moving or mixing solids.
[0000] ii) a system of inert gas injection is required to maintain pressure. This is required because the temperature must be kept as low as possible to avoid denaturing of the oil, or the process will not work properly.
[0029] The applicant's proposed method teaches away from this '557 disclosure and in fact works better at higher temperatures. In the applicant's method, the pressure is maintained by having sufficient liquid solvent in the container so that the pressure will be the vapor pressure of the solvent at the bulk temperature of the materials in the container.
[0000] iii) a solvent injection system which enters the container in a manner to cause a vortex flow.
[0030] The circulation of solvent in the applicant's method is upwards rather than radial. In this manner, small solid lumps are carried upwards, larger lumps fall and abrade against each other. Further, the turbulent mixing at the bottom of the container causes more abrasion and mixing.
[0000] iv) the batch method described in the '557 patent is based on a filter separation method. Application of filters to oil sands is problematic. The filter in the container must be physically robust to withstand battering when the ore is dumped in from above, yet the filter passing size must be quite small, around 0.1 mm (100 μm) to retain even half of the solids in the container. The filter would be subject to clogging with fines and would be difficult to clean.
[0031] The applicant's proposed design is based on a gravity separation method. The use of gravity settling is a substantial and non-obvious change from the conventional filter design.
SUMMARY OF THE INVENTION
[0032] Among the objects of the present invention are to provide a method and apparatus to extract bitumen from oil sands ore that uses a single light paraffinic solvent in a discontinuous or batched process.
[0033] The method is summarized in FIG. 4 and comprises the following steps: adding a quantity of oil sand ore in a container and sealing, pressurizing and filling the container with a light paraffinic solvent, agitating the oil sand ore and solvent to create a first mixture of enriched bitumen and solvent, allowing the fines to settle out, adding some water to displace solvent and bitumen upwards out of the solids layer, rotating the container to fully drain the first mixture of bitumen enriched solvent to other equipment for further separation of solids, depressurizing the container to a vapor recovery system, rotating and unsealing the container and then removing the first mixture of bitumen depleted sand, and finally, cleaning the remaining sand from the container and rotating to the filling position.
[0034] FIG. 3 depicts the machine to be used in this method. The main components of the machine are as follows:
a) A container or vessel capable of retaining the material comprising bitumen and solvent under pressure at the operating temperature. b) A sealing mechanism or mechanisms that allow the container to be opened and closed at the beginning and end of the cycle for filling and dumping with ore. c) A rotating mechanism or mechanisms to allow the orientation of the envelope to be changed to allow for the various steps in the cleaning cycle. d) A solvent recycle system that flushes the solvent upwards through material comprising bitumen to ensure mixing. e) A flexible piping system that moves with the machine for filling the envelope with liquids. f) A flexible piping system that moves with the machine for draining fluids from the envelope. g) A flexible piping system that moves with the machine for venting the envelope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Embodiments of the invention will now be described with reference to the accompanying drawings, in which:
[0043] FIG. 1 depicts the solids particle size distribution for various oil sand ore bodies in the Athabasca region of Alberta. FIG. 1 also depicts the proportion of solids that may be separated in the machine and by other means.
[0044] FIG. 2 depicts the viscosity of the solvent-bitumen mixture as a function of the solvent mass fraction for mixture temperatures from 20° C. to 80° C.
[0045] FIG. 3 is a schematic diagram representing an embodiment of a machine or apparatus for separating bitumen from oil sand ore.
[0046] FIG. 4 is a summary flow chart describing a proposed embodiment for separating bitumen from oil sand ore.
[0047] FIG. 5 is a detailed flow chart describing another proposed embodiment for separating bitumen from oil sand ore.
[0048] FIG. 6 a illustrates the mechanical arrangement of the first machine embodiment during the filling stage.
[0049] FIG. 6 b illustrates the mechanical arrangement of the first machine embodiment during the recycle stage.
[0050] FIG. 6 c illustrates the mechanical arrangement of the first machine embodiment during the draining stage.
[0051] FIG. 6 d illustrates the mechanical arrangement of the first machine embodiment in its fully drained and depressuring stages.
[0052] FIG. 6 e illustrates the mechanical arrangement of the first machine embodiment in the depressured state, and
[0053] FIG. 6 f illustrates the mechanical arrangement of the first machine embodiment during the emptying and cleaning stages.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Mixture Viscosity and Particle Settling Time Calculations
[0054] The viscosity reduction gained by means of the use of light hydrocarbon solvents is the most important factor driving the design of this method and machine. The viscosity of the solvent-bitumen mixture is accurately calculated using Lederer's equation 1):
[0000] μ mix =μ Solvent fs *μ Bitumen fb 1)
[0055] In equation 1), μ is dynamic viscosity, measured in milliPascal seconds, mPa-s. The dimensionless exponents for solvent and bitumen, f s and f b , sum to unity and are calculated using equation 2)
[0000]
2
)
f
b
=
α
*
C
vb
α
*
C
vb
+
C
vs
[0056] In equation 2), α is an empirical constant defined in equation 3) by Shu. C vb and C vs are the volume fractions of bitumen and solvent in the mixture which sum to unity.
[0000]
3
)
α
=
17.04
*
Δρ
0.5237
*
ρ
b
3.2745
*
ρ
s
1.6316
ln
(
μ
b
μ
s
)
[0057] In equation 3), ρ is the specific gravity of bitumen, b and solvent, s. Δρ is the specific gravity of bitumen less that of solvent. The dynamic viscosities of bitumen and solvent are used in the natural logarithm term in the denominator.
[0058] The dynamic viscosities of 1:1 solvent-bitumen mixtures for the various light solvents, listed in Table 4 below, were calculated using equations 1), 2) and 3). The input densities and viscosities are also listed. The viscosity of bitumen was fixed as 75,762 mPa-s (3) and the density as 998 kg/m 3 (4) at a temperature of 35° C., according to FIG. 2 . A 1:1 solvent-bitumen ratio was chosen because it provides a substantial viscosity reduction while maintaining modest recovery costs. The mixture density is calculated by using equation 4:
[0000]
4
)
ρ
mix
=
[
∑
Xi
ρ
i
]
-
1
[0059] In equation 4) x i is the mass fraction and ρ i the density of the ith component.
[0000]
TABLE 4
1:1 Solvent-Bitumen Mixture Properties at 35° C.
1:1 Solvent-Bitumen
Solvent Properties
Mixture
Dynamic
Dynamic
Density
Viscosity
Density
Viscosity
ρ S
μ S
ρ mix
μ mix
Solvent
kg/m 3
mPa-s
kg/m 3
mPa-s
Propane
476
0.088
645
0.40
Butane
561
0.144
718
1.10
Pentane
611
0.200
758
2.02
Hexane
645
0.267
784
3.21
Heptane
674
0.348
802
4.70
Naphtha
720
0.960
836
15.12
[0060] Having determined the viscosity and density of the solvent-bitumen mixture, it is now possible to use Stokes' law is used to determine the time needed for solids to settle through the solvent-bitumen mixture. Stokes law determines the falling velocity of a sphere through a viscous liquid in laminar flow. There is evidence that Stokes law is very conservative in that it shows excessively slow falling velocities for fine particles. Stokes' law has been used as the basis of this analysis because it demonstrates that the proposed method will work even under very conservative assumptions. Stokes' law is defined in equation 5).
[0000]
5
)
v
s
=
2
*
(
ρ
Solid
-
ρ
liquid
)
*
r
2
*
g
9
*
μ
liquid
[0061] Here, v s is the particle falling velocity in m/s. The ρ variables are densities in kg/m 3 . The particle radius is r, in m. The acceleration due to gravity is g at 9.81 m/s 2 . The liquid viscosity, μ liquid , is in Pascal seconds.
[0062] It is important to recognize that there is a synergistic effect of using lighter and lighter solvents. Both the density and viscosity of the mixture decrease with lighter solvents. This increases the ability of the mixture to allow finer particles to settle out in a given time.
[0063] It is possible to calculate the finest particles that will settle out in a given period under gravity by re-arranging Stokes' law. The Stokes velocity, Vs, is calculated by dividing the falling distance by the settling time. For the vessel, the settling distance was fixed as 2 m and the settling time, 10 min. Knowing Vs, it is possible to solve for r, the radius of the spherical particle, and then, multiplying by two to determine the diameter. Table 5 below shows the minimum particle size, D, that could be expected to settle in the vessel for each type of paraffinic solvent and naphtha. These calculated values are based on the input densities and viscosities listed in table 4. Line B in FIG. 1 represents the boundary between solids that will settle in the allotted time in the vessel. The actual line location shown in FIG. 1 corresponds to propane solvent.
[0000]
TABLE 5
Minimum Particle Size to Settle
FIG. 1
Line B
μm
Propane
35
Butane
59
Pentane
81
Hexane
103
Heptane
126
Naphtha
228
[0064] Line B would shift to the left for the other solvents listed above. Clearly, propane is the most advantageous solvent because it removes most of the solids in vessel. For solids curve 3 in FIG. 1 , propane would remove 81% of the solids in the vessel, whereas pentane would only remove 69%. Naphtha would settle less than 50% of the solids in this time. The amount of water required to wash the fines away is directly proportional to the amount of fines. This indicates the difficulties present when using heavier solvents described in the prior art.
[0065] The operating pressure for the machine is the vapor pressure of the solvent at the desired temperature. The vessel must be capable of being sealed and re-opened each cycle. With each opening and closing there is a possibility of the seal failing to retain pressure. The vapor pressure of propane is 1.22 MPaa at 35° C., whereas the vapor pressure of pentane is only 0.098 MPaa. The higher the pressure, the greater the likelihood that the sealing system may leak. This is a counterbalancing requirement to using the lightest possible solvent.
Method of Bitumen Separation
[0066] The following steps describe the detailed preferred embodiment and are depicted in FIG. 5 . The equipment numbers are shown in FIG. 3 and the mechanical arrangement of the machine is depicted in FIGS. 6 a through 6 f.
[0067] In step 200 , the container 1 , in an open state shown in FIG. 6 a , is filled with bitumen ore. The container is tilted to such an angle that the ore will hit the side of the container as it is filled from the top, lessening any battering. A predetermined amount of ore is dumped into the vessel. The amount will allow sufficient space for the solvent to be added later.
[0068] The container is rotated to a vertical position in step 210 , FIG. 6 b . The lid 4 is rotated into the closed position using hinge system 5 . The sealing mechanism 6 locks the lid to the container and may confirm that the container is sealed by means of position sensors that indicate that the mechanism has achieved full locked position.
[0069] In step 220 , the container pressure is drawn down to near vacuum pressure to remove as much air as possible from the container. This may be accomplished by drawing the air through the vapor recovery system valve 22 . The air must be separated from the solvent because oxygen causes corrosion in downstream equipment, and because of possible explosive/flammable mixtures of oxygen and solvent. The container is then pressurized with solvent in step 230 . The air is then allowed to rise above the solvent, due to its lower density, and then vented to the flare system via valve 24 . This method has the disadvantage that some solvent is lost to the flare system.
[0070] In step 230 , valve 7 is opened and second mixture bitumen enriched (gray) solvent flows into header 10 up to valve 13 . Valve 13 is then opened and the gray solvent liquid flashes to vapor as it enters the vessel. The pressure is the vapor pressure of the solvent at the temperature of the ore and the solvent as they mix together. The solvent flushes upward through the ore providing an initial mixing period during the filling phase. The amount of solvent to be added will be determined by the composition of the ore. High quality ore will require more solvent to maintain the 1:1 ratio that has been used as the design basis. Valve 13 and valve 7 close once the correct amount of solvent has been added to the vessel.
[0071] Valve 14 is opened and pump 16 is turned on for a pre-determined period in step 240 to flush the ore with solvent. For high quality ore, the mixing period could be as low as five minutes. For lower grade ore, this period could be extended to ten minutes or longer. The solvent will flow down recycle pump header pipe 15 to the pump. The pump will push the solvent up through the discharge header 17 , and through the openings in the vessel. This will cause zones of high turbulence to be created at the bottom of the container where the various inlet streams impinge on the ore body. The ore will be washed quickly in this zone. Smaller particles will be carried upward because the upward velocity of the solvent stream is greater than their settling velocity. Larger unwashed particles will then settle between the inlet streams and be washed in turn. At the end of the period, the ore will be stratified with the largest particles at the bottom and the smaller particles at the top of the ore body in the vessel. Depending on the solvent used, some fines will settle immediately while others will remain suspended in the solvent-bitumen mixture. In another embodiment, the method of this step could be accomplished by replacing the recycle pump and associated piping with a ring assembly, as part of the support system 3 . The ring (or rings) around the circumference of the container would permit the container to rotate on its longitudinal axis, like a cement mixer, agitating and mixing the ore. At the end of step 240 pump 16 is stopped but valve 14 remains open to allow drainage of pipe 15 in subsequent steps.
[0072] In step 250 the fines flushed upwards during step 240 are allowed to settle downward towards the solids layer by gravity. The fines do not need to be allowed to settle completely. The fines layer only needs to descend to a level below the drain point such that the draining cycle, step 260 may begin without carrying them out of the vessel. The drain cycle will itself take time which will allow the fines level to descend down to the main solids layer below.
[0073] In step 260 , the container is rotated to an angle away from the vertical as shown on FIG. 6 c . The container pivot assemblies 3 are slowly powered to tilt the container. Valves 18 and 20 are opened. The solvent-bitumen-fines mixture drains out to the main drain to be collected and processed by other equipment. The speed of rotation of the vessel is such as to allow the quickest possible draining of the vessel while minimizing the fines carry over. An analogy would be the process of decanting wine. At the end of this step, Valves 14 , 18 and 20 are closed, the vessel is filled with solvent vapor and there is liquid solvent-bitumen mixture in the solids layer. The orientation of the vessel is as per FIG. 6 d.
[0074] In step 270 , the vessel is rotated to the upright position ( FIG. 6 b ) and valves 8 and 13 are opened to fill the vessel with clean solvent. As in step 230 , the solvent is flushed upwards through the ore body. Once the same amount of solvent as step 230 has been added, valves 8 and 13 are closed.
[0075] Step 280 's purpose is mainly to recover the bitumen trapped in the solids body. Valve 14 is opened and pump 16 is turned on for a period of time to ensure complete mixing of the solvent with the solids body. If sufficient mixing has already occurred in step 270 , this step may be omitted. At the end of this step, pump 16 is stopped and valve 14 remains open for drainage.
[0076] In step 290 , valves 9 and 13 are opened to add water to the vessel to displace solvent-bitumen mixture trapped in the solids body upwards. Typically this volume would be in the range of 35-40% of the solids volume. At the end of this step valves 9 and 13 are closed. It is important to note that this water will be largely made up of fines water that has already been used in downstream equipment to wash fines from the solvent bitumen mixture. As such, it contributes little or nothing to the water requirements of the system as a whole.
[0077] In step 300 , the vessel is rotated to drain the second solvent-bitumen mixture to the gray drain. Valves 18 and 21 are opened and the pivoting mechanism 3 is powered to move the vessel. This step differs from step 260 in that the fines have already been removed so the draining may be executed more quickly. At the end of this step some water may be carried over with the solvent. This is acceptable. Valves 18 , 21 and 14 are closed at the end of this step and the vessel is oriented as per FIG. 6 d.
[0078] In step 310 , the vessel contains solvent vapor and some liquid solvent in the solids body. A two stage depressuring operation is executed. Valve 22 is opened to vent the solvent to the vapor recovery header. Once the pressure of the vessel has equalized with the vapor recovery header, valves in the recovery system will close and a vacuum pump in that system will draw the pressure down to near vacuum to withdraw all solvent from the vessel. During this step it may be necessary to rotate the vessel via pivot system 3 to shift the solids body to allow vapors to escape. At the end of step 310 , valve 22 is closed and the vessel is oriented as per FIG. 6 d.
[0079] In step 320 , valve 28 is opened to allow air to re-enter the vessel.
[0080] In step 330 , the vessel is rotated to the vertical. When the vessel pressure has reached atmospheric it is unsealed using mechanism 6 . Valve 28 is closed and the lid is opened using hinge system 5 . The vessel will now be oriented as per FIG. 6 e.
[0081] In step 350 , the container is rotated to the dump position, using pivots 3 , as shown in FIG. 6 f . The bitumen depleted sand in the container is dumped out by gravity to a collection system below. The water system may be used to flush out the recycle system and encourage sand to fall out of the vessel. This may be done by opening valves 9 and 13 for a period. Additionally, special purpose cleaning piping may be added to use this water system to spay various parts of the vessel and sealing surfaces. Further, cleaning equipment outside the machine itself may be required. As in step 290 the water to be used will come from the fines wash effluent.
[0082] In step 360 , The container is rotated back to the filling position, as shown in FIG. 6 a , using pivots 3 .
[0083] The batch cleaning machine is comprised of the following parts, as illustrated in FIG. 3 .
[0084] The pressure container 1 is designed in the first embodiment as a pressure vessel capable of containing the ore and solvent at the solvent vapor pressure at the operating temperature.
[0085] In another embodiment, the vessel could be a flexible tube with openings at the top and bottom to allow the oil sand ore to be dumped in and then be opened to dump the cleaned sand out at the end of the cycle. The container supports 2 connect the machine to the supporting structure.
[0086] The container pivot assemblies 3 allow the container to rotate for filling, cleaning, draining and dumping. The pivot assemblies may be hydraulic, gear driven or even cable driven. The assemblies will have position sensors to allow the control system to automatically orient the container. In another embodiment, the pivot assembly would include a circumferential ring which would permit the vessel to be rotated on its longitudinal axis. This feature would replace the recycle pump system 16 .
[0087] The container lid 4 forms part of the pressure containing part of the machine along with the container 1 .
[0088] The container hinge mechanism 5 rotates the lid upward to permit filling and dumping, and downward for sealing. The mechanism may be hydraulic or electric gear driven and is equipped with position sensors to permit the control system to automatically orient the lid.
[0089] The container sealing system 6 may be a ring (as shown) like that seen on sealing jars holding the lid onto the pressure container. The ring may be a segmented screw which would mate with threads on the pressure container and seal with a 1/16 th turn. In other embodiments, the sealing system is a series of hydraulically operated clamps. Another embodiment has a series of bolts on the pressure container which mate with nuts in the lid (or the reverse). The nuts or bolts may be power driven to close and seal the container. The sealing system may be hydraulic, pneumatic or electric gear driven. The system has position sensors to indicate that the lid and container have mated. In another embodiment, the sealing system for the flexible vessel is comprised of two plates which press together to seal a flexible tube 1 .
[0090] The sealing system has dual seal rings in yet another embodiment. The dual seal rings would allow the inter seal ring annulus to be pressurized to a pressure intermediate between atmospheric and the operating pressure. Failure of the outer or inner seal ring would instantly be noted by a change of pressure in the annulus. This feature provides positive indication that the container is sealed properly and prevents undetected leakage of solvent. The air removal in step 220 permits indication of loss of containment before solvent is added to the vessel.
[0091] The automated gray solvent inlet valve 7 opens to add second mixture bitumen enriched solvent from the gray solvent system to the vessel.
[0092] The automated clean solvent inlet valve 8 opens to add clean solvent to the vessel from the solvent recovery system.
[0093] The water inlet valve 9 opens to add water to the vessel from fines wash effluent system.
[0094] All fluids entering the pressure container flow through the inlet header 10 which is fixed to the machine support structure. The header must be free draining into the vessel so that solvents are not trapped there in between cycles. As depicted in FIG. 3 , the header is a solid pipe material; however in some embodiments the pipe is made of completely or partially flexible hose.
[0095] Pipe joints 11 are 90° elbow pairs which have a seal which permits one elbow to rotate with respect to the other elbow. One side of the joint is fixed to the machine support structure. This joint permits the pipe on the rotating side to move with the pressure container. These joints may also be flexible hoses
[0096] Pipe joints 12 are 90° elbow pairs which have a seal which permits one elbow to rotate with respect to the other elbow. Both sides of the joint are connected to pipe which is free to move with the pressure container 1 . These joints may also be flexible hoses.
[0097] Pressure container inlet valve 13 is an automated valve that opens to permit the main inlet flows to the pressure container. Valve 13 also serves to seal the pressure container to leaks in any of the upstream valves ( 7 , 8 or 9 ).
[0098] Recycle pump inlet header valve 14 allows solvent to drain from the top of the pressure container to the inlet of the recycle pump.
[0099] Recycle piping 15 allows solvent to flow to the recycle pump, and is also the inlet point for liquids to the vessel.
[0100] The recycle pump 16 circulates the solvent upward through the material comprising bitumen to speed the solution of the bitumen in the solvent. This pump is designed as a slurry pump to be able to pass stones of moderate size.
[0101] The recycle pump discharge header 17 is comprised of a series of pipes connected to the discharge side of the recycle pump. The pipes carry the recycle solvent to a number of inlet ports on the bottom of the container 1 . These pipes are especially fabricated to have long radius bends and smooth transitions to discourage any solids that may pass through the pump from getting stuck in the header.
[0102] The automated container drain valve 18 opens during the draining and depressuring phases of the cleaning cycle to allow liquids and then solvent vapors to be removed from the vessel.
[0103] The outlet drain header 19 is used to remove all fluids from the vessel. It is comprised of a linkage of pipes which move with the vessel as it rotates. During the settling and draining steps 260 and 300 the header is free draining to the clean solvent and gray solvent systems.
[0104] The automated main drain valve 20 opens to allow the first stage bitumen enriched solvent mixture to be sent to the next stage of separation.
[0105] The automated gray drain valve 21 opens to allow the second stage bitumen enriched solvent mixture to be sent to the gray drain system.
[0106] The automated vapor recovery valve 22 opens to allow solvent vapors to flow to the vapor recovery system.
[0107] The vent header 23 is required to connect the vessel to the flare system so that vapors can be safely routed away from the vessel in the case of an emergency. The vent header is comprised of a linkage of pipes which move with the vessel as it rotates.
[0108] In some embodiments, the vent header may also contain a separate pipe and valve to permit vented air with a small component of solvent vapor to be sent to some of the various heaters associated with the overall plant to be used as fuel.
[0109] The depressuring valve 24 is an automated valve which opens to depressure the vessel in the case of an emergency. In other embodiments, it may also be used to permit air trapped in the vessel when it is sealed to be vented to the flare system.
[0110] Pressure safety valves 25 , 26 and 27 are required by safety code to protect the container 1 , inlet header 10 and outlet header 19 from overpressure.
[0111] Air vent valve 28 is an automated valve that opens at the end of the cleaning cycle, when all the solvents have been removed to allow atmospheric air into the vessel prior to unsealing the lid 4 .
[0112] As used herein, spatial or directional terms, such as “left,” “right,” “front,” “back,” and the like, relate to the subject matter as it is shown in the drawing Figures However, it is to be understood that the subject matter described herein may assume various alternative orientations and, accordingly, such terms are not to be considered as limiting. Furthermore, as used herein (i.e., in the claims and the specification), articles such as “the,” “a,” and “an” can connote the singular or plural. Also, as used herein, the word “or” when used without a preceding “either” (or other similar language indicating that “or” is unequivocally meant to be exclusive—e.g., only one of x or y, etc.) shall be interpreted to be inclusive (e.g., “x or y” means one or both x or y). Likewise, as used herein, the term “and/or” shall also be interpreted to be inclusive (e.g., “x and/or y” means one or both x or y). In situations where “and/or” or “or” are used as a conjunction for a group of three or more items, the group should be interpreted to include one item alone, all of the items together, or any combination or number of the items. Moreover, terms used in the specification and claims such as have, having, include, and including should be construed to be synonymous with the terms comprise and comprising. | A single solvent method and machine for separating bitumen from oil sand ore are disclosed. The method includes the use of a single light paraffinic solvent, such as propane or butane as the agent to separate the bitumen from mined oil sand ore. Since light paraffinic solvents are vapors at atmospheric pressure and temperatures, the ore is placed in a pressurized container so that the solvent remains in a liquid state. When the container is pressurized, by the addition of the solvent itself, the liquid solvent is mixed with the ore to effect separation. The proposed machine settles more than 80% of the solids out under gravity in a modest period of time. The solvent-bitumen mixture is drained after the cleaning cycle, the container is depressured to a vapor recovery system and the remaining solids dumped out. The fine solids, drained with the liquids, are separated from the liquid mixture with relative ease by the use of current technology in other downstream equipment. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of pending patent application Ser. No. 14/858,417, filed Sep. 18, 2015, and European Patent Application No. 15185813.1, filed on Sep. 18, 2015, both of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to an acoustical module configured to separate sound pressure signals from external sources. In particular, the present invention relates to an acoustical module where the influence of self-generated signals is attenuated.
BACKGROUND OF THE INVENTION
[0003] Various arrangements involving two sound detectors have been suggested over the years.
[0004] An example is U.S. Pat. No. 8,259,976 where an assembly comprising a sound emitter and at least two sound detectors fixed to each other is disclosed. Each detector has a sound receiving opening. The sound receiving openings of at least two of the detectors point in opposite directions. However, there is in U.S. Pat. No. 8,259,976 no disclosure of a feedback suppression algorithm for reducing the influence of self-generated signals, such as acoustic signals and vibration signals.
[0005] It may be seen as an object of embodiments of the present invention to provide an acoustical module where the influence of self-generated signals is attenuated. Such self-generated signals may involve acoustical signals and vibration signals.
SUMMARY OF INVENTION
[0006] The above-mentioned object is complied with by providing, in a first aspect, an acoustical module comprising
[0007] a receiver unit for generating audio sound,
[0008] a plurality of microphone units for receiving acoustical pressure signals,
[0009] a plurality of acoustical pressure pick-up points, each of said acoustical pressure pick-up points being acoustically connected to a microphone unit, and
[0010] an acoustical filter for attenuating an acoustical pressure signal arriving at a first acoustical pressure pick-up point relative to a second acoustical pressure pick-up point.
[0011] The acoustical module of the present invention is thus adapted to receive incoming acoustical pressure signals via a plurality of microphone units and regenerate the received signal via the receiver unit. The acoustical module of the present invention may be applicable in relation to hearing devices, such as various types of hearing aids.
[0012] In the present content pressure pick-up points are to be understood as openings and/or holes through which incoming acoustical pressure signals are allowed to enter the acoustical module. In order to convert the incoming acoustical pressure signals to electrical signals at least one microphone unit may be acoustically connected to each of the pressure pick-up points.
[0013] In the present content acoustical pressure signals are to be understood as acoustical sound/audio signals representing for example speech, music etc.
[0014] The receiver unit may comprise a single receiver or a plurality of receivers. In case of a single receiver a single acoustical signal and a signal vibration signal is generated. A plurality of receivers may collectively generate both acoustical signals and vibration signals. The contribution of all receivers may be combined into a total acoustic signal and a total vibration signal.
[0015] The acoustical filter may advantageously be positioned between the first and the second acoustical pressure pick-up points. In this manner an incoming acoustical signal may be attenuated upon passing the acoustical filter so that the acoustical pressure pick-up points receive an incoming acoustical signal with different strengths.
[0016] In view of the remarks set forth above a first microphone unit may be acoustically connected to the first acoustical pressure pick-up point, and a second microphone unit may be acoustically connected to the second acoustical pressure pick-up point.
[0017] The acoustical filter may form a dome shaped structure or at least a part of a dome shaped structure. Alternatively, it may be attached to a dome shaped structure. Dome shaped structures may exhibit additional properties in relation to the acoustical module. Such additional properties may include proper fixation of the acoustical module in an ear channel. Along this line the acoustical filter may form part of, or being attached to, an element which is adapted to support fixation of the acoustical module in an ear channel.
[0018] The acoustical module may further comprise one or more additional domes or elements for additional support of the fixation of the acoustical module in the ear channel.
[0019] The acoustical module may further comprise an additional acoustical filter and a third acoustical pressure pick-up point being acoustically connected to a microphone unit. In this embodiment the additional acoustical filter may either be positioned between the second and the third acoustical pressure pick-up points or between the first and second pressure pick-up points. Additionally, acoustical filters can be placed between all off the pressure pick-up points. By applying more than two acoustical pressure pick-up points the suppression of the unwanted signals can be further improved. In addition, the reconstruction of the head-related transfer function (HRTF) could be at least partly achieved which is otherwise lost due to the fact that the microphone units are not at the exact position of the ear drum. Finally, additional acoustical pressure pick-up points may also be used to generate another desired directionality of the acoustical module. The additional acoustical filter may form part of a dome shaped structure or it may be attached to a dome shaped structure being shaped in a manner so that it supports fixation of the acoustical module in an ear channel.
[0020] The plurality of microphone units may comprise omni-directional microphone units and/or directional microphone units.
[0021] A sleeve may be provided to ease fixation of a dome to the exterior of the acoustical module. As already stated the dome may either comprise or have an acoustical filter attached thereto. The sleeve may be manufactured using an injection mouldable material, such as a polymer material. Preferably, the sleeve and the dome form a one-piece component.
[0022] The plurality of acoustical pressure pick-up points may act as one or more venting holes for the receiver unit. Thus, in case the acoustical module comprises for example two acoustical pressure pick-up points a single or both of these pressure pick-up points may be used for venting the receiver unit. In case the acoustical module comprises for example three acoustical pressure pick-up points one, two or three pressure pick-up points may be used for venting the receiver unit. Alternatively or in combination therewith, a plurality of dedicated venting holes may act as one or more venting holes for the receiver unit may be provided.
[0023] The acoustical module may further comprise a protection arrangement for preventing dust or other impurities to enter the plurality of acoustical pressure pick-up points. The protection arrangement may comprise a number of barrier structures being either secured to or forming part of the sleeve.
[0024] In a second aspect the present invention relates to a hearing device comprising an acoustical module according to the first aspect. The hearing device may comprise a hearing aid of any type, including in-the-channel (ITC) type hearing aids.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The present invention will now be described in further details with reference to the accompanying figures, wherein
[0026] FIG. 1 shows a first embodiment of an acoustical module having two acoustical pressure pick-up points and an acoustical filter realized by means of a dome positioned therebetween,
[0027] FIG. 2 shows an acoustical module having three acoustical pressure pick-up points and two acoustical filters by means of domes positioned therebetween,
[0028] FIG. 3 shows a second embodiment of an acoustical module having two acoustical pressure pick-up points and an acoustical filter by means of a dome positioned therebetween,
[0029] FIG. 4 shows an acoustical module having two acoustical pressure pick-up points and an acoustical dome positioned therebetween, the acoustical filter by means of a dome being secured to a sleeve of a first type,
[0030] FIG. 5 shows an acoustical module having two acoustical pressure pick-up points and an acoustical filter by means of a dome positioned therebetween, the dome being secured to a sleeve of a second type,
[0031] FIG. 6 shows an acoustical module having two protected acoustical pressure pick-up points and an acoustical filter by means of a dome positioned therebetween, the dome being secured to a sleeve of a second type, and
[0032] FIG. 7 shows an acoustical module having two acoustical pressure pick-up points, an acoustical filter by means of a dome positioned therebetween, the dome being secured to a sleeve of a first type, and a locking mechanism.
[0033] While the invention is susceptible to various modifications and alternative forms specific embodiments have been shown by way of examples in the drawings and will be described in details herein. It should be understood, however, that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In its most general aspect the present invention relates to an acoustical module being capable of suppressing self-generated acoustical signal and self-generated vibrations. In its most simple implementation the acoustical module comprises a sound generating receiver and two acoustical pressure pick-up points where acoustical sound is allowed to enter the module. One or more acoustical filters are provided between the acoustical pressure pick-up points.
[0035] Each of the two acoustical pressure pick-up points picks up the following signals:
[0036] 1) external sound, i.e. the signal to be detected
[0037] 2) self-generated acoustical sound
[0038] 3) self-generated vibration signal
[0039] The acoustical module of the present invention is adapted to be positioned inside the ear channel. In this position the two acoustical pressure pick-up points form an outer pick-up point, A, and an inner pick-up point, B.
[0040] As stated above each of the two acoustical pressure pick-up points will pick up a self-generated acoustical receiver signal, S Rec,acc , a self-generated vibration receiver signal, S Rec,vib , and the external acoustical sound, S Ext . This may be expressed as follows:
[0000] S MicA =S Rec,acc A +S Rec,vib A +S Ext A (1)
[0000] S MicB =S Rec,acc B +S Rec,vib B +S Ext B (2)
[0041] where S MicA and S MicB are microphone signals being acoustically connected to the acoustical pressure pick-up points A and B, respectively.
[0042] Since the two contributions of the receiver (S Rec,acc and S Rec,vib ) are generated by the same source they are highly correlated, and may therefore be combined into one source (eq. (3) and (4))
[0000] S Rec A =S Rec,acc A +S Rec,vib A (3)
[0000] S Rec B =S Rec,acc B +S Rec,vib B (4)
[0043] which when substituted into eq. (1) and (2) yields
[0000] S MicA =S Rec A +S Ext A (5)
[0000] S MicB =S Rec B +S Ext B (6)
[0044] The ratio between the total contributions from the receivers
[0000]
δ
Rec
A
-
B
=
S
Rec
A
S
Rec
B
(
7
)
[0045] can be assumed as being frequency dependent, but constant over time. Moreover, the influence of the external acoustic scenery is minimized by the fact, that the acoustical module is placed inside the ear channel.
[0046] By knowing the ratio δ Rec A−B for the acoustical module in a given wearing position, an artificial microphone signal can be calculated from two acoustical pressure pick-up points, which does not contain a self-generated component originating from the receiver.
[0000] S Mic art =S A −δ Rec A−B ·S B (8)
[0047] By applying eq. (5), this can be rewritten as:
[0000] S Mic art =S Ext A −δ Rec A−B S ext B (9)
[0048] Similarly, by knowing the ratio
[0000]
δ
Ext
B
-
A
=
S
Ext
B
S
Ext
A
[0000] in which external sound is picked up by the module in a given wearing position, the sensitivity of the artificial microphone signal S Mic art can be compared to the external sound sources of a single microphone.
[0000] S Mic art =S Ext A (1−δ Rec A−B δ Ext B−A ) (10)
[0049] Since the noise of the microphones can be assumed as being non-correlated, the total noise of the artificial microphone can be assumed as:
[0000] N Mic art =√{square root over (( N MicA ) 2 +(δ Rec A−B ·N MicB ) 2 )} (11)
[0050] Under the assumption that two identical microphones are used in relation to acoustical pressure pick-up points A and B, the total noise can be assumed as:
[0000] N Mic art =N Mic √{square root over (1+(δ Rec A−B ) 2 )} (12)
[0051] The signal-to-noise ratio (SNR) of a single microphone being acoustically connected to pressure pick-up point A, without considering the acoustical and vibration feedback signals of the receiver, would be:
[0000]
S
N
R
Mic
A
=
S
Ext
A
N
Mic
(
13
)
[0000] The SNR of the artificial microphone would be:
[0000]
S
N
R
Mic
art
=
S
Ext
A
N
Mic
·
(
1
-
δ
Rec
A
-
B
δ
Ext
B
-
A
)
1
+
(
δ
Rec
A
-
B
)
2
(
14
)
[0052] The SNR of the acoustical module can be optimized by adding a filtering element, which reduces the external sound signal in pressure pick-up point B relative to pressure pick-up point A, whereby minimizing the term δ Ext B−A as well as the SNR of the artificial microphone.
[0053] Moreover, by applying more than two acoustical pressure pick-up points the robustness of the suppression of the receiver signals (S Rec,acc and S Rec,vib ) can be further improved. In addition, the reconstruction of the HRTF could be at least partly achieved, which is partially lost due to the fact that the microphones are not at the exact position of the ear drum. Additional acoustical pressure pick-up points could also be used to generate another desired directionality of the acoustical module.
[0054] As stated above the SNR of the acoustical module can be improved by adding a damping and/or a filtering element between the acoustical pressure pick-up points A and B in order to reduce the external sound signal in pressure pick-up point B relative to pressure pick-up point A.
[0055] A suitable filtering element may be implemented as a dome as already used in today's receiver-in-channel (RIC) hearing aids to hold the receiver in place. Alternatively, any other acoustic sealing/filtering element or another support element to hold the acoustic module in a certain position relative to the ear canal may be applied as a filter. This type of dome may be seen as a passive acoustic element. The dome provides an acoustic resistance, a mass and a compliance which is mainly defined by the leakage around the dome and through-going openings/holes in the dome. The openings/holes can be designed in such a way, that a wanted combined resistance/mass/compliance is achieved. The created effective acoustic filter is defined by these values and the surrounding acoustic environment.
[0056] By adding an acoustic filtering element, such as a dome, between two acoustical pick-up points a beneficial change in signal attenuation between the two pick-up points can be achieved. Moreover, the influence of self-generated acoustic and vibration feedback signals can be suppressed by proper signal processing.
[0057] In the following various embodiments of the present invention will be disclosed.
[0058] Referring now to FIG. 1 an embodiment 100 of the present invention is depicted. As seen the acoustical module 101 comprises two acoustical pressure pick-up points 102 , 103 for receiving incoming sound from the outer ear 108 . The acoustical module is positioned in the ear channel 107 with a sound generating receiver 104 facing the eardrum (not shown). A pair or dome shaped acoustical filters 105 , 106 improve the wearing comfort of the acoustical module while being positioned in the ear channel 107 . The dome 106 forms an acoustical filter between acoustical pressure pick-up points 102 , 103 so that acoustical sound arriving from the outer ear 108 is attenuated before arriving at pressure pick-up point 103 . Thus, the acoustical sound signal reaching pressure pick-up point 103 is attenuated relative to the acoustical sound pressure reaching pressure pick-up point 102 . By applying the above-mentioned signal processing algorithm the influence of self-generated acoustical signals as well as self-generated vibration signals can be attenuated.
[0059] The acoustical module depicted further comprises an arrangement of microphone units (not shown) being acoustically connected to the acoustical pressure pick-up points 102 , 103 . The microphone units applied may be omni-directional and/or directional microphones in suitable combinations. Also, microphone modules comprising for example two microphone units and a common back volume are applicable as well.
[0060] The acoustical pressure pick-up points 102 , 103 may optionally be used as one or more venting holes for the sound generating receiver 104 . Alternatively or in combination therewith one or more dedicated venting holes (not shown) may be provided. A dedicated venting hole is to be understood as a venting hole not serving any other purpose than being a venting hole for the receiver.
[0061] Several advantages are associated with the arrangement depicted in FIG. 1 . Firstly, the wearing comfort and/or the retention force of the acoustical module are both improved. The reason for this being that two domes leads to an increase of the surface touching the ear channel. This increased surface area can either be used to reduce the local contact pressure while keeping the retention force at the same level as with a single dome, or to increase the retention force without increasing the contact pressure. Secondly, the stable positioning of the acoustical pressure pick-up points relative to the ear channel prevents blockage of the pick-up points.
[0062] Referring now to FIG. 2 another embodiment 200 of the present invention is depicted. As seen the acoustical module 201 comprises three acoustical pressure pick-up points 202 , 203 , 204 for receiving incoming sound from the outer ear 210 . The acoustical module is positioned in the ear channel 209 with a sound generating receiver 205 facing the eardrum (not shown). Three dome shaped acoustical filters 206 , 207 , 208 improve the wearing comfort of the acoustical module while being positioned in the ear channel 209 . The domes 207 , 208 form acoustical filters between acoustical pressure pick-up points 203 , 204 and 202 , 203 , respectively. This ensures that acoustical sound arriving from the outer ear 210 is attenuated before arriving at pressure pick-up points 203 , 204 . By applying the above-mentioned signal processing algorithm the influence of self-generated acoustical signals as well as self-generated vibration signals can be attenuated. Moreover, by applying a third acoustical pressure pick-up point the robustness of the suppression of the receiver signals (S Rec,acc and S Rec,vib ) can be further improved, cf. the above algorithm. In addition, the reconstruction of the HRTF could be at least partly achieved.
[0063] Similar to FIG. 1 the acoustical module depicted in FIG. 2 further comprises an arrangement of microphone units (not shown) being acoustically connected to the acoustical pressure pick-up points 202 , 203 , 204 . As already addressed the microphone units applied may be omni-directional and/or directional microphones in suitable combinations. Also, microphone modules comprising for example two microphone units and a common back volume are applicable as well. The acoustical pressure pick-up points 202 , 203 , 204 may optionally be used as one or more venting holes for the sound generating receiver 205 . Alternatively or in combination therewith one or more dedicated venting holes (not shown) may be provided. A dedicated venting hole is to be understood as a venting hole not serving any other purpose than being a venting hole for the receiver.
[0064] FIG. 3 shows a simple embodiment 300 of the present invention. As seen the acoustical module 301 comprises two acoustical pressure pick-up points 302 , 303 for receiving incoming sound from the outer ear 307 . The acoustical module is positioned in the ear channel 306 with a sound generating receiver 304 facing the eardrum (not shown). A dome shaped acoustical filter 305 is positioned between acoustical pressure pick-up points 302 , 303 so that acoustical sound arriving from the outer ear 307 is attenuated before arriving at pressure pick-up point 303 . Thus, the acoustical sound signal reaching pressure pick-up point 303 is attenuated relative to the acoustical sound pressure reaching pressure pick-up point 302 . The acoustical pressure pick-up points 302 , 303 may optionally be used as one or more venting holes for the sound generating receiver 304 . Alternatively or in combination therewith one or more dedicated venting holes (not shown) may be provided. A dedicated venting hole is to be understood as a venting hole not serving any other purpose than being a venting hole for the receiver.
[0065] Referring now to FIG. 4 an embodiment 400 of the present invention is depicted. As seen the acoustical module 401 comprises two acoustical pressure pick-up points 402 , 403 for receiving incoming sound from the outer ear 408 . The acoustical module is positioned in the ear channel 407 with a sound generating receiver 404 facing the eardrum (not shown). A pair or dome shaped acoustical filters 405 , 406 improve the wearing comfort of the acoustical module while being positioned in the ear channel 407 . The dome 406 forms an acoustical filter between acoustical pressure pick-up points 402 , 403 so that acoustical sound arriving from the outer ear 408 is attenuated before arriving at pressure pick-up point 403 . By applying the above-mentioned signal processing algorithm the influence of self-generated acoustical signals as well as self-generated vibration signals can be attenuated. The acoustical pressure pick-up points 402 , 403 may optionally be used as one or more venting holes for the sound generating receiver 404 . Alternatively or in combination therewith one or more dedicated venting holes (not shown) may be provided. A dedicated venting hole is to be understood as a venting hole not serving any other purpose than being a venting hole for the receiver.
[0066] The dome 406 is attached to or integrated with the sleeve 409 which is dimensioned to match the outer dimension of the acoustical module 401 . The sleeve 409 makes it easier to mount the dome 406 to the acoustical module 401 . Preferably, the sleeve 409 is manufactured by a flexible/elastic material so that it may be kept in position relative to the acoustical module 401 by contractive forces. Also, the dome 406 and the sleeve 409 are preferable made as an integrated component, i.e. a one-piece component.
[0067] In the embodiment 500 depicted in FIG. 5 the length of the sleeve 509 has been increased so that it now surrounds the two acoustical pressure pick-up points 502 , 503 of the acoustical module 501 . Similar to the previous figures the acoustical module of FIG. 5 is positioned in an ear channel 507 with a sound generating receiver 504 facing the eardrum (not shown). Again, a pair or dome shaped acoustical filters 505 , 506 improve the wearing comfort of the acoustical module while being positioned in the ear channel 507 . The dome 506 forms an acoustical filter between acoustical pressure pick-up points 502 , 503 so that acoustical sound arriving from the outer ear 508 is attenuated before arriving at pressure pick-up point 503 . As previously stated, by applying the above-mentioned signal processing algorithm the influence of self-generated acoustical signals as well as self-generated vibration signals can be attenuated. The acoustical pressure pick-up points 502 , 503 may optionally be used as one or more venting holes for the sound generating receiver 504 . Alternatively or in combination therewith one or more dedicated venting holes (not shown) may be provided. A dedicated venting hole is to be understood as a venting hole not serving any other purpose than being a venting hole for the receiver.
[0068] In FIG. 6 protection grids have been arranged in front of the two acoustical pressure pick-up points 602 , 603 . The protection grids may be separate grids or they may form an integral part of the sleeve 609 . Otherwise the embodiment 600 of FIG. 6 is similar to that of FIG. 5 thus comprising an acoustical module 601 having domes 605 , 606 attached thereto—the latter via the sleeve 609 . A sound generating receiver 604 faces the eardrum of the ear channel 607 which terminates at the outer ear 608 . Again, the acoustical pressure pick-up points 602 , 603 may optionally be used as one or more venting holes for the sound generating receiver 604 . Alternatively or in combination therewith one or more dedicated venting holes (not shown) may be provided. A dedicated venting hole is to be understood as a venting hole not serving any other purpose than being a venting hole for the receiver.
[0069] The embodiment 700 shown in FIG. 7 has an integrated sports lock 710 . Otherwise it us similar to the embodiment shown in FIG. 4 thus comprising an acoustical module 701 comprises two acoustical pressure pick-up points 702 , 703 for receiving incoming sound from the outer ear 708 . The acoustical module is positioned in the ear channel 707 with a sound generating receiver 704 facing the eardrum (not shown). The two dome shaped acoustical filters 705 , 706 improve the wearing comfort while being positioned in the ear channel 707 . The dome 706 forms an acoustical filter between acoustical pressure pick-up point 702 and 703 . By applying the above-mentioned signal processing algorithm the influence of self-generated acoustical signals as well as self-generated vibration signals can be attenuated. As disclosed in relation to the previous embodiments the acoustical pressure pick-up points 702 and 703 may optionally be used as one or more venting holes for the sound generating receiver 704 . Alternatively or in combination therewith one or more dedicated venting holes (not shown) may be provided. A dedicated venting hole is to be understood as a venting hole not serving any other purpose than being a venting hole for the receiver.
[0070] The implementation of the dome 706 /sleeve 709 is disclosed in detail in relation to the embodiment shown in FIG. 4 .
[0071] In the above embodiment the domes 105 , 206 , 405 , 505 , 605 and 705 have been disclosed as acoustical filters. However, this may necessary not be the case in that these domes have the primary purpose of supporting the acoustical module. | The present invention relates to an acoustical module comprising a receiver unit for generating audio sound, a plurality of microphone units for receiving acoustical pressure signals, a plurality of acoustical pressure pick-up points, each of said acoustical pressure pick-up points being acoustically connected to a microphone unit, and an acoustical filter for attenuating acoustical pressure signals from a first acoustical pressure pick-up point relative to a second acoustical pressure pick-up point. The invention further relates to a hearing device comprising an acoustical module. | 7 |
FIELD OF THE INVENTION
The present invention relates to a total refacing system for conventional suspended ceilings. Easy snap on sections cover the lengths of all of the T-bar grids and cross grids as well as corners, intersections and peripheral grids. Thin self-adhering sheets cover the removable ceiling panels.
BACKGROUND OF THE INVENTION
Suspended ceilings are common in commercial buildings as well as in private residences. Such ceilings provide a variety of decorator finishes as well as a means to conceal an unsightly ceiling, conduits, electrical circuitry and sprinkler system supply pipes, while maintaining easy access to same.
In a suspended ceiling, a series of parallel T-bar grids is suspended from the structural ceiling by wires or other means. Perpendicular grids are joined at regularly spaced intervals and rectangular panels are placed on the flanges of the grids to complete the system. After a period of time the ceiling often becomes stained and soiled but the structural integrity of ceiling has not been compromised. This is especially true in commercial settings where industrial fumes, smoke, and other airborne particulates are deposited over time and where water leakage can cause rusting and stains. Even when a decorating change is not anticipated but only a clean look is desired, funds to replace the ceiling may not be available or it is not cost effective for the use of the premises. In residential settings a change in room decor may be desired and the suspended ceiling is not usually amenable to such changes. Painting a suspended ceiling is not easily accomplished and would not yield a satisfactory result.
There have been patents issued for a variety of ceiling systems utilizing the conventional T-bar grids. Most of these are for a particular decorator effect, primarily the three-dimensional effect of an expensive wood ceiling or an old fashioned "tin ceiling". In such cases inlaid panels are required to complete the decor. These may be practical in a smaller setting or where the cost of resurfacing is not in issue, but they do not solve the problem where larger areas are involved and cost is a major factor.
Many of the additions to the standard grid system must be installed initially with the grids and cannot be used to redecorate at a later time. These components must be installed by sliding the refacing strips over the ends of each T-bar grid before it is suspended (U.S. Pat. Nos. 3,319,389 to Levine; No. 4,722,161 to Young). A patent has isssued for a three dimensional strip that is bonded to the grids during manufacture and has a companion molded panel that gives a single construction three dimensional appearance to the finished ceiling (U.S. Pat. No. 4,189,888 to Blitzer). The ceiling of Blitzer is permanent and does not lend itself to refacing. Carved wooden moldings attached to the grids by means of special clips are taught by Anderson (U.S. Pat. Nos. 4,452,021) and Adams (U.S. Pat. No. 5,239,801).
Sanborn teaches the use of wood or wood grain beams affixed to the grids by means of hook and loop fastener strips or adhesives (U.S. Pat. No. 4,747,246). These beams also give a flamed or three dimensional appearance to the finished ceiling. Bischel et al. (U.S. Pat. No. 5,265,393) and Blitzer (U.S. Pat. No. 4,849,054) teach a three dimensional ceiling whereby beams attach to the grids to provide recessed areas in the ceiling.
None of the above systems would be practical in a commercial building where a ceiling has become dingy or damaged but the owner has no desire to invest a large sum of money in a decorator look. Weinar (U.S. Pat. Nos. 4,055,930 and 4,115,970) has developed refacing strips that are applied over the existing grids to give a fresh appearance. These strips are supported along their lengths on one side only and the strip could begin to drop or sag under its own weight or under the weight of a ceiling panel or lighting fixture resting thereon. There are no corner pieces and peripheral strips are formed by cutting the regular strips along a preformed cut line. Weinar also uses special cross caps to be applied over the intersection points to cover and conceal unsightly joints at the intersections. These caps rest on top of the strips and add another dimension or layer to the grid refacing. To cover a T-intersection the cross cap is cut along a preformed cut line.
In all of these systems the grid facing strips or beams must be cut to size before installation. This process requires time and allows for human error in cutting the strips in the exact lengths needed. This can often result in gaps or rough sections along the cut edges so that the two pieces cannot be perfectly contiguous along their entire abutments. The resulting refacing will not appear smooth and homogenous. Also, if the cuts are not perfectly perpendicular to the longitudinal edges the entire grid system can be forced out of proper alignment.
There is a need for a simple, inexpensive refacing system that can be snapped over the existing grids easily without special tools, with a minimum of on-site cutting, resulting in a smooth, planar and homogeneous appearance, and which provides refacing for the ceiling panels as well.
BRIEF SUMMARY OF THE INVENTION
The present invention provides ready cut strips, cross covers, T-covers and corner covers to be snapped over the grids of a conventional dropped ceiling to reface grids that have become damaged, rusted, stained or where a new color is desired. All of the components of the system lie in the same plane so as not to add another dimension or layer to the grids. Refacing sheets are provided for the ceiling panels. The original integrity of the ceiling remains basically the same.
It is an object of the present invention to provide a refacing system for an existing dropped ceiling that is quick and easy to install, remove or replace, and requires no special tools.
It is another object of the present invention to provide a refacing system for an existing dropped ceiling that is relatively inexpensive.
A further object of the present invention is to be able to reface the grids and the panels with complimenting colors or finishes.
Another object of the present invention is to have a series of grid refacing components to fit the various lengths and shapes needed so that, except for the peripheral areas, no cutting of the components is required.
An object of the present invention is to have grid refacing components that can be snapped onto the grids with very little force such as not to cause distortion, bending, or misalignment of the suspended grids and whereby the new components are light in weight so as not to add additional stress to the superstructure.
A still further object of the present invention is to have the components abut each other with no overlap or visible spaces between them and such that the finished system lies in a single plane.
Another object of the present invention is to provide self-adhering pre-cut sheets to easily and quickly reface the ceiling panels and which do not add appreciative weight or bulk to the panels.
A further object of the present invention is to have the grid refacing components removable so that further refacing can occur at a future time.
Other features and advantages of the invention will be seen from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is plan view looking up at a suspended ceiling and showing in outline all of the components of the instant invention.
FIG. 2 is a perspective view of a T-bar molding and an adjacent cross piece molding proper alignment.
FIG. 3 is a perspective view of an L-bar molding and an adjacent inside corner molding in proper alignment.
FIG. 4 is an end elevation of an L-bar molding showing the 50° angle of the upward facing surface of the return flange.
FIG. 5 is an end elevation of a T-bar molding showing the 30° angle of the upward facing surface of the return flange.
FIG. 6 is a perspective view of portions of an L-bar molding.
FIG. 7 is a perspective view of an inside corner molding.
FIG. 8 is a perspective view of an outside corner molding.
FIG. 9 is a perspective view of a cross piece molding.
FIG. 10 is a perspective view of a T-piece molding.
FIG. 11 is a perspective view of portions of a T-bar molding.
FIG. 12 is a perspective view of a facing cover for a 2'×2' ceiling tile and its backing sheet.
FIG. 13 perspective view of a facing cover for a 2'×4' ceiling tile and its backing sheet.
FIG. 14 is a perspectiver view of a 2' wide roll of ceiling tile facing with backing.
FIG. 15a is an end elevation of a T-bar grid and T-bar molding before installation.
FIG. 15b is an end elevation of a T-bar grid and T-bar molding during installation.
FIG. 15c is an end elevation of a T-bar grid and T-bar molding after installation.
FIG. 15d is a perspective view of a portion of a T-bar grid and T-bar molding after installation.
FIG. 16a is an end elevation of an L-bar grid and L-bar molding before installation.
FIG. 16b is an end elevation of an L-bar grid and L-bar molding during installation.
FIG. 16c is an end elevation of an L-bar grid and L-bar molding after installation.
FIG. 16d is a perspective view of a portion of an L-bar grid and L-bar molding after installation.
FIG. 17a is a perspective view of a 2'×2' ceiling tile showing the facing being applied.
FIG. 17b is a perspective view of a 2'×2' ceiling tile showing the facing in place.
DETAILED DESCRIPTION OF THE INVENTION
The ceiling refacing system of the present invention consists of a series of component parts to reface the T-bar and L-bar grids of the conventional suspended ceiling and provides sheets to reface the ceiling panels so that a fresh overall surface is obtained. The present system is not designed to provide a recessed or multidimensional effect to the finished ceiling, but to put a new face on the old ceiling. When in place, all eight grid molding components are designed to lie in a single plane and to cleanly abut each other for a continuous and uniform appearance. (See FIGS. 2 and 3) The components have been designed to accommodate all possible linear and angular portions and intersections of a conventional suspended ceiling grid system. The only cutting necessary during installation is to fit the components near the corners and peripheral areas of the room. This system not only makes installation quick and easy, but results in clean and linear abutments of all components for a very finished look. The complementary self-adhering refacing sheets for the ceiling panels are quickly and easily applied to complete the refacing.
This system 20 is designed for use with the suspended ceilings that utilize 2'×4' ceiling panels 33 and 2'×2' ceiling panels 34 supported on appropriately arranged T-bar grids 31 and L-bar grids 32. The T-bar grids are suspended in longitudinal and transverse alignment and the L-bar grids are suspended about the periphery of the room. The various components of the system 20 of the instant invention are fitted over the exposed surfaces of the T-bar and L-bar grids to form a smooth, one dimensional continuous cover or new facing. These components are dimensioned to exactly fit all exposed grid areas and to lie in abutment with each other and in a single plane.
When the original suspended ceiling is erected, it is necessary to cut the grids to conform to the dimensions of the room. This neccessitates sections that are smaller than the 2'×2' or 2'×4' panels about the peripheral areas. To fit these sections the ceiling panels must be cut appropriately. The components of the system 20 are designed to fit the standard dimensions and need only be cut to fit along those peripheral areas. FIG. 1 illustrates the various components of the system 20 and the existing suspended ceiling being refaced. The components are not shown in abutment, but are properly positioned to show how each is to be utilized.
The basic T-bar molding 36 is designed to be snapped on over the T-bar grids with minimal upward force so as not to cause distortion or misalignment of the suspended grids. The T-bar molding is a long strip of stiff but pliable material with a vertical wall 37 along each longitudinal edge providing, in cross-section, substantially a U-shape, to securely seat and form a snug fit about the T-bar grid 31 as in FIG. 15c and d. There are return flanges 38 on the upper edge of each vertical wall 37.(FIG. 11) The return flanges 38 extend inward and have an upward facing surface 39, a downward facing surface 40 and an inward facing edge 41. (FIG. 5) The downward facing surface 40 is horizontal and when the molding is in place it extends over the flange 42 of the T-bar grid 31 to support the molding. (FIG. 15c)
The upward facing surface 39 forms a 30° angle with the vertical wall 37 of the molding as shown in FIG. 5. This angle assists in the installation of the molding which is accomplished by holding the molding directly under the T-bar grid 31 and gently pressing it up against the grid. The angled upward facing surfaces 39 slide against the flanges 42 of the grid causing the side walls 37 to be displaced outwardly until the inward facing edges 41 of the return flanges pass the edges of the grid flanges 42 and the sidewalls 37 snap back into vertical alignment. The grid is then securely seated against the interior bottom surface 43 of the molding and the return flanges 38 extend over the grid flanges 42. This can be seen in FIGS. 15a-d. The smooth inclined surface helps the T-bar grid to slide into the molding smoothly without the installer having to exert too much pressure. The T-bar grids are not caused to be bent, distorted or forced out of alignment. There are two sizes of T-bar moldings, the four foot length T-bar molding 21 (actually 44.5 in.) and the two foot length T-bar molding 22 (actually 20.5 in.). These are sized to fit the necessary distances between the sites where the grids abut or intersect each other in the standard suspended ceiling with allowance for the intersection moldings. They are seen in FIG. 1.
To provide a smooth and uniform appearance to the completed ceiling special components are designed to cover the intersections of the T-bar grids. Where the grids cross each other cross piece moldings 23 are provided. (FIGS. 2 and 9) These are in the form of a symmetrical X having perpendicular arms 44. Each arm 44 extends 1.25 inches from the square central portion. The cross-section of each arm is the same as the cross-section of the T-bar molding 36, as seen in FIG.5, having two vertical sidewalls 45 with the return flanges 46 having upward facing surfaces 47 forming 30° angles from the vertical. The cross piece moldings are installed in the same manner, by gentle upward pressure against the intersection of the T-bar grids. Once in place, the exposed surfaces of the intersecting grids are seated securely on the interior bottom surface 48 of the cross piece molding. FIG. 2 shows a cross piece molding in contact alignment with a T-bar molding.
In some ceiling installations one T-bar grid may abut the longitudinal edge of another to form a T joint. A T-piece molding 24 is placed over this point of abutment. The T-piece molding has a T-shaped base or a three arm T structure as seen in FIG. 10. There are vertical side walls 50 along the opposing edges of each arm 49 and return flanges 51 along the upper edge of each vertical sidewall with the same acute angle configuration as those of the cross piece moldings and the T-bar moldings. The method of installation is the same.
Around the periphery of the room L-bar grids 32 are used where the ceiling abuts the walls. L-bar moldings 35 (FIGS. 4 and 6) are designed to reface these grids. The L-bar moldings are formed in four foot lengths. Along one longitudinal edge there is a vertical wall 52 with a return flange 53. The return flange 53 has an upward facing surface 54, a horizontal downward facing surface 55 and an inward facing edge 56. The upward facing surface 54 forms a 50° angle with the vertical. See FIG. 4. The return flange 53 and downward facing surface 55 of the L-bar molding are longer than the corresponding parts of the T-bar moldings because the L-bar moldings are supported on one side only. There is a straight vertical wall 57 along the opposing longitudinal edge of the L-bar molding 35. This straight vertical wall 57 is higher than the vertical wall 52 with the return flange and it does not have a return flange. See FIGS. 3, 4, 6 and 16a-d.
To install the L-bar molding, it is held below the L-bar grid, the straight vertical wall 57 is slipped between the L-bar grid and the wall of the room. The L-bar grid molding 35 is pressed upward so that the flange 53 is in contact with the L-bar grid flange 72. This contact causes the flanged vertical wall 52 to be displaced outwardly until the inward facing edge 56 passes over the flange 72 of the L-bar grid. The flanged vertical wall 52 thereafter snaps back to the vertical position and the bottom of the L-bar grid is seated securely against the interior bottom 58 of the L-bar molding. See FIGS. 16a-d.
In a conventional suspended ceiling the T-bar grids abut L-bar grids at regularly spaced intervals around the periphery of the room. Instead of constructing an additional molding to accommodate these abutments, the L-bar moldings are made with notches 59 in the flanged vertical wall 52. (FIG. 6) These notches are the width of a T-bar grid so the T-bar grid fits the notch smoothly. There are two 4 foot L-bar grid moldings, one identified by number 25 in FIG. 1 and having one notch 59 in the center, and the second identified by number 26 in FIG. 1 and having two notches 59, 11.5 inches from each end to accommodate the standard T-bar grid placement. These two L-bar moldings eliminate the need for additional T joints and result in less cutting of the moldings during installation.
To provide finished corners to the ceiling facing and to conform the system to most room configurations two corner moldings are provided. The inside corner molding 27 is L-shaped with two equivalent arms. (FIG. 7) There are two L-shaped edges, a long L-shaped edge 60 and a short L-shaped edge 61, and two transverse edges. Contiguous with the short L-shaped edge 61 is a vertical sidewall 62 with a return flange 63. This return flange 63 is the same as that of the L-bar moldings where the upward facing surface forms a 50° angle with the vertical sidewall. Contiguous with the long L-shaped edge 60 is a taller vertical sidewall 64 with no return flange. FIG. 3 shows an inside corner molding in contact alignment with an L-bar molding.
The outside corner molding 28 is also L-shaped with two equivalent arms. (FIG. 8) There are two L-shaped edges, a long L-shaped edge 65 and a short L-shaped edge 66, and two transverse edges. Contiguous with the long L-shaped edge 65 is a vertical sidewall 67 with a return flange 68. The return flange 68 is the same as that of the L-bar moldings where the upward facing surface of the return flange forms a 50° angle with the vertical sidewall. Contiguous with the short L-shaped edge 66 is a taller vertical sidewall 69 with no return flange.
Both the inside corner molding 27 and the outside corner molding 28 are used against the walls of the room and are installed in the same manner as the L-bar moldings with the taller unflanged vertical walls of the moldings abutting the walls of the room.
The ceiling panels are easily refaced by coveting their surfaces with a thin flexible sheet. This ceiling panel resurfacing provides a clean surface and can also provide a change of color or a new design or texture, but no appreciable weight is added to the panel. Ceiling panels come in two standard sizes, a 2'×2' ceiling panel 34 and a 2'×4' ceiling panel 33. To accommodate these two sizes, ready cut panel refacing sheets are provided, the 2'×2' ceiling panel facing 30 (FIG. 12) and the 2'×4' ceiling panel facing 29 (FIG. 13). These panel refacing sheets can be applied to the ceiling panels with any common adhesive, but to make the refacing as quick and easy as possible they can be manufactured with a pressure sensitive adhesive and a backing sheet 70 that is removed immediately prior to application. The only cutting necessary is for peripheral areas. The sheets can also be manufactured in long rolls 71 that are two feet wide, with the adhesive and backing sheet 70. (See FIG. 14) When the roll 71 is used, each sheet is cut to the length needed. To reface the ceiling panel it need only be removed and placed face up on a flat surface. The ceiling panel facing 30 is removed from the backing sheet 70 and applied to the ceiling panel 34 as in FIGS. 17a-b. The ceiling panel can thereafter be reinstalled. A heat sensitive adhesive can also be used.
The moldings of the present invention can be made of any lightweight flexible resilient material, preferably a polymeric material. The refacing sheets can also be made of polymeric material, but they can also be made of any cloth or of paper.
The actual dimensions of the various components are determined by the size and placement of the standard suspended ceiling grids and panels. The moldings are sized to fit their respective positions and lie contiguous to the adjacent moldings and in the same plane for a smooth, finished appearance. Typical dimensions of the components of the instant invention identified by their assigned parts numbers are as follows:
______________________________________21 T-bar molding (4 ft) 44.5 in22 T-bar molding (2 ft) 20.5 in23 cross piece molding 3.5 in × 3.5 in24 T-piece molding 3.5 in × 2.25 in25 L-bar molding 48 in 1 in center notch26 L-bar molding 48 in 1 in notces 11.5 in from each end27 inside corner molding 2.25 in on each long edge28 outside corner molding 2.25 in on each long edge29 4 × 2 ceiling panel facing 47.75 in × 23.75 in30 2 × 2 ceiling panel facing 23.75 in × 23.75 in71 roll of panel facing 23.75 in wide______________________________________
The exterior width of all moldings is one inch. The number of components of the present invention provides coverage of all existing grids and grid intersections of the standard suspended ceilings. Since the moldings adjacent the walls slip up behind the L-bar grids they lie closer to the walls than the unfaced grids and give a very finished appearance to the completed ceiling, much as wall moldings. The close linear abutment of the components due to precutting to size during manufacture help to maintain the proper perpendicular orientation and alignment of the suspended grids.
When large areas that open into other rooms are refaced, the planar nature of the refacing system ailows one room to be refaced when the adjoining room does not need refacing. There will be no drastic change in appearance, other then a clean look or new color. It is even possible to reface one area of the ceiling of a large room when there has been some ceiling damage, while leaving the rest of the ceiling alone.
In cases where the grids require refacing but the ceiling panels are not damaged it is possible to install the refacing moldings without even removing the panels. This can be done because the panels are not heavy and just rest on the grid flanges. The ceiling panels can be easily lifted up or shifted slightly from their seated positions, the moldings snapped into place, and the ceiling panels reseated. If the ceiling panels sustain damage and the grids are intact, only the ceiling panels can be refaced without refacing the grids.
The nature and design of the moldings permits them to be removed as easily as installed so that further refacings at a later time are just as easy to accomplish.
While one embodiment of the present invention has been illustrated and described in detail, it is to be understood that this invention is not limited thereto and may be otherwise practiced within the scope of the following claims. | An integrated system of components to completely reface a conventional suspended ceiling. The components are manufactured in discrete sizes and shapes to cover the grids and all grid intersections so that all installed components lie contiguously in the same plane to maintain the original appearance of the ceiling but with a fresh face. The components are designed to be snapped onto the grids using minimal upward force so as not to cause distortion or misalignment of the suspended grids. The installation can be accomplished expeditiously. The only cutting necessary is to adjust the components at the peripheral areas where the precut pieces will not fit the spaces remaining. Very little skill or special tools are required. Complementary panel cover sheets are provided to complete the refacing. The system can be constructed in a variety of colors and textures to blend with or enhance many different styles and modes of decoration. The components can be removed if another refacing is later desired. | 4 |
[0001] The present invention relates to a method and equipment for the transfer of workpieces which are processed in at least one first group of work stations and in at least one second group of work stations of a production line, wherein a first transfer device moves workpiece carriers with the workpieces from work station to work station of the first group, and a second transfer device moves workpiece carriers with the workpieces from work station to work station of the second group and wherein the first transfer device hands over the workpiece carriers to an interchange device and the interchange device feeds the workpiece carriers to the second transfer device.
BACKGROUND OF THE INVENTION
[0002] A transfer device in which workpieces are transported by means of workpiece carriers from work station to work station of a production line has become known from laid-open specification DE 198 26 627 A1. The work stations are arranged in a line and provided with assembly devices and/or processing devices. A first group of work stations executes time-intensive work procedures and a second group of work stations executes less time-intensive work procedures, wherein the first group is disposed upstream of the second group production with reference to the direction of workflow. A first transfer device moves the workpiece carriers from work station to work station of the first group. A second transfer device moves the workpiece carriers from work station to work station of the second group. An interchange device is connected between the two transfer devices, wherein the first transfer device hands over the workpiece carriers to the interchange device and the interchange device feeds the workpiece carriers to the second transfer device. The workpiece carriers pass from the first transfer device to a transport belt of the interchange device, wherein the transport belt pre-positions the workpiece carriers in that the workpiece carriers are moved up to a retaining element. At the entry side the second transfer device has a coupling section which, by means of a stroke movement, grips a workpiece carrier at a toothed profile at its base side and passes it on to a belt drive. The stroke movement of the coupling section is derived from a control shaft for the work stations of the second group.
[0003] A disadvantage of the known equipment resides in the fact that the onward movement of the workpiece carriers within the interchange device is effected by means of a frictional force between the workpiece carriers and a flat belt. If the frictional force falls below the requisite traction force of the workpiece carrier, the workpiece carrier is left standing in uncontrolled manner. A greater mass of the workpiece carrier can increase the tractive force. Heavier workpiece carriers, however, cause greater wear and require lower transport speeds.
BRIEF DESCRIPTIONS OF THE INVENTION
[0004] The present invention, as characterised in claims 1 and 4, meets the object of avoiding the disadvantages of the known equipment and of advancing the workpiece carriers independently of the frictional force between the workpiece carrier and the transport belt. In accordance therewith, the present invention provides independent drives for the transfer devices and the interchange device. The motion of the interchange device can be synchronized with the motion of the transfer devices to maintain proper work flow. Means may be provided on the transfer devices, interchange device, and workpiece holders to insure a positive, non-slip interconnection. In a preferred embodiment each of the transfer devices and the interchange device are independently driven, and incorporate cogged belts which engage complementary-profiled workpiece holders.
[0005] The advantages achieved by the invention are essentially to be seen in that the workpiece carriers are transported within the entire production line in a mechanically positively coupled manner. The production line can thereby be optimised in length and the processing plant can thus be constructed to be shorter and requires less space. The interchange device can operate with a smallest possible pitch, or transport workpiece carrier against workpiece carrier, and subsequently pass them over to a transport unit at a different pitch. Moreover, the equipment for the transfer of the workpiece carriers can be constructed substantially more simply in mechanical terms, which in turn has a favourable effect on the production costs of the processing plant. In addition, the equipment manages with few wear parts, which increases reliability and reduces maintenance expenditure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present invention is explained in more detail in the following description with reference to the accompanying figures, in which:
[0007] [0007]FIG. 1 shows a production line with work stations and equipment for the transfer of workpiece carriers, in accordance with the invention;
[0008] [0008]FIG. 2 shows a first transfer device, an interchange device and a second transfer device with the associated drive motors and sensors for detecting the position of the workpiece carriers, as used in the production line of FIG. 1;
[0009] [0009]FIG. 3 shows a schematic illustration of a workpiece carrier in the handover from a transfer device to an interchange device or in the handover from an interchange device to a transfer device;
[0010] [0010]FIGS. 4, 5 and 6 show successive schematic illustrations of the synchronisation of the drive motors during handover of a workpiece carrier from a transfer device to an interchange device or during handover a workpiece carrier from an interchange device to a transfer device;
[0011] [0011]FIGS. 7 a - d show successive schematic illustrations of the transfer of the workpiece carriers with the same spacing within the production line;
[0012] [0012]FIGS. 8 a - f show schematic illustrations of the transfer of the workpiece carriers with different spacings within the production line; and
[0013] [0013]FIGS. 9 g - h show schematic illustrations of the transfer of the workpiece carriers with different spacings and with different time-intensive work procedures within the production line.
DETAILED DESCRIPTION OF THE INVENTION
[0014] [0014]FIG. 1 shows a production line for the processing of workpieces, for example small parts or conductor ends, which are transported by means of workpiece carriers 2 from work station to work station. The production direction is symbolized by an arrow P 0 . The workstations are arranged in a line and provided with assembly devices and/or processing devices, wherein a first work station group 3 with large work stations 3 . 1 , 3 . 2 and a work station second group 4 with small work stations 4 . 1 , 4 . 2 , 4 . 3 , 4 . 4 are provided. The first group 3 causes a large spacing between workpiece carriers 2 (large pitch dimension) and the second group 4 causes a small spacing between workpiece carriers 2 (small pitch dimension). In the illustrated embodiment the first group 3 of work stations 3 . 1 , 3 . 2 executes less time-intensive working procedures than the second group 4 of work stations 4 . 1 , 4 . 2 , 4 . 3 , 4 . 4 . The work procedures of the first group 3 can also be equally time-intensive or more time-intensive than the work procedures of the second group 4 .
[0015] A first transfer device 5 and a first extension 6 move the workpiece carriers 2 from work station to work station of the first group 3 , wherein the first transfer device 5 mechanically drives the first extension 6 by means of a first coupling 7 . A first transfer drive 8 drives the first transfer device 5 .
[0016] A second transfer device 9 and a second extension 10 move the workpiece carriers 2 from work station to work station of the second group 4 , wherein the second transfer device 9 mechanically drives the second extension 10 by means of a second coupling 11 . A second transfer drive 12 drives the second transfer device 9 .
[0017] By use of the extensions 6 , 10 the belt drives of the transfer devices 5 , 9 are not too long and belt elasticity is thus minimized, so as to have a positive effect on the positional accuracy of the workpiece carriers 2 .
[0018] An interchange device 13 with an interchange drive 14 is connected between the two transfer devices 5 , 9 , wherein the first transfer device 5 hands over the workpiece carriers to the interchange device 13 and the interchange device 13 feeds the workpiece carriers 2 to the second transfer device 9 . The interchange device 13 serves as an adapter for the different pitch dimensions of the first work station group 3 and the second work station group 4 . If more than two groups of work stations are provided, more than two transfer devices and more than one interchange device are provided.
[0019] The return run of the workpiece carriers 2 is symbolised by arrows P 1 , P 2 , P 3 , P 4 and P 5 , wherein P 1 , P 3 and P 5 are, for example, horizontal belt drives and P 2 , P 4 are vertical conveyors for the workpiece carriers 2 . As a variant, the return run of the workpiece carriers 2 can take place exclusively in a horizontal plane. This return run variant is symbolized by the arrows P 1 , P 2 . 1 , P 3 . 1 , P 4 . 1 and P 5 .
[0020] [0020]FIG. 2 shows the first transfer device 5 with a first drive motor 15 , a first sensor 16 and a first double-sided cogged belt 17 , which is deflected by means of a first gearwheel 18 and a second gearwheel 19 , wherein the first drive motor 15 acts on the second gearwheel 19 . The first sensor 16 consists of a first toothed disc 16 . 1 , which images the teeth of the second gearwheel 19 , and a first scanner 16 . 2 , which detects the teeth of the rotating first toothed disc 16 . 1 . The first transport device 5 is shown as transporting two workpiece carriers 2 .
[0021] [0021]FIG. 2 also shows the interchange device 13 with a second drive motor 20 , a second sensor 21 and a second double-sided cogged belt 22 , which is deflected by means of a third gearwheel 23 and a fourth gearwheel 24 , wherein the second drive motor 20 acts on the third gearwheel 23 . The second sensor 21 consists of a second toothed disc 21 . 1 , which images the teeth of the third gearwheel 23 , and a second scanner 21 . 2 , which detects the teeth of the rotating second toothed disc 21 . 1 . The interchange device 13 is shown as transporting two workpiece carriers 2 .
[0022] [0022]FIG. 2 further shows the second transfer device 9 with a third drive motor 25 , a third sensor 26 and a third double-sided cogged belt 27 , which is deflected by means of a fifth gearwheel 28 and a sixth gearwheel 29 , wherein the third drive motor 25 acts on the fifth gearwheel 28 . The third sensor 26 consists of a third toothed disc 26 . 1 , which images the teeth of the fifth gearwheel 28 , and a third scanner 26 . 2 , which detects the teeth of the rotating third toothed disc 26 . 1 . The second transfer device 9 is shown as transporting four workpiece carriers 2 .
[0023] [0023]FIG. 3 shows a schematic illustration of a workpiece carrier 2 during a handover from the first transfer device 5 to the interchange device 13 or during a handover from the interchange device 13 to the second transfer device 9 . The double-sided first cogged belt 17 of the first transfer device 5 serves as a transport means for the workpiece carriers 2 , wherein the teeth 17 . 1 of one belt side engage the gearwheels 18 , 19 and the teeth 17 . 2 of the other belt side engage a toothed profile 30 arranged at the underside of the workpiece carrier 2 . The double-sided second cogged belt 22 of the transfer device 13 similarly serves as a transport means for the workpiece carriers 2 , wherein the teeth 22 . 1 of one belt side engage the gearwheels 23 , 24 and the teeth 22 . 2 of the other belt side engage the toothed profile 30 arranged at the underside of the workpiece carrier 2 . The same applies to the handover of the workpiece carrier 2 from the interchange device 13 to the second transfer device 5 . The transport of the workpiece carrier 2 in the production direction P 0 thus takes place exclusively by the mechanically positive coupling between the cogged belts 17 , 22 , 27 and the workpiece carrier 2 without mechanical coupling between the first transfer device 5 and the interchange device 13 or between the interchange device 13 and the second transfer device 9 .
[0024] [0024]FIG. 4 shows a schematic illustration of the synchronization of the drive motors 15 , 20 during a handover of a workpiece carrier 2 from the first transfer device 5 to the interchange device 13 . Workpiece carrier 2 is in engagement with teeth 17 . 2 of the first cogged belt 17 and with teeth 22 . 2 of the second cogged belt 22 . 2 . During the handover of the workpiece carrier 2 from the first transfer device 5 to the interchange device 13 the first drive motor 15 and the second drive motor 20 have to run synchronously. The synchronization between the two motors 15 , 20 is symbolized by an arrow S 1 .
[0025] [0025]FIG. 5 shows a schematic illustration of the synchronization of the drive motors 20 , 25 during a handover of a workpiece carrier 2 from the interchange device 13 to the second transfer device 9 . Workpiece carrier 2 is in engagement with teeth 22 . 2 of the second cogged belt 22 and with teeth 27 . 2 of the third cogged belt 27 . 2 . During the handover of workpiece carrier 2 from the interchange device 13 to the second transfer device 9 the second drive motor 20 and the third drive motor 25 have to run synchronously. The synchronization between the two motors 20 , 25 is symbolized by the arrow S 2 . The pitch dimension R 1 of the first transfer device 5 differs from the pitch dimension R 2 of the interchange unit 13 .
[0026] [0026]FIG. 6 shows a schematic illustration of the synchronization of all drive motors 15 , 20 , 25 during a handover of a workpiece carrier 2 from the first transfer device 5 to the interchange unit 13 and during simultaneous handover of a further workpiece carrier 2 from the interchange device 13 to the second transfer device 9 . The pitch dimension is uniform and is denoted by R 1 .
[0027] [0027]FIGS. 7 a - d show schematic illustrations of the transfer of workpiece carriers 2 at the same spacing within the production line 1 . The distance statements refer, by way of example, to millimeters. Workpiece carrier 2 . 1 stands in engagement with the first cogged belt 17 , wherein the workpiece is processed by work station 3 . 1 (FIG. 7 a ). After the processing, the first drive motor moves the first cogged belt 17 by 400 mm in production direction P 0 . The workpiece carrier 2 . 1 now stands at the position for processing of the workpiece by work station 3 . 2 and at the same time a further workpiece carrier 2 . 2 stands at the position for processing by work station 3 . 1 (FIG. 7 b ). In the next step (FIG. 7 c ) the first cogged belt 17 is moved by a further 400 mm and the second cogged belt 22 is moved by means of the second drive motor 20 by 400 mm, wherein the cogged belts 17 , 22 are accelerated synchronously at the same speed. The workpiece carrier 2 . 1 is received by the second cogged belt 22 and is stopped at the shown position. In the step of FIG. 7 d the cogged belts 17 , 22 are moved by a further 400 mm and the third cogged belt 27 by means of the third drive motor 25 by 400 mm, wherein the cogged belts 17 , 22 , 27 are accelerated synchronously at the same speed. The workpiece carrier 2 . 1 is taken over by the third cogged belt 27 and stopped at the shown position, at which position work station 4 . 2 processes the workpiece of workpiece carrier 2 . 1 . The positions of the further workpiece carriers 2 . 2 , 2 . 3 , 2 . 4 have also been changed in an analogous manner. The mode of transfer shown in FIG. 7 is provided for work stations of the first group 3 and the second group 4 with equal pitch dimension R 1 and equal time-intensive work procedures.
[0028] [0028]FIGS. 8 a - f show schematic illustrations of the transfer of the workpiece carriers 2 with different spacings within the production line 1 . The distance statements again refer, by way of example, to millimeters. The workpiece carrier 2 . 1 of FIG. 8 a stands in engagement with the first cogged belt 17 , wherein the workpiece is processed by the work station 3 . 1 . After the processing, the first drive motor 15 moves the first cogged belt 17 by 400 mm in production direction P 0 . Workpiece carrier 2 . 1 now stands at the position for processing of the workpiece by work station 3 . 2 , and at the same time a further workpiece carrier 2 . 2 stands at the position for processing by work station 3 . 1 (FIG. 8 b ). In the next step (FIG. 8 c ) the first cogged belt 17 is moved by a further 400 mm and the second cogged belt 22 is moved by means of the second drive motor 20 by 200 mm, wherein the cogged belts 17 , 22 are accelerated synchronously at the same speed. Workpiece carrier 2 . 1 is received by the second cogged belt 22 and stopped at the shown position. In the step of FIG. 8 d the first cogged belt 17 is moved by a further 400 mm and the second cogged belt 22 by a further 200 mm, wherein the cogged belts 17 , 22 are accelerated synchronously at the same speed. Two workpiece carriers 2 . 1 , 2 . 2 are now arranged on the second cogged belt 22 . In the step of FIG. 8 e the first cogged belt 17 is moved by a further 400 mm, the second cogged belt 22 by a further 200 mm and the third cogged belt 27 by means of the third drive motor 25 by 200 mm, wherein the cogged belts 17 , 22 , 27 are accelerated synchronously at the same speed. In that case workpiece carrier 2 . 1 is received by the third cogged belt 27 and stopped at the shown position, at which position work station 4 . 1 processes the workpiece of workpiece carrier 2 . 1 . In the step of FIG. 8 f the transfer procedure is repeated in an analogous manner, wherein work station 4 . 2 processes the workpiece of workpiece carrier 2 . 1 . The positions of the further workpiece carriers 2 . 2 , 2 . 3 , 2 . 4 , 2 . 5 , 2 . 6 have also been changed in an analogous manner. The mode of transfer shown in FIG. 8 is provided for work stations of the first group 3 with the pitch dimension R 1 and for work stations of the second group 4 with the pitch dimension R 2 , wherein the work stations of the two groups 3 , 4 execute equally time-intensive work procedures.
[0029] [0029]FIGS. 9 a - h show schematic illustrations of the transfer of the workpiece carriers with different spacings and different time-intensive work procedures within the production line. The steps of FIG. 9 a to FIG. 9 d are identical with the steps of FIG. 8 a to FIG. 8 d . In the step of FIG. 9 e the first cogged belt 17 remains stationary and the second cogged belt 22 and the third cogged belt 27 are moved by 400 mm, wherein the cogged belts 22 , 27 are accelerated synchronously at the same speed. Workpiece carrier 2 . 1 and workpiece carrier 2 . 2 are received by the third cogged belt 27 and stopped at the shown position, at which position the work station 4 . 2 processes the workpiece of the workpiece carrier 2 . 1 and the work station 4 . 1 processes the workpiece of workpiece carrier 2 . 2 . The work procedures are identical. The step of FIG. 9 f is identical with the step of FIG. 9 c . The step of FIG. 9 g is identical with the step of FIG. 9 d . In the step of FIG. 9 h the step of FIG. 9 e is repeated, wherein workpiece carrier 2 . 3 and the workpiece carrier 2 . 4 are received by the third cogged belt 27 and stopped at the shown position. With the movement of the third cogged belt 27 the workpiece carriers 2 . 1 , 2 . 2 have also been moved on by 400 mm. Work station 4 . 2 processes the workpiece of the workpiece carrier 2 . 3 and work station 4 . 1 processes the workpiece of workpiece carrier 2 . 4 . The work procedures are identical. Work station 4 . 3 processes the workpiece of workpiece carrier 2 . 2 and the work station 4 . 4 processes the workpiece of workpiece carrier 2 . 1 . The work procedures are identical. The mode of transfer shown in FIG. 9 is provided for work stations of the first group 3 with the pitch dimension R 1 and for work stations of the second group 4 with the pitch dimension R 2 , wherein the work stations of the second grid 4 execute work procedures which are twice as time intensive and wherein each two work stations execute the same work procedures at the same time. The cycle time of the less time-intensive work procedures of the first group 3 can thus be maintained for the entire production line 1 .
[0030] In a further variant of embodiment the third drive motor 25 determines the pitch dimension within the third cogged belt 27 . | In a production line small parts or conductor ends are transported by means of workpiece carriers from work station to work station in a production direction. First and second groups of work stations. First and second transfer devices move the workpiece carriers from work station to work station in the groups. An interchange device is connected between the two transfer devices, the first transfer device handing over the workpiece carriers to the interchange device and the interchange device feeding the workpiece carriers to the second transfer device. The interchange device serves as an adapter for different workpiece carrier spacings (pitch dimensions) of the first and second groups. The workpiece carriers are maintained in positive positions upon the transfer devices and the interchange device, each of which is independently driven to allow synchronism to be accomplished when a carrier is transferred to or from the interchange device. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the benefit of U.S. Provisional Application No. 61/804,836, filed Mar. 25, 2013.
TECHNICAL FIELD
[0002] The present invention generally relates to performance analysis, and more particularly relates to a system and method for adaptively controlling performance margin synchronization in a multi-engine system.
BACKGROUND
[0003] Helicopters typically have two engines that are connected through a combiner transmission to share the load of the rotor. It is desirable to share the load equally between the two engines so that the engines are more likely to deteriorate at the same (or similar) pace, and impart less stress to the combiner transmission. Helicopter engine controllers are typically configured to selectively implement one of a plurality load sharing control methods, and control logic that selects the control method. These control methods may include, for example, torque matching, a temperature matching, and a speed matching. With the torque matching method, measured engine torque is equalized, with the temperature matching method, measured engine temperatures are equalized, and with the speed matching method, measured engine speeds are equalized.
[0004] Unfortunately, none of the above-described control methods can continuously produce identical or synchronized performance margins for the two engines. Performance margin is an engine condition indicator and, as is generally known, is defined as the difference between one or more performance parameters at rated power and the corresponding limits of the performance parameters. As may be readily understood, because performance margin is measured at max rated power, two engines can have very different performance margins even if the engines have similar performance characteristics at lower power. Moreover, each engine will typically exhibit its own unique performance deterioration characteristics.
[0005] When the performance margin of an engine reaches zero, the engine is removed from the aircraft for repair, overhaul or replacement. Significant performance margin differences occur when a new or overhauled engine is installed with an engine that has already lost some performance margin. Thus, it is desirable to match the performance margins of both engines so that the engines can be simultaneously removed. However, the commonly used load sharing methods mentioned above do not ensure that the performance margins are matched. In particular, torque matching tends to cause the engine with a lower temperature margin to run hotter and increase the temperature margin split between the two engines. Temperature matching at part power does not guarantee that the temperature margins match at max rated power since the engines may have differently shaped temperature vs. torque characteristic curves. And speed matching at part power does not guarantee that the speed margins match at max rated power since the engines may have differently shaped speed vs. torque characteristic curves.
[0006] When the performance margins of two engines are not matched, this can lead to reduced engine life, reduced aircraft availability, and increased maintenance costs. Moreover, helicopter engine controls are typically configured such that a pilot may manually select the control method to be used in order to attain maximum power from both engines. This can lead to increased pilot workload. For example, if one engine reaches the temperature margin limit before the other engine while operating in the torque matching mode, the pilot will need to switch to the temperature matching mode to allow the other engine to attain its maximum power.
[0007] Hence, there is a need for a system and method of matching the performance margins of two engines. In doing so, the system and method will provide increased engine life, increased aircraft availability, reduced maintenance costs, and reduced pilot workload. The present invention addresses this need.
BRIEF SUMMARY
[0008] In one embodiment, a method of adaptively synchronizing the performance margin of a multi-engine system includes continuously, and in real-time, determining the performance margin of a first engine and the performance margin of the second engine. A difference between the performance margins of the first and second engines is calculated, and the first and second engines are controlled to attain a predetermined difference between the performance margins of the first and second engines.
[0009] In another embodiment, a system for adaptively synchronizing the performance margin of a multi-engine system includes a first engine, a second engine, a first engine controller, and a second engine controller. The first engine is configured to generate a first torque and has a determinable first engine performance margin. The second engine is configured to generate a second torque and has a determinable second engine performance margin. The first engine controller is coupled to, and is associated with, the first engine, and is configured to continuously, and in real-time, determine the first engine performance margin. The second engine controller is coupled to, and is associated with, the second engine, and is configured to continuously, and in real-time, determine the second engine performance margin. The first and second engine controllers are in operable communication with each other, and each is further configured to calculate a difference between the first engine performance margin and the second engine performance margin, and to control its associated engine to attain a predetermined difference between the first and second engine performance margins.
[0010] Furthermore, other desirable features and characteristics of the system and method will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the preceding background.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
[0012] FIG. 1 depicts a functional block diagram of a portion of a multi-engine power train system for a rotary-wing aircraft;
[0013] FIG. 2 depicts a functional block diagram of a feedback controller that may be implemented in the system of FIG. 1 ;
[0014] FIG. 3 graphically depicts the multi-engine power train system of FIG. 1 operating with imbalanced performance margins; and
[0015] FIG. 4 graphically depicts the multi-engine power train system of FIG. 1 operating with balanced performance margins.
DETAILED DESCRIPTION
[0016] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Thus, any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. All of the embodiments described herein are exemplary embodiments provided to enable persons skilled in the art to make or use the invention and not to limit the scope of the invention which is defined by the claims.
[0017] Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary, or the following detailed description. In this regard, although embodiments are described herein as being implemented in a rotary-wing aircraft, such as a helicopter, it will be appreciated that the systems and methods described herein may be implemented in various other environments and applications that utilize a multi-engine output. Moreover, although embodiments are described herein as being implemented with two gas turbine engines, other numbers of engines greater than two could be used, and various other engine types, including diesel and combustion engines, may also be used.
[0018] Referring first to FIG. 1 , a functional block diagram of a portion of a multi-engine power train system 100 for a rotary-wing aircraft, such as a helicopter, is depicted. The power train includes two engines 102 (a first engine 102 - 1 and a second engine 102 - 2 ), a gear train 104 , and two engine controllers 106 (a first engine controller 106 - 1 and a second engine controller 106 - 2 ). It should be noted that although the system 100 of FIG. 1 is depicted as including only two engines 102 , it could be implemented with more than this number of engines 102 , if needed or desired.
[0019] The engines 102 , at least in the depicted embodiment, are implemented using gas turbine engines, and more particularly single-spool turbo-shaft gas turbine propulsion engines. Thus, each engine 102 includes a compressor section 108 , a combustion section 112 , and a turbine section 114 . The compressor section 108 , which may include one or more compressors 116 , draw air into its respective engine 100 and compresses the air to raise its pressure. In the depicted embodiment, each engine includes only a single compressor 116 . It will nonetheless be appreciated that each engine 102 may include one or more additional compressors.
[0020] No matter the particular number of compressors 116 that are included in the compressor sections 108 , the compressed air is directed into the combustion section 112 . In the combustion section 112 , which includes a combustor assembly 118 , the compressed air is mixed with fuel supplied from a non-illustrated fuel source. The fuel and air mixture is combusted, and the high energy combusted air mixture is then directed into the turbine section 114 .
[0021] The turbine section 114 includes one or more turbines. In the depicted embodiment, the turbine section 114 includes two turbines, a high pressure turbine 122 and a free power turbine 124 . However, it will be appreciated that the engines 102 could be configured with more or less than this number of turbines. No matter the particular number, the combusted air mixture from the combustion section 112 expands through each turbine 122 , 124 , causing it to rotate an associated power shaft 126 . The combusted air mixture is then exhausted from the engines 102 . The power shafts 126 are each coupled to, and supply a drive torque to, the gear train 104 .
[0022] The gear train 104 is coupled to receive the drive torque supplied from each of the engines 102 . The gear train 104 , which may include one or more gear sets, preferably includes at least a combiner transmission, which in turn supplies the combined drive torque to one or more rotors.
[0023] The engine controllers 106 are each in operable communication with one of the engines 102 . In the depicted embodiment, for example, the first engine controller 106 - 1 is in operable communication with the first engine 102 - 1 , and the second engine controller 106 - 2 is in operable communication with the second engine 106 - 2 . Each engine controller 106 is configured, among other things, to control the operation of its associated engine 102 so as to minimize the performance margin difference between the engines 102 . To implement this functionality, the engine controllers 106 are each coupled to receive various control and performance data from its associated engine 102 . Thus, as FIG. 1 further depicts, each engine 102 additionally includes a plurality of sensors 128 . Each of the sensors 128 is coupled to its associated engine controller 106 and is operable to sense an engine parameter and supply control and performance data representative of the sensed parameter to the engine controller 106 . It will be appreciated that the particular number, type, and location of each sensor 128 may vary. It will additionally be appreciated that the number and types of control and performance data supplied by the sensors 128 may vary depending, for example, on the particular engine type and/or configuration. In the depicted embodiment, however, at least a subset of the depicted sensors 128 supply control and performance data representative of, or that may be used to determine, engine inlet pressure, engine inlet temperature, engine speed, fuel flow, compressor discharge pressure, power turbine inlet temperature, engine torque, shaft horsepower, and thrust, to name just a few.
[0024] The engine controllers 106 may be variously configured to implement the associated functionality. In the depicted embodiment, each engine controller 106 includes one or more processors 132 (for clarity, only one shown). The processors 132 are coupled to receive at least a portion of the control and performance data from the sensors 128 and are each configured, in response to these data, to continuously conduct performance analyses of its associated engine 102 . Moreover, each engine controller 106 also receives various sensor data, such as torque, turbine inlet temperature, and engine speed, from the other engine controller 106 via a data link 134 that interconnects the two engine controllers 106 . The processors 132 are additionally configured, based on the performance analyses, to control the operation of its associated engine 102 to minimize the difference between the performance margins of each engine 102 . To do so, the processors 132 are each configured to conduct continuous, real-time performance analyses of its associated engine 102 to thereby continuously determine, in real-time, the performance margin of its associated engine 102 . The processors 132 are additionally configured to implement identical feedback controllers that will shift the load between the engines 102 so that there is more load on the engine 102 with higher performance margin. One embodiment of the feedback controllers 200 are implemented in each of the processors 132 is depicted in FIG. 2 , and will now be described in more detail.
[0025] Before proceeding with the description, it is noted that the feedback controller 200 depicted in FIG. 2 is the one implemented in the first engine controller 106 - 1 , and is thus associated with the first engine 102 - 1 (e.g., “Engine 1”). It will be appreciated that the feedback controller 200 implemented in the second engine controller 106 - 2 , and thus associated with the second engine (e.g., “Engine 2”) is an identical, “mirror-image,” copy of the one implemented in the first engine controller 106 - 1 . It is additionally noted that although the depicted feedback controller 200 is configured to implement a torque matching function, various other load matching functions may be implemented. For example, the feedback controller 200 may be configured to implement a load matching function based on temperature or speed, just to name a few.
[0026] Turning now to the description of the feedback controller 200 , it is seen that the feedback controller 200 receives the control and performance data supplied by the sensors 128 . The control and performance data are supplied, at least in the depicted embodiment, to signal conditioning and BIT (built-in-test) logic, which provides appropriate signal conditioning and testing of the data supplied from the sensors 128 . At least a portion of the control and performance data are supplied to and processed by a continuous performance analysis (CPA) function 202 - 1 . The CPA function 202 - 1 is configured to conduct continuous, real-time performance analyses of the first engine 102 - 1 , and supply data representative of the instantaneous performance margin of the first engine 102 - 1 . As FIG. 2 also depicts, the feedback controller 200 also receives, from a CPA function 202 - 2 in the feedback controller 200 of the second engine controller 106 - 2 , data representative of the instantaneous performance margin of the second engine 102 - 2 .
[0027] Before proceeding further, it is additionally noted that the continuous, real-time performance analyses conducted by the CPA functions 202 may be implemented using any suitable algorithm capable of supplying instantaneous performance margins. Preferably, however, the continuous, real-time performance analyses are preferably conducted using the methodology described in U.S. Pat. No. 8,068,997, entitled “Continuous Performance Analysis System and Method,” and assigned to the assignee of the instant application. The entirety of this patent, which issued on Nov. 29, 2011, is hereby incorporated by reference.
[0028] Returning now to the description of the feedback controller 200 , the instantaneous performance margins of each engine (MRG1, MRG2) are supplied to a first difference function 204 . The first difference function 204 determines a performance margin difference (MRG_DIFF) between the two engines 102 , and supplies the determined performance margin difference (MRG_DIFF) to a margin matching control function 206 . The margin matching control function 206 is configured, in response to the performance margin difference (MRG_DIFF), to generate and supply a torque bias signal (Q_BIAS). Though not depicted in FIG. 2 , it should be noted that the instantaneous performance margins supplied from the CPA functions 202 - 1 , 202 - 2 may be filtered to remove noise. If not adequately filtered, noise in the instantaneous performance margins can cause undesirable swings in the torque bias signal (Q_BIAS). It will be appreciated that the margin matching control function 206 may be implemented using any one of numerous types of controllers. In a particular preferred embodiment, the margin matching control function 206 is implemented as a proportion-plus-integral (PID) controller. This is because the proportional action provides relatively fast and measured correction, the integral action eliminates any steady state error of synchronization, and the derivative action provides anticipatory correction to avoid overshoot and hunting issues.
[0029] No matter how the margin matching control function 206 is implemented, the torque bias signal (Q_BIAS), at least in the depicted embodiment, is supplied to a limiter 208 . The limiter 208 , as is generally known, is configured to limit the torque bias signal supplied from the margin matching control function 206 . In particular, it is configured to limit the torque bias signal to less than the maximum allowable torque split between the first and second engines 102 - 1 , 102 - 2 . The limit values may vary, but are preferably chosen to limit stress to the gear train 104 . The limited torque bias signal (Q_BIAS_LMT) is supplied to a second difference function 212 .
[0030] The second difference function 212 is coupled to receive, in addition to the limited torque bias signal (Q_BIAS_LMT), a torque matching error signal (Q_ERR). The torque matching error signal (Q_ERR) is supplied from a third difference function 214 , which receives, and determines the difference between, a first engine torque signal 216 and a second engine torque signal 218 . The determined difference is supplied as the torque matching error signal (Q_ERR). As may be appreciated, the first engine torque signal 216 is a signal representative of the instantaneous torque (Q1) being supplied by the first engine 102 - 1 , and the second engine torque signal 218 is a signal, supplied from the second engine controller 106 - 2 , representative of the instantaneous torque (Q2) being supplied by the second engine 102 - 2 .
[0031] The output of the second difference function 212 is supplied to a torque matching function 222 . The torque matching function 222 is preferably configured to implement a conventionally known torque matching algorithm. It will be appreciated, however, that any one of numerous torque matching algorithms developed in the future could also be used. The torque matching function 222 supplies a speed control signal to the speed governor 224 in the first engine 102 - 1 , which in turn supplies a fuel control signal to a fuel control function 226 . The fuel control function 226 , which is implemented in the first engine controller 106 - 1 , supplies appropriate commands to appropriate control devices to meter an appropriate amount of fuel to the first engine 102 - 1 .
[0032] From the above description it may be readily understood that when there is a non-zero performance margin difference between the first and second engines 102 - 1 , 102 - 2 , the feedback controllers 200 use the determined performance margin difference (MRG_DIFF) to purposely create, within acceptable torque split limits, a load imbalance. The feedback controllers 200 are also configured to indirectly control load shifting via the torque matching function 222 . In particular, the feedback controllers 200 supply the limited torque bias signal (Q_BIAS_LMT) to the torque matching error signal (Q_ERR) such that both engines will settle into a desirable unbalanced load condition as long as performance margin difference exists between the two engines 102 .
[0033] For completeness, a brief description of the operation of the system 100 implementing the feedback controllers 200 will be provided. Initially, it is assumed that the instantaneous performance margins (MRG1, MRG2) of the first and second engines 102 - 1 , 102 - 2 are equal (or at least substantially equal). Such a situation may occur, for example, when both engines 102 are new. As a result, the performance margin difference (MRG_DIFF) will be zero and the limited torque bias signal (Q_BIAS_LMT) supplied to the second difference function 212 will also be zero. This will result in the first and second engines 102 - 1 , 102 - 2 being controlled in accordance with a conventional torque matching control loop. If any divergence in the performance margins (MRG1, MRG2) of the first and second engines 102 - 1 , 102 - 2 occurs, the feedback controllers 200 will implement immediate corrective action to drive the performance margin difference (MRG_DIFF) to zero in closed-loop fashion.
[0034] For example, as graphically depicted in FIG. 3 , the performance margin (MRG2) of the second engine 102 - 2 has decreased faster and becomes smaller relative to the performance margin (MRG1) of the first engine 102 - 1 . As a result, the performance margin difference (MRG_DIFF) will be non-zero and the limited torque bias signal (Q_BIAS_LMT) supplied to the second difference function 212 will also be non-zero. More specifically, the margin matching control function 206 associated with the first engine 102 - 1 , which has the higher performance margin, will supply a positive value for the torque bias signal (Q_BIAS) and the limited torque bias signal (Q_BIAS_LMT), such that it will reduce the torque error value (Q_ERR) before it is used in the torque matching function 222 . This operation has an equivalent effect of lowering the torque signal value of the first engine and thus causes the torque matching function 222 to increase the power and load share of the first engine 102 - 1 . The opposite will occur in the feedback controller 200 associated with the second engine 102 - 2 , which has the lower performance margin. Thus, a desirable torque split condition is purposely created as a result of the power imbalance of the first and second engines 102 . Because the first engine 102 - 1 (the higher performance margin engine) now has a greater power usage than the second engine 102 - 2 (the lower performance margin engine), the first engine 102 - 1 will degrade faster than the second engine 102 - 2 . As FIG. 4 depicts, over time this will result in the performance margin differences of the two engines 102 converging to zero (e.g., MRG1=MRG2). Once the performance margins are matched, the feedback controllers 200 will continue to keep them matched until both engines 102 are fully degraded
[0035] It should be noted that in some contexts, such as certain helicopter engine control systems, even though the engine with lower performance margin will bias its associated torque signal to a higher value, it will not decrease the engine power directly. This is because the torque matching control loops in some helicopter do not allow lowering the power of the high torque signal engine. Thus, the increased power to the engine with the higher performance margin will result in the speeds of both engines increasing, and further result in a power reduction from the speed governor of the lower performance margin engine.
[0036] It is generally known that various parameters can be used as a measure of performance margin. For example, in the context of gas turbine engines, turbine inlet temperature and turbine speed can be used. Although multiple performance margin types could be used in the feedback controllers 200 , it is preferable to choose one margin type for synchronization, rather than switching among a plurality of different margin types. Different types of performance margins (e.g., temperature margin, speed margin, etc.) typically move in the same direction. Thus, if one performance margin type is in synch, then the other types are likely to be in synch (or at least closely in sync). Moreover, it is preferable to choose the performance margin type that reaches its performance limit more frequently and/or cause more engine removals. In the context of a helicopter, the turbine inlet temperature margin is typically chosen because it meets these criteria.
[0037] The system and method described herein provides numerous significant benefits for various multi-engine systems, such as multi-engine helicopters. In particular, the system and method provides reduced maintenance cost, reduced pilot workload, increased engine life, and increased aircraft availability. Maintenance costs can be reduced since the removal of engines with small performance margins, which are often removed along with fully degraded engines, can be avoided, and because only a single maintenance test flight is needed after engine replacements. Pilot workload is reduced since the pilot does not need to manually switch from one load sharing method to another in order to get maximum power from both engines when one engine reaches a performance limit before the other. Engine life is increased since two engines with matched performance margins will experience lower maximum temperature and speed during transients than unmatched engines over their life span. As a result, the rate of damage to hot section life-limited components, which accelerates at higher engine speed and temperature, will be reduced. Moreover, the rate of performance degradation, which also accelerates at higher engine speed and temperature, is reduced due to slower surface oxidation or blade tip deformation. Aircraft availability is increased since aircraft downtime for fully degraded engine removal and replacement is reduced by 50 percent, since two maintenance events are reduced to just one.
[0038] Those of skill in the art will appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. Some of the embodiments and implementations are described above in terms of functional and/or logical block components (or modules) and various processing steps. However, it should be appreciated that such block components (or modules) may be realized by any number of hardware, software, and/or firmware components configured to perform the specified functions. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention. For example, an embodiment of a system or a component may employ various integrated circuit components, e.g., memory elements, digital signal processing elements, logic elements, look-up tables, or the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will appreciate that embodiments described herein are merely exemplary implementations.
[0039] The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
[0040] The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such that the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal
[0041] In this document, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Numerical ordinals such as “first,” “second,” “third,” etc. simply denote different singles of a plurality and do not imply any order or sequence unless specifically defined by the claim language. The sequence of the text in any of the claims does not imply that process steps must be performed in a temporal or logical order according to such sequence unless it is specifically defined by the language of the claim. The process steps may be interchanged in any order without departing from the scope of the invention as long as such an interchange does not contradict the claim language and is not logically nonsensical.
[0042] Furthermore, depending on the context, words such as “connect” or “coupled to” used in describing a relationship between different elements do not imply that a direct physical connection must be made between these elements. For example, two elements may be connected to each other physically, electronically, logically, or in any other manner, through one or more additional elements.
[0043] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims. | A system and method of adaptively synchronizing the performance margin of a multi-engine system includes continuously, and in real-time, determining the performance margin of a first engine and the performance margin of the second engine. A difference between the performance margins of the first and second engines is calculated, and the first and second engines are controlled to attain a predetermined difference between the performance margins of the first and second engines. | 5 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to metallic seals and seal components which are energized in a novel manner, which have improved reliability and which can be made smaller than conventional metal-to-metal seals. Although for illustrative purposes the invention is discussed below largely in the context of completions for oil and gas wells, it is applicable to metallic seals in general, for dynamic as well as static uses.
[0002] There is a trend towards subsea completions incorporating increasingly larger bores. Current subsea xmas tree system configurations (both parallel and concentric) can be inefficient in terms of space usage within the tubing hanger assembly. For large completion bore systems it would be advantageous to reconfigure the subsea xmas tree system whilst maintaining a large number of down-hole lines through the tubing hanger. A solution for releasing additional radial space to facilitate larger completion bores would be to reduce the size of the mechanism for sealing off the annulus void.
[0003] The design of large bore subsea xmas trees and completions is constrained due to requirements of utilizing existing standard BOP configurations. Therefore in order to run larger completion tubing, space must be saved elsewhere to permit using existing BOP'S. Additionally, particularly in the case of deepwater developments, significant cost savings can be achieved by using smaller standard BOP and casing programs while still maintaining—or increasing—the radial space available for the completion tubing. In this way vessel selection is made easier, and hence costs decreased, due to smaller handling requirements associated with the smaller BOP size.
[0004] The problematic situation of a drive toward larger bore completions coupled with potentially utilizing smaller BOP stacks makes the radial space taken within the well system for annular packoffs of prime importance. Any space saved here can have a direct impact on the size of the completion tubing that can be accommodated.
[0005] Essentially, the sealing requirement for a slick bore tubing hanger is to seal the annulus between the tubing hanger and spool (wellhead, xmas tree or tubing spool), maintaining a clearance while running in the hanger, and once the hanger is in position, energizing the seal to a set (sealed) condition. In the particular case of horizontal production outlet tubing hangers, it is usual to seal the annulus above and below the horizontal outlet. In the case of conventional tubing hangers (or casing hangers), only one seal barrier is required to seal off the annulus.
[0006] The prior art is replete with descriptions of seal systems involving a metal seal element that bears against a metallic surface to establish a metal-to-metal sealing interface preventing the passage of corrosive or non-corrosive pressurized fluid throughout a wide temperature and pressure range. Although many of these seals have been employed successfully, most have limitations that preclude satisfactory performance under a combination of unusual and relatively severe conditions occurring, for example, when the seal area is subject to cyclical loading, extreme pressure changes and/or large thermal movements. Accordingly, as well as a more compact seal arrangement, there exists a need for a reliable metal-to-metal seal system that will function both statically and dynamically to prevent the escape of fluids.
[0007] Packoffs providing metal-to-metal seals are disclosed for example in U. S. Pat. Nos. 4,900,041 and 5,174,376. Both of these patents disclose annular metal seal elements having a generally U-shaped cross-section. The seal elements concerned are expanded and set by energizing mandrels which incorporate resilient portions, designed to deform elastically on setting. This provides stored energy (potential energy) that can be used to maintain the seal contact forces in the event of slight relative movements between the mandrel, seal element and its co-operating sealing surface. However such mechanisms can fail to prevent leakage under the severe conditions mentioned above.
SUMMARY OF THE INVENTION
[0008] The invention lies in the realization that a particular class of alloys may be used to provide metallic seals which are more reliable under extreme conditions than prior metal-to-metal seals. Accordingly, the invention provides a metallic seal component comprising an alloy which in use exhibits super-elastic properties.
[0009] Super-elasticity is a property exhibited by shape memory alloys and similar metallic materials. The crystalline lattice structure of a shape memory alloy (SMA) changes from the austenitic form at higher temperatures to the martensitic form at lower temperatures. The austenitic form of the alloy is typically much stronger than the martensitic form. In the martensitic form, the alloy can be easily worked to attain new geometries. However, the original shape can be recovered by heating the alloy above its phase transformation temperature to produce austenite. During this process, the alloy will impart a considerable force against anything resisting the change back to the original geometry. Hence the name shape memory. Super-elasticity is a further property of shape memory alloys and similar materials. When a stress load is applied to these materials at just above the phase transformation temperature, the austenite is progressively changed to the more easily deformable martensite. Considerable deformations can therefore be produced for only relatively modest increases in applied stress. When the load is removed, the martensite changes back to austenite, and the original geometry is recovered. During this loading/unloading process, these materials therefore behave elastically, but with a remarkably low Young's modulus. Such materials are sometimes referred to as “pseudo-elastic”, as the phenomenon only occurs at the right temperatures and over a particular region of the stress-strain curve.
[0010] By careful modification of the chemistry and crystalline structure of the alloys, the transformation temperature can be altered to meet design requirements. The phase transformation can be controlled so as to take place over a sharply defined temperature range of only a few degrees Centigrade. Also, the absolute temperature at the start or end point of this range can be accurately adjusted, perhaps by up to several hundred degrees Centigrade.
[0011] Materials that exhibit shape memory only upon heating are referred to as having a one-way shape memory. A special class of SMA's also undergoes a change in shape upon re-cooling. Such alloys are referred to as two-way shape memory alloys (TWSMA).
[0012] Although a relatively wide variety of alloys are known to exhibit the shape memory effect, only those that can recover substantial amounts of strain or that generate significant force upon changing shape are of commercial interest. To date, this has been the nickel-titanium alloys and copper-base alloys such as CuZnAl and CuAINi.
[0013] A typical stress-strain curve for a super-elastic metal alloy is shown in FIG. 1. Over the range a-b, a large change in strain can occur at relatively constant stress levels. In this range, as stress is applied the austenite to martensite transformation occurs, absorbing potential energy. The mechanical strain energy input (and hence the applied stress increment) required to effect a given strain increment is reduced. As the austenite to martensite transformation is reversible upon release of the applied stress, the material continues to behave elastically in the pseudo-elastic region a-b, but with a much reduced Young's modulus.
[0014] The super-elastic nature of the seal component of the present invention permits the generation of near constant sealing contact loads even under differing strains. Therefore metallic components such as energizing mandrels, seal backup springs, or a sealing element or its co-operating surface, that have been stressed into the pseudo-elastic region to maintain a sealing contact load, may move or deform significantly without disrupting this stress. At the level of the crystal structure, the potential energy that in the prior art is stored as mechanical strain energy in order to maintain the sealing contact, is instead partly stored and released in the austenite—martensite—austenite transformation, meaning that much larger strains can be accommodated without disrupting the required sealing contact forces. The overall effect of this is that the components are elastically “softer”. Thus, for example, an energizing mandrel made of pseudo-elastic SMA can continue to exert a near constant load on the sealing element even under differing strains—i.e., the mandrel may move due to settling or thermal effects; however the load exerted on the sealing element will not be significantly affected. Similarly, a sealing element or seal ring of pseudo-elastic SMA will be much more softly elastic (have a lower Young's modulus) and hence much more able to accommodate strain and movement than a metallic sealing element of the prior art. Such sealing elements are therefore much more reliable under extreme conditions.
[0015] The stressing required to maintain the pseudo-elasticity and sealing contact forces can be generated by any suitable conventional means, such as hydraulically, by adjustment nuts and other mechanical wedging arrangements, by weight or simply by force fits. Pseudo-elasticity is a property of SMA's that occurs isothermally at slightly above the transformation temperature. The ability of SMA's to change shape on heating or cooling (shape memory), also discussed above, is a separate property that can be independently exploited to provide an alternative means for energizing seal components.
[0016] Advantageously, the invention may therefore provide a seal component that in use changes its shape or size between an energized, seal enabling state and a released, unsealed state, the change of shape or size being effected by heating or cooling.
[0017] In addition to being made in whole or in part from an SMA (ether one-way or two-way), the seal component could also have a bimetallic construction. In the energized condition, the component is preferably stressed so as to generate a sealing contact force. The thermo-mechanical properties of the component are preferably selected so that this stress and hence the sealing contact force arises under ambient conditions when the component is in use. Because the seal component is thermally energized, it requires no bulky actuators such as adjustment nuts or hydraulic chambers. The seal assembly in which the component is accommodated may therefore be made much more compact than seal assemblies of the kind requiring external actuators for energization.
[0018] In its preferred forms, the invention allows seal components and assemblies to be produced that meet some or all of the following objectives:
[0019] 1. To provide reliability under cyclical loading and wide pressure variations.
[0020] 2. To accommodate 10,000 psi (69 MNm 31 2 ) nominal maximum working pressure as a typical base case. However, a family of such seal assemblies may be produced, also including, for example, members for 5,000 psi (35 MNm −2 ), 15,000 psi (104 MN −2 ) and other applications as required.
[0021] 3. Effective over a temperature range of at least 0° F. to 250° F. (−17.8° C. to 121° C.) and beyond at either end.
[0022] 4. To utilize the principles of shape memory alloys (SMA) to effect a reliable seal.
[0023] 5. To provide a compact seal assembly.
[0024] These and other objects and advantages of the present invention will be made apparent from the following detailed description, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 shows, as mentioned above, a typical stress-strain curve for a pseudo-elastic material;
[0026] [0026]FIG. 2 is a diagrammatic representation of a metal-to-metal seal assembly using a pseudo-elastic energizing mandrel;
[0027] [0027]FIG. 3 diagrammatically represents, in two different states, a metal-to-metal seal assembly that uses a shape memory alloy sealing element;
[0028] [0028]FIG. 4 is a diagram of another embodiment of the invention having an SMA sealing element;
[0029] [0029]FIG. 5 diagrammatically shows, in three different states, an embodiment using a bimetallic sealing element; and
[0030] [0030]FIGS. 6 and 7 indicate possible modified forms of SMA sealing elements embodying the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The present invention advantageously seeks to overcome the unreliability of known energized metal seals attributable to their inability to store energy in the system to cope with movement of any of the components. Preferably, it comprises a metallic sealing system utilizing shape memory alloys that when properly installed between two metallic surfaces, such as between a tubing hanger and well system, will establish and maintain a metal-to-metal fluid-tight sealing system between said surfaces under both static and dynamic conditions, in the presence of corrosive materials, and during and after exposure to a wide range of temperatures and/or large pressure fluctuations.
[0032] In the embodiment illustrated in FIG. 2, a sealing assembly 100 comprises a sealing element in the form of an annular metallic ring 10 of generally U-shaped cross-section. At least one sealing bump 12 is provided around its outer periphery and at least one sealing bump 14 around its inner bore, at the tips of the limbs of the U-shaped cross-section. The bumps 12 , 14 are sealingly engageable with co-operating seal surfaces 16 , 18 provided for instance on a well system spool 20 (wellhead housing, xmas tree or tubing spool) and a tubing hanger 22 , respectively. The surfaces of the bumps can be angular, arcuate or otherwise curved, or can comprise both angular and curved configurations, and the number of bumps can be increased as desired and/or spaced along the limbs of the U-shaped cross-section.
[0033] The sealing assembly further comprises an energizing mandrel 24 made from an SMA. Prior to installation, and as the tubing hanger 22 and mandrel 24 with attached sealing ring 10 are run in hole, the tip of the mandrel may be in a crushed condition, with the outer limb of the seal ring in the dotted line position as shown. In this state, there is sufficient clearance for installation of the seal ring 10 adjacent to the sealing surface 16 . During installation, the SMA energizing mandrel is heated, causing it to change from the weaker, low temperature form (Martensite) to the stronger, high temperature form (Austenite). Its tip thereby reverts to its original, uncrushed state, forcing the limbs of the sealing ring apart and into tight sealing engagement with the surfaces 16 , 18 (their full line positions as shown). Compressive stresses are thereby set up in the mandrel tip and sealing ring limbs which generate sealing contact forces between the bumps 12 , 14 and the sealing surfaces 16 , 18 .
[0034] The localized heating necessary for proper installation of certain of the sealing elements described herein may be achieved for example by electric resistance or induction heating and may require a high-current capacity electrical coupling between the surface and the sealing element.
[0035] Alternatively, the mandrel tip need not be pre-crushed, and heat need not be applied. Instead, the mandrel tip can be forced downwardly between the seal ring limbs by any of the usual well known methods (axial movement of the energizing mandrel by electric, hydraulic or mechanical means), thus moving the outer seal ring limb to its full line position, and setting up the seal ring and mandrel tip compressive stresses and the sealing contact forces.
[0036] The compressive loading of the mandrel tip in the energized condition is arranged to be at a level maintaining it in the pseudo-elastic range of its stress-strain curve. The super-elastic nature of the alloy therefore permits the energizing mandrel to exert a near constant load on the sealing ring even under differing strains, i.e., the mandrel or other components may move slightly, e.g., due to settling or thermal effects; however the compressive load exerted on the sealing ring limbs will not be significantly affected. Hence the sealing contact forces can be maintained more reliably.
[0037] The use, in an energizing mandrel or seal backup spring, of shape memory alloys in their austenitic state whereby they exhibit pseudo-elastic properties can allow energized seals of substantially any known configuration to be used more reliably.
[0038] A seal component according to the present invention can be used not only to seal between a tubing hanger and well system, but also to statically and dynamically seal other applications such as shafts, pipes, couplings, joints, flanges, pistons, bores and further apparatus wherein a fluid medium is to be contained and not allowed to leak to the atmosphere or another chamber.
[0039] The embodiment shown in FIG. 3 is similar to the previously described embodiment. However, in this instance the SMA is incorporated within the sealing element rather than the mandrel. The sealing ring 10 can be heated so as to move it from the crushed state A (in which it has the necessary clearance for installation next to the well system spool 20 ) to the energized condition B. Alternatively, the energizing mandrel 24 may posses the necessary wedging surfaces (not shown) so that by relative downward movement it expands and energizes the sealing ring 10 in the well known ordinary manner. In the case where the sealing ring 10 is heated, the mandrel 24 merely acts as a seal ring retainer and can even be omitted if the sealing ring is otherwise retained on the tubing hanger 22 for running in hole. This embodiment can utilize either “one way” or “two way” shape memory alloys.
[0040] One-Way SMA (A-B-STRIP OUT)
[0041] With the one-way shape memory alloy, it is possible to run the sealing element into the seal bore in a cold and “crushed” state (A). Once in the correct position, heat is applied and the SMA recovers to its “hot” shape and is thereby energized to form the seal (B). In this case, the sealing ring must be stripped out of the bore, as there is no way to regain shape (A) by heat application. When energized, the sealing ring 10 is compressed so as to be maintained in the pseudo-elastic condition, thereby tolerating substantial movements without disruption of the sealing contact forces.
[0042] Two-Way SMA (A-B-A)
[0043] Two way memory effect refers to the memorization of two shapes. A cold shape is spontaneously obtained during cooling. Different from the one way memory effect, no external forces are required for obtaining the memorized cold shape. During subsequent heating the original hot shape is restored. The two way memory effect is only obtained after a specific thermo-mechanical treatment, called training, in which recovery stresses are built into the “cold shape”. This treatment can be given by the SMA supplier. In use, heat is applied to the sealing ring during running into the bore so that the “hot” shape allows clearance (A). Removal of the heat is followed by a recovery to the “cold” shape and the seal is formed (B). Application of heat moves the material into its “hot” shape and retrieval is possible (A).
[0044] The shape memory effects described for the previous embodiments require temperature changes. In contrast, the pseudo-elastic effect is isothermal in nature and involves the storage of potential energy. Isothermal loading of the shape memory element in the “hot shape condition” results in large reversible deformations (up to 8%) at nearly constant stress levels. The alloy exhibits pseudo-elasticity and a near constant stress can be maintained over a large range of strain. The deformations are completely recovered at a lower stress level during unloading. These stress levels are alloy and temperature dependant. In general, the stress levels increase linearly with temperature (215 MPa/K). The elasticity of NiTi is approximately ten times that of steel.
[0045] The embodiment of FIG. 4 exploits the pseudo-elastic effect by using a mandrel 24 to deform an SMA sealing ring 10 out into an undercut bore 26 in the well system spool 20 to effect a seal. The solid annular sealing ring 10 has a pair of outer peripheral bumps or ridges 12 and a similar pair of bumps or ridges 14 in its bore. In the energized state, the bumps 12 establish sealing contact with the bore 26 and the bumps 14 with the mandrel 24 . The mandrel 24 in turn possesses a sealing ridge or bump 28 that makes sealing contact with the tubing hanger 22 . When energized, the sealing ring 10 is maintained in radial compression between the mandrel 24 and bore 26 . The potential energy generated is retained within the sealing ring 10 until the mandrel is removed. The sealing ring 10 is thus maintained in a super-elastic state in which the sealing contact forces at the bumps 12 , 14 , 28 are not easily disrupted. Removal of the mandrel permits the seal to return to its original shape, i.e., clear of the bore 26 , for removal.
[0046] The embodiment shown in FIG. 5 again seeks to overcome the unreliability of previous energized metal seals attributable to their inability to store energy in the system to cope with movement of any of the components. It comprises a bi-metallic composite sealing element 50 that when properly installed between two metallic surfaces, such as between a tubing hanger and well system, will establish and maintain a metal-to-metal fluid-tight sealing system between those surfaces under both static and dynamic conditions, in the presence of corrosive materials, and during and after exposure to a wide range of temperatures.
[0047] Similarly to FIG. 2, the sealing element 50 comprises an annular metallic member of U-shaped cross-section, with at least one sealing bump 12 around its outer periphery and at least one sealing bump 14 around its inner surface. The number and configuration of the bumps can again be varied as desired. Material 52 with a relatively lower coefficient of thermal expansion is fused or otherwise bonded to the remaining part 54 of the sealing element 50 . Alternatively, material 52 may have a larger coefficient of thermal expansion than material 54 .
[0048] This sealing element has a linear response to temperature, making sealing difficult under fluctuating well temperatures. It is therefore manufactured as a bi-metallic shape memory alloy sealing element. This is installed in the “crushed” condition (B), and heating above the SMA transition temperature causes the sealing element to try to recover its as-machined shape (A) and form the seal as a result of the shape memory effect. In its installed position (C), the sealing element remains under compression between the co-operating sealing surfaces to provide the necessary sealing contact forces, with the super-elastic effect ensuring that those forces are maintained even under extreme conditions. For removal, the seal would be heated or cooled to enable the bi-metallic effect (differential thermal expansion) to pull the outer leg away from the co-operating sealing surface (B).
[0049] [0049]FIGS. 6 and 7 are variants showing different SMA sealing element profiles, in which a seal is obtained due to expansion of the SMA from a “cold shape” condition (A) to the “hot shape” condition (B). FIG. 6 shows an O-ring profile 60 which expands to fill an annular cavity on local application of heat. FIG. 7 shows a composite SMA/corrosion resistant alloy seal, expanding radially only, so that the corrosion resistant alloy 70 forms the seal. The corrosion characteristics of the SMA 62 are therefore not so critical (subject to the SMA being fully encapsulated).
[0050] It should be recognized that, while the present invention has been described in relation to the preferred embodiments thereof, those skilled in the art may develop a wide variation of structural and operational details without departing from the principles of the invention. Therefore, the appended claims are to be construed to cover all equivalents falling within the true scope and spirit of the invention. | Shape memory alloy (SMA) technology and bi-metallic sealing elements are used to provide compact, reliable super-elastic sealing mechanisms, e.g., for use in the oilfield environment. Novel designs for sealing of annular areas are presented. | 5 |
[0001] This application is a continuation of U.S. application Ser. No. 10/516,243, filed May 24, 2005, which is a national stage filing under 35 U.S.C. §371 of International Application No. PCT/FR03/01515, filed on May 20, 2003, which claims benefit of French Application No. 0206736; filed on May 31, 2002, the entire contents of which are hereby incorporated by reference in their entireties for all purposes.
[0002] The present invention relates to a process for the production of an inorganic substrate which is surface-modified by organic groups, and the modified substrates obtained.
BACKGROUND OF THE INVENTION
[0003] The use of coupling agents, which make it possible to improve adhesion between an organic matrix and an inorganic substrate by forming an intermediate film, is increasingly widespread. Self-assembled monolayers, called SAMs, which are formed by aliphatic long-chain organic molecules on a silica substrate, constitute an alternative to the films formed by physisorption according to the Langmuir-Blodgett technique. These SAM monolayers possess great stability and resistance to various disruptions, in particular to corrosion and to the presence of solvents, because the organic molecules are attached to the silica by covalent bonds.
[0004] Various techniques for grafting an organic layer onto the surface of a silica substrate are known: organization of the layer by physisorption, for example grafting of an alkane onto a gold or silver substrate, starting with alkanediols; organization of the layer by chemisorption, for example grafting of an alkane onto a platinum substrate starting with alcohols or amines, or onto an alumina substrate starting with carboxylic acid; grafting of organic groups onto a substrate containing surface OH groups, by covalent bonding starting with organosilanes such as alkylchlorosilanes, alkylalkoxysilanes or alkylaminosilanes (cf. in particular A. Ulman, Chem. Rev., 1996, 96, 1533-1554). In a method for grafting organic groups onto a silica substrate carrying Si—OH groups, starting with organtrichlorosilanes, hydrochloric acid is formed which catalyzes both the hydrolysis reaction which causes the attachment of the organosilane to the surface of this substrate, and the homocondensation of organosilanes with each other. The overall process is thus accelerated at the expense of selectivity. In the case of short-chain organochlorosilanes, which are the silanes most widely used in industrial applications, the deposits obtained are in the form of multilayers whose thickness is difficult to control. When an organotrialkoxysilane is used, the corresponding alcohol, which can become adsorbed to the surface of the substrate, is formed, causing an increase in the heterogeneity of the grafting.
[0005] Through E. Lukevics et al., (J. Organomet. Chem. 1984, 271, 307), processes are known which consist in reacting organosilanes with compounds having an active hydrogen, such as acids, alcohols and thiols. This process requires, however, the use of a catalyst, for example a Lewis base, or of a nucleophilic solvent.
[0006] Through A. Fadeev, et al., (J. Am. Chem. Soc. 1999, 121, 12184), a process is known which consists in reacting an organosilane RSiH 3 , R 2 SiH 2 or R 3 SiH with titanium oxide. Through A. Ulman et al., (Chem. Mat. 2002, 14, 1778), a process is known which consists in reacting octadecyltrihydrosilane with γ-Fe 2 O 3 particles. The films obtained according to these processes are not very stable because the reactions result in the formation of labile Si—O-M bonds (M being depending on the case Ti or Fe), which can be redistributed as Si—O—Si+M-O-M which are more stable.
SUMMARY OF THE INVENTION
[0007] The aim of the present invention is to provide a process for the production of silica substrates which are surface-modified by deposition of a homogeneous and well organized dense layer.
[0008] The process according to the invention consists in bringing an inorganic substrate carrying silanol functional groups at its surface into contact with a solution of an organotrihydrosilane in an organic solvent, at a temperature of less than 30° C.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWING
[0009] FIG. 1 illustrates the state of a drop of water on a hydrophilic surface, the angle θ being less than 90°.
[0010] FIG. 2 illustrates the state of a drop of water on a hydrophobic surface, the angle θ being greater than 90°.
[0011] FIG. 3 illustrates the state of the surface of a platelet after grafting p-methylstilbenzyltrihydrosilane.
[0012] FIG. 4 illustrates the state of the surface of a platelet after post-grafting p-bromotoluene.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] As an example of an inorganic substrate carrying silanol functional groups at its surface, there may be mentioned in particular silica particles, glass plates, quartz plates or mica plates, and wafer-type silicon coated with a silica layer deposited by an appropriate preliminary treatment.
[0014] A wafer-type silicon substrate carrying a silica layer at its surface may be obtained according to various processes. A first process consists in removing the native silica layer by immersing the silicon substrate in a solution of HF containing at least 10% by volume of HF in ultrapure water under ultrasound, in rinsing with ultrapure water, and then in treating with ozone under UV. Such a treatment, which is particularly preferred, is described in particular by J. R. Vig, J. Vac. Sci. Technol., 1985, 3, 1027-1034. A second process consists in subjecting said silicon substrate to an oxygen stream at high temperature, for example at 1150° C., as described in particular by D. L. Angst, Langmuir, 1991, 7, 2236-2242. In another process, the silicon substrate is subjected to a chemical oxidation by the basic route: after cleaning the surface of the substrate with a solvent under ultrasound, the substrate is left in an H 2 0, NH 4 OH, H 2 O 2 5/1/1 mixture, and then rinsed with deionized water, dried and rehydrated (cf. for example “J. D. Legrange, et al., Langmuir, 1993, 9, 1749-1753”). In another process, the silicon substrate is subjected to a chemical oxidation by the acidic route: the substrate is cleaned with a basic solution, and then dipped in an acidic mixture of the H 2 SO 4 /H 2 O 2 type (cf. A. K. Kakkar, et al., Langmuir, 1998, 14, 6941-6947).
[0015] The grafting step itself, that is to say the bringing of the organotrihydrosilane and the silica substrate into contact, is performed in a neutral atmosphere (preferably under argon), using a solution of organotrihydrosilane in an aprotic solvent. Among the aprotic solvents, it is preferable to use those which have a low hygroscopic character. By way of example, there may be mentioned carbon tetrachloride, trichloroethylene and toluene.
[0016] The organotrihydrosilane may be chosen from the compounds X-E-SiH 3 in which E is a spacer segment and X represents H or a reactive terminal functional group.
[0017] X may be chosen from any functional group capable of allowing the attachment of other organic groups (for example B043 7US 4 an amine group, a halogen, an epoxy, a pyridyl, an ester, a tosylate (p-toluenesulfonyl), a heterocumulene (such as an isocyanate, an isothiocyanate or a carbodiimide) or a metal-complexing agent (for example a crown ether, a cryptant, a calixarene which is a macrocycle obtained by condensation of a phenolic derivative with formaldehyde).
[0018] The spacer group E makes it possible to confer particular properties to the film obtained using the process. The group E is chosen from radicals which make it possible to obtain an organized monolayer. A radical E of the long-chain alkylene type allows interchain interaction. Among the radicals E of the alkylene type, those particularly preferred have from 8 to 24 carbon atoms. A radical E comprising two —C≡C— triple bonds allows crosslinking. A radical E comprising a conjugated aromatic chain confers nonlinear optical properties. By way of example, there may be mentioned phenylene-vinylene and phenylene-acetylene radicals. A radical E of the pyrrole, thiophene or polysilane type confers electronic conduction. A radical E of the heterosubstituted polyaromatic type confers photo/electroluminescence properties. By way of example, there may be mentioned quinones and diazo compounds. A group E of the alkyl or fluoroalkyl type, in particular an alkyl or fluoroalkyl group having from 3 to 24 carbon atoms, makes it possible to use the layers obtained in chromatography or in electrophoresis.
[0019] The organotrihydrosilane solution preferably contains from 10 −3 to 10 −1 mole/1. Solutions in which the organotrihydroxilane concentration is of the order of 10 −2 mole/1 are particularly preferred.
[0020] The duration of grafting is preferably between 4 and 24 hours. A duration of the order of 12 h makes it possible to obtain good results.
[0021] During grafting, the reaction medium should be kept at a temperature of less than 30° C. The maximum value depends on the substituent X-E-. This maximum value tends to decrease when the number of carbon atoms of the substituent decreases. The determination of the maximum value for a given substituent is within the capability of persons skilled in the art. Useful information may be found in particular in Brzoska et al., (Langmuir, 1994, 10, 4367), which mentions the existence of a critical temperature Tc controlling the quality of the self-assembled monolayers obtained from various alkyltrichlorosilanes. The maximum temperature is generally less than 30° C. For example, the temperature should be less than 30° C. if R is C 18 H 37 and less than 10° C. if R is C 12 H 25 .
[0022] It is preferable to carry out the reaction under an inert atmosphere, in order to avoid pollution of the monolayer with organic compounds.
[0023] The use of an organosilane X-E-SiH 3 as coupling agent allows the initial formation of an Si—O—Si bond by direct condensation between the Si—H functional group of the reagent with a silanol Si—OH functional group carried by the surface of the substrate. This grafting mode considerably limits the formation of aggregates, which are damaging to the deposition of a homogeneous layer. The use of X-E-SiH 3 additionally has the advantage of producing by-products which are easy to remove, namely H 2 . There is no risk of finding on the treated substrate anionic entities or protic compounds inherent to prior art processes using chlorosilanes or alkoxysilanes.
[0024] It should also be noted that the process proposed may be carried out without using a catalyst, unlike the prior art processes consisting in reacting organosilanes with compounds having an active hydrogen, such as acids, alcohols or thiols (cf. E. Lukevics et al., cited above).
[0025] The silica substrate modified according to the process of the present invention contains at its surface a monolayer of segments X-E-attached by a covalent bond Si—O—Si, said layer containing functional groups X which are uniformly distributed on the surface and which are accessible.
[0026] The process of the invention consists in depositing an organic monolayer on a surface layer of silica which is initially very hydrophilic, the angle of contact being less than 10°. After grafting, the wettability of the surface toward ultrapure water greatly depends on the nature of the groups X-E- of the silane used to form the layer. In the case of alkylsilanes (E being a linear alkylene), the hydrophobic character of the surface results in an angle of contact θ H20 ≈95-100°. When E is an aryl, the presence of aromatic groups reduces the hydrophobic character of the surface, which results in an angle of contact θ H20 ≈69-77°. FIG. 1 illustrates the state of a drop of water on a hydrophilic surface, the angle θ being less than 90°. FIG. 2 illustrates the state of a drop of water on a hydrophobic surface, the angle 0 being greater than 90°.
[0027] The images obtained by AFM (atomic force microscopy) show that the surface is homogeneous and has a very low mean surface roughness (MSR), generally of less than 0.2 nm. The roughness of the treated substrate is independent of the nature of the organic group grafted, it remains very close to that of the untreated initial substrate.
[0028] The thickness of the layer obtained is determined by ellipsometry (taking n=1.45 as the value of the refractive index of the surface film, which is the value generally used). This thickness depends on the length of the group X-E- and on its orientation relative to the surface of the substrate. The thickness is of the order of 1.7 nm when X-E is octadecyl, which corresponds to a dispersed layer occupying=70% of the surface of the substrate.
[0029] The substrate coated with a monolayer obtained by the proposed process is characterized in general by a good covering rate and a good organization of the chains at its surface.
[0030] In a substrate modified using a silane of the alkyl-SiH 3 type, the covalent bond through which the substrate is attached to the organic group is of the —SiH 2 O—Si-type. The presence of SiH 2 groups is revealed by the vibration band √Si—H at 2150 cm −1 . This band is not observed on the substrates modified according to the prior art processes with the aid of an alkyltrichlorosilane or an alkyltrialkoxysilane comprising the same alkyl group.
[0031] The present invention is described in greater detail with the aid of the following examples, to which it is, however, not limited.
Example 1
[0032] A series of silicon substrates coated with an organic layer were prepared by treatment with octadecyltrihydrosilane.—As substrate, silicon (100) disks cut in order to obtain 1×2 cm 2 rectangular platelets were used.
[0033] In a first stage, each platelet was immersed in a solution of concentrated HF for a few seconds, until the surface became completely hydrophobic. Next, each platelet was rinsed with ultrapure water, and then treated with ozone under UV.
[0034] Each platelet thus treated was immediately introduced is into a Schlenck tube containing 20 ml of a 10 −2 M solution of octadecyltrihydrosilane in CCl 4 , and kept in the tube for 24 h at a temperature of 15° C., without stirring. After 24 h, the platelets were extracted from the Schlenck tubes, washed with CCl 4 , with absolute ethanol, and then with chloroform, each washing being carried out under ultrasound, for a period of the order of 5 min.
[0035] The platelets thus obtained may be stored in an ambient atmosphere, without undergoing degradation.
[0036] The angle of contact at the surface of the platelets, measured by the drop method at equilibrium, is 98°±2, which indicates a hydrophobic and homogeneous surface.
[0037] Under the same conditions as above, silicon platelets were treated with the aid of octadecyltrichlorosilane, for comparison.
[0038] Analysis by infrared spectroscopy in attenuated total reflection (ATR) mode of the surfaces treated with octadecyltrihydrosilane and of the surfaces treated with octadecyltrichlorosilane gave the results grouped together in the following table.
[0000]
C 18 H 37 SiH 3
C 18 H 37 SiH 3
C 18 H 37 SiCl 3
C 18 H 37 SiCl 3
solution
grafted
grafted
solution
√asCH 3 (cm −1 )
2958
2959
2959
2958
√sCH 3 (cm −1 )
2872
2873
2874
2872
√asCH 2 (cm −1 )
2927
2922
2918
2927
√sCH 2 (cm −1 )
2855
2850
2850
2855
√Si—H (cm −1 )
2148
2150
—
—
[0039] The substrates treated according to the invention have a band √Si—H at 2150 cm −1 which does not exist for the substrates obtained from C 18 H 37 SiCl 3 and which corresponds to the existence of Si—H bonds in an environment of the R—SiH 2 —O type at the surface of the substrate.
[0040] The other bands obtained show that the organization of octadecyltrihydrosilane at the surface is a compromise between a complete crosslinking obtained for octadecyltrichlorosilane grafted and the absence of organization observed for octadecyltrihydrosilane and for octadecyltrichlorosilane in solution.
[0041] The images obtained by AFM for the platelets of the invention show a homogeneous surface with a very low 15 roughness, of the order of 0.15-0.20 nm.
[0042] The thickness of the layers obtained according to the process of the invention was determined by ellipsometry, taking n=1.45 as the value of the refractive index. This thickness is of the order of 1.7 nm, which corresponds to a dispersed layer occupying=70% of the surface of the substrate.
Example 2
[0043] The procedure of example 1 was repeated using octadecyltrihydrosilane, changing only the reaction temperature in the Schlenck tube. Two series of trials were performed at 5° C. and at 20° C., respectively. The analyses carried out on the platelets gave identical results.
Example 3
[0044] The procedure of example 1 was repeated, but replacing 30 octadecyltrihydrosilane with phenyltrihydrosilane, all the other conditions being identical.
[0045] The angle of contact measured at the surface of the modified platelets is 74°±4.
[0046] The images obtained by AFM for the platelets of the invention show a homogeneous surface with a very low roughness, of the order of 0.2 nm.
[0047] The thickness of the layers obtained according to the process of the invention was determined by ellipsometry, taking n=1.45 as the value of the refractive index. This thickness is of the order of 0.8 nm, which corresponds to a monolayer of high density.
Example 4
[0048] A series of platelets were treated according to the procedure of example 1, but replacing octadecyltrihydro-silane with p-methylstilbenzyltrihydrosilane, all the other conditions being identical. FIG. 3 illustrates the state of the surface of the platelet after grafting of the p-methylstilbenzyltrihydrosilane.
[0049] The angle of contact measured at the surface of the 20 modified platelets is 85°+3.
[0050] The images obtained by AFM for the platelets show a homogeneous surface with a very low roughness, of the order of 0.2 nm.
[0051] The thickness of the layers obtained was determined by ellipsometry, taking n=1.619 as the value of the refractive index. This thickness is of the order of 19 nm, which corresponds to a monolayer of high density.
Example 5
[0052] A series of platelets were treated according to the procedure of example 1, but replacing octadecyltrihydrosilane with vinylphenyltrihydrosilane, all the other conditions being identical.
[0053] The angle of contact measured at the surface of the modified platelets is 75°±4.
[0054] The images obtained by AFM for the platelets show a homogeneous surface with a very low roughness, of the order of 0.2 nm.
[0055] The thickness of the layers obtained was determined by ellipsometry, taking n=1.546 as the value of the refractive index. This thickness is of the order of 11 nm, which corresponds to a monolayer of high density.
[0056] Each platelet thus treated was placed in a 25 ml flask surmounted by a condenser and containing 1 mmol of p-bromotoluene, 9 mg (0.04 mmol) of palladium diacetate, 46 mg (0.15 mmol) of triorthotolylphosphine, 2 ml of triethylamine and 10 ml of toluene, the whole under an inert atmosphere. The reaction mixture was heated to 110° C. with gentle magnetic stirring overnight. After returning to room temperature, each platelet was taken out of the flask, and then carefully rinsed with toluene and with pentane under ultrasound. FIG. 4 illustrates the state of the surface of the platelet after post-grafting reaction of p-bromotoluene.
[0057] The platelets thus obtained may be stored under an ambient atmosphere, without undergoing degradation.
[0058] Analyses carried out on the platelets gave results identical to those obtained for the analyses of the platelets treated in example 4.
Example 6
[0059] The process according to the invention was carried out for a silica substrate in the form of colloidal silica.
[0060] The substrate is an activated silica marketed by the company Merck under the name Merck 60F silica.
[0061] 0.5 g of the activated silica was treated with 1 g of octadecyltrihydrosilane in 20 ml of CCl 4 at 19-20° C. for 24 h, with magnetic stirring. The powder obtained was filtered, washed twice with 20 ml of CCl 4 , and then 4 times with 20 ml of THF in order to remove any silanes physisorbed.
[0062] It is observed that grains of the powder obtained, when deposited at the surface of ultrapure water, remain at the surface after 48 hours, which demonstrates a perfectly hydrophobic character.
[0063] The presence of grafted silane is characterized by infrared spectroscopy and NMR. An IR band at 2165 cm −1 and a signal at −31 ppm in 29 Si NMR show the presence of —O—SiR(H)—O— functional groups. This result presupposes the hydrolysis of an Si—H bond, following the attachment of the organosilane to the surface. | Provided is a method for the production of a mineral substrate with a surface modified by organic groups. The method comprises placing the surface of a mineral substrate with silanol functional groups in contact with a solution of an organotrihydrosilane in an organic solvent at a temperature of less than 30° C. The mineral substrate with silanol functions can comprise silica particles, a sheet of glass, quartz or mica as well as silicon of the wafer type covered by a layer of silica deposited by an appropriate preliminary treatment. | 2 |
BACKGROUND OF THE INVENTION
[0001] The coronary artery tree is a system of arteries that supplies oxygen and nutrient-rich blood directly to the heart muscle. When these arteries begin to calcify, or build up fatty deposits along their walls, adverse cardiac events can occur, such as myocardial infractions or coronary artery disease. Proper diagnosis and treatment of these calcifications (also referred to as stenoses or lesions) are critical to reducing the high fatality rate associated with such adverse cardiac events.
[0002] Medical procedures, such as cardiac catheterization, generally result in reports created by the performing clinician that detail the procedure, including the diagnosis and the intervention performed. Such reports typically include graphics representative of the coronary artery tree pattern for the patient. Conventionally, the clinician creating the report must manually select an appropriate coronary artery tree pattern that represents the coronary anatomy of the patient. In addition, the clinician must remember the location and quantity of lesions in the patient's arteries or must manually input the lesion data into coronary annotation software.
[0003] Conventional imaging systems may include Quantitative Coronary Analysis (QCA) software. A clinician uses the QCA software during a QCA session to measure lesions in a patient's coronary arteries. Conventional imaging systems may also include coronary annotation software that is used to generate a coronary artery tree image for the patient. Currently, the clinician can use the coronary annotation software to only manually annotate the coronary artery tree image with information regarding lesions measured during the QCA session. The results of the QCA session currently cannot be saved and cannot be automatically transferred to the coronary annotation software for display on the coronary artery tree image for the patient. Also, conventional coronary annotation software only offers visual size interpretation of the lesions. In addition, the manual annotation and the visual size interpretation generally occur on different screens and at different times during the clinician's use of the coronary annotation software.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In light of the problems and limitations described above, a need exists for the automatic input of the patient-specific data from QCA software into coronary annotation software in order to increase the efficiency and accuracy of coronary artery lesion mapping. Automatic input can eliminate or drastically reduce report time for the clinician, can ensure inclusion and accurate location of all lesions, and can ensure secure data transfer.
[0005] One embodiment of the invention includes a method of generating an image of a coronary artery tree for a patient. The method can include acquiring data from the patient for one or more coronary artery segments of the coronary artery tree, generating a coronary artery tree image including the coronary artery segments, and accessing coronary artery tree patterns. The method can also include comparing the coronary artery tree image to the coronary artery tree patterns using a pattern recognition module and automatically selecting one of the coronary artery tree patterns as a representative coronary artery tree image for the patient. The method can further include detecting a lesion in one of the coronary artery segments, and automatically adding a measurement of the lesion to the coronary artery tree image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic illustration of a coronary imaging system according to one embodiment of the invention.
[0007] FIGS. 2A and 2B include a flowchart illustrating the operation of the coronary imaging system of FIG. 1 according to one embodiment of the invention.
[0008] FIG. 3 is an illustration of a computer screen including original coronary artery tree images that are displayed using the coronary imaging system of FIG. 1 .
[0009] FIG. 4 is an illustration of a computer screen including a graphical user interface that is displayed using the coronary imaging system of FIG. 1 .
[0010] FIG. 5 is an illustration of a computer screen including an annotated coronary artery tree image that is displayed using the coronary imaging system of FIG. 1 .
DETAILED DESCRIPTION
[0011] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect.
[0012] In addition, it should be understood that embodiments of the invention include both hardware and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic based aspects of the invention may be implemented in software. As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components may be utilized to implement the invention. Furthermore, and as described in subsequent paragraphs, the specific mechanical configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative mechanical configurations are possible.
[0013] FIG. 1 illustrates a coronary imaging system 10 according to one embodiment of the invention. The coronary imaging system 10 can include an imaging device 14 , a pattern recognition module 18 , coronary artery tree patterns 22 stored in a database 26 , a quantitative coronary analysis (QCA) module 30 , a coronary tree generation module 38 , and a display device 42 . The imaging device 14 can include any one or more of the following imaging devices: an x-ray machine, a magnetic resonance imaging system, a computerized axial tomography system, a digital imaging and communications in medicine (DICOM) image review system, and a positron emission tomography system. The imaging device 14 can acquire data from a patient in order to generate an original coronary artery tree image 34 , as shown in FIGS. 3 and 4 .
[0014] In some embodiments, the pattern recognition module 18 can access the coronary artery tree patterns 22 in the database 26 . The database 26 can store coronary artery tree patterns 22 having a known condition, a known diagnosis, and/or a known physiology. Using pattern matching algorithms, the pattern recognition module 18 can compare the original coronary artery tree image 34 to the coronary artery tree patterns 22 . In one embodiment, the pattern recognition module 18 can automatically select one of the coronary artery tree patterns 22 as a representative coronary artery tree that can be annotated to indicate the patient's lesions (as shown in FIG. 5 ). In some embodiments, the pattern recognition module 18 receives image positioning information from the imaging device 14 to assist in selecting the representative coronary artery tree pattern for the patient. In another embodiment of the invention, the pattern recognition module 18 can be omitted and the coronary tree generation module 38 can generate a coronary artery tree image including each coronary artery segment of the patient's actual coronary artery tree. In other words, rather than choosing a representative coronary artery tree that is similar to the patient's coronary artery tree, the coronary tree generation module 38 can generate a patient-specific coronary artery tree that is a replication of the patient's actual coronary artery tree. Whether the coronary artery tree image is a representative image or an actual image, an annotated coronary artery tree image 36 for the patient can be displayed as shown in FIG. 5 .
[0015] Referring to FIG. 3 , the QCA module 30 can be used by a clinician to measure any lesions shown in the original coronary artery tree image 34 . The clinician can calibrate a measurement device of the QCA module 30 and can then use a mouse (or any other suitable pointer device) to select a lesion 66 located in a coronary artery tree segment 94 . The QCA module 30 can detect the edge of the coronary artery and can measure the diameter and/or the cross-sectional area of the coronary artery along the length of the lesion, including the diameter at an obstructed point and the diameter at an unobstructed point. As shown in FIG. 3 , the lesion 66 has resulted in a diameter of 0.96 mm at the most obstructed point. Also, the coronary artery has a diameter of 2.25 mm at an unobstructed point.
[0016] The QCA module 30 or the coronary tree generation module 38 can generate a graphical user interface 100 (as shown in FIG. 4 ) for the display device 42 . The graphical user interface 100 can include a list of parameters 102 and values 104 corresponding to each of the parameters 102 . The parameters 102 can include stenosis ratio, reference diameter, stenosis diameter, ideal diameter at stenosis, and lesion length. The stenosis ratio parameter can include a first percentage (which is 56.42% in FIG. 4 ) indicating the amount by which the diameter of the coronary artery has been reduced by the lesion. The stenosis ratio parameter can include a second percentage (which is 81.01% in FIG. 4 ) indicating the amount by which the cross-sectional area of the coronary artery has been reduced by the lesion.
[0017] The graphical user interface 100 can also include an X-Y graph 105 with the X-axis representing a length of a coronary artery segment and the Y-axis representing a diameter of the coronary artery. For example, as shown in FIG. 4 , the lesion is 22.27 mm long as represented by the X-axis of the X-Y graph 105 . At its most unobstructed point, the coronary artery has a diameter of 3.55 mm as represented by a first data point 106 . The beginning of the lesion can be represented by a second data point 108 . The most obstructed point of the lesion can be represented by a third data point 110 . At its most obstructed point, the coronary artery has a diameter of 1.55 mm, which is located 7.6 mm from beginning of the lesion and the first data point 106 . The end of the lesion can be represented by a fourth data point 112 , which is located 22.7 mm from the beginning of the lesion and the first data point 106 . The X-Y graph 105 can also include a curve 114 that represents the change in diameter along the length of the lesion. In addition, the X-Y graph 105 can include a lesion length indicator 116 indicating that the lesion is 22.3 mm long.
[0018] The QCA module 30 can automatically provide data to the coronary tree generation module 38 through an internal software connection. In some embodiments, the coronary imaging system 10 includes an application program interface (API) that automatically reads and transmits the results of the QCA session to the coronary tree generation module 38 . The QCA module 30 can automatically update the coronary tree generation module 38 with a patient-specific coronary artery tree image generated from actual measurements and accumulated analyses.
[0019] The coronary tree generation module 38 can output an annotated coronary artery tree image 36 (as shown in FIG. 5 ) to the display device 42 . The annotated coronary artery tree image 36 can be displayed in a window with various menus for performing various tasks (such as the conventional save, open, and print functions, along with any other suitable functions). The annotated coronary artery tree image 36 can include labels 117 for many of the coronary arteries and other blood vessels (such as the aorta). A clinician can use the QCA module 30 or the coronary tree generation module 38 to assign a descriptor to each lesion from a drop-down list of lesion descriptors. A clinician can use the QCA module 30 or the coronary tree generation module 38 to place a comparable percentage stenosis mark 118 and/or a length measurement for each lesion on the annotated coronary artery tree image 36 . In addition to the annotated coronary artery tree image 36 , additional patient data 120 , input fields 122 , and a tree check list 124 can be displayed adjacent to the annotated coronary artery tree image 36 . The additional patient data 120 can include the patient's name, a study identification, and a procedure date. The input fields 122 can include Procedure (Diagnostic or Intervention), Dominance (Left, Right, or Mixed), Valve Disease (Yes, No, Unknown), and Injected (LAD, RCA, and Circumflex). The tree check list 124 can include a listing of the coronary arteries that are currently displayed.
[0020] In some embodiments, the coronary tree generation module 38 automatically updates the annotated coronary artery tree image 36 with any lesions detected throughout the course of the QCA session. Upon completion or during the course of the QCA session, the clinician can view the annotated coronary artery tree image 36 shown in FIG. 5 , including any descriptors, comparable percentage stenosis marks, and length measurements.
[0021] FIGS. 2A and 2B include a flowchart illustrating the operation of the coronary imaging system 10 according to one embodiment of the invention. The clinician can acquire (at 46 ) data from the patient using the imaging device 14 . The imaging device 14 can generate (at 50 ) the original coronary artery tree image 34 (as shown in FIGS. 3 and 4 ). The pattern recognition module 18 can compare (at 54 ) the original coronary artery tree image 34 to the coronary artery tree patterns 22 stored in the database 26 . The pattern recognition module 18 can automatically select (at 58 ) a representative coronary artery tree pattern for the patient.
[0022] Referring to FIG. 2B , the clinician can initiate (at 62 ) a Quantitative Coronary Analysis (QCA) session. The clinician can measure (at 70 ) a lesion 66 (as shown in FIG. 3 ). The QCA module 30 can automatically transfer (at 74 ) the results of the QCA session to the coronary artery tree generation module 38 . The coronary tree generation module 38 can automatically populate (at 78 ) the annotated coronary artery tree image 36 (as shown in FIG. 5 ) with the results of the QCA session. In other words, the coronary tree generation module 38 can automatically add a measurement of the lesion 66 to the annotated coronary artery tree image 36 for the patient.
[0023] The clinician can use the QCA module 30 to determine (at 82 ) if there are additional lesions in the patient's coronary artery tree. If there are additional lesions, the QCA module 30 can measure (at 70 ) the additional lesions, transfer (at 74 ) the results, and populate (at 78 ) the annotated coronary artery tree image 36 . If there are no additional lesions, the coronary tree generation module 38 can display (at 86 ) the annotated coronary artery tree image 36 populated with the lesions.
[0024] Various features and advantages of the invention are set forth in the following claims. | A method of generating an image of a coronary artery tree for a patient. The method can include acquiring data from the patient for coronary artery segments and generating a coronary artery tree image including the coronary artery segments. The method can also include accessing coronary artery tree patterns, comparing the coronary artery tree image to the coronary artery tree patterns, and automatically selecting one of the coronary artery tree patterns as a representative coronary artery tree image for the patient. The method can further include measuring lesions and automatically adding the lesion measurements to the coronary artery tree image for the patient. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Japanese Patent Application No. 2014-121579 filed on Jun. 12, 2014, Japanese Patent Application No. 2015-105675 filed on May 25, 2015 and Japanese Patent Application No. 2015-114340 filed on Jun. 4, 2015, the entire contents of which are incorporated by reference herein.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention relates to a urea water supply system that supplies urea water to the exhaust emission for reduction of NOx using a selective reduction NOx catalyst provided in an exhaust passage of an internal combustion engine.
[0004] 2. Description of the Related Art
[0005] A known configuration of an exhaust emission control device provides a selective reduction NOx catalyst (hereinafter simply referred to as “NOx catalyst”) that reduces NOx included in the exhaust emission discharged from an internal combustion engine by using ammonia as a reducing agent. A supply valve is provided in the upstream of the NOx catalyst to supply urea water to the exhaust emission, in order to control the adsorption amount of ammonia on the NOx catalyst to a suitable condition for reduction of NOx. Urea water used for producing ammonia causes deposition of urea after vaporization of its water content. This may adversely affect components involved in supply of urea water, for example, the supply valve and a pump for pressure-feeding urea water.
[0006] For example, Patent Literature 1 describes the adverse effects of the released urea on the pump. More specifically, Patent Literature 1 has noted that urea depositing by vaporization of water after a stop of operation of the pump is likely to enter the clearance between components of the pump and cause a trouble and provides a configuration of making a continuous flow of urea water in the pump even after a stop of operation of the pump, in order to suppress deposition of urea.
CITATION LIST
Patent Literature
[0000]
PTL 1: JP 2010-7617A
PTL 2: JP 2014-1835A
SUMMARY
[0009] A proposed technique provides two NOx catalysts placed in the exhaust passage for the purpose of removing NOx in the exhaust emission discharged from the internal combustion engine. The two NOx catalysts may be provided for various reasons, for example, providing two exhaust passages extended from an internal combustion engine or enhancing the efficiency of removal of NOx as much as possible. In any reason, in the technique of providing two NOx catalysts in the exhaust passage, one applicable configuration may place two supply valves corresponding to the two NOx catalysts for supplying ammonia efficiently to the respective NOx catalysts and supply the amount of urea water required for each NOx catalyst from the supply valve to the exhaust emission. In the above configuration of placing the two supply valves for supply of urea water, a pump used to pressure-feed the urea water to the respective supply valves may be shared by the respective supply valves, in order to reduce an increase in total number of components. The configuration of supplying urea water from a common pump to a plurality of supply valves is called “pump share-type” in the description below.
[0010] The urea included in urea water is the precursor of ammonia. When urea water is not supplied from the supply valve to the exhaust emission but remains in the supply valve or in a supply path connecting with the supply valve, ammonia may be produced from the remaining urea water by, for example, heat energy from the exhaust passage and accelerate corrosion of the supply valve or the supply path. The urea water filled in the supply valve and the supply path is thus required to be sucked back to a tank, when there is no need to continue supplying the urea water to the exhaust emission for the purpose of reduction of NOx. When supply of urea water to the exhaust emission is needed again, the supply valve and the supply path are filled with urea water again to prepare for resuming supply of urea water to the exhaust emission.
[0011] In the case that the configuration of filling urea water for the purpose of supply of ammonia to the NOx catalyst is applied to the pump share-type exhaust emission control device described above, the different capacities of the supply paths connecting with the respective supply valves may result in different filling behaviors of urea water in the respective supply paths. More specifically, the different capacities of the supply paths may cause a failure in supply of urea water (hereinafter may be simply referred to as “failure in supply”), for example, insufficient filling into one of the supply valves through one of the supply paths or leakage of urea water by excessive filling.
[0012] By taking into account the problems described above, an object of the invention is to suppress the occurrence of a failure in supply of urea water as much as possible in filling control of urea water in two supply paths in a pump share-type urea water supply system with two supply valves and two supply paths connecting with the respective supply valves.
[0013] In order to solve the above problems, the inventors have noted the open-close control of the two supply valves during operation of the pump in the pump share-type urea water supply system. Open-close control of the respective supply valves is required for moving and filling urea water by the operation of the pump in the supply path of urea water. More specifically, in order to move urea water by the pressure-feed capacity of the pump, the supply valve needs to be opened to set the internal pressure of the supply path to a condition that allows for migration of urea water. The invention thus aims to adequately control the respective valve-opening times of the two supply valves during operation of the pump, in order to eliminate a failure in supply of urea water due to the difference between the capacities of the supply paths connecting with the respective supply valves.
[0014] According to one aspect of the invention, in an exhaust emission control device that is provided in an exhaust passage of an internal combustion engine and has a first NOx catalyst and a second NOx catalyst configured to reduce NOx by using ammonia as a reducing agent, there is provided a urea water supply system that supplies urea water to the exhaust passage. The urea water supply system may comprise a first supply valve that is located in upstream of the first NOx catalyst and is configured to supply urea water to an exhaust emission flowing into the first NOx catalyst; a second supply valve that is located in upstream of the second NOx catalyst and is configured to supply the urea water to the exhaust emission flowing into the second NOx catalyst; a urea water tank that is configured to store the urea water; a urea water supply path that is arranged to connect the urea water tank with each of the first supply valve and the second supply valve and includes a first supply path which only the urea water to be supplied to the first supply valve flows through and a second supply path which only the urea water to be supplied to the second supply valve flows through, wherein the second supply path has a larger capacity than capacity of the first supply path by a predetermined volume; a pump that is configured to pressure-feed the urea water in the urea water supply path; an acquirer that is configured to obtain a pressure value in the urea water supply path or in the pump or a pressure variation per unit time in the urea water supply path or in the pump; and a controller that is configured to perform filling control of the urea water into the first and second supply valves and into the urea water supply path by operating the pump in a specified operating state and performing open-close control of the first supply valve and the second supply valve. In the filling control, the controller may pressure-feed the urea water to the first supply valve and the first supply path by the pump operated in the specified operating state in a state that at least the first supply valve out of the first and second supply valves is opened, and may close the first supply valve based on the pressure value or the pressure variation per unit time obtained by the acquirer.
[0015] The exhaust emission control device has the two NOx catalysts, i.e., the first NOx catalyst and the second NOx catalyst as described above. The urea water supply system of the invention is provided with the first supply valve for supply of urea water corresponding to the first NOx catalyst and the second supply valve for supply of urea water corresponding to the second NOx catalyst. Each of the supply valves may have any configuration that enables urea water to be supplied suitably for the corresponding NOx catalysts. Accordingly, in a range that ensures suitable supply of urea water, the respective supply valves may have an identical specification with regard to supply of urea water or may have different specifications.
[0016] In the above urea water supply system, the urea water is pressure-fed by one pump to be filled into the first supply valve and the second supply valve. In other words, the urea water supply system employs the configuration of pump share-type urea water supply. Migration of urea water from the urea water tank to each of the supply valves is through the urea water supply path. The urea water supply path is configured to enable the urea water to be flowed between the urea water tank and each of the supply valves by pressure-feeding of the pump and includes the first supply path which only the urea water to be supplied to the first supply valve flows through and the second supply path which only the urea water to be supplied to the second supply valve flows through. Accordingly, when the urea water supply path includes an additional supply path other than the first supply path and the second supply path, both the urea water to be supplied to the first supply valve and the urea water to be supplied to the second supply valve flows through this additional supply path. In other words, this additional supply path is shared by the two supply valves.
[0017] In the urea supply system of this configuration, the controller performs the filling control of urea water into the respective supply valves. More specifically, the controller operates the pump in the specified operating state and subsequently performs open-close control of the first supply valve and the second supply valve. The specified operating state denotes an operating state that enables the pressure-feed capacity of the pump for filling urea water and may be any operating state that allows for filling of urea water. For example, an operating unit in the pump is rotated in a predetermined rotating direction to feed urea water to the supply valve side, while being rotated in a reverse direction to suck back urea water from the supply valve side.
[0018] After the controller operates the pump in the specified operating state, opening the first supply valve allows for migration of urea water in the first supply valve and in the first supply path, while opening the second supply valve allows for migration of urea water in the second supply valve and in the second supply path. Opening both the first supply valve and the second supply valve allows for migration of urea water in the respective supply valves and in the respective supply paths. The pump is operated to move the urea water by its pressure-feed capacity. During filling control of opening both the supply valves to move the urea water from the urea water tank into both the supply valves and the supply paths, filling the urea water on the basis of the first supply path having the smaller capacity may result in insufficient filling of urea water into the second supply path. Filling the urea water on the basis of the capacity of the second supply path, on the other hand, may cause urea water to be leaked from the first supply valve connecting with the first supply path having the smaller capacity.
[0019] In the urea water supply system of the invention, by taking into account that the capacity of the first supply path is smaller than the capacity of the second supply path by the predetermined volume, the controller controls open/close of the first supply valve at least in the case of filling urea water into the first supply valve and the first supply path, based on the pressure value or the pressure variation per unit time obtained by the acquirer. In the filling control, the controller opens at least the first supply valve to fill urea water. More specifically, the controller may open only the first supply valve or may open both the first supply valve and the second supply valve.
[0020] In the former case, opening the first supply valve causes urea water to be filled into the first supply valve and the relevant first supply path. On completion of filling of urea water into the first supply path, the supply path connecting the first supply valve with the pump is filled with urea water. This provides a change of the pressure value or the like obtained by the acquirer, in response to completion of filling urea water into the first supply path. In the latter case, opening both the supply valves causes urea water to be filled into both the first supply valve and the relevant first supply path and the second supply valve and the relevant second supply path. The capacity of the first supply path is smaller than the capacity of the second supply path, so that filling urea water is completed at the earlier timing for the first supply path. At this moment, the supply path connecting the first supply valve with the pump is filled with urea water. This provides a change of the pressure value or the like obtained by the acquirer, in response to completion of filling urea water into the first supply path. This adequately determines the timing of completion of filling urea water in the first supply valve and the first supply path, based on the pressure value or the like obtained by the acquirer, and thereby enables just the enough amount of urea water to be filled. In the filling control of the latter case, the valve-opening timings of the first supply valve and the second supply valve to start filling may be determined based on the difference between the capacities of the first supply path and the second supply path (predetermined volume), such that the first supply path is filled with urea water first. It is, however, preferable to open the first supply path and the second supply path simultaneously.
[0021] In the filling control, the controller may pressure-feed the urea water to the second supply valve and the second supply path by means of the pump operated in the specified operating state in the state that the second supply valve is opened, and may close the second supply valve based on the pressure value or the pressure variation per unit time obtained by the acquirer. This adequately determines the timing of completion of filling urea water in the second supply valve and the second supply path and enables just the enough amount of urea water to be filled.
[0022] In the urea water supply system of the above aspect, the controller may close the first supply valve, when the pressure value or the pressure variation per unit time obtained by the acquirer during pressure-feeding of the urea water by the pump operated in the specified operating state in the state that at least the first supply valve is opened is increased from a previously obtained pressure value or pressure variation per unit time. This notes an increase in pressure value or an increase in pressure variation per unit time, as the change in pressure value or the like in response to completion of filling urea water in the first supply path described above. In general, pressure-feeding by the pump causes a certain degree of pressure pulsation. In order to adequately detect an increase of the pressure value or the like for the purpose of determining completion of filling, it is preferable to set a threshold value exceeding the pressure pulsation by the pump. In this application, completion of filling urea water is determined when the detected pressure value or the like has an increase beyond the threshold value.
[0023] The urea water supply system of the above aspect may further comprise a determiner that is configured to perform a determination process of determining whether either of the first supply valve and the first supply path is clogged, based on a pressure in the urea water supply path or in the pump during the filling control. In this aspect, when the determiner determines that the first supply valve or the first supply path is clogged after the first supply vale is closed in the filling control, the controller may reopen the first supply valve while operating the pump in the specified operating state.
[0024] The urea water is moved through the urea water supply path by the pressure-feed capacity of the pump. Accordingly, when the urea water is smoothly moved through the urea water supply path, a specific pressure condition that allows for migration of urea water is provided. When the first supply valve or the first supply path is clogged, for example, due to soot entering the first supply valve, on the other hand, controlling the valve-closing timing of the first supply valve based on the pressure value or the like obtained by the acquirer described above may fail in providing a target state with regard to urea water (i.e., the state that urea water is filled, hereinafter referred to as “predetermined target state”) inside of the first supply valve or inside of the first supply path after the valve-closing. This may result in providing a pressure condition in the urea water supply path or the pump different from an expected pressure condition. The determiner may thus determine whether the first supply valve or the first supply path is clogged, based on the pressure in the urea water supply path or in the pump after the valve-closing of the first supply valve.
[0025] When the determiner determines that the first supply valve or the first supply path is clogged, it is expected that the filling control does not cause inside of the first supply valve and inside of the first supply path to reach the predetermined target state as described above. In this case, reopening the first supply valve with operating the pump in the specified operating state definitely causes the state inside of the first supply valve and inside of the first supply path to reach the predetermined target state and thereby suppresses the occurrence of a failure in supply of urea water.
[0026] A configuration described below may be employed with respect to the determination process performed in the urea water supply system of the above aspect with the determiner. In the urea water supply system of the above aspect, in the filling control, the controller may pressure-feed the urea water to the first supply valve, the first supply path, the second supply valve and the second supply path by the pump operated in the specified operating state in a state that both the first supply valve and the second supply valve are opened, and may close the first supply valve based on the pressure value or the pressure variation per unit time obtained by the acquirer. In this configuration, the determiner may determine that the first supply valve or the first supply path is clogged when a pressure condition of urea water induced by valve-closing of the first supply valve continues for a predetermined time after valve-closing of the first supply valve. When the determiner determines that the first supply valve or the first supply path is clogged, the controller may close the second supply valve and reopen the first supply valve while operating the pump in the specified operating state.
[0027] This configuration starts filling urea water simultaneously into the first supply valve and the second supply valve. When the first supply valve or the first supply path is clogged, urea water is unlikely to be filled into the first supply valve side. This causes a larger amount of urea water than expected to be filled into the second supply valve side and results in filling the second supply valve and the second supply path of the relatively larger capacity prior to the first supply valve and the first supply path. The controller closes the first supply valve, based on a change of the pressure value or the like due to filling of the second supply valve and the like. In spite of this, there is a high possibility that filling of urea water is not completed in the first supply valve and the first supply path. The second supply valve and the second supply path have already been filled, while the first supply valve or the first supply path is clogged. This results in maintaining the pressure condition induced by the change of the pressure value or the like. The determiner may thus determine that the first supply valve or the first supply path is clogged, when the pressure condition continues for the predetermined time.
[0028] While the above pressure condition continues, the second supply valve is kept open, so that urea water is leaked from the second supply valve. It is accordingly preferable to set a time as short as possible to the predetermined time to accurately determine clogging of the first supply valve or the like while reducing the amount of leakage of urea water as much as possible. When the determiner determines that the first supply valve or the like is clogged, the controller closes the second supply valve to suppress leakage of urea water, and reopens the first supply valve to restart filling urea water into the first supply valve and the first supply path.
[0029] In the urea water supply system of any of the above aspects with the determiner, the first NOx catalyst and the second NOx catalyst may be arranged in series along a flow of the exhaust emission in the exhaust passage of the internal combustion engine, and the first NOx catalyst may be placed in upstream of the second NOx catalyst. In the exhaust emission control device having such configuration of the NOx catalysts, the first supply valve corresponding to the first NOx catalyst located on the upstream side is placed nearer to the internal combustion engine than the second supply valve. The first supply valve is accordingly exposed to the environment that makes soot in the exhaust emission more likely to enter the supply valve through its opening. The determination process by the determiner described above is thus especially advantageous in this configuration. This is, however, not intended to interfere with employing any other configuration of NOx catalysts in the urea water supply system of the invention. For example, the configuration with regard to the determiner described above may be applied to a configuration that the first NOx catalyst and the second NOx catalyst are arranged in parallel in the exhaust passage of the internal combustion engine. In this latter configuration, the amount of soot included in the exhaust emission flowing into the first NOx catalyst may not be necessarily greater than the amount of soot included in the exhaust emission flowing into the second NOx catalyst.
[0030] The above aspects of the invention suppress the occurrence of a failure in supply of urea water as much as possible in filling control of urea water in two supply paths in a pump share-type urea water supply system with two supply valves and two supply paths connecting with the respective supply valves.
BRIEF DESCRIPTION OF DRAWINGS
[0031] FIG. 1 is a first diagram schematically illustrating a configuration of a urea water supply system for an exhaust emission control device of an internal combustion engine according to the invention;
[0032] FIG. 2 is a second diagram schematically illustrating another configuration of the urea water supply system for the exhaust emission control device of the internal combustion engine according to the invention;
[0033] FIG. 3 is a flowchart showing a first flow of filling control of urea water performed in the urea water supply system shown in FIG. 1 or FIG. 2 ;
[0034] FIG. 4 is a first time chart showing variations of control elements such as supply valves in the course of the filling control of FIG. 3 ;
[0035] FIG. 5 is a second time chart showing variations of the control elements such as the supply valves in the course of the filling control of FIG. 3 ;
[0036] FIG. 6 is a flowchart showing a second flow of filling control of urea water performed in the urea water supply system shown in FIG. 1 or FIG. 2 ; and
[0037] FIG. 7 is a time chart showing variations of the control elements such as the supply valves in the course of the filling control of FIG. 6 .
DESCRIPTION OF EMBODIMENTS
[0038] The following describes some concrete embodiments of the invention with reference to the drawings. The dimensions, the materials, the shapes, the positional relationships and the like of the respective components described in the following embodiments are only for the purpose of illustration and not intended at all to limit the scope of the invention to such specific descriptions.
First Embodiment
[0039] The following describes the schematic configurations of a urea water supply system (hereinafter may simply be referred to as “system”) and an exhaust emission control device of an internal combustion engine which the system is applied to, with reference to FIGS. 1 and 2 . An internal combustion engine 1 shown in FIG. 1 is a diesel engine for driving a vehicle. The internal combustion engine of the invention is, however, not limited to the diesel engine but may be a gasoline engine or the like. The urea water supply system of the invention is configured to supply urea water to supply valves that are arranged to supply ammonium as a reducing agent to two NOx catalysts provided in an exhaust passage of the internal combustion engine 1 . Exhaust emission control devices of FIGS. 1 and 2 are illustrated as examples of the exhaust emission control device of the internal combustion engine which the system is applied to and are not at all intended to limit the application of the invention to both or either of the exhaust emission control devices.
<First Configuration>
[0040] The following describes a first configuration of the urea water supply system of the invention and the exhaust emission control device of the internal combustion engine 1 which the urea water supply system is applied to, with reference to FIG. 1 . The internal combustion engine 1 is a V engine and has two connected exhaust passages 2 and 12 corresponding to respective banks of the V engine. The respective exhaust passages 2 and 12 basically have similar schematic configurations. A first NOx catalyst 5 is placed in the exhaust passage 2 to selectively reduce NOx in exhaust emission using ammonia as the reducing agent. In order to produce ammonia that works as the reducing agent in the first NOx catalyst 5 , urea water as a precursor of ammonia is stored in a urea water tank 9 and is supplied to the exhaust emission by means of a first supply valve 6 that is located in the upstream of the first NOx catalyst 5 . The urea water supplied by the first supply valve 6 is hydrolyzed with heat of exhaust emission to produce ammonia. The ammonia then flows into and is adsorbed to the first NOx catalyst 5 , so that NOx in the exhaust emission is removed through reduction reaction of ammonia with NOx. An oxidation catalyst for oxidizing ammonia slipped from the first NOx catalyst 5 (hereinafter referred to as “ASC catalyst”) is provided in the downstream of the first NOx catalyst 5 , although not being illustrated in FIG. 1 .
[0041] Additionally, an oxidation catalyst 3 having oxidation function and a filter 4 for trapping particulate substances in the exhaust emission are provided in the upstream of the first NOx catalyst 5 and the first supply valve 6 . The oxidation catalyst 3 serves to oxidize a fuel component included in the exhaust emission, raise the temperature of the exhaust emission and flows out the heated exhaust emission to the filter 4 , so that the particulate substances trapped by the filter 4 are oxidized and removed. The temperature rise of the exhaust emission by the oxidation catalyst 3 is achieved by adequately controlling the combustion conditions in the internal combustion engine 1 to regulate the fuel component (uncombusted component) in the exhaust emission and accelerate oxidation of the fuel component by the oxidation catalyst 3 . Alternatively, a fuel supply valve may be provided in the upstream of the oxidation catalyst 3 to supply the fuel of the internal combustion engine 1 to the oxidation catalyst 3 via the exhaust emission.
[0042] A second NOx catalyst 15 and a second supply valve 16 for supply urea water corresponding to the NOx catalyst are also provided in the exhaust passage 12 provided in parallel to the exhaust passage 2 . Additionally, an oxidation catalyst 13 having oxidation function and a filter 14 for trapping particulate substances in the exhaust emission are provided in the upstream of the second NOx catalyst 15 and the second supply valve 16 .
[0043] The following describes a configuration of supplying urea water from the urea water tank 9 to the first supply valve 6 and the second supply valve 16 . The urea water tank 9 is connected with the first supply valve 6 by a supply path L 1 (supply path division from a point P 1 on the urea water tank 9 -side to a branch point P 2 ) and a supply path L 2 (supply path division from the branch point P 2 to a first supply valve P 3 ) that are arranged to supply the urea water. The urea water tank 9 is, on the other hand, connected with the second supply valve 16 by the supply path L 1 and a supply path L 3 (supply path division from the branch point P 2 to a second supply valve P 4 ) that are arranged to supply the rear water. Accordingly, the supply path L 1 is shared by the supply paths formed between the urea water tank 9 and the first supply valve 6 and between the urea water tank 9 and the second supply valve 16 , and only the flow of urea water to be supplied to each of the supply valves is pressure-fed through the supply path from the branch point P 2 to each supply valve. A pump 7 for pressure-feeding the urea water in the supply paths L 1 to L 3 is provided in the common supply path L 1 . Normal rotation of the pump 7 causes the urea water to be pressure fed from the urea water tank 9 to each supply valve, and reverse rotation of the pump 7 causes the urea water to be pressure fed from each supply valve to the urea water tank 9 .
[0044] The exhaust passages 2 and 12 , the urea water tank and the supply paths of urea water are placed along the vehicle body frame. In this embodiment, the urea water tank 9 is placed at the position nearer to the exhaust passage 2 . With regard to the supply paths of urea water, the overall length of the supply path L 2 for the flow of urea water including the first supply valve 6 is thus shorter than the overall length of the supply path L 3 for the flow of urea water including the second supply valve 16 (i.e., L 2 <L 3 ). In this embodiment, the supply paths L 1 , L 2 and L 3 have an identical sectional area. The different lengths of the supply paths L 2 and L 3 accordingly causes the capacity of the supply path L 3 to be greater than the capacity of the supply path L 2 by a specified volume ΔV.
[0045] A pressure sensor 8 is mounted to the pump 8 to detect the internal pressure of the supply path L 1 for the urea water. The internal combustion engine 1 is provided with an electronic control unit (ECU) 20 that controls the operating conditions of the internal combustion engine 1 and the exhaust emission control device. The ECU 20 is electrically connected with a crank positions sensor 21 and an accelerator position sensor 22 in addition to the above pressure sensor 8 to receive detection values sent from the respective sensors. The ECU 20 accordingly obtains the operating conditions of the internal combustion engine 1 , such as the detected internal pressure of the supply path L 1 , the engine rotation speed based on the detection of the crank position sensor 21 and the engine load based on the detection of the accelerator position sensor 22 . The internal pressure of the supply path L 1 may alternatively be estimated from, for example, the relationship between the driving power and the rotation speed of the pump 7 . For example, in the pump 7 , based on the phenomenon that an increase in pressure of urea water reduces the increase rate of rotation speed relative to driving power, the pressure of urea water may be estimated by using the relationship between the driving power and the rotation speed. This modified configuration allows for omission of the pressure sensor 8 . Additionally, the ECU 20 is electrically connected with an ignition switch 23 to receive an ignition ON/OFF signal of the internal combustion engine 1 . The pump 7 , the first supply valve 6 and the second supply valve 16 are also electrically connected with the ECU 20 and are driven in response to control signals from the ECU 20 .
<Second Configuration>
[0046] The following describes a second configuration of the urea water supply system of the invention and the exhaust emission control device of the internal combustion engine 1 which the urea water supply system is applied to, with reference to FIG. 2 . The like components of the urea supply system and the exhaust emission control device of the second configuration that are substantially similar to the components of the first configuration are expressed by the like signs and are not specifically described here.
[0047] The internal combustion engine 1 of this configuration has one exhaust passage 2 . Two NOx catalysts are arranged in series in the exhaust passage 2 . More specifically, a first NOx catalyst 5 is arranged in the upstream along the flow of the exhaust emission, and a second NOx catalyst 15 is arranged in the downstream. In order to produce ammonia that works as the reducing agent in the first NOx catalyst 5 , urea water stored in a urea water tank 9 is supplied to the exhaust emission by means of a first supply valve 6 that is located in the upstream of the first NOx catalyst 5 . Similarly, in order to produce ammonia that works as the reducing agent in the second NOx catalyst 15 , the urea water stored in the urea water tank 9 is supplied to the exhaust emission by means of a second supply valve 16 that is located in the upstream of the second NOx catalyst 15 but in the downstream of the first NOx catalyst 5 . An oxidation catalyst 3 having oxidation function and a filter 4 for trapping particulate substances in the exhaust emission are provided in the upstream of the first NOx catalyst 5 and the first supply valve 6 .
[0048] The following describes a configuration of supplying urea water from the urea water tank 9 to the first supply valve 6 and the second supply valve 16 in the urea water supply system applied to the exhaust emission control device described above. Like the first configuration, in the second configuration, the urea water tank 9 is connected with the first supply valve 6 by a supply path L 1 (supply path division from a point P 1 on the urea water tank 9 -side to a branch point P 2 ) and a supply path L 2 (supply path division from the branch point P 2 to a first supply valve P 3 ) that are arranged to supply the urea water. The urea water tank 9 is, on the other hand, connected with the second supply valve 16 by the supply path L 1 and a supply path L 3 (supply path division from the branch point P 2 to a second supply valve P 4 ) that are arranged to supply the rear water. Accordingly, the supply path L 1 is shared by the supply paths formed between the urea water tank 9 and the first supply valve 6 and between the urea water tank 9 and the second supply valve 16 , and only the flow of urea water to be supplied to each of the supply valves is pressure-fed through the supply path from the branch point P 2 to each supply valve.
[0049] In this embodiment, the urea water tank 9 is placed at the position nearer to the first supply valve 6 than the second supply valve 16 . With regard to the supply paths of urea water, the overall length of the supply path L 2 for the flow of urea water including the first supply valve 6 is thus shorter than the overall length of the supply path L 3 for the flow of urea water including the second supply valve 16 . Like the first configuration, this results in making the capacity of the supply path L 3 greater than the capacity of the supply path L 2 by a specified volume ΔV.
[0000] <Control with Regard to Supply of Urea Water>
[0050] In the first and the second configurations described above, the urea water is pressure-fed from the urea water tank 9 to each supply valve and is supplied to the exhaust emission, in order to reduce NOx included in the discharged exhaust emission during operation of the internal combustion engine 1 . When the urea water remains in any of the supply valves and the supply paths in the state that the internal combustion engine 1 is stopped or at a stop, ammonia is likely to be produced from the remaining urea water due to, for example, external heat and cause corrosion of the supply valve or the supply path. The urea water supply system of the invention performs control with regard to supply of urea water, in order to prevent the urea water from remaining in any of the supply valves and the supply paths when there is no requirement for using the urea water in the exhaust emission control device of the internal combustion engine 1 .
[0051] More specifically, the urea water supply system of the invention performs suck-back control to return the urea water remaining in any of the supply valves and the supply paths to the urea water tank 9 at a stop of the internal combustion engine 1 and filling control to fill urea water into the vacant supply valves and supply paths to allow for supply of urea water to the exhaust emission at a start of the internal combustion engine 1 , as the control with regard to supply of urea water. The following describes the details of filling control to fill urea water into the first supply valve 6 , the second supply valve 16 and the relevant supply paths, in which no urea water substantially remains by the previous suck-back control. The description is on the assumption that the filling control is performed in the the urea water supply system and the exhaust emission control device of the first configuration shown in FIG. 1 as a typical example. This is, however, only for the purpose of illustration and is not intended at all to limit the conditions of the control to this configuration.
<Filling Control>
[0052] A control flow of filling control performed in the urea water supply system of the invention is described with reference to FIG. 3 . FIG. 3 is a flowchart of filling control performed by the ECU 20 . The filling control is repeatedly performed at predetermined time intervals by the ECU 20 during operation of the internal combustion engine 1 . The ECU 20 executes a predetermined control program to perform the control shown in the flowchart of FIG. 3 .
[0053] At S 101 , the flow determines whether the current state is the state that is ready for supply of urea water from the urea water tank 9 to the respective supply valves 6 and 16 . More specifically, when the internal combustion engine 1 is started and warm-up of both the NOx catalysts is completed, a filling ready flag for the filling control is changed from OFF to ON. An affirmative answer is given at S 101 in response to the ON setting of the filling ready flag, and a negative answer is given at S 101 in response to the OFF setting of the filling ready flag. In response to the affirmative answer at S 101 , the flow proceeds to S 102 . In response to the negative answer at S 101 , the flow terminates this control. Prior to a start of the internal combustion engine 1 , no urea water substantially remains in the respective supply valves and the respective supply paths as described above.
[0054] At S 102 , the flow normally rotates the pump 7 . This applies a pressure to feed urea water from the urea water tank 9 to the supply paths L 1 to L 3 and the respective supply valves 6 and 16 . The normally rotating state of the pump 7 corresponds to the specified operating state for filling of the claims. On completion of the processing of S 102 , the flow proceeds to S 103 .
[0055] At S 103 , the flow starts open-close control of the respective supply valves 6 and 16 , while the pump 7 is maintained in the normally rotating state. The details of open-close control will be described later. On completion of the processing of S 103 , the flow proceeds to S 104 . At S 104 , the flow determines whether filling of urea water into the first supply valve 6 is completed. More specifically, the determination process of S 104 determines an estimated time when filling of urea water into the first supply valve 6 is expected to be completed, based on a variation in internal pressure of the supply path L 1 as described later. In response to an affirmative answer at S 104 , the flow proceeds to S 105 . In response to a negative answer at S 104 , the flow repeats the processing of S 104 . At S 105 , the flow closes the first supply valve 6 .
[0056] Subsequently the flow proceeds to S 106 to determine whether filling of urea water into the second supply valve 16 is completed. More specifically, the determination process of S 106 determines an estimated time when filling of urea water into the second supply valve 16 is expected to be completed, based on a variation in internal pressure of the supply path L 1 as described later. In response to an affirmative answer at S 106 , the flow closes the second supply valve 16 at S 107 and then terminates this control. In response to a negative answer at S 106 , the flow repeats the processing of S 106 .
[0057] The following describes the open-close control of the respective supply valves for filling urea water performed in the filling control of FIG. 3 , with reference to FIGS. 4 and 5 . FIGS. 4 and 5 are time charts showing (a) variation in setting of the filling ready flag, (b) variation in pump rotation signal, (c) variation in open-close signal of the first supply valve 6 , (d) variation in open-close signal of the second supply valve 16 , (e) variation in amount of urea water in the supply path L 2 , ( 0 variation in amount of urea water in the supply path L 3 and (g) variation in internal pressure of the supply path L 1 with respect to the open-close control of the respective supply valves in various different filling patterns. The internal pressure of the supply path L 1 denotes the pressure detected by the pressure sensor 8 . The following describes the open-close control of the respective supply valves in the respective patterns of FIGS. 4 and 5 .
[0058] (1) First Pattern
[0059] The following describes a first pattern of the open-close control of the respective supply valves for filling with reference to FIG. 4 . The filling ready flag is set ON at a time t 11 as shown in FIG. 4( a ), and the pump 7 is normally rotated at the time t 11 as shown in FIG. 4( b ) (processing of S 102 ). The pump 7 has the constant rotation speed and maintains the substantially constant pressure-feed capacity as described above. In the first pattern, as shown in FIGS. 4( c ) and 4 ( d ), the first supply valve 6 and the second supply valve 16 are simultaneously opened at a time t 12 , so that filling of urea water from the urea water tank 9 into the respective supply valves 6 and 16 is started. FIGS. 4( e ) and 4 ( f ) show variations in amount of urea water in the supply paths L 2 and L 3 by such valve open-close control.
[0060] In the first pattern, in an initial stage of filling (time period from time t 12 to time 17 ), urea water is first filled into the supply path L 1 and is subsequently filled into the supply paths L 2 and L 3 and the respective supply valves 6 and 16 . In the first pattern, a time Tov 1 after the time t 17 corresponds to the valve-opening time of the first supply valve 6 to fill the supply path L 2 , and a time Tov 2 after the time t 17 corresponds to the valve-opening time of the second supply valve 16 to fill the supply path L 3 . The time period from the time t 12 to the time t 17 may be given as V 2 /α, where V 2 represents the capacity of the supply path L 1 and a represents the pressure-feed capacity of the pump 7 .
[0061] In the first pattern, completion of filling of urea water into each of the supply valves is determined, based on a variation in internal pressure of the supply path L 1 . As described above, simultaneously opening both the supply valves 6 and 16 at the time t 12 fills urea water into the supply paths L 2 and L 3 . The capacity of the supply path L 2 is smaller than the capacity of the supply path L 3 by a predetermined volume ΔV, so that filling of urea water into the supply path L 2 and the first supply valve 6 is expected to be completed at an earlier timing than filling of urea water into the supply path L 3 and the second supply valve 16 . At the time when filling of urea water into the supply path L 2 and the first supply valve 6 is completed (at a time t 15 shown in FIG. 4( e )), the resistance with regard to migration of urea water on the first supply valve 6 -side increases to increase the pressure applied to the urea water in the course of filling. According to this embodiment, completion of filling of urea water into the first supply valve 6 is detected at the time when a time rate of change (rise rate) in internal pressure of the supply path L 1 is significantly increased from the previous time rate of change of the pressure as shown in FIG. 4( g ). Based on this detection result, the first supply valve 6 is closed at a time t 13 slightly delayed from the time t 15 (processing of S 105 ). The valve-closing time t 13 is slightly delayed from the filling completion time t 15 , since a certain delay time is required between completion of filling of urea water into the supply path L 2 and the first supply valve 6 and reflection of the completion of filling on the pressure of urea water to be detectable by the pressure sensor 8 .
[0062] When the first supply valve 6 is closed on completion of filling, urea water from the urea water tank 9 is only filled into the second supply valve 16 . As in the case of the first supply valve 6 , at a time when filling of urea water into the second supply valve 16 is expected to be completed (at a time t 16 shown in FIG. 4( f ), a time rate of change (rise rate) in internal pressure of the supply path L 1 is significantly increased from the previous time rate of change of the pressure in the time period from the time t 15 to the time t 16 as shown in FIG. 4( g ). At this time, filling of urea water into the second supply valve 16 is detected. Based on this detection result, the second supply valve 16 is closed at a time t 14 slightly delayed from the time t 16 (processing of S 107 ). The valve-closing time t 14 is slightly delayed from the filling completion time t 16 , because of the same reason as that described above with regard to the first supply valve 6 .
[0063] Such open-close control of the respective supply valves 6 and 16 enables just enough amounts of urea water to be filled into the first supply valve 6 and the second supply valve 16 . A difference between the valve-opening time Tov 1 of the first supply valve 6 and the valve-opening time Tov 2 of the second supply valve 16 for filling urea water reflects the predetermined volume ΔV that is the difference between the capacities of the supply paths L 2 and L 3 . Accordingly, the valve-opening time Tov 1 of the first supply valve 6 is shorter than the valve-opening time Tov 2 of the second supply valve 16 by a time required for filling urea water into the predetermined volume ΔV of the supply path L 3 . In the urea water supply system of the invention, the valve-closing timings of the first supply valve 6 and the second supply valve 16 are determined based on the pressure value detected by the pressure sensor 8 and its time rate of change, so as to ensure efficient filling of urea water.
[0064] (2) Second Pattern
[0065] The following describes a second pattern of the open-close control of the respective supply valves for filling with reference to FIG. 5 . The filling ready flag is set ON at a time t 11 as shown in FIG. 5( a ), and the pump 7 is normally rotated at the time t 11 as shown in FIG. 5( b ) (processing of S 102 ). The pump 7 has the constant rotation speed and maintains the substantially constant pressure-feed capacity as described above. The open-close control of the respective supply valves is started at a time t 12 . In the second pattern, as shown in FIGS. 5( c ) and 5 ( d ), at the time t 12 , only the first supply valve 6 is opened, so that filling of urea water into the first supply valve 6 is performed. At this moment, however, the second supply valve 16 is kept closed, and filling of urea water into the second supply valve 16 is not performed. On completion of filling of urea water into the first supply valve 6 , only the second supply valve 16 is opened, so that filling of urea water into the second supply valve 16 is performed. FIGS. 5( e ) and 5 ( f ) show variations in amount of urea water in the supply paths L 2 and L 3 by such valve open-close control.
[0066] In the second pattern, in an initial stage of filling (time period from time t 12 to time 17 ), urea water is first filled into the supply path L 1 and is subsequently filled into the supply path L 2 and the first supply valve 6 . In the second pattern, a time Tov 1 after the time t 17 corresponds to the valve-opening time of the first supply valve 6 to fill the supply path L 2 , and a time Tov 2 after closing the first supply valve 6 corresponds to the valve-opening time of the second supply valve 16 to fill the supply path L 3 . The time period from the time t 12 to the time t 17 may be given as V 2 /α.
[0067] In the second pattern, completion of filling of urea water into each of the supply valves is also determined, based on a variation in internal pressure of the supply path L 1 . As described above, opening only the first supply valve 6 at the time t 12 causes urea water to be filled into the supply path L 2 after the time t 17 . At the time when filling of urea water into the supply path L 2 and the first supply valve 6 is completed (at a time t 15 shown in FIG. 5( e )), the second supply valve 16 is still kept closed, so that the internal pressure of the supply path L 1 abruptly increases. Completion of filling of urea water into the first supply valve 6 is detected at the time of the abrupt pressure increase. Based on this detection result, the first supply valve 6 is closed at a time t 13 slightly delayed from the time t 15 . The valve-closing time t 13 is slightly delayed from the filling completion time t 15 , since a certain delay time is required to make the pressure increase detectable by the pressure sensor 8 .
[0068] At the time t 13 , the first supply valve 6 is closed on completion of filling (processing of S 105 ) and the second supply valve 16 is opened at the same time. This suppresses the increase in internal pressure of the supply path L 1 . Subsequently urea water is filled through the supply path L 3 into the second supply valve 16 . At a time when filling of urea water into the second supply valve 16 is expected to be completed (at a time t 16 shown in FIG. 5( f )), a time rate of change (rise rate) in internal pressure of the supply path L 1 is significantly increased from the previous time rate of change of the pressure in the time period from the time t 15 to the time t 16 as shown in FIG. 5( g ). At this time, filling of urea water into the second supply valve 16 is detected. Based on this detection result, the second supply valve 16 is closed at a time t 14 slightly delayed from the time t 16 (processing of S 107 ). The valve-closing time t 14 is slightly delayed from the filling completion time t 16 , because of the same reason as that described above with regard to the first supply valve 6 .
[0069] Such open-close control of the respective supply valves 6 and 16 enables just enough amounts of urea water to be filled into the first supply valve 6 and the second supply valve 16 . A difference between the valve-opening time Tov 1 of the first supply valve 6 and the valve-opening time Tov 2 of the second supply valve 16 for filling urea water reflects the predetermined volume ΔV that is the difference between the capacities of the supply paths L 2 and L 3 . Accordingly, the valve-opening time Tov 1 of the first supply valve 6 is shorter than the valve-opening time Tov 2 of the second supply valve 16 by a time required for filling urea water into the predetermined volume ΔV of the supply path L 3 . In the urea water supply system of the invention, the valve-closing timings of the first supply valve 6 and the second supply valve 16 are determined based on the pressure value detected by the pressure sensor 8 and its time rate of change, so as to ensure efficient filling of urea water.
Second Embodiment
[0070] The following describes a second embodiment with regard to open-close control of the respective supply valves in filling control of urea water with reference to FIG. 6 . FIG. 7 shows a time chart showing (a) variation in setting of the filling ready flag, (b) variation in pump rotation signal, (c) variation in open-close signal of the first supply valve 6 , (d) variation in open-close signal of the second supply valve 16 , (e) variation in amount of urea water in the supply path L 2 , (f) variation in amount of urea water in the supply path L 3 and (g) variation in internal pressure of the supply path L 1 with respect to the open-close control of the respective supply valves in the filling control shown in FIG. 6 . The filling control shown in FIG. 6 is performed by the ECU 20 like the filling control shown in FIG. 3 . The like steps in the filling control of FIG. 6 that are substantially similar to the steps in the filling control of FIG. 3 are expressed by the like step numbers and are not specifically described here. In this embodiment, it is assumed that the open-close control in the first pattern described above is performed as the open-close control of the respective supply valves at S 103 .
[0071] In this embodiment, after the processing of S 105 , the flow performs a clogging detection process with regard to clogging in the first supply valve 6 at S 201 . According to this embodiment, like the first pattern described above, completion of filling of urea water into each of the supply valves is determined, based on a variation in internal pressure of the supply path L 1 . More specifically, at a time t 20 when the internal pressure of the supply path L 1 has an increase after the first supply valve 6 and the second supply valve 16 are opened, the flow determines that filling of urea water into the first supply valve 6 is completed (affirmative answer is given at S 104 ) and closes the first supply valve 6 (processing of S 105 ). As a result, only the second supply valve 16 is kept open. In this embodiment, however, even after elapse of a predetermined time T 0 from the time t 20 , the pressure is maintained at the increased level or more specifically at the increased level based on which it is determined that filling of the first supply valve 6 is completed. This is attributed to the following phenomenon. Even though both the supply valves 6 and 16 are opened at the time t 12 , clogging of the first supply valve 6 causes filling of urea water to be actually focused on the second supply valve 16 -side. As a result, filling of urea water into the supply path L 3 and the second supply valve 16 is completed at a time t 24 slightly before the time 20 (as shown in FIG. 7( f )).
[0072] When the internal pressure of the supply path L 1 is maintained at the increased level which is induced by valve-closing of the first supply valve 6 for the predetermined time T 0 after the first supply valve 6 is closed upon determination that filling into the first supply valve 6 is completed, the flow determines that the first supply valve 6 is clogged (processing of S 201 ). The predetermined time T 0 is preferably set to be as short as possible in such a range that allows for detection of clogging of the first supply valve 6 , in order to suppress urea water from leaking from the second supply valve 16 that has already been filled with urea water. At a time t 21 after elapse of the predetermined time T 0 from the time t 20 when clogging is detected at S 201 , the flow closes the second supply valve 16 in order to suppress urea water from leaking from the second supply valve 16 that has already been filled with urea water, while additionally opening the first supply valve 6 (processing of S 202 ) in order to additionally fill urea water into the first supply valve 6 in the insufficient filling state. In this case, completion of filling into the first supply valve 6 may be determined, based on a variation in internal pressure of the supply path L 1 at a time t 22 when urea water is actually filled into the supply path L 2 and reaches the first supply valve 6 (processing of S 203 ). The flow then closes the first supply valve 6 (processing of S 204 ) at a time t 23 slightly delayed from the time t 22 when an affirmative answer is given at S 203 . If the flow determines that the first supply valve 6 is not clogged at S 201 (negative answer is given at S 201 ), the flow proceeds to S 106 and S 107 .
[0073] Such open-close control of the respective supply valves 6 and 16 enables urea water to be efficiently filled into the respective supply valves 6 and 16 even when the first supply valve 6 is clogged. | An object is to suppress the occurrence of a failure in supply of urea water as much as possible in filling control of urea water in a pump share-type urea water supply system with two supply valves. In the pump share-type urea water supply system with a first supply valve and a second supply valve, a urea water tank is connected with the respective supply valves by a urea water supply path. The urea water supply path includes a first supply path for the first supply valve and a second supply path for the second supply valve. The second supply path has a larger capacity than the capacity of the first supply path by a predetermined volume. Filling control of urea water pressure-feeds urea water to the first supply valve and the first supply path by a pump operated in a specified operating state in a state that at least the first supply valve out of the first and second supply valves is opened, and closes the first supply valve based on a pressure value or a pressure variation per unit time obtained by an acquirer. | 5 |
FIELD OF THE INVENTION
This invention relates to multi-layer thermoplastic packaging films and receptacles such as pouches, bags, and casings made therefrom. In particular, this invention relates to plastic films and bags which are heat shrinkable and have improved shrink, tear, and puncture resistance properties. The films should also have good flexibility and extension properties for improved vacuum packaging.
BACKGROUND OF THE INVENTION
Shrinkable thermoplastic films have found many applications in packaging of meats, cheeses, poultry, seafood and numerous other food and non-food products. For packaging some foodstuffs, for instance meat and some cheeses, the film should include a layer that is a barrier to the passage of gases, particularly oxygen. For packaging other foodstuffs, for instance poultry and some other cheeses, and also for packaging non-food materials, no such barrier layer is required.
There is always the search for improvement in these films to give them better abuse resistance, better tear resistance, improved clarity, easier handling and better barrier properties. One film of this type is a multi-layer film having layers of polyethylene/saran/polyethylene which is disclosed in U.S. Pat. No. 3,821,182 which issued on Jun. 28, 1974 to William G. Baird, Jr. et al. The shrink and abuse resistance of such a film is improved by irradiating the film to cross-link the polyethylene layers prior to heating and orienting the film by the trapped bubble technique.
U.S. Pat. No. 3,741,253, which issued on Jun. 26, 1973 to Harri J. Brax et al, discloses a multi-ply laminate which has a first layer of cross-linked ethylene-vinyl acetate copolymer directly joined to a middle layer of a copolymer of vinylidene chloride which is joined to another ethylene-vinyl acetate copolymer layer. The ethylene-vinyl acetate copolymer (hereinafter EVA) layer has improved properties over the previously used polyethylene and, in the extrusion coating method used to produce the multi-layer film according to the Brax et al patent, the substrate EVA layer is preferably cross-linked by irradiation before the saran layer is extrusion coated thereon, thus avoiding irradiation of the saran layer. Saran (vinylidene chloride homo- or copolymer) tends to discolor under high energy irradiation.
An alternative and successful multi-layer film where a hydrolysed ethylene-vinyl acetate copolymer is used as a barrier layer instead of saran is disclosed in U.S. Pat. No. 4,064,296 which issued on Dec. 29, 1977, to Normal D. Bornstein et al. A heat shrinkable multi-layer film is formed by coextruding the hydrolysed ethylene-vinyl acetate copolymer (sometimes abbreviated "HEVA" or called ethylene-vinyl alcohol and abbreviated "EVAL" or "EVOH".) Since EVOH does not suffer from the effects of radiation a coextruded product such as EVA/EVOH/EVA can readily be cross-linked by irradiation before orientation.
Another way of improving the performance of packaging films has been to blend various polymers. U.S. Pat. No. 3,090,770, which issued on May 21, 1973 to Razmic S. Gregorian, discloses the blending of cross-linked polyethylene with non-cross-linked polyethylene to improve the clarity of a film. Such blends use differing proportions of high, low and medium density polyethylene. This patent also discloses a cross-linked polyethylene; and, U.S. Pat. No. 3,118,866, which issued on Jan. 28, 1964 to the same inventor, is directed to an ethylene composition and the process of cross-linking by chemical means. The olefin polymers and copolymers have been particularly attractive because of low cost, availability, and wide range of satisfactory characteristics for packaging films.
Recently, medium and low density linear polyethylenes have become commercially available and have begun to be used in a number of packaging applications. One early patent in this field is U.S. Pat. No. 4,076,698, which issued on Feb. 28, 1978 to Arthur William Anderson and discloses an interpolymer composed of ethylene and mono-alpha-olefinic hydrocarbons containing five to ten carbon atoms per molecule, the proportion of the mono-olefinic hydrocarbon being 3 to 7 percent of the weight of the interpolymer, with a melt index from 0.3 to 20 and a density of 0.93 to 0.94 g/cc. Linear polymers of this type are characterized by actually being an interpolymer or copolymer with another olefin and having a relatively straight molecular chain, that is, having a chain with no side branches or limited side branching. Low density versions of this type of film, where density is in the range of 0.920 to.0.926, are produced by a low pressure process, as opposed to the high pressure process which produces a branched, low density polyethylene. Linear low density polyethylene, sometimes abbreviated hereinafter as "LLDPE", has found many applications and uses as exemplified by U.S. Pat. No. 4,364,981 which issued on Dec. 21, 1982 to Jerome T. Horner and discloses an EVA/LLDPE/EVA, structure as does also U.S. Pat. No. 4,399,180 which issued on Aug. 16, 1983 to William F. Briggs et al. In U.S. Pat. No. 4,457,960 a multi-layer structure is disclosed of EVA/Saran/EVA-LLPDE-blend.
Still another polymeric material has more recently entered the market having different properties from the copolymers which comprise the LLDPE class of materials. These copolymers are known as very low density polyethylene (hereinafter abbreviated "VLDPE"). Whereas conventional polyethylenes and LLDPE have densities as low as 0.912, the VLDPE currently on the market have densities below 0.910, specifically down to about 0.860. European Published Patent Application No. 120,503 (Union Carbide), published Oct. 3, 1984, discloses a method of making VLDPE. In "Plastics Technology" magazine for September 1984 at page 113, a news item entitled "Introducing Very Low Density PE" briefly described some of VLDPE properties and stated that it's what the manufacturer ". . . calls an entirely new class of polyethylene, consisting of linear copolymers that can be produced at densities down to 0.89 or lower. What makes them special is a unique combination of properties in between those of standard PE's and polyolefinic rubbers". In the October 1984 issue of "Plastics Technology" at page 13 another article appeared entitled "New Kind of Polyethylene Combines Flexibility, Toughness, Heat Resistance". This article lists a number of the properties of VLDPE and compares them with ethylene-vinylacetate (EVA) and states that uses for this material is for squeeze tubes, bottles, hoses, tubing, drum liners and film. VLDPE is also listed as having potential as an additive. It is expected to be used as a blending resin in high density polyethylene, polypropylene, EVA, and some ethylene-propylene rubbers (EPR), with all of which VLDPE is compatible. According to the article, the first two commercially available grades are from Union Carbide. One resin, designated "DFDA-1138 NT7", has a narrow molecular weight distribution, higher toughness, clarity, and gloss and FDA clearance for food contact. The other resin is DFDA-1138 which is aimed particularly at film, has a broad molecular weight distribution, and is superior in processability. On page 15 in the same article, it is stated that "the new resins have been injection molded, extruded, blow molded, and thermoformed on standard equipment". It is noted that blown film can be extruded on systems designed either for conventional LDPE or LLDPE. However, the company generally recommends LLDPE-type screw designs in higher torque capability, especially with narrow-MWD grades. The article observes that the enlarged die gaps required by LLDPE are not required for VLDPE and that conventional blown film die gaps of 30-40 mil have proven satisfactory at blow up ratios of 2-3:1. For blown film, DFDA1137 and 1138 are said to extrude much like 2-Melt Index LLDPE or 0.5-Melt Index LDPE. An article similar to the one in "Plastics Technology" appeared in the October 1984 issue of "Plastics World" at page 86.
In the above mentioned European Patent Application a process for preparing very low density ethylene polymers in a fluidized bed is described. These ethylene polymers are classified as having a density of less than 0.91 and having a melt flow index which is preferably from 0.2 to 4.0.
The incorporation into heat shrinkable films of conventional ethylene/alpha-olefins produced by Ziegler-Natta catalyst systems is well known. Ziegler-Natta catalystic methods are commonly used throughout the polymer industry and have a long history tracing back to about 1957.
These systems are often referred to as heterogeneous since they are composed of many types of catalytic species each at different metal oxidation states and different coordination environments with ligands. Examples of Ziegler-Natta heterogeneous systems include metal halides activated by an organometallic co-catalyst, such as titanium or magnesium chlorides complexed to trialkyl aluminum and may be found in patents such as U.S. Pat. Nos. 4,302,565 and 4,302,566. Because these systems contain more than one catalytic species, they possess polymerization sites with different activities and varying abilities to incorporate comonomer into a polymer chain.
The result of such multi-site chemistry is a product with poor control of the polymer chain architecture both within the sequence of a single chain, as well as when compared to a neighbouring chain. In addition, differences in catalyst efficiency produce high molecular weight polymer at some sites and low molecular weight at others. Therefore, copolymers produced using these systems lead to polymer products which are mixtures of chains some high in comonomer and other with almost none. For example, conventional Ziegler-Natta multi-site catalysts may yield a linear ethylene/alpha-olefin copolymer having a mean comonomer percentage of 10, but with a range of 0% to 40% comonomer in individual chains. This, together with the diversity of chain lengths results in a tryl heterogeneous mixture also having a broad molecular weight distribution (MWD).
Linear low density polyethylene (LLDPE) has enjoyed great success as a raw material choice for packaging films. The term LLDPE is generally understood to describe copolymers of ethylene and one or more other alpha olefin monomers which are polymerized at low pressure using a Ziegler-Natta catalyst to achieve a density range of about 0.915 to about 0.940. Although no clear standard exists, LLDPE polymers are often marketed in subgroups of densities such as linear medium density (LMDPE), linear low density polyethylene, linear very low density (VLDPE), or linear ultra low density polyethylene (ULDPE). These classifications are for marketing use and will vary by supplier.
These materials are different from high pressure low density polyethylene (LDPE) which is generally understood in the trade as a highly branched homopolymer having a single low melting point. For example, a 0.92 density LDPE would typically have a melting point at about 112° C. while a corresponding density LLDPE would have melting point at 107°, 120°, and 125° C. The multiple melting points are commonly observed with LLDPE and are a consequence of the above mentioned heterogeneous incorporation of comonomer.
Recently a new type of ethylene copolymer has been introduced which is the result of a new catalyst technology. Examples of introductory journal articles include "Exxon Cites `Breakthrough` in Olefins Polymerization," Modern Plastics, July 1991, p.61; "Polyolefins Gain Higher Performance from New Catalyst Technologies," Modern Plastics, October 1991, p.46; "PW Technology Watch," Plastics World, November 1991, p. 29; and "," Plastics Technology, November 1991, p. 15.
These new resins are produced using metallocene catalyst systems, the uniqueness of which resides in the steric and electronic equivalence of each catalyst position. Metallocene catalysts are characterized as having a single, stable chemical type rather than a volatile mixture of states as discussed for conventional Ziegler-Natta. This results in a system composed of catalyst positions which have a singular activity and selectivity. For this reason, metallocene catalyst systems are often referred to as "single site" owing to the homogeneous nature of them, and polymers and copolymers produced from them are often referred to as single site resins by their suppliers.
Generally speaking, metallocene catalysts are organometallic compounds containing one or more cyclopentadienyl ligands attached to metals such as hafnium, titanium, vanadium, or zirconium. A co-catalyst, such as but not limited to, oligomeric methyl alumoxane is often used to promote the catalytic activity. By varying the metal component and the cylopentadienyl ligand a diversity of polymer products may be tailored having molecular weights ranging from about 200 to greater than 1,000,000 and molecular weight distributions from 1.5 to about 15. The choice of co-catalyst influences the efficiency and thus the production rate, yield, and cost.
Exxon Chemical, in U.S. Pat. No. 4,701,432 sets out examples of which olefin catalyst systems are of the metallocene class and which are non-metallocene. The cite bis(cyclopentadienyl) dichloro-transition metal, bis(cyclopentadienyl) methyl, chloro-transition metal, and bis(cyclopentadienyl) dimethyl-transition metal as examples of metallocene catalysts, where the metals include choices such as titanium, zirconium, hafnium, and vanadium. The patent further provides examples of non-metallocene catalysts as being TiCl 4 , TiBr 4 , Ti(0C 4 H 9 ) 2 Cl 2 , VCl 4 , and VOCl 3 .
Similarly, C. P. Cheng, at SPO 91, the Specialty Polyolefins Conference sponsored by Schotland and held in Houston, Tex. in 1991, cited TiCl 3 /AlR 2 Cl and MgCl 2 /TiCl 4 /AlR 3 as examples of non-metallocene Ziegler-Natta catalysts and transitions metal cyclopentadienyl complexes as examples of metallocene homogeneous polyolefin catalysts.
As a consequence of the single site system afforded by metallocenes, ethylene/alpha-olefin copolymer resins can be produced with each polymer chain having virtually the same architecture. Therefore, the copolymer chains produced from single site systems are uniform not only in chain length, but also in average comonomer content, and even regularity of comonomer spacing, or incorporation along the chain.
In contrast to the above mentioned Ziegler-Natta polymers, these single site metallocene polymers are characterized as having a narrow MWD and narrow compositional distribution (CD). While conventional polymers have MWD's of about 3.5 to 8.0, metallocenes range in MWD from about 1.5 to about 2.5 and most typically about 2.0. MWD refers to the breadth of the distribution of molecular weights of the polymer chains, and is a value which is obtained by dividing the number-average molecular weight into the weight-average molecular weight. The low CD, or regularity of side branches chains along a single chain and its parity in the distribution and length of all other chains, greatly reduces the low MW and high MW "tails". These features reduce the extractables which a rise from poor LMW control as well as improve the optics by removing the linear, ethylene-rich portions which are present in conventional heterogeneous resins.
Thus, conventional Ziegler-Natta systems produce heterogeneous resins which reflect the differential character of their multiple catalyst sites while metallocene systems yield homogeneous resins which, in turn, reflect the character of their single catalytic site.
Another distinguishing property of single site catalyzed ethylene copolymers is manifested in their melting point range. The narrow CD of metallocenes produces a narrow melting point range as well as a lower Differential Scanning Calorimeter (DSC) peak melting point peak. Unlike conventional resins which retain a high melting point over a wide density range, metallocene resin melting point is directly related to density. For example, an ethylene/butene copolymer having a density of 0.905 g/cc produced using a metallocene catalyst has a peak melting point of about 100° C., while a slightly lower density ethylene/butene copolymer which was made using a conventional Ziegler catalyst reflects its heterogeneous nature with a melting point at about 120° C. DSC shows that the Ziegler resin is associated with a much wider melting point range and actually melts higher despite its lower density.
While providing improved physical properties such as optics, low extractables and improved impact, the narrow compositional distribution of some typical metallocene catalyzed resins can cause some processing difficulties. It has been found that such processing problems are avoided if some limited long chain branching is introduced. That is, a typical metallocene catalyzed ethylene alpha-olefin may be thought of as a collection of linear chains each of substantially identical length, each having approximately the same number of short chain (comonomer) branches distributed at regular intervals along that length. Splicing an abbreviated linear chain with the same regular comonomer distribution onto each of the linear chains, or at least some of the chains in the collection, yields an ethylene alpha-olefin with essentially all of the physical properties of the original copolymer, but which an improved "body" or melt strength for improved processability including improved extrudability, orientation speeds and susceptibility to irradiation.
In recent years several resin suppliers have been researching and developing metallocene catalyst technology. The following brief discussion should be viewed as representative rather than exhaustive of this active area of the patent literature.
Dow in EP 416,815 disclosed the preparation of ethylene/olefin copolymers using monocyclopentadienylsilane complexed to a transition metal. The homogenous ethylene copolymers which may be prepared using this catalyst are said to have better optical properties than typical ethylene polymers and be well suited for film or injection molding.
As will be shown below, it has been found that resins produced by the Dow process exhibit improved physical properties characteristic of single site catalyzed resins but also possess a processability similar to that of conventional Ziegler-Natta copolymers. It is believed that the Dow metallocene resins possess the limited long chain branching discussed above.
Welborn in Exxon U.S. Pat. No. 4,306,041 discloses the use of metallocene catalysts to produce ethylene copolymers which have narrow molecular weight distributions.
Chang, in Exxon U.S. Pat. No. 5,088,228 discloses the production of ethylene copolymers of 1-propene, 1-butene, 1-hexane, and 1-octene using metallocene catalysts.
Exxon in U.S. Pat. No. 4,935,397 discloses the production of ethylene copolymers using metallocene catalysts to manufacture polymer suitable for injection molding or thermoforming.
Welborn, in Exxon U.S. Pat. No. 5,084,534 discloses the use of bis(n-butylcyclopentadienyl) zirconiumdichloride to produce high molecular weight polyethylene having a polydispersity of 1.8 and a density of 0.955 g/cc.
In Exxon U.S. Pat. No. 3,161,629 a cyclopentadienyl complex is disclosed which may be used to produce polyolefins having controlled molecular weight and density suitable for use in extrusion or injection molding.
Canich in Exxon U.S. Pat. Nos. 5,055,438 and 5,057,475 discloses the use of mono-cyclopentadienyl catalysts having a unique silicon bridge which may be employed to select the stereo-chemical structure of the polymer. Catalysts such as methyl, phenyl, silyl, tetramethylcyclopentadienyl-tertbutylamido zirconium dichloride may be used to produce polyethylene and ethylene copolymers suitable for films and fibers.
Mitsui Toatsu in JP 63/175004 employed bis(cyclopentadienyl) ethoxy-ZrCl to prepare homogenous ethylene copolymers.
Mitsubishi in JP 1,101,315 discloses the use of bis (cyclopentadienyl)ZrCl 2 for the preparation of ethylene butene copolymers.
It should be noted that at least some previously available ethylene based linear polymers approximated the physical and compositional properties achieved by the present metallocene catalyzed polyolefins. For example, in "Sequence and Branching Distribution of Ethylene/1-Butene Copolymers Prepared with a Soluble Vanadium Based Ziegler-Natta Catalyst," Macromolecules, 1992, 25, 2820-2827, it was confirmed that a soluble vanadium based Ziegler-Natta catalytic system VOCl 3 /Al 2 (C 2 H 5 ) 3 Cl 3 , acts essentially as a single site catalyst although VOCl 3 is not a metallocene. Homogeneous copolymers produced by such a catalyst system have been commercially available for several years. An example of such are the resins sold under the trade-mark Tafmer(TM) by Mitsui.
U.S. Pat. No. 4,501,634 to Yoshimura et al is directed to an oriented, multilayered film which includes a Tafmer as a blend component in at least one layer.
Japanese Kokoku 37307/83 to Gunze Limited was directed to a heat-sealable biaxially oriented composite film wherein the heat seal layer contains Tafmer in a blend.
The foregoing patents disclose homogeneous ethylene alpha-olefins having densities below 0.90 g/cc.
A successful and useful film is made according to the process shown in U.S. Pat. No. 3,741,253 mentioned above. A heat shrinkable bag can be made from such film which has wide application, particularly for meat, poultry, and some dairy products. Heat shrinkable polymeric films have gained widespread acceptance for packaging meat, particularly fresh meat and processed meat. Bags made from the heat shrinkable film are sealed at one end with the other end open and ready to receive a meat product. After the cut of meat is placed in the bag, the bag will normally be evacuated and the open end of the bag closed by heat sealing or by applying a clip, e.g., of metal. This process is advantageously carried out within a vacuum chamber where the evacuation and application of the clip or heat seal is done automatically. After the bag is removed from the chamber it is heat shrunk by applying heat. This can be done, for instance, by immersing the filled bag into a hot water bath or conveying it through a hot water shower or a hot air tunnel, or by infra red radiation.
In the usual distribution chain, a whole primal or sub-primal is packaged within shrink bags of this type. The meat within the bag will travel from a central slaughterhouse where it has been packaged to a retail supermarket where the bag will be opened and the meat will be cut for retail portions. Thus, the bags of this type must satisfy a number of requirements which are imposed by both the slaughterhouse or packing house and by the bag user. Furthermore, often the bag is placed in the showcase at the retail supermarket for special promotions when a whole loin, for example, is to be sold to a consumer. For retail use, particularly, it is desirable to have an attractive package. This requires relatively complete shrinkage of the bag around the product, so that the bag is not wrinkled and blood and juices are not trapped in the folds of the wrinkles.
Another important characteristic of a bag is the capability of the bag to physically survive the process of being filled, evacuated, sealed, closed, heat shrunk, boxed, shipped about the country, unloaded, and stored at the retail supermarket. This type of abuse rules out many polymeric films.
Another feature required by bags used for the foregoing described application is that the bag must also be strong enough to survive the handling involved in moving packaged meat which may weigh 100 pounds or more or large chunks of cheese weighing 60 lbs. or more. In particular, when the chunk of meat or cube of cheese is pushed into the bag its bottom seal must withstand the force of the meat or cheese as it hits the seal. Also, in bags that are made by folding a sheet with the fold as the bottom of the bag and by sealing the sides, seal strength is an important factor.
One of the more common hazards in packaging and distributing products in flexible packaging materials is the hazard of the material receiving a puncture which will release the vacuum inside the bag and allow oxygen to enter. Anything from the application of the clip to the presence of a bone in the meat can cause a puncture.
Canadian Patent Application Serial No. 502,615 of Ferguson et al discloses multi-layer thermoplastic barrier film comprising:
(a) a layer comprising very low density polyethylene having a density of less than 0.910 g/cc,
(b) a barrier layer comprising a material selected from the group consisting of: 1) copolymers of vinylidene chloride and 2) hydrolyzed ethylene-vinyl acetate copolymers; and
(c) a thermoplastic polymer layer, said layer being on the side of the barrier layer opposite to that of layer (a);
the multi-layer film being oriented and heat shrinkable at a temperature below 100° C. This film hag been used to make heat-shrinkable bags to contain meat, cheese, and the like. A commercial product, within the scope of this patent application, that has met with success is in fact composed of four layers. An inner layer is formed from a blend of 90% of an EVA copolymer containing 6% vinyl acetate and 10% of an ethylene-alpha-olefin copolymer of density 0.912 g/cc. A second layer is composed of a blend of 80% of linear ethylene-alpha-olefin copolymer of density 0.912 g/cc and 20% of an EVA copolymer containing 20% vinyl acetate. A third, barrier layer is composed of a copolymer of vinylidene chloride. A fourth, outer layer is composed of a blend of 91% of an EVA copolymer containing 9% vinyl acetate and 9% of linear ethylene-alpha-olefin copolymer of density 0.912 g/cc. This film is prepared by co-extruding the two inner layers to form a tape of circular cross-section, irradiating to cause cross-linking, coextruding the barrier layer and the outer layer onto the outside wall of the tape, biaxially stretching the product, cutting it into lengths and heat-sealing each length at one end to form a heat-sealable, heat-shrinkable bag. The four layer wall of the bag has a thickness of about 2.4 mil.
Although this commercial product works well, there are some difficult applications for which this product could be improved upon, for instance packaging picnic hams, and improvements are still sought in the areas of abuse resistance and shrinkage. Abuse is the term used to describe the treatment that a bag is subjected to when it is packed in a high speed packing operation for instance in a meat packing plant. A bag must withstand the impact of the meat entering the bag, without that causing any breakage in the heat seal at the initially closed end of the bag. If the meat has projecting bone the bag must withstand the impact of the bone without puncturing. The bag when evacuated and sealed must with stand hydrostatic pressures of blood and juices from the meat.
One approach to improving abuse resistance is to increase the thickness of the laminate film. It has been expected that this approach would lead to improvement in abuse resistance only at the expense of deterioration in other important properties, and would therefore be unacceptable. An increase in the thickness leads to a reduction of the elasticity of the film which results in increased stiffness of the film. This increased stiffness leads to formation of creases and increases the risk of crease fractures, resulting in increased leakage in handling. Another disadvantage is reduced heat shrinkage. It is desirable that the film shall have high heat shrinkage for several reasons. Film with high heat shrinkage encloses the packed foodstuff more closely to yield a packed product with greater aesthetic appeal, which is particularly important at the retail level. Also, high shrinkage reduces the formation of ears in the package. Regions of a sealed and heat shrunk package that are not separated by the packed material are referred to as ears, that is regions where the two inner surfaces of the bag are in contact with each other. Ears are unsightly, and for this reason should be as small as possible. Also ears project and with large ears there is increased risk that ears will catch on projections encountered during handling and be torn, resulting in a leaking pack.
There has now surprisingly been found a film composition with enhanced tensile strength, interply adhesion and resistance to tear propagation.
SUMMARY OF THE INVENTION
The invention provides a multi-layer, oriented, heat shrinkable thermoplastic film comprising:
(i) a layer composed of an ethylene-vinyl acetate copolymer or a linear ethylene-alpha-olefin copolymer or a blend of an ethylene-vinyl acetate copolymer and a linear ethylene-alpha-olefin copolymer; and
(ii) a layer composed of a blend of (a) a linear ethylene-alpha-olefin copolymer; (b) a material selected from the group consisting of ethylene-vinyl acetate copolymers, ethylene-butyl acrylate copolymers, ethylene-methyl acrylate copolymers, ethylene-methyl methacrylate copolymers, ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymer and ethylene-carbon monoxide copolymers; and (c) a narrow molecular weight linear ethylene-alpha-olefin copolymer having a density of less than 0.9 g/cc, preferably 0.870 to less than 0.900 g/cc, preferably 0.870 to 0.885 g/cc.
Among preferred features of the invention are:
a) a film wherein layer (i) is a blend of an ethylene-vinyl acetate copolymer and a linear ethylene-alpha-olefin copolymer;
b) a film wherein the linear ethylene-alpha-olefin copolymer present in layer (i) has a density of about 0.920 g/cc;
c) a film wherein layer (ii) has a substantially greater thickness than layer (i);
d) a film which comprises a further layer of material resistant to oxygen transmission; this material may be a copolymer of vinylidene chloride, especially a copolymer of vinylidene chloride with vinylchloride or methyl acrylate. Alternatively the material resistant to oxygen transmission is a copolymer of ethylene-vinyl acetate in which the acetate-moieties have been partially or completely hydrolyzed. This may be mixed with the vinylidene chloride copolymer. If the material resistant to oxygen transmission is a copolymer of ethylene-vinyl acetate in which the acetate moieties have been partially or completely hydrolyzed to give ethylene-vinyl alcohol copolymer then adhesive layers will be required to make this layer adhere to adjacent layers thereby giving a film with a further two (adhesive) layers. Typical adhesives include acrylic acid modified ethylene-vinyl acetate, anhydride modified ethylene-vinyl acetate and methacrylate resins;
e) a film which comprises a further layer of a thermoplastic polymeric material. The further layer may comprise a copolymer of ethylene-vinyl acetate;
f) a film which comprises;
(i) a layer composed of a blend of ethylene-vinyl acetate copolymer and a linear ethylene-alpha-olefin copolymer preferably having a density of below about 0.920 g/cc;
(ii) a layer composed of (a) a linear ethylene-alpha-olefin copolymer preferably butene, hexene or octene; (b) a material selected from the group consisting of ethylene-vinyl acetate copolymers and ethylene-n-butyl acrylate copolymers; and (c) a narrow molecular weight linear ethylene-alpha-olefin copolymer having a density of less than 0.900 g/cc;
(iii) a layer composed of a vinylidene chloride copolymer or an ethylene-vinyl acetate copolymer in which the acetate moieties have been partially or completely hydrolyzed; and
(iv) a layer composed of a copolymer of ethylene-vinyl acetate or a blend of ethylene-vinyl acetate copolymer and ethylene-alpha-olefin copolymer preferably in the proportion 91%:9% by weight, particularly 92.5%:7.25% by weight. The ethylene-alpha-olefin copolymer commonly will have a density of greater than 0.915 g/cc.
Multilayer films of the invention may comprise as many as, for example, nine layers and may include, for example, three or four adhesive layers for reasons outlined above.
Preferably in such a film in layer (i) the ethylene-vinyl acetate copolymer has a vinyl acetate content of about 6% and the blend is composed of about 90% by weight of the ethylene-vinyl acetate copolymer and about 10% by weight of the linear ethylene-alpha-olefin copolymer.
Also, preferably layer (ii) (c) comprises a linear ethylene-alpha-olefin copolymer having a density of about 0.885 g/cc.
Further preferred is a film wherein layer (ii) includes about 50% by weight of the layer of the linear ethylene-alpha-olefin copolymer, about 20% by weight of the layer of an ethylene-n-butyl acrylate copolymer and about 30% by weight of the layer of the linear ethylene-alpha-olefin copolymer having a density of less than 0.900 g/cc. A ethylene-n-butyl acrylate copolymer which is preferred has a butyl acrylate content of about 18.5% by weight.
Alternatively layer (ii) includes an ethylene-vinyl acetate copolymer that has a vinyl acetate content of about 18% by weight.
In a further preferred embodiment layer (iii) is composed of a copolymer of vinylidene chloride and methyl acrylate and layer (iv) is composed of an ethylene-vinyl acetate copolymer or a blend. In a particularly preferred embodiment in layer (iii) the copolymer of vinylidene chloride and methyl acrylate contains about 91.5% by weight of vinylidene chloride and about 8.5% by weight of methyl acrylate and in layer (iv) the ethylene-vinyl acetate copolymer has a vinyl acetate content of about 9%.
One preferred use for film of the invention is in receptacles such as bags or pouches that are used to contain meats, some cheeses, seafood, and the like, the receptacle being heat shrunk about the packaged foodstuff. For this particular use the film contains an extra layer that serves as a barrier to the transmission of gases, particularly oxygen, and also a layer to protect this barrier layer against abrasion. Thus, in a preferred embodiment the invention provides a film composed of four layers. Layer (1) is as defined above and when the film is used to form a receptacle to contain foodstuff this layer will form the interior surface and also be in direct contact with the foodstuff. This layer will also provide the seal when two sides of the receptacle are heat sealed together, so this layer is sometimes referred to as the sealant layer. Layer (2) is preferably substantially thicker than layer (1). Layer (2) is sometimes known as the core or substrate layer. The third layer provides the oxygen barrier and is therefore known as the barrier layer. The fourth layer provides abrasion resistance and is therefore sometimes known as the abuse layer.
The first layer, or sealant-layer, is preferably composed of about 90% of an ethylene-vinyl acetate (EVA) copolymer and about 10% of a linear ethylene-alpha-olefin copolymer. This latter copolymer preferably has a density of greater than 0.915 g/cc. The EVA copolymer preferably has a vinyl acetate content of about 6%.
Useful operable ranges of the three components of the core or substrate layer are as follows:
______________________________________ Particularly Preferred preferred range proportionsComponent of Layer (by weight) (by weight)______________________________________(a) linear ethylene-alpha- 30-70% 50% olefin copolymer, density preferably greater than 0.915 g/cc(b) ethylene-vinyl acetate 15-20% 20% copolymer or ethylene-n- butyl acrylate copolymer or equivalent(c) linear ethylene-alpha- 20-50% 30% olefin copolymer having density of less than 0.900 g/cc.______________________________________
The third layer is resistant to oxygen transmission and is also known as the barrier layer. One suitable material is an EVA copolymer that contains at least 35% of VA prior to hydrolysis and has been partially (at least 50% and preferably at least 90%) or completely hydrolysed to convert acetate ester moieties to hydroxy groups. Such a hydrolyzed EVA copolymer is sometimes known as an EVOH. More preferred are homopolymers of vinylidene chloride and copolymers containing at least about 80% of vinylidene chloride, known as saran. The comonomer can be for example, vinyl chloride, methyl acrylate, methyl methacrylate, acrylonitrile or butyl rubber, of which vinyl chloride or methyl acrylate is preferred.
The properties of the material used in the fourth abuse layer are not particularly critical, except that the material should be clear, resistant to abrasion and able to accept ink for printing. Many thermoplastic materials are suitable, and mention is made of ethylene polymers and copolymers, especially EVA copolymers. Blends of such materials can be used, and ethylene-propylene rubber (EPR) can be incorporated in such blends.
The film of the invention can be used at the same gauge as the current commercial product, i.e., 2-4 mil. A common thickness is 2.4 mil. For premium applications, for instance packing bone-in meats such as bone-in hams, it is preferred to use film of a thicker gauge, about 3.5 to 4.0 mil.
Advantageously, the linear ethylene-alpha-olefin copolymer material may be cross-linked. A preferable method of cross-linking is by irradiation although the material may be cross-linked by chemical means. Also, in certain instances where the barrier material is EVOH, it may be advantageous to cross-link the barrier material. As EVOH does not adhere as well as saran to the other layers of the film, if EVOH is used as the barrier layer it may be necessary to use it sandwiched between two thin layers of materials that have good adhesive properties and resistance to moisture, for example EVA.
In still another aspect, the present invention is a seamless tubular film made from any one of the multi-layer film combinations set forth above by a tubular or annular extrusion or coextrusion process.
In yet another aspect, the invention provides a receptacle such as a bag or pouch made from the film of the invention.
DEFINITIONS
Polyvinylidene chloride, sometimes called saran, means vinylidene chloride usually copolymerized with at least one other monomer which includes, but is not limited to, vinyl chloride, C 1 to C 8 alkyl acrylates (such as methyl acrylate), C 1 to C 8 methacrylates and acrylonitrile. Saran is then plasticized for better processability.
The term "LLDPE" refers to linear low density polyethylene which is generally understood to include that group of ethylene/alpha-olefin copolymers having limited side chain branching when compared with non-linear polyethylenes and which fall into a density range of 0.916 to 0.940 g/cc. The alpha-olefin copolymers are typically butene-1, pentene-1, hexane-1, octene-1, etc.
The term "ethylene-vinyl acetate copolymer" (EVA) as used herein refers to a copolymer formed from ethylene and vinyl acetate monomers wherein the ethylene units are present in a major amount and the vinyl-acetate units are present in a minor amount. More preferably, when using an EVA copolymer the amount of vinyl-acetate may range from about 5 to about 20% When EVA is followed by a present figure this refers to vinyl acetate content as percent by weight of EVA. It is preferred that EVA layers that may come in contact with grease from cooked meats, i.e., EVA in the sealant layer shall have a vinyl acetate-content towards the lower end of this range.
The compositions can include additional materials that do not affect their essential character, for instance stabilizers, pigments, processing aids such as waxes, deodorizing agents anti-static agents, anti-blocking agents, plasticizers and the like.
A "heat shrinkable" material is defined herein as a material which, when heated to an appropriate temperature above room temperature (to, for example 96° C.) will have a free shrink of 10% or greater in at least one linear direction. Shrink properties are after measured at 85° C.
The term alpha-olefin copolymers as defined herein refers to the newer copolymers of ethylene (or propylene or butene) with one or more comonomers selected from C 3 to about C 10 alpha-olefins but especially comprises ethylene copolymers with C 4 to about C 10 alpha-olefins such as butene-1, pentene-1, hexane-1, octene-1, and the like in which the polymer molecules comprise long chains with few side chains or branches and sometimes are referred to as linear polymers. These polymers are obtained by low pressure polymerization processes. This copolymer is sometimes called "low pressure", low density polyethylene thereby referring to the polymerization process which produces it. The copolymer can contain a small amount, usually up to about 10 mol percent, of a conjugated or non-conjugated diene, for example butadiene, 1,-hexadiene, 1,5-hexadiene, vinylnorbornene, ethylidenenorbornene or dicyclopentadiene. The side branching which is present will be short as compared to non-linear polyethylenes. The molecular chains of a linear polymer may be intertwined, but the forces tending to hold the molecules together are physical rather than chemical and thus may be weakened by energy applied in the form of heat. The ethylene alpha-olefin polymer has a density in the range from about 0.910 g/cc to about 0.940 g/cc, more preferably in the range of from about 0.912 g/cc to about 0.928 g/cc for film making purposes. The melt flow index of these polyethylenes generally ranges from between about 0.1 to about 10 grams per ten minutes and preferably between from about 0.5 to about 3.0 grams per ten minutes (ASTM D 1238). The lower density alpha-olefin copolymers as referred to herein, such as ethylene alpha-olefin copolymers have a density from less than about 0.910 g/cc to about 0.860 g/cc, or even lower. In the core or substrate layer of this invention the alpha-olefin copolymer should have a density below about 0.90 g/cc, preferably about 0.885 g/cc, be more homogeneous than traditional polymers of this type and have a narrower molecular weight range.
Recently, a new type of ethylene-based linear polymers has been introduced. These new resins are produced by metallocene catalyst polymerization and are characterized by narrower or more homogeneous compositional properties, such as molecular weight distribution, than resins produced by more conventional metallic catalyst polymerization systems (see detailed discussion above). Conventional metallic catalyst polymerization systems have discrete catalyst composition differences which are manifested as different catalyst reaction sites with each site having different reaction rates and selectivities. Metallocene catalyst systems are characterized as a single identifiable chemical type which has a singular rate and selectivity. Thus, the conventional systems produce resins that reflect the differential character of the different catalyst sites versus metallocene systems that reflect the single catalytic site. However, it should be noted that at least some previously available ethylene-based linear polymers approximated the physical and compositional properties achieved by the present metallocene catalyzed polyolefins. That is, traditional metallic catalyzed polymerization processes operating at low reaction rates can produce relatively homogeneous resins that compare favourably with the homogeneity of metallocene catalyzed resins. An example of such are the resins sold under the trade-mark Tafmer by Mitsui.
DETAILED DESCRIPTION
A preferred method of making the film of the present invention is that according to the process outlined and described in U.S. Pat. No. 3,741,253 (Brax et al). In this process the first sealant layer and the second substrate layer of the film are coextruded through a tubular extruder whose die is modified in known manner to handle very low density polyethylene resin to form a tubular tape or film. The extruded tube has a diameter in the range of about 11/2 to 6 inches (about 40 to 153 mm) with a wall thickness of 19 to 31 mils (about 500 to 800 microns) as it leaves the die. After leaving the die the substrate is cooled and flattened through nip, haul-off rolls. At this point it may be sent through an irradiation vault where it is irradiated by high energy electrons. Depending on the characteristics desired, this dosage can vary from 2 to 20 MR, but is preferably about 4.5 MR.
The irradiation has the effect of enhancing cross-linking and thereby enhancing adhesion between the layers composing the film of the invention. It is possible to include a cross-linking enhancer in the material. Suitable cross-linking enhancers are mentioned on page 7 of Canadian Patent No. 1,125,229.
If EVOH is used as the barrier layer this can be extruded onto the tube prior to the irradiation step. If the barrier layer is a vinylidene chloride homopolymer or copolymer it is normally preferred to irradiate prior to the application of the barrier layer, as vinylidene polymers are discoloured by irradiation. The extent of discolouration depends upon the comonomer and the extent of irradiation. Vinylidene chloride-methyl acrylate copolymers discolour less readily than vinylidene chloride-vinyl chloride copolymers.
After leaving the irradiation vault the substrate tube is again inflated and sent through a tubular extrusion coating die where, in a coextrusion process, it receives a coating of vinylidene chloride copolymer and layer of ethylene vinyl acetate copolymer or blend. After receiving the final coating, the film is cooled, collapsed and rolled up. It is now a four layer tubular tape having a wall thickness of approximately 700 μm (approximately 27.5 mils). The sealant layer is approximately 90 μm in thickness, the substrate layer is approximately 400 μm in thickness, the barrier layer is approximately 60 μm in thickness and the abuse layer is approximately 150 μm in thickness.
This tape is subsequently unrolled, fed through a bath of hot water held at 205° to 210° F., preferably close to 210° F., and as it leaves the hot water it is inflated and blown into thin tubing where its wall thickness will preferably be about 30 to 150 microns. This is the trapped bubble technique which is well known in the art. The film is rapidly cooled to set the orientation and then rolled up for further processing.
One further processing step can be taken to make end seal bags by transversely sealing and severing across the seamless tubular film as it is laid flat to make individual bags. Side sealed bags may be made by slitting the seamless tubular film along one of its edges after which it is transversely sealed and severed into bags. The side seals are the sealing and severing seams and the bottom of the bag is the unslit edge of the film.
Other bag and pouch making methods known in the art may be readily adapted to making receptacles from the multi-layer film of the present invention.
Film of the present invention is particularly advantageous when used in the form of bags for packaging meat with projecting bones. The packaging of meat with projecting bones is a constant problem, as the bone, which in uncooked meat can "float" and is therefore somewhat mobile, tends to puncture the bag. A common but unsatisfactory solution to this problem is to use a patch that is located over the projecting bone to enhance puncture resistance. It has surprisingly been found that with the film of the present invention the thickness used can be increased, thereby enhancing puncture resistance, without the expected disadvantages of loss of heat shrink properties and loss of clarity of the film. Furthermore, the film has a slightly softer feel to it than other known films and it appears to "give" somewhat but not puncture in situations where other materials puncture.
It has been found, and is demonstrated in examples below that when used under normal production conditions the number of unsatisfactory bags (leakers) is reduced. Inspection for leakers takes place when bags leave the heat-shrinking operation (pack off) in the meat packing plant. Leakers discovered at this stage are stripped of the leaking bag, the bag is discarded and the meat is immediately repacked. The cost of bag failure at this stage is therefore not particularly great.
The substrate film of linear ethylene-alpha-olefin copolymer may be extruded as a monolayer substrate or coextruded as a multi-layer substrate and then irradiated depending upon the desired characteristics of the final film. Furthermore, additional layers may be extrusion coated upon the inflated substrate so that films having 5, 6 or more layers result.
Multilayer film is defined as the film comprising of more than one layer. Depending on the end use of a particular product the film structure is defined. It could be two or more layers based on the expected performance of the product.
The following factors are very important while structuring a multilayer formulation:
______________________________________Barrier Properties Oxygen and/or Moisture Mechanical/physical properties Puncture resistance/Impact strength, etc. Free shrink properties % Shrink Seal characteristics Hot tack, seal through contamination Stress crack resistance Effect of grease, environment, cryogenic conditions, etc Abrasion/abuse Physical abrasion Machinability Compatibility to filing machines Cost Competitive cost Compatibility Good bond strength between layers to give integrity Others Environmental and food laws.______________________________________
A product is usually designed and developed based on the criteria as listed above. Number of layers are thus determined depending on the customer's needs and the performance levels expected from the product.
The thickness of each layer and total thickness of the product depend largely on the properties desired, optimum cost to benefit ratio and the limitation of the equipment process.
Thickness Range
______________________________________ Most Preferred Range Preferred (FormulationLayer (microns) (Typical T gauge) Z670)______________________________________Sealant (inner) 5-20 10 10Substrate (core) 15-85 35 50Barrier (coated) 5-25 5 8Abuse (outer) 10-35 15 20Total 30-150 60 88______________________________________
The invention is further illustrated in the following examples.
As a standard for comparison a film denoted as Z608 or B747 was used. Physical properties compared include tensile strength, tear propagation, interply adhesion, gauge control and productivity.
Z608 (5747) film comprises:
Sealant layer: blend of 90% EVA with 6% VA content and 10% linear ethylene-alpha-olefin copolymer of density 0.920 g/cc (Dowlex* 2045, available from Dow Chemical Company).
Substrate (core) layer: blend of 80% of linear ethylene-alpha-olefin copolymer of density 0.905 g/cc (Attane* 4203 available from Dow Chemical Company) and 20% of EVA with 18% VA content.
Barrier layer: 96% of a copolymer composed of 91.5% vinylidene chloride and 8.5% methyl acrylate, and 4% of epoxidized soya bean oil plasticizer, plus Irganox* 1010 antioxidant.
Outer layer: 100% EVA copolymer with 9% VA content (this layer may include 5% of masterbatch containing usual additives including antioxidant, antiblocking agent, etc. if required).
In developing new formulations to compare with Z608 (B747) the resins/blends and the layer thickness of outer, inner and barrier layers were not changed to make such comparison easier.
The core layer being the principal contributory layer in imparting major inventive properties, was modified and only details of this layer are given in the examples. The developmental work was divided mainly in three stages:
Evaluation of Processing Conditions--viz. Temperature Profile, Back Pressure in extruders, Cooling, Motive Load, Rates & Yields.
Evaluation of Desired Physical Properties in different blends and thicknesses.
Final Assessment & Pilot Plant Run.
In the Examples which follow the following terms are used.
Tafmer is the trade name for the generically known Ethylene/Alpha-Olefin Copolymer manufactured by Mitsui Petrochemical Industries Ltd. Ethylene/Alpha-Olefin Copolymer is broadly classified in two basic categories, viz. crystalline and amorphous.
Crystalline grade have the nomenclature with a prefix "A", amorphous grades have the nomenclature with a prefix "P".
P-0480--Amorphous grade with density 0.870 gms/cc.
A-1085--Crystalline grade with density 0.885 gms/cc.
Other linear ethylene-alpha-olefin copolymers which are available and can be employed in films and bags of the invention include:
(a) "Constrained Geometry Catalyst Technology" resin (CGCT) available from Dow;
(b) "Single-Site" Catalyzed (metallocene catalyst) resins (SSC) available from Exxon.
These resins have densities in the range of 0.860 g/cc to less than 0.900 g/cc. Resins of these types have Narrow Molecular Weight Distribution (NMWD) and Composition Distribution (CD). The molecular weight range is narrower than prior art resins and there is a narrow distribution of types of comonomers found as side chains to the main ethylene chain.
Bynel CXA 3101--an acid modified EVA copolymer used in Example 1. It was found not to give as good results as ethylene-n-butyl acrylate (see Example 3).
EXAMPLE 1 (Z665) (Z666)
______________________________________ ResultsCore Layer (as compared to Z608)______________________________________50% LLDPE (OCTENE)/Dowlex comparable Tensile 2045.03 Strength 30% Ethylene-α-Olefin TAFMER favourable shrink, Copolymer/A1085/ elongation & tear (TAFMER PO480) propagation 20% Acid Modified Eva Polymer/ marginally lower (Bynel CXA 3101) puncture resistance adequate Interply Adhesion (Substrate- Barrier)______________________________________
Note:
Z665--TAFMER P-0480 in core layer
Z666--TAFMER A-1085 in core layer
EXAMPLE 2 (Z667) (COMPARATIVE EXAMPLE) (Z668)
______________________________________70% LLDPE (OCTENE)/ Practically no Dowlex 2045.03 Interply Adhesion 30% Ethylene-α-olefin TAFMER Tensile, Puncture & Copolymer/A-1085 Tafmer Other Mechanical R0480- Properties lower than Z665/Z666 Z668 found impossible to rack coupled with a few other process problems______________________________________
Note:
Z667--TAFMER P-0480 in core layer
Z668--TAFMER A-1085 in core layer
EXAMPLE 3 (Z669) (Z670)
______________________________________50% LLDPE (OCTENE/Dowlex Comparable Tensile 2045.03 30% Ethylene-α-olefin TAFMER Strength, Puncture copolymer/A-1085/ TAFMER Resistance, Tear P-0480 Propagation and Shrink 20% Ethylene-n-butyl acrylate Lower Modulus of Elasticity resulting into superior elongation properties Improved Interply Adhesion Higher Energy to break______________________________________
Note:
Z669--TAFMER P-0480 in core layer
Z670--TAFMER A-1085 in core layer
Note: The properties compared pertain to formulations of TAFMER A-1085 grade.
Z670 modified with Ethylene-α-olefin copolymer and n-Butyl Acrylate Copolymer resins offer better properties related to the performance of the package.
Mechanical & Adhesion properties are derived from a blend of the core layer components whereas improved shrink and extension properties can be attributed to linear ethylene-α-olefin copolymer Resin.
The relative thicknesses of the layers are as follows:
______________________________________ LayerLayer Resin/Blend (%) Thickness (%)______________________________________SEALANT 90% (EVA-6%) 11.76(INNER) 10% (LLDPE/OCTENE)SUB- 50% (LLDPE/OCTENE) 55.56STRATE 30% (LINEAR(CORE) ETHYLENE/-α. OLEFIN- COPOLYMER 20% (ETHYLENE n- BUTYL ACRYLATE)BARRIER 100% PLASTICIZED 8.50(COATED) PVDCABUSE 100% (EVA - 9%) 24.18(OUTER) 100.00______________________________________
The new formulation offers high abuse and high extension properties as well as high shrink.
Ethylene/Alpha-Olefin Copolymer when blended with Linear Low Density Polyethylene and Ethylene n-Butyl Acrylate produces a synergistic balance of properties, e.g. toughness, high shrink and extendability. The optimum blend and the correct choice of resins have exhibited desired performance of the product acceptable to our users.
The narrow molecular weight linear ethylene-alpha olefin copolymer having a density of less than 0.900 g/cc which is employed in the core or substrate layer in this invention and which gives the previously discussed properties (i.e. those copolymers produced by modified Ziegler-Natta catalyst or produced by single-site metallocene catalyst or "CGCT" resins) can also be used in other layers (e.g. sealant and/or abuse) if desired. | A multi-layer, oriented, heat shrinkable thermoplastic film comprising: (i) a layer composed of a blend of ethylene-vinyl acetate copolymer and a linear ethylene-alpha-olefin copolymer; (ii) a layer composed of (a) a linear ethylene-alpha-olefin copolymer; (b) a material selected from the group consisting of ethylene-vinyl acetate copolymers and ethylene-n-butyl acrylate copolymers; and (c) a narrow molecular weight linear ethylene-alpha-olefin copolymer having a density of less than 0.900 g/cc; (iii) a layer composed of a vinylidene chloride copolymer or an ethylene-vinyl acetate copolymer in which the acetate moieties have been partially or completely hydrolyzed; and (iv) a layer composed of a copolymer of ethylene-vinyl acetate or a blend of ethylene-vinyl acetate copolymer and ethylene-alpha-olefin copolymer. | 8 |
FIELD OF INVENTION
This invention relates to aerodynamically wide range applicable cylindrical blade profiles for axial steam turbines.
BACKGROUND OF THE INVENTION AND PRIOR ART
The designers of steam turbines seek for quick selection of useful blades with a minimum number of inventory. One would prefer a few efficient blades to cover a wide flow range prevailing in turbine stages. There are publications such as Deich et al. (Atlas of Blades Profiles for Axial Turbines 1965) for a set of profiles. Further, two patents U.S. Pat. No. 5,211,703 (1993) and U.S. Pat. No. 5,192,190 (1993) on stationary blade have been filed by the authors, viz. Ferteger, Jurek and Evans, David H. Such patents were for a twisted stationary blade with varying stagger angle from hub to tip (from 42 deg at hub to 52 deg at shroud). The blade is non-cylindrical and twisted over the span. A recent patent by the present author (U.S. Pat. No. 6,709,239) is for design of three dimensional twisted blade for use in entry stages of HP/IP cylinders of axial steam turbines. A related patent by Purcaru et al. (U.S. Pat. No. 4.695.228) deals with the construction of profiles through ellipse, parabola and circle segments. The present author has also filed an application (Pub. No. U.S. 2003/0231961A1, U.S. Pat. No. 6,979,178B2) for two cylindrical profiles for subsonic flow application and for a specified range of stagger angles. One of the profiles, P2822 is the reference profile for the present invention which concerns with a new blade profile; that can be used for forming a cylindrical blade i.e. with constant stagger from hub to tip. The blades formed by this profile are untwisted or cylindrical in shape. In addition, the present invention deals with both stationary (guide) and rotating (moving) type of blades for axial steam turbines.
While converting heat energy into kinetic energy, turbines blades suffer two kinds of aerodynamic losses; one—the profile loss due to stream wise boundary layer growth (along blade surfaces), and, mixing in blade wakes, the second—the profile loss due to secondary flow resulting from boundary layer growth along the hub and casing and flows resulting from turning of inlet boundary layer (passage vortex; pressure face to suction face in a cascade passage). The reduction in losses is achieved by various means such as smooth surface and aft-loaded pressure distribution along the blade surfaces (instead of fore-loaded or flat-topped design). Smooth contour variation usually ensures lower profile losses for incompressible and subsonic flows. The lower velocity and cross-channel pressure gradient in the first part of cascade passage where the secondary flow originates; and higher diffusion in the rear part of suction face are the desired features in aft-loaded profiles which in turn reduces secondary flow losses.
The cylindrical blade is defined herein as one of constant cross-section over the blade height. FIG. 1 shows a schematic base profile. At any cross-section, the shape of the profile remains same as shown typically in FIG. 2 . The profile or section is made of two surfaces; suction face and pressure face, each joining leading edge to trailing edge. X-axis and U-axis coincide with the turbine axis and circumferential directions, respectively. Usually the center of gravity lies at the origin of co-ordinate axes. The blade or profile is set at angle betabi or y, tg, also known as stagger or setting angle with respect of U-axis. Chord is defined as axial distance of base profile measured between two farthest tangents to the profile; one at leading edge side and other at trailing edge side. The tangents are normal to the chord. Axial chord is the projected length of the profile on X-axis; hence varies with profile stagger. Inlet and exit flow angles β 1 , tg and β 2 , tg are fluid flow angles with respect to tangent (U-axis); also referred as beta 1 x and beta 2 x with reference to turbine axis, respectively. The profile faces can be specified by various ways; e.g. through discrete points (x, y co-ordinates), through a set of arcs and through Bezier points. The basic difference between any two cylindrical blades is the profile shape and what is being claimed here is the unique quantitative shape of the proposed blade (e.g. geometrical ratios as shown in FIG. 3 ).
OBJECTS OF THE INVENTION
An object of the present invention is to propose an aerodynamic efficient blade profile and relate and complement with another profile from application point of view.
Another object of the present invention is to propose an aerodynamic efficient blade profile which is applicable for a wide stagger variation.
Still another object of the present invention is to propose an aerodynamic efficient blade profile and wherein tooling is minimum.
DESCRIPTION OF THE INVENTION
According to this invention there is provided two cylindrical blades for axial steam turbines comprising a leading edge and a trailing edge with specified circles and a pressure face and suction face and joining at said trailing and leading edges and an inlet flow angle characterized in that the trailing edge is below the base line.
BRIEF DESCRIPTION OF DRAWINGS
The nature of invention, its objective and further, advantages residing in the same will be apparent from the following description made with reference to the non-limiting exemplary embodiments of the invention represented in the accompanying drawings.
FIG. 1 Profile Geometry Description (Base Profile)
FIG. 2 Profile Geometry Description (Stacked Profile)
FIG. 3 e 3 Profile: Geometrical Ratios
FIG. 4 e 3 Profile: (Stacked View)
FIG. 5 e 3 Profile: Loss characteristics as function of M 2 , S/c & gamatg
FIG. 6 e 3 Profile: Outlet flow angles as function of M 2 , S/c & gamatg
FIG. 7 e 3 Profile: Loss characteristics as function of inlet angle & gamatg
FIG. 8 e 3 Profile: Outlet flow angle as function of inlet angle & gamatg
FIG. 9 e 3 Profile: Loss characteristics as function of Gamatg & M 2
FIG. 10 e 3 Profile: Outlet flow angle as function of Gamatg & M 2
FIG. 11 e 9 Profile: Geometrical Ratios
FIG. 12 e 9 Profile: (Stacked View)
FIG. 13 e 9 Profile: Loss characteristics as function of inlet angle & gamatg
FIG. 14 e 9 Profile: Outlet flow angle as function of inlet angle & gamatg
FIG. 15 e 9 Profile: Loss characteristics as function of M 2 , s/c & gamatg
FIG. 16 e 9 Profile: Outlet Flow angles as function of M 2 , s/c & gamatg
FIG. 17 e 9 Profile: Loss characteristics as function of Gamatg & M 2
FIG. 18 e 9 Profile: Outlet Flow angle as function of Gamatg & M 2
The Profile Geometry: FIG. 1 indicates a typical profile geometry L (or C) denotes the length of base chord, Diameters of leading edge circle, nearly the largest in-circle and trailing edge circles, are denoted by d 1 , D and d 2 . The peak locations (maximum height) of suction and pressure faces are denoted by ( 11 ,b 1 ) and ( 12 ,b 2 ); respectively. The coordinates of center of largest in-circle is ( 13 ,b 3 ). B 4 is the difference (b 1 −b 2 ). The vertical shift of lowest point at trailing edge (pressure face) from base line is denoted by b 5 . Pitch s is the circumferential distance between two adjacent blades in a turbine blade row. It is defined mathematically as S=2 nr/z; r being section radius of the blade where profile section is taken and z is no of blades in the blade-row. Blade turning angle (from inlet edge to outlet edge) is called as camber angle.
Performance Analysis: The proposed blade profiles are analyzed by a CFD (Computational Fluid Dynamics) software for various flow conditions to simulate incompressible as well as subsonic flow regime. The profiles are numerically experimented for a set of stagger angle y,tg (gamatg); pressure ratios (hence exit Mach no.), inlet flow angles and pitch-by-chord ratios to result outlet flow angles β 2 ,tg (or beta 2 x ) and energy loss coefficient. In total; result from 148 successful CFD runs are included herein to establish the nomograms.
Energy loss coefficient is defined as
ϛ = 1 - { 1 - ( p2 / po2 ) k - 1 k } / { { 1 - ( p2 / po2 ) k - 1 k }
Where p 2 is mass-averaged static pressure at the outlet; po 1 and po 2 are mass averaged stagnation pressure at the inlet and exit of the cascade. K is the ratio of specific heats of working fluid (1.4 for air). Also note that beta 2 x =β 2 ,tg−90; beta 1 x =90−β 1 ,tg. It may be noted that the results quoted herein for energy loss coefficient ζ, is more indicative in nature than the absolute value, since it may vary quantitatively with the use of other CFD software. However the graphical patterns may not change significantly.
The reference blade profile e 3 :
1. Geometry: FIG. 3 indicates a typical profile geometry e 3 having profile thickness value as 38% of chord located at 25% of chord distance from the leading edge. Other geometrical ratios are also shown in the same figure. The unique geometrical feature of the base profile is that the trailing edge (depth b 5 ) is below the base line. The stacked views of profiles for 2 extreme stagger angles (gamatg=43 and 63 degrees) are shown in FIG. 4 . 2. Performance Analysis: The first proposed blade profile is analyzed and results are shown in graphical forms for quick use during design. ( FIGS. 5–10 ).
FIGS. 5 and 6 show the effect of exit Mach number M 2 ; pitch-chord ratio s/c and two useful extreme range of stagger angles; gamatg (47 and 57 deg) on energy loss coefficient ζ and outlet flow angles (beta 2 x ). The range of s/c and M 2 chosen is very wide: 0.65–1.05 and 0.3 to 1.2; respectively. The following observations may be noted:
1. Higher the stagger angle, the lower is the loss at every exit Match on M 2 2. Loss increases with M 2 except at s/c=0.65 and gamatg=57 3. The suggested profile is useful for a range for a range of M 2 (M<0.9) 4. Loss is minimum for s/c=0.85 and any M 2 (N 2 <0.9) 5. Loss is maximum for s/c=0.65 for any M 2 (M 2 <0.7) and also for s/c=1.05 for a M 2 ; M 2 >0.7 6. Exit flow angle beta 2 x decreases with increase in M 2 for M 2 =0.9 and below. The trend is opposite for M 2 >0.9 7. Higher the stagger, the higher the exit flow angle beta 2 x 8. Beta 2 x increases with increase in pitch-chord ratio s/c. 9. FIGS. 5 and 6 indicate that s/c=0.85 is optimum ratio, from the point of view of loss.
FIGS. 7 and 8 show the behavior of profile for various inflow angle (incidence effects). The loss is independent of large variation of beta 1 x (−10 to 30 degree) for both extreme stagger (gamatg=47 and 57) at s/c=0.85 and M 2 =0.6. Similarly there is very negligible change in outlet angle for a large variation in beta 1 x . The trend is valid for other M 2 and intermediate stagger angles. FIGS. 9 and 10 are summary nomograms of performance for optimum pitch chord ratio=0.85. They indicate that the profile is useful for stagger angle range 47–63 resulting beta 2 x=− 76 to −60 for exit Mach no. range M 2 =0.3–0.9.
The invented blade profile e 9 :
1. Geometry: FIG. 11 indicates a typical profile geometry e 9 having profile thickness value as 33% of chord located at 27.8% of chord distance from the leading edge. Other geometrical ratios are also shown in the same FIG. It is more cambered profile then e 3 hence useful for low reaction blade. The unique geometrical feature of the base profile is that the trailing edge (depth b 5 ) is below the base line. The stacked views of profiles for 2 extreme stagger angles (gamatg=50 and 70 degrees) are shown in FIG. 12 .
II. Performance Analysis: The first proposed blade profile is analyzed and results are shown in graphical forms for quick use during design ( FIGS. 13–18 ).
This profile shows the outlet angle variation independent of inlet flow angle (10–50 degree) for two extreme stagger angles 57 and 67 degrees for s/c=0.85 and M 2 =0.6. However, there is noticeable variation in loss coefficient and outlet angles as function of M 2 , s/c and stagger angles is shown in FIGS. 15 and 16 . There is little variation in beta 2 x for M 2 =0.9 and below. Beta 2 x increases with M 2 for M 2 >0.9. Energy loss coefficient is minimum for s/c=0.85 for M 2 <0.9 and below. Two summary performance graphs are shown for optimum s/c=0.85 in FIGS. 17 and 18 . Profile behavior is reasonably good for stagger angle range 57–67 covering beta 2 x=− 75 to −65 with relatively low loss. Thus with the help a pair profiles e 3 and e 9 , a range of inlet flow angles (10 to 50 degrees), exit Mach numbers (0.3 to 0.9) and stagger angles (47 to 67 degrees), the requirement of cylindrical blades with low energy loss can be accomplished. | The present invention relates to the improved aerodynamic design of a pair of blade profiles valid over a wide range of flow regime. The so formed blades, pertain to high pressure, intermediate pressure and first few stages of low pressure cylinders of axial steam turbines.
The invented blades cover a wide range of stagger angles; pitch/chord ratios; inlet flow angles and outlet Mach numbers. | 5 |
BACKGROUND OF THE INVENTION
The present resides in a hydraulic power steering for motor vehicles with a servomotor having first and second double-acting piston-cylinder units which are arranged co-axially and include a common piston rod.
Motor vehicles are generally provided with factory installed hydraulic power steerings wherein a steering handle or rather steering wheel and the steered vehicle wheels are mechanically coupled with one another. The power steering includes a servomotor with a double acting piston-cylinder unit which is operated depending on the forces and torques effective between the steering handle or steering wheel and the vehicle wheels in such a way that only limited forces are required for actuating the steering handle or turning the steering wheel. As a result, large forces or torques effective between the steering handle or steering wheel and the steered vehicle wheels are mainly taken up, or generated, by the hydraulic piston cylinder unit.
Furthermore, there are presently steering systems for normal street vehicles in the design stage which have no mechanical coupling between the steering wheel and the steered vehicle wheels. In these systems, the steering handle or steering wheel and the steered vehicle wheels are rather coupled only by way of a control system wherein only a setting means for the respective desired steering angle is operated by the steering handle or steering wheel to which angle the steered vehicle wheels are then adjusted by the control system. The control system can take additional parameters into consideration and can for example change the transmission ratio between the steering control movement of the steering handle or the steering wheel and the adjustment angle of the steered vehicle wheels depending on the vehicle speed. Furthermore, skidding movements of the vehicle can be automatically counteracted before the driver makes the appropriate steering correction or without the driver making any steering correction.
DE 29 44 833 C2 discloses a steering system which includes the features mentioned initially. It is basically a hydrostatic steering system with two parallel hydraulic operating mechanisms. It permits the elimination of the steering column which requires a relatively large amount of space and which increases the chances for a driver to be injured during an accident
EP 0 307 612 A1 discloses a power steering system wherein the steered vehicle wheels and the driver-operated steering wheel are mechanically interconnected. In addition, a hydraulic power steering unit with two parallel hydraulic circuits is provided which includes two piston-cylinder units separated by a cylinder separating wall which separates the cylinders hydraulically but through which the piston rod extends. The two cylinders are formed in a common single-piece cylindrical tube component.
DE 44 35 848 A1 discloses a servomotor consisting of a piston-cylinder unit with an annular piston member which has axial annular flanges at its inner circumference which are received in corresponding grooves formed in the piston rod.
DE 43 31 291 C1 and JP57-198168A disclose rack and pinion steering systems with a piston-cylinder units with boots disposed at the ends of the cylinders enclosing spaces which are in communication by way of an axial bore extending through the piston rod or pinion. In addition, the last mentioned reference discloses joints arranged at the opposite ends of the piston rod which cooperate with end portions of the cylinder so as to form stops for limiting travel of the piston rod.
The present invention resides in a steering system which has no need for a firm mechanical connection between a steering handle or wheel and the steered vehicle wheels. This system is similar to the control of control flaps of modern airplanes; such systems are known there under the designation "fly-by-wire" systems.
In order to provide for vehicle steering systems without mechanical coupling between the steering handle or steering wheel which are safe under any circumstances, redundancies or so called back-up arrangements must be provided which insure safe operation of the vehicle even if an essential part of the system fails. Continued travel should be possible essentially without limitations.
It is the object of the invention to provide a simple vehicle steering system without a direct mechanical coupling between the steering wheel or handle and the steered vehicle wheels wherein nevertheless continued vehicle operation is possible even if an essential part of the system fails.
SUMMARY OF THE INVENTION
In a hydraulically operated steering for a motor vehicle comprising a control motor with first and second double acting piston and cylinder units arranged in axial alignment and a single piston rod extending through the first and second double acting piston and cylinder units, at least one of the double acting piston and cylinder units includes an annular piston which is fastened on the pistons rod in a predetermined axial position and an annular divider wall is disposed between the pistons for slidably supporting the piston rod and separating the cylinders of the first and second double acting piston and cylinder units fluidically from one another so as to form cylinder chambers for the pistons limited at one side by the annular divider wall and by guide sleeve members disposed in the opposite ends of the cylinder units.
The invention is based on the general concept of using redundant steering systems, that is, to use for the control of the steered vehicle wheels two parallel piston-cylinder units of which one is normally in use for controlling the steered vehicle wheels whereas the other is used during an emergency as a backup system. The two piston cylinder units consist of a single unit which, in its design, is similar to conventional power steering units wherein the piston rod of a double-acting piston cylinder unit and the toothed rack comprises a single piece which is engaged by a pinion associated with a steering wheel so as to be driven thereby. With the arrangement according to the invention, however, instead of the toothed rack, essentially only an elongated piston rod is required which is provided with a first and a second piston disposed in first and second cylinders. The first and second cylinders are disposed axially adjacent one another and receive the first and second pistons respectively. The double cylinder and piston arrangement is formed as an integral unit.
Preferred embodiments and features of the invention will be described in greater detail below on the basis of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a power steering according to the invention without mechanical connection between a steering wheel and the steered vehicle wheels.
FIG. 2 is an axial cross-sectional view of one embodiment of a power steering with two double-acting piston cylinder units included in a single unitary cylinder structure,
FIG. 3 is a cross-sectional view like that shown in FIG. 2 for a somewhat modified embodiment, and
FIG. 4 is an axial cross-sectional view of an embodiment of the invention, wherein for each piston cylinder unit a separate cylinder structure is provided, the two cylinder structures being firmly interconnected.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a motor vehicle which is not shown in detail includes two steered vehicle wheels 1 which are coupled mechanically, by way of tie rods 2, with a piston rod 3 of a piston-cylinder assembly 4 such that axial movement of the piston rod 3 causes a change of the steering angle of the steered vehicle wheels 1.
The piston-cylinder assembly 4 includes two double acting piston-cylinder units 5 and 6 including pistons 7 and 8 respectively, disposed in cylinders 9 and 10 and dividing the cylinder units 9 and 10 each into two chambers.
The two chambers of the cylinder unit 9 are in communication with a switch-over valve 13 by way of conduits 11 and 12 and further by way of conduits 14 and 15 with a double acting piston cylinder arrangement 16 whose piston is operatively connected mechanically to a steering wheel 17 of a vehicle.
The cylinder unit 10 is in communication, by way of conduits 18 and 19, with a control valve 20 and further, with the pressure side of a hydraulic pump 21 or another hydraulic pressure source and a low pressure hydraulic fluid reservoir 22. The suction side of the hydraulic pump 21 is also in communication with the hydraulic fluid reservoir 22.
The control valve 20 is operated by a control unit 23 which is connected at its input side to a desired valve setting means 24 operated by the steering wheel 17 and an actual value sensor 25 for indicating the actual steering angle of the steered vehicle wheels 1. The control unit 23 has further inputs for additional parameters which are not shown, however. On the output side, the control unit is connected to the control magnet of the switch-over valve 13.
The arrangement, as shown in FIG. 1 operates as follows: Under normal operation, the control magnet of the switch-over valve 13 is energized by the control unit 23 such that the switch-over valve 13 is held against the force of a return spring in its other position not shown in FIG. 1, wherein the pistons in the piston-cylinder assembly 5 as well as in the piston-cylinder arrangement 16 are freely movable. The steering wheel 17 operates the desired value setting means 24 which provides accordingly a desired value for the steering angle of the steered vehicle wheels 1. Depending on a desired value to actual value comparison, which is performed by the control unit 23 utilizing the signals from the desired value setting means 24 and the actual value sensor 25, the control unit 23 operates the control valve 20 in such a manner that a certain pressure difference between the two chambers of the piston-cylinder unit 6 is established when there is a need for a position adjustment so as to provide for a piston force in one or the other direction for actuating the steering mechanism for the steered vehicle wheels 1. The control unit 23 constantly supervises itself for proper operation. If a malfunction should occur, the electromagnetic control structures of the control valve 20 and the control magnet of the switch-over valve 13 are de-energized with the result that the control valve 20 is switched, by the return spring arrangement, to a position in which the piston 8 is freely movable in the cylinder 10. At the same time, the switch-over valve 13 is switched to the position as shown in FIG. 1, wherein the piston cylinder unit 5 and the piston cylinder arrangement 16 are hydraulically coupled. Consequently, the steering wheel 17 and the steered vehicle wheels are coupled with each other by way of a hydraulic "steering column".
The piston-cylinder assembly 4 as shown in FIG. 2 includes for both piston-,cylinder units 5 and 6 a common cylinder tube component 26 with connections 27 at the side thereof for the conduits 11, 12, 18 and 19 (see FIG. 1). The opposite ends of the cylinder tube component are slightly widened in a step-like fashion and receive guide sleeve members 28 with external annular grooves receiving a seal ring for sealing any gap between the guide sleeve members 28 and the cylinder tube component 26. The piston 3 extends through the guide sleeve members 28 and is radially supported therein by means of bearing sleeves 29 mounted on the guide sleeve members 28. Axially adjacent the bearing sleeve 29, the inner surface of the guide sleeve member 28 includes an annular recess receiving a seal 20 which sealingly surrounds the piston rod 3 but permits axial movement thereof.
The pistons 7 and 8 are annular members which are sled onto the piston rod 3. They have at their inner axial ends annular axial flanges which are pressed into annular grooves 31 formed in th piston rod 3 by deforming the annular axial flanges by means of a roller tool. The pistons 7 and 8 are firmly engaged in this manner with the piston rod 3.
Disposed in the cylinder tube component 26 between the pistons 7 and 8 is a divider wall ring 32 which is mounted to the cylinder tube component 23 by pins 33. For mounting, the divider wall ring 32 is placed on the piston rod 3 between the pistons 7 and 8 and the piston rod with the pistons and the divider wall ring 32 are then inserted into the cylinder tube component until the divider wall ring reaches the axial position as shown in FIG. 2. Then the pins 33 are inserted through radial bores in the cylinder tube component 26 so that they project into a circumferential groove in the divider wall ring 32 to thereby hold the divider wall ring 32 in position within the cylinder tube component 26. In addition to the circumferential groove for the pins 33, the divider wall ring 32 includes two additional circumferential grooves in which seal rings are disposed for sealing the gap between the outer circumference of the divider wall ring 32 and the inner surface of the cylinder tube component 26. At its inner circumference, the divider wall ring 32 is provided with annular grooves receiving seals for the piston rod 3 and, between these grooves a bearing sleeve 34 for slidably supporting the piston rod 3.
The embodiment as shown in FIG. 3 is essentially the same as that shown in FIG. 2 except that the left hand cylinder unit 5 includes a cylinder sleeve 35 on the left side of the divider wall ring 32 for reducing the cross-section of the cylinder 9. The associated piston 7 has a correspondingly smaller outer diameter. At its axial ends, the cylinder sleeve 35 is provided with axial slots or other recesses such that the connections 27 of the cylinder 9 are in communication with the respective chambers of the cylinder sleeve 35.
In the embodiment of FIG. 4, the cylinders 9 and 10 are separate components which are joined at their adjacent ends. For joining, the cylinder 10 which has a somewhat larger diameter than the cylinder 9, extends over, and receives, an end portion of the cylinder 9. In the example as given in FIG. 4, the end of the cylinder 10 is compressed so as to extend into a circumferential groove 36 in the cylinder 9 for firm engagement therewith.
The divider wall ring 32 of the arrangement as shown in FIG. 4 has a flange-like annular shoulder formed at one axial end thereof which shoulder is received in an annular recess formed between an annular shoulder at the axial end of the cylinder 10 and the front end face of the cylinder 9.
The gaps between the outer circumference of the divider wall ring 32 or its annular flange portion and the inner circumference of the cylinders 9 and 10 are sealed by seal rings which are disposed in annular grooves formed in the innner circumference of the cylinder 9 and, respectively, the outer circumference of the annular flange portion of the divider wall ring 32.
In the embodiment as shown in FIG. 4, the divider wall ring 32 has at its inner circumference only a single seal 37 which is disposed axially adjacent the bearing sleeve 34 in order to seal the annular gap between the piston rod and the inner circumference of the divider wall ring 32. FIG. 4 further shows one of the pistons 7 and 8, that is, piston 7 to be integrally formed with the piston rod 3. The other piston 8 is again an annular member which is disposed on the piston rod 3 where it is mounted in this particular example by rings 38 which are seated in corresponding annular grooves formed in the piston rod 3. In this embodiment, the annular gap between the piston rod 3 and the piston 8 is sealed by a seal ring which is disposed in an annular groove formed in the inner circumference of the annular piston 8.
In all the embodiments as shown in FIGS. 2 to 4, the cylinders 9 and 10 or the cylinder tube component 26 may be provided with support legs or parts 39 (only shown in FIGS. 2 and 3) for mounting the piston cylinder assembly 4 to the chassis or frame structure of a vehicle.
In order to protect the connection joints between the piston rod 3 and the tie rods 2 and also the support bearing structure for the piston rod 3 in the sleeve guide members 28 from dust, there are provided protective boots 40 which are attached at one end to the adjacent ends of the cylinders 9 and 10, or respectively, the cylinder tube component 26, and at the other end to tie rods 2. It is advantageous if the spaces enclosed by the boots are in communication by an axial bore extending through the piston rod 3 so that, during axial movement of the piston rod 3, air can flow from one of the boot spaces to the other through the axial bore in the piston rod 3. During such axial movement of the piston rod 3, the space enclosed by one of boots 40 increases while the space enclosed by the other boot decreases at the same rate. | In a hydraulically operated steering for a motor vehicle comprising a control motor with first and second double acting piston and cylinder units arranged in axial alignment and a single piston rod extending through the first and second double acting piston and cylinder units, at least one of the double acting piston and cylinder units includes an annular piston which is fastened on the pistons rod in a predetermined axial position and an annular divider wall is disposed between the pistons for slidably supporting the piston rod and separating the cylinders of said first and second double acting piston and cylinder units fluidically from one another so as to form cylinder chambers for said pistons limited at one side by an annular divider wall and by guide sleeve members disposed in the opposite ends of the cylinder units. | 5 |
CROSS-REFERENCE
[0001] The present application claims priority to Russian Patent Application No. 2015141517, filed Sep. 30 , 2015 , entitled “METHODS OF FURNISHING SEARCH RESULTS TO A PLURALITY OF CLIENT DEVICES VIA A SEARCH ENGINE SYSTEM”, the entirety of which is incorporated herein by reference.
FIELD
[0002] The present technology relates to methods of furnishing search results to a plurality of client devices via a search engine system.
BACKGROUND
[0003] Currently, the Internet provides access to a vast amount of information. Generally speaking, a user can access a resource on the communications network by two principle means. The user can access a particular resource directly, either by typing an address of the resource (typically an URL or Universal Resource Locator, such as http://www.webpage.com) or by clicking a link in an e-mail or in another web resource. Alternatively, the user may conduct a search using a search engine to locate a resource of interest. The latter is particularly suitable in circumstances where the user knows a topic of interest, but does not know the exact address of the resource he is interested in.
[0004] There are numerous search engines available to the user. Some of these are considered to be general purpose search engines (such as Yandex™, Google™, Yahoo™ and the like). Others are considered to be vertical search engines—i.e. search engines dedicated to a particular topic of search—such as Momondo™ search engine dedicated to searching flights.
[0005] Irrespective of which search engine is used, it is known in the art that the search engine is generally configured to receive a search query comprising a single or multiple search terms from a user, which can be submitted by the user from a variety of client devices (desktop, laptop, notebook, smartphone, tablets, etc.) in which a variety of applications can be running. The search engine then performs the search and identifies a plurality of documents matching the one or more search terms.
[0006] Typically, the search engine presents the search results to the user on a search engine results page (SERP) generated by the search engine. The search results are organized on the page in a specific manner determined by the search engine. Usually, the search results are organized in a generally vertical list in which the most relevant search result is presented first (i.e., at the top of the SERP), followed by the next most relevant search result (i.e., immediately below the most relevant search result), and so on. A generic description of a conventional SERP may be that published by Google Inc. found at http://www.googleguide.com/results_page.html, which is incorporated herein by reference in its entirety for all purposes.
[0007] In order to determine the sequence in which the search results will appear on the SERP, the search engine generally ranks search results according to their relevance using a ranking algorithm which may take into account various factors indicative of relevance. This is known in the art as query specific ranking, or “QSR”. A fuller discussion of search engine ranking concepts and operations may be found in International Application Publication No. WO 2015/004607 A2, published Jan. 15, 2015, entitled “Computer-Implemented Method of and System for Searching an Inverted Index Having a Plurality of Posting Lists” (the “'607 Application”, which is incorporated by reference in its entirety for all purposes. As is discussed in the '607 Application, one of the ways in which a search engine system derives a query specific ranking is via information, such as click-through data described in that Application, related to users' interactions with search results provided in respect of specific search queries. Click-through data is not the only type of information related to users' interactions with search results available to search engine systems to improve on QSR derivation. Other information, such as that related to users' cursor movements and users' gaze tracking, is also conventionally available to search engine systems for this purpose.
[0008] While conventional methods of organizing search results on a SERP according to their QSR are adequate and of deriving a QSR itself are adequate for their intended purposes, additional improvements are possible and might be useful in certain circumstances.
SUMMARY
[0009] It is thus an object of the present technology to improve searching via search engines.
[0010] The conventional visual configuration of search results on a SERP (as described above) is believed to be optimal as it is premised on the belief that it is in this manner that users actually interact with the search results. Le., it pre-supposes that when presented with a SERP, users look first to the first listed search result at the top of the page, assuming it to be the most relevant. And, if it is not, then users progress down the page, from the top to the bottom, looking at each listed search result in the list sequentially, until they find the search result most matching the information that they were seeking.
[0011] It has been discovered that, in actual fact, this is not always the case. Users do not always interact with a SERP in this manner For example, there are circumstances where a user starts by looking at a listed search result at the top of the SERP and then they progress irregularly through the search results. In a more specific example, for a given set of search results being a list of 6 items shown on a SERP in QSR (or more rarely in QIR order—whichever the case may be in a particular circumstance, being referred to hereinafter as “relevance rank order”), a user provided with the search results may first look at the first listed search result at the top of the SERP. If that first listed search result does not provide the user with the information that they are seeking, the user may then (unexpectedly) jump to the fifth listed search result from the top of the page. If that fifth listed search result does not provide the user with the information they are seeking, the user may then jump back to the second listed search result from the top of the page, and so on as the case may be. (This description is intended only an example of the concept attempting to be explained, and not as a description of what always actually occurs for every (or any) given SERP.)
[0012] Moreover, starting at the top of the page with the first listed search result is not always the case either. In a specific non-limiting example, for a given set of search results being a list of 6 items shown on a SERP in QSR, the user may start with the fourth listed search result from the top of the page. If that fourth listed search result does not provide the user with the information that they are seeking, the user may then jump to the sixth listed search result from the top of the page. If that sixth listed search result does not provide the user with the information that they are seeking, the user may then jump to the second listed search result from the top of the page, and so on as the case may be. (Again, this description is intended only an example of the concept attempting to be explained, and not as a description of what always actually occurs for every (or any) given SERP.)
[0013] In addition, in some circumstances, user behavior on a SERP may even be non-columnar. For example, in an example similar one of those described above, the user may first look at the first listed search result at the top of the SERP, then move to a specialized result on the right hand side of the SERP, followed by looking at the fifth listed search result in the middle of the SERP, and then followed by returning to the second listed search result near the top of the SERP.
[0014] Conventionally, user interactions with the SERP in the manner described in the above examples are taken into account when determining a QSR for similar search queries in the future. This is premised on the belief that users quickly scan the search result listing, determine which one of the listed search results is the most relevant to the information that they are seeking, and start there. If that listed search result does not provide them with the information that they are seeking, then they go back to the search result listing and move to the listing that is then the one that they believe is most relevant to the information that they are seeking. And so on, and so forth, until they find the information that they are seeking. Thus, the search engine system collects data on which of the results of a search engine results listing are considered by the users of the system to be relevant to a search query, and in which order they should be ranked. The goal being to having a search engine results listing being in perfect QSR. In a very over-simplistic example (used for illustrative purposes only), the next time that a user runs that particular search query, the search result listing could have its individual listings re-ordered to be in the order (starting from the top of the SERP) that had been determined to be most relevant based on the prior user's interactions with the SERP as described above.
[0015] In the aforementioned examples, a user “starting” with a particular listed search result, does not necessarily mean that a user “clicks” on that search result (although it may), only that the user considers the information present on the SERP about that particular listed search result to determine whether or not relevant information has been provided to them. Typically, conventionally, this is judged by tracking user cursor movements or user eye gazing, as well as user click-throughs and returns to the SERP.
[0016] What has been realized is that that premise set forth above no longer holds true in some circumstances. In some circumstances, counterintuitively, users actually start with a listed search result that is actually a lower ranked search result than the highest ranked search result for reasons other than the fact that they believe that the listed search result that they are starting with is the most relevant of the listed search results provided. Without wishing to be bound by any particular theory, it may be that the reason users so act is related to how they are accessing the search engine system. For example, if the search engine system is being accessed through a desktop web-brower, the search results will be provided in a very different visual format than if the search engine system is being accessed though a dedicated app on a smartphone. The former will usually provide the results along with other information in a graphically rich format (which format can differ greatly as is described hereinbelow.) The latter will usually provide the results as a simply list of textual items, without any graphics.
[0017] For example, today's SERPs are in many cases no longer simple single column textual listings of search results having a hyperlink to the URL of internet resource (being the search result) with a textual snippet providing a bit of a preview of the information that can be found on that resources. For example, in FIG. 1 , there is a shown a conventional SERP 10 of the Google™ search engine system operated by Google Inc. for the search query “eiffel tower”, accessed via a desktop web browser. As can be seen in the figure, the SERP is generally divided into two columns 12 , 14 . In the left column 12 , there is a listing of URLs that the search engine system believes to be relevant to the specific query “eiffel tower” listed in QSR order, along with a textual snippet of information that may be found at that URL, 16 a, 16 b, 16 c, 16 d, 16 e, 16 f, 16 g. In the middle of the column 12 , below the third listed search result 16 c and above the fourth listed search result 16 d, is a news search result section 18 and an images search result section 20 . The news search result section 18 provides a listing of news items relevant to the search query “eiffel tower”. The images search result section 20 , providing a collection of images relevant to the search query “eiffel tower”. In the right column 16 , there is an “object card” 22 for the “eiffel tower” object. The object card 22 provides a map snippet 24 showing the location of the Eiffel Tower in Paris, France as well as an image 26 of the Eiffel Tower in Paris, France. (The Eiffel Tower in Paris, France, being the most probable object resulting form the search query “eiffel tower”.) In addition, the object card contains (i) a snippet 28 from the Wikipedia™ entry on the Eiffel Tower in Paris, France; (ii) information 30 related to popular visiting times for the Eiffel Tower in Paris, France (source unknown); (iii) reviews 32 of the Eiffel Tower in Paris, France (from Google™ Reviews); and (iv) an indication 34 of some other searches that people who have submitted the search request “eiffel tower” have also submitted.
[0018] The visual effect of a SERP such as the one shown in FIG. 1 , is very different from a more conventional SERP, such as the one shown in FIG. 2 . The SERP shown in FIG. 2 is a conventional SERP 40 of the DuckDuckGo™ search engine system operated by DuckDuckGo, Inc. for the search query “eiffel tower”, accessed via a desktop web browser. As can been seen in the figure, the SERP 40 is generally of a single column configuration. At the top of the SERP 40 there is a simple object card 42 . Below the object card 42 are two simple textual side-by-side advertisements 44 a, 44 b. Below the two advertisements 44 a, 44 b a listing of URLs that the search engine system believes to be relevant to the specific query “eiffel tower” listed in QSR order, along with a textual snippet of information that may be found at that URL, 46 a, 46 b, 46 c, 46 d.
[0019] The visual effect of SERP such as the one shown in FIG. 3 , is very different from the ones shown in FIGS. 1 & 2 . The SERP shown in FIG. 3 is a conventional SERP 50 of the Yandex™ search engine system operated by Yandex LLC for the search query “eiffel tower”, accessed from a dedicated app running under iOS on Apple Inc.'s iPhone™ smartphone. As can been seen in the figure, the SERP 50 is of a single column configuration providing a simple textual listing of URLs that the search engine system believes to be relevant to the specific query “eiffel tower” listed in QSR order, along with a textual snippet of information that may be found at that URL, 52 a, 52 b, 52 c. No other information is provided on SERP 50 .
[0020] In a more extreme example, when the search engine system is accessed via voice in connection with an intelligent personal assistant (e.g., Apple Inc.'s Siri™ or Microsoft Inc.'s Cortana™), the results will generally simply be spoken words. The search result presented to the user first will generally have been chosen by the search engine system itself, without any choice having first been offered to the user. There is little or no visual presentation of the search results at all, and no SERP is provided to the user for use in selection among the various search results.
[0021] Keeping this in mind, again, without wishing to be bound by any particular theory, it appears that the method of presentation of the search results is influencing user interaction with the search results. The difficulty this scenario presents is that the QSR of the search results should generally be the same no matter how the user is interacting with the search engine system (although it may vary between search engine system). Thus, for a given identical (in every respect) search query, no matter how the search engine system is accessed, the search results should be the same. Yet conventionally, because user interactions with the search results are used in calculating the QSR for future similar search queries, incorrect data is being gathered by the search engine system in this respect. This leads to incorrect QSRs for future similar search queries. For users, incorrect QSRs are in many circumstances a minor inconvenience, since the information that they are seeking is usually still within the top ranked search results, although those search results may be out order. For the search engine system, however, incorrect QSRs are a significant waste of resources. To put this in context, it should be understood that a modern search engine may conduct 50,000 searches per second, every second of every day of month. A number that is not constant, but is ever increasing. Search engine systems need to keep track of users' interactions with the search results, for many varied reasons. One reason is that referred to above, which is to get feedback to improve future searches. But this is not the only one. The more interactions a user has to have with a SERP to find the information that they are seeking, the more resources are required of the search engine system with respect to that one single search. Multiply that inefficiency by every search, and the drain on the search engine system resources becomes enormous. The present technology has resulted from the above realization and a desire to improve search engine efficiency.
[0022] Thus, in one aspect, implementations of the present technology provide a method of furnishing search results to a plurality of client devices via a search engine system, the search engine system including:
at least one server, a first database having a plurality of posting lists in electronic communication with the at least one server, a second database having information related to previous user interactions with search results having been provided by the system in electronic communication with the at least one server, a communications network configured to provide for electronic communication between the at least one server and the plurality of client devices,
the method comprising, via the at least one server:
receiving a search query from a one of the plurality of client devices via the communications network, the search query including information indicative of a property of an application running on the client device originating the search query; effecting a search via at least the first database to determine search results in respect of the search query, the search results having a relevance rank order; determining a probable user search result interaction sequence based on information in the second database and on the information indicative of the property of the application running on the one of the client devices originating the search query, the probable user search result interaction sequence being different from the relevance rank order of the search results; sending the search results to the one of the client devices via the communications network, the search results including information allowing for visual configuration of the search results provided to the user by the application originating the search query according to probable user search result interaction sequence, while maintaining the relevance rank order.
[0031] The present technology attempts to improve upon conventional technology, by having the search engine system keep track of user interactions with search results in order to be able to allow for the visual configuration of search results taking into account a property (or properties) of the application (running on a client device) accessing the search engine system, with modifying the relevance rank order (e.g., QSR) of the search results.
[0032] Thus, the present technology may allow (depending on the circumstances) for the visual configuration of the search results to differ in different circumstances, without affecting the relevance rank order.
[0033] Thus, in some implementations of the present technology, the client device is provided instructions to display the search results out of relevance rank order (while maintaining the order).
[0034] In some implementations of the present technology, the client device is provided with instructions to display the search results in a non-columnar arrangement.
[0035] In some implementations of the present technology, the client device is provided with instructions to display the search results in a non-row arrangement.
[0036] In some implementations of the present technology, the client device is provided with instructions to display at least one of the search results differently from others of the search results. In some such implementations at least one of the search results has at least one of the following from the other search results: a different font, a different font size, a different color, a different font style, a different font underline, and a different font effect.
[0037] In some implementations of the present technology, the client device is provided with instructions to solely display the search results in images associated with a one of the search results next to that one of the search results.
[0038] In some implementations of the present technology, the property of an application running on the client device originating the search query is that the application is a desktop web-browser.
[0039] In some implementations of the present technology, the information related to previous user interactions with search results having been provided by the system has resulted from use of a machine-learned algorithm
[0040] In some implementations of the present technology the method further comprises,
receiving from the one of the plurality of client devices via the communications network, information related to then current user interaction with the results; and updating the information in the second database information related to previous user interactions with search results having been provided by the system, without updating information in the system related to the relevance rank order.
[0043] In another aspect, implementations of the present technology provide a search engine system including:
at least one server, the server configured to furnish search results to a plurality of client devices via the search engine system in accordance with a method described hereinabove; a first database having a plurality of posting lists in electronic communication with the at least one server; a second database having information related to previous user interactions with search results having been provided by the system in electronic communication with the at least one server; and a communications network configured to provide for electronic communication between the at least one server and the plurality of client devices.
[0048] In the context of the present specification, a “server” is a computer program that is running on appropriate hardware and is capable of receiving requests (e.g. from client devices) over a network, and carrying out those requests, or causing those requests to be carried out. The hardware may be one physical computer or one physical computer system, but neither is required to be the case with respect to the present technology. In the present context, the use of the expression a “server” is not intended to mean that every task (e.g. received instructions or requests) or any particular task will have been received, carried out, or caused to be carried out, by the same server (i.e. the same software and/or hardware); it is intended to mean that any number of software elements or hardware devices may be involved in receiving/sending, carrying out or causing to be carried out any task or request, or the consequences of any task or request; and all of this software and hardware may be one server or multiple servers, both of which are included within the expression “at least one server”.
[0049] In the context of the present specification, “client device” is any computer hardware that is capable of running software appropriate to the relevant task at hand. Thus, some (non-limiting) examples of client devices include personal computers (desktops, laptops, netbooks, etc.), smartphones, and tablets, as well as network equipment such as routers, switches, and gateways. It should be noted that a device acting as a client device in the present context is not precluded from acting as a server to other client devices. The use of the expression “a client device” does not preclude multiple client devices being used in receiving/sending, carrying out or causing to be carried out any task or request, or the consequences of any task or request, or steps of any method described herein.
[0050] In the context of the present specification, a “database” is any structured collection of data, irrespective of its particular structure, the database management software, or the computer hardware on which the data is stored, implemented or otherwise rendered available for use. A database may reside on the same hardware as the process that stores or makes use of the information stored in the database or it may reside on separate hardware, such as a dedicated server or plurality of servers.
[0051] In the context of the present specification, the expression “information” includes information of any nature or kind whatsoever capable of being stored in a database. Thus information includes, but is not limited to audiovisual works (images, movies, sound records, presentations etc.), data (location data, numerical data, etc.), text (opinions, comments, questions, messages, etc.), documents, spreadsheets, etc.
[0052] In the context of the present specification, the expression “component” is meant to include software (appropriate to a particular hardware context) that is both necessary and sufficient to achieve the specific function(s) being referenced.
[0053] In the context of the present specification, the expression “computer usable information storage medium” is intended to include media of any nature and kind whatsoever, including RAM, ROM, disks (CD-ROMs, DVDs, floppy disks, hard drivers, etc.), USB keys, solid state-drives, tape drives, etc.
[0054] In the context of the present specification, the words “first”, “second”, “third”, etc. have been used as adjectives only for the purpose of allowing for distinction between the nouns that they modify from one another, and not for the purpose of describing any particular relationship between those nouns. Thus, for example, it should be understood that, the use of the terms “first server” and “third server” is not intended to imply any particular order, type, chronology, hierarchy or ranking (for example) of/between the server, nor is their use (by itself) intended imply that any “second server” must necessarily exist in any given situation. Further, as is discussed herein in other contexts, reference to a “first” element and a “second” element does not preclude the two elements from being the same actual real-world element. Thus, for example, in some instances, a “first” server and a “second” server may be the same software and/or hardware, in other cases they may be different software and/or hardware.
[0055] Implementations of the present technology each have at least one of the above-mentioned object and/or aspects, but do not necessarily have all of them. It should be understood that some aspects of the present technology that have resulted from attempting to attain the above-mentioned object may not satisfy this object and/or may satisfy other objects not specifically recited herein.
[0056] Additional and/or alternative features, aspects and advantages of implementations of the present technology will become apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] For a better understanding of the present technology, as well as other aspects and further features thereof, reference is made to the following description which is to be used in conjunction with the accompanying drawings, where:
[0058] FIG. 1 shows a conventional SERP of the Google™ search engine system operated by Google Inc. for the search query “eiffel tower”;
[0059] FIG. 2 shows a conventional SERP of the DuckDuckGo™ search engine system operated by DuckDuckGo, Inc. for the search query “eiffel tower”;
[0060] FIG. 3 shows a conventional SERP of the Yandex™ search engine system operated by Yandex LLC for the search query “eiffel tower”;
[0061] FIG. 4 is a diagram of various networked computer systems in communication with one another via a communications network, including a search engine system according to the present technology;
[0062] FIGS. 5 and 6 illustrate example searches performed according to the present technology;
[0063] FIGS. 7A, 7B, and 7C show a SERP of the Yandex™ search engine system for the search query “home gym”, via the Yandex Search app for iOS running on an Apple™ iPhone™ smartphone according to the present technology; and
[0064] FIG. 8 shows a SERP of the Yandex™ search engine system for the search query “home gym”, via a desktop web browser according to the present technology.
DETAILED DESCRIPTION
[0065] Referring to FIG. 4 , there is shown a diagram of various networked computer systems in communication with one another via a communications network, including search engine system 100 . It is to be expressly understood that the various computer systems are merely some implementations of the present technology. Thus, the description thereof that follows is intended to be only a description of illustrative examples of the present technology. This description is not intended to define the scope or set forth the bounds of the present technology. In some cases, what are believed to be helpful examples of modifications to computer systems may also be set forth below. This is done merely as an aid to understanding, and, again, not to define the scope or set forth the bounds of the present technology. These modifications are not an exhaustive list, and, as a person skilled in the art would understand, other modifications are likely possible. Further, where this has not been done (i.e. where no examples of modifications have been set forth), it should not be interpreted that no modifications are possible and/or that what is described is the sole manner of implementing that element of the present technology. As a person skilled in the art would understand, this is likely not the case. In addition, it is to be understood that the computer systems may provide in certain instances simple implementations of the present technology, and that where such is the case they have been presented in this manner as an aid to understanding. As persons skilled in the art would understand, various implementations of the present technology may be of a greater complexity.
Search Engines—General Discussion
[0066] Typically, in building a search-efficient data collection management system, data items are indexed according to some or all of the possible search terms that may be contained in search queries. Thus, an “inverted index” of the data collection is created, maintained, and updated by the system. The inverted index will comprise a large number of “posting lists” to be reviewed during execution of a search query. Each posting list corresponds to a potential search term and contains “postings”, which are references to the data items in the data collection that include that search term (or otherwise satisfy some other condition that is expressed by the search term). For example, if the data items are text documents, as is often the case for Internet (or “Web”) search engines, then search terms are individual words (and/or some of their most often used combinations), and the inverted index comprises one posting list for every word that has been encountered in at least one of the documents.
[0067] Search queries typically have the form of a simple list of one or more words, which are the “search terms” of the search query. Every such search query may be understood as a request to the search engine to locate every data item in the data collection containing each and every one of the search terms specified in the search query. Processing of a search query will involve searching through one or more posting lists of the inverted index. As was discussed above, typically there will be a posting list corresponding to each of the search terms in the search query. Posting lists are searched as they can be easily stored and manipulated in a fast access memory device, whereas the data items themselves cannot (the data items are typically stored in a slower access storage device). This generally allows search queries to be performed at a much higher speed.
QIR & QSR
[0068] Typically, each data item in a data collection is numbered. Rather than being ordered in some chronological, geographical or alphabetical order in the data collection, data items are commonly ordered (and thus numbered) within the data collection in descending order of what is known as their “query-independent relevance” (abbreviated herein to “QIR”). QIR is a system-calculated heuristic parameter defined in such a way that the data items with a higher QIR value are statistically more likely to be considered by a search requester of any search query as sufficiently relevant to them. The data items in the data collection will be ordered so that those with a higher QIR value will be found first when a search is done. They will thus generally appear at (or towards) the beginning of the search result list (which is typically shown in various pages, with those results at the beginning of the search result list being shown on the first page). Thus, each posting list in the inverted index will contain postings, a list of references to data items containing the term with which that posting list is associated, with the postings being ordered in descending QIR value order.
[0069] It should be evident, however, that such a heuristic QIR parameter may not provide for an optimal ordering of the search results in respect of any given specific query, as it will clearly be the case that a data item which is generally relevant in many searches (and thus high in terms of QIR) may not be specifically relevant in any particular case. Further, the relevance of any one particular data item will vary between searches. Because of this, conventional search engines implement various methods for filtering, ranking and/or reordering search results to present them in an order that is believed to be relevant to the particular search query yielding those search results. This is known as “query-specific relevance” (hereinafter abbreviated “QSR”). Many parameters are typically taken into account when determining QSR. These parameters include: various characteristics of the search query; of the search requester; of the data items to be ranked; data having been collected during (or, more generally, some “knowledge” learned from) past similar search queries.
[0070] Thus, the overall process of executing a search query can be considered as having two broad distinct stages: A first stage wherein all of the search results are collected based (in part) on their QIR values, aggregated and ordered in descending QIR order; and a second stage wherein at least some of the search results are reordered according to their QSR. Afterwards a new QSR-ordered list of the search results is created and delivered to the search requester. The search result list is typically delivered in parts, starting with the part containing the search results with the highest QSR.
[0071] In the first stage, the collecting of the search results stops after some predefined maximum number of results has been attained or some predefined minimum QIR threshold has been reached. This is known in the art as “pruning”; and as it occurs, once the pruning condition has been reached, it is very likely that the relevant data items have already been located.
[0072] Typically, in the second stage, a shorter, QSR-ordered, list (which is a subset of the search results of the first stage) is produced. This is because an Internet search engine, when conducting a search of its data collection (which contains several billions of data items) for data items satisfying a given search query, may easily produce a list of tens of thousands of search results (and even more in some cases). Obviously the search requester cannot be provided with such an amount of search results. Hence the great importance of narrowing down the search results actually provided to the requester to a few tens of result items that are potentially of highest relevance to the search requester.
Click-Through Data
[0073] One of the ways in which the system narrows down the search results is by using “knowledge learned” by from past similar search queries. One very important type of such information from previous search queries is what is termed “click-through” data. At the end of any search query execution, the search requester is usually presented with a search engine result page (“SERP”) that shows a portion of the search results. On the SERP, each data item being a search result is typically shown with its title, a hyperlink to the data item's location on the Internet, and a “snippet” (a short citation from the body of the data item typically containing some or all of the search terms of the search query). The information shown on the SERP can be used by the search requester in selecting the data items most interesting to them for further inspection. Typically, the search requester selects just a few of the data items, by clicking on their hyperlinks, to open them for further reading. Thus, many other data items are left alone without too much attention having been paid to them. While not every data item clicked on (“clicked through to”) by the search requester will be considered by them as an interesting data item, those “clicked through” data items can nevertheless be considered on average as a group as being of greater interest to the search requester than those data items not clicked through. Such clicked through data items can thus be considered as being of a higher QSR with respect to that search query than the non-clicked through data items.
[0074] Such “click through” data is conventionally stored in the search engine's database(s). This information can be very helpful for future similar search queries as it can be used later to improve the QSR-ranking of the search results (for future search queries with the same or mostly the same search terms). When ranking the search results of such a future search query, click-through data from past similar queries can be used to assign the clicked-through data items a higher QSR. Thus, such data items can be shown to the then current search requester before other data items having been found during the result collecting stage (the first stage) of the current search query but that were not clicked-through in the past in respect of similar search queries.
[0075] Search Engines—Server Types & Functionalities
[0076] Referring to FIG. 4 , in one implementation, an Internet search engine system 100 of the present technology, includes four different types of servers (or groups of servers), shown in FIG. 4 as “web-crawler” server 112 , “indexing” server 114 , “searching” server 116 , and “query” server 118 , which are each individually described below.
[0077] Web-crawler server 112 implements an Internet “web crawler”, whose function it is to seek out and collect copies of webpages from the World-Wide Web (shown as “Web” 128 in FIG. 4 ) and store each of those pages as “data items” in the “data items” database 120 . For each data item, web-crawling server 112 calculates and stores in the data items database 120 a “query-independent relevance” (“QIR”) value. (In some other systems, this functionality may be carried out by a separate server that is independent of the web-crawler server 112 .)
[0078] Indexing server 114 is an indexing server that (re)numbers the data items in the data items database 120 . (Indexing server 114 thus received the QIR value for each data item from the web-crawler server 112 .) Indexing server 114 also creates and maintains an inverted index in the data items in the “inverted index” database 122 . Thus, indexing server 114 is responsible for actually reviewing each data item and determining what key words are in the data item and then inserting a posting to the relevant posting lists in respect of that data item.
[0079] Searching server 116 is a searching server that receives search queries from query server 118 (see below), performs searches across the inverted index stored in the inverted index database 122 in respect of such search queries, and builds a QIR-ordered search result list.
[0080] Query server 118 is a query server that receives and parses search queries from search requesters (represented by personal computer icon 126 ); and for each search query received, query server 118 initiates a search operation by the searching server 116 . Query server 118 obtains the QIR-ordered “search result list” from searching server 116 in respect of the search. Query server 118 calculates for at least some of the data items in the search result list a “query-specific relevance” (“QSR”), and query server 118 builds a QSR-ranked search result list in respect of the search. Query server 118 also builds the visual presentation for the search list. Query server 118 extracts a “title” and a query-specific “snippet” from the data items database 120 (not particularly shown in the drawings) for each data item in the search result list. Query server 118 delivers to the search requester 126 portions of the QSR-ranked search list, together with their titles and snippets, and the visual presentation to be used.
[0081] Query server 118 further records the search requester's actions of “clicking through” on some of the data items shown to them as part of the search results, and stores appropriate data regarding such click-throughs in its “query database” 124 . Query server 118 also searches information regarding past queries in the query database 124 when preparing the search results for a current query and defines the QSR-ranking of at least some search results as a function of the information found in the query database 124 before delivering the search results to the search requester.
Search Engines—Server Operations
[0082] Having described the general overall functions of each of the servers 112 , 114 , 116 , and 118 , some of the specific operations of the servers 112 , 114 , 116 and 118 will now be described. In this respect, web-crawling server 112 implements a web crawler that (permanently or periodically—as the case may be) explores the World Wide Web finding new (or recently updated) web pages (illustrated by data path 130 ). For each such web page that is found a data item is created in the data items database 120 (illustrated by data path 132 ). Each data item in the data items database 120 includes a local copy of the corresponding web page on the Internet, a hyperlink to the original web page on the Internet (also called its web address), and a set of data-item attributes that were assigned to the data item during the course of its processing by the search engine system 100 .
[0083] With respect to any new data item, the first operation carried out is to define that data item's QIR value. As QIR values are used for data items ordering, they are typically implemented as a numerical (although not necessarily an integerial) characteristic of a data item. A QIR value is calculated by the search engine system 100 using many different attributes of the data item itself (including, but not limited to, its title, creation date, original web page location, etc.), and using the number and qualities of references to that data item on other Web pages, and likely also using some “historical” data having been “learned” by the system 100 from data items having been previously entered into the system, from previously executed search queries, and other conventionally-used information. In this respect, there exist a few methods that are well-known in the art for defining a QIR value in a practical suitable manner In most Internet search engine systems, the calculation of a QIR value for each new data item is performed by the web-crawler server 112 ; however in some others it is performed by a different server, such as, for example, indexing server 114 or a dedicated QIR server.
[0084] Each data item stored in the data items database 120 is known within the system 100 by its unique system-assigned identifier, which is typically an ordinal number. Typically, the entire collection of data items managed by a large Internet search engine is too large to be contained on one database server, and thus it is customarily split into several database “shards”. Where such is the case, each shard will typically have its own data item numbering scheme and its own logic for performing a search on its portion of the document database. When executing a search query each of the partial per-shard search result lists, once generated, are merged into one common QIR-ordered list, which is then QSR ordered.
[0085] Data items are numbered by the system 100 in descending order of their QIR, rather than in the order that they were obtained by the web-crawler server 112 . Data items having the same QIR can be numbered in any order, for example in inverse chronological order (the latest data items being assigned lesser numbers, in order to be found before the earlier ones). Hence, if a newly received data item D appears to have its QIR value less than that of an existing data item (say #999), but greater than or equal to the QIR value of the next data item (#1000), then D will be assigned #1000, while the old #1000 will become #1001 and so on. Hence, both the data item numbers and the content of the inverted index (see below) are permanently and periodically updated. Typically, the data item (re)numbering operation is performed by the indexing server 114 , but this is not required to be the case.
[0086] Once a data item (e.g. D) is received by the web crawler server 112 , stored in the data items database 120 , assigned its QIR value, assigned its data item number (e.g. #1000), it is passed on to the indexing server 114 (data path 134 on FIG. 4 ) for further processing by the latter (bidirectional data path 136 ). The indexing server 114 manages its database 122 (bidirectional data path 138 ), which basically comprises an inverted index of the data item collection contained in the data items database 120 .
Postings & Posting Lists
[0087] As was described hereinabove, the inverted index basically comprises a number of posting lists. The indexing server 114 inspects the new data item #1000, discerns in it various “searchable terms”, and for each searchable term found in the data item it creates a new entry (e.g. a “posting”) in the appropriate posting list.
[0088] A posting in a posting list basically includes a data item number (or other information sufficient to calculate a data item number), and optionally includes some additional data.
[0089] Every posting list corresponds to a searchable term, and comprises a series of postings referencing each of those data items in the data items database 120 that contain at least one occurrence of that searchable term.
[0090] Additional data may also be found in a posting; for example, the number of occurrences of a given searchable term in a given data item; whether this search term occurs in the title of the data item, etc. This additional information may be different depending on the search engine.
[0091] Searchable terms are typically, but not exclusively, words or other character strings. A general use Internet search engine typically deals with practically every word in a number of different languages, as well as proper names, numbers, symbols, etc. Also included may be “words” having commonly found typographical errors. In the present specification, any such searchable term may be referred to as a “word” or a “term”. For each searchable term that has been encountered in at least one data item, the indexing server 114 updates the corresponding posting list, or creates a new one if the term is being encountered for the first time. Hence the total number of posting lists may be as large as a few million. The length of a given posting list depends on how commonly used the corresponding word is in the data items universe (e.g. on the Internet). A very commonly used word may have a posting list of as long as one billion entries (or even more—there is no limit). (In practical use, when the data items database 120 is split into several “shards”, each shard maintains its own separate inverted index 122 , thus greatly reducing the length of posting lists in each shard.)
[0092] In each posting list, data item postings are placed in an ascending order of their data item numbers, that is, in the descending order of their QIR. Hence, the process of indexing a new data item D is not limited to inserting the data item number of D, say #1000, into the posting list of every word T 1 occurring in D. Rather, when assigning to D an already existing data item number #1000, every existing posting in every posting list, to data item number equal or greater than #1000, must be updated (incremented by 1 in this example). In actuality, search engines typically perform this update operation periodically for batches of data items having been received since the previous time that the inverted index database 122 was updated.
Execution of Search Queries
[0093] Data items stored in the data items database 120 and indexed in the inverted index database 122 can then be searched for. Again with reference to FIG. 4 , search queries are made by human users (“search requesters” which are collectively depicted on FIG. 1 by an image of a personal computer 126 ) and are received by the query server 118 (data path 150 in FIG. 4 ). The query server 118 parses each search query received into its various search terms (which may include optionally dropping auxiliary words such as prepositions and conjunctions not to be searched for because of their ubiquity), and may also perform some other convention actions. For example, a search query Q 1 , received at time t 0 , may comprise four search terms T 1 , T 2 , T 3 , T 4 , which may be denoted as Q 1 [T 1 ,T 2 ,T 3 ,T 4 ].
[0094] The query Q 1 is then passed by the query server 118 to the searching server 116 (data path 144 ). The latter basically operates on the inverted index database 122 , that is, on the inverted index with its many posting lists. In this example, the search process, or execution of a search query, consists of finding the data item numbers of all those data items that contain occurrences of each search term specified in the search query (as was discussed above this is the simplest form of a search process; in a further example described below a quorum principle will be introduced). Typically, this is done by exploring in parallel each of the posting lists corresponding to the search terms of the query, starting from the beginning of each posting list. In the present example, posting lists P 1 , P 2 , P 3 , P 4 correspond to the search terms T 1 , T 2 , T 3 , T 4 respectively. (In a more general manner the posting list corresponding to a term T n is denoted in this specification as P n ). A data item whose number is encountered in each posting list relevant to the search query is considered to be a search result (sometimes also called a “hit”), and is placed in a search result list as the search result list's then next element (i.e. after hits already having been placed in the result list). In this way, the search result list of a search query is in ascending order of data item numbers, and thus in descending order of QIR value.
[0095] This procedure of finding further search results stops either when reaching the end of one of the posting lists, or when some “pruning condition” (as was mentioned above) has been satisfied. In various examples, the pruning condition might, for example, be defined by the query server 118 on a per query basis and provided with each query Q by the query server 118 to the searching server 116 ; alternatively the pruning condition might be fixed with respect to the system and be the same for all queries. In either case, the pruning condition could be expressed, for example, as a maximum number of data items in the search result list, or as a minimum QIR value for a data item to be included in the search result list, or in another different conventional matter. In any case, application of a pruning condition is supposed to “pick” the best results in terms of their QIR.
[0096] The search result list prepared by the search server 116 for a given query, e.g. for Q 4 , is then sent back by searching server 116 to the query server 118 (data path 142 ). (In the following description the search result list for a query Q m is denoted as “R(Q m )”, with each of the individual listings in list R(Q m ) being denoted R y (Q m )). In terms of two-stage query execution described above, the first stage—collection of search results—is now terminated, and the second stage, that of ranking, or reordering, of the search result list starts. In this respect, the query server 118 , before delivering the results to the search requester, reorders them in a way presumably most suitable for this particular given query, by placing at the highest positions in the list those search results (data items) that have the highest query-specific relevance (QSR) for that particular given query. This QSR-ranking and reordering of the originally QIR-ordered search result list is probably the most sophisticated operation performed by a Web search engine, and the one most influencing final user (e.g. search requester) satisfaction.
[0097] In order to define in a best QSR ranking for a particular given query, information from many different sources is taken into account at the same time. Part of the information used assessing the QSR of a data item may be found in the data item itself; for example, the total number of occurrences in the data item of each search term of the given search query; occurrences of two or more of the search terms found in close proximity to each other (e.g. in the same phrase), or, yet better, following each other in the same order as in the search query; search terms found in the title of the document, etc. However, all these are limited-scope criteria that might not necessary reflect the level of “user satisfaction” with a given data item in the context of a given particular query.
[0098] Web search engines make use of historical information collected from a large quantity of previously executed search queries, and stored in a database. This “query database” is shown on FIG. 4 in association with reference number 124 , and accessed by the query server 118 via bidirectional data-path 146 . From each query, diverse information can be extracted, stored and processed, and then used for better QSR-ranking of results for the next query. In the context of the present example, only “click-through” data as was briefly discussed above is considered to be relevant. In this respect, a user U 1 having made a search query, say, Q 1 [T 1 ,T 2 ,T 3 ,T 4 ], receives from the query server 118 a list of search results having been found for the query by the searching server 116 and further having been ranked by the query server 18 (as was previously discussed above). In many cases the list is very long, so it is sent to the user in portions (or “pages”) of, for example, 120 entries each. Every entry is “clickable”, that is, if clicked by the user with their mouse or other pointing device, causes the data item to open, for example, in another window or another tab of the browser application on the user's computer. It is likely beneficial for the user to be provided with a quick glance at each of the search results prior to opening them, so that they do not waste their time having to open data item after data item trying to locate the right one. To that end, the query server 118 typically provides the user with a “snippet”, a short citation (or a few yet shorter fragments collected together) from the data item where the requested search terms occur in a presumably self-explanatory context. After looking at the snippet (as well as the other information provided) the user can decide whether to open the data item (by “clicking through” to it), or not.
Illustration of Use of Click-Through Data
[0099] Upon opening a data item, the user can look at it more carefully and decide whether it is definitely of interest to them or not. While the search engine has no way of explicitly “knowing” whether or not the data item is of interest to the user, the search engine can record the mere fact of the user having clicked-through to a given data item appearing on the search result page. This is because the search result page is typically provided to the user by the search engine in a Web application that is typically programmed in a way that every “click-through” action on the page is first sent back to the search engine (in the present example to query server 118 of the system 100 ). The query server 118 then redirects the user to the web-page of the requested data item (or, alternatively, shows them a copy of the data item stored in the data items database 120 ). In this way, the query server 118 is capable of recording all the click-through actions performed by users on search result pages provided to them.
[0100] It has been statistically verified that, among search results of a query that have been effectively shown to the query issuer, those that have been clicked-through by them were on average of more interest to them than those not clicked-through. Moreover, the last clicked-through data item in the list, that is, the one after which the user stopped further inspection of the list and did not click through to any other items, has proven to be on average of yet more interest to the user than all the previously clicked-through documents. These statistical considerations and “click-through history” are used for better ranking a search result list for every next search query, by using the “click-through history” from past search queries.
[0101] The query database 124 stores click-through data from past queries in the form of records <D k ; Q m [T 1 ,T 2 ,T 3 , . . . T n ]> indicating that the document D k had been clicked through by the issuer of the query Q m [T 1 , T 2 , T 3 , . . . T n ] when he/she was exploring the search results for that query. Optionally, there could also be recorded (and then used at same later time) data with respect to the search requester (e.g. their IP address), the query execution time; etc. The above collection of records represents a database that can be sorted by documents clicked through, or by some or all the search terms used in queries, or in any other way.
[0102] In FIG. 5 , for example, the user U 1 issues a query Q 1 [T 1 ,T 2 ,T 3 ,T 4 ], which is executed by the searching server 116 by examining the posting lists P 1 , P 2 , P 3 , P 4 of the search terms T 1 , T 2 , T 3 , T 4 (respectively) of the search query Q 1 . Illustratively, a data item D 1 (more exactly, a posting (i.e. a reference) to D 1 ) is found in each of these posting lists; hence D 1 is included in the search result list R(Q 1 ) for the query Q 1 . The search result list is, after some QSR reordering, presented to the user U 1 . The user U 1 clicks through the entry corresponding to the data item D 1 in the list, considering that it might be of interest to them. (The fact of a data item having been clicked through is schematically indicated on both FIG. 5 and FIG. 6 by an asterisk “*”.) This information is stored in the query database 24 as a record <D 1 ; Q 1 [T 1 , T 2 , T 3 , T 4 ]>.
[0103] At some later point in time, by comparing queries with “almost the same” search terms, and/or with “mostly the same” search result lists, especially those with “mostly the same” subsets of their “clicked-through” results, the system 100 (namely, its query server 118 ) can establish some “degree of similarity” among past queries, and also between a next query, e.g. Q 2 , and some of the past queries, e.g. Q 0 . As how this occurs is both complicated and conventional the details thereof will not be discussed herein; what is important for present purposes is to understand how information from past queries similar to a current query Q 2 is conventionally used to help a search engine to deliver more appropriate results to the current search requester.
[0104] In this respect, if a then current query, e.g. Q 2 , is found to be similar to some past query, e.g. Q 1 , and if among the search results for Q 2 there is a data item D 1 , for which a record <D 1 ; Q 1 [ . . . ]> exists in the query database 124 , signifying that the document D 1 was among the results for Q 1 as well, and, moreover, had been clicked through by a past issuer of Q 1 , then the data item D 1 is considered as being of higher QSR for Q 2 than other results for Q 2 with same or similar other characteristics. In other words, the above criterion of “having been clicked through in one or more past similar queries”, while not decisive, is used as one of the criteria capable of increasing the QSR of D 1 for Q 2 , and hence of pushing D 1 higher in the ordered list of search results for Q 2 . Thus D 1 will be shown to the search requester in the search result list at an earlier time (i.e. at a higher position in the list) than it would have been had D 1 not previously been clicked through.
[0105] This is illustratively shown on FIG. 5 . A user U 2 (which may be the same as U 1 or may be another user) issues a search query Q 2 [T 1 ,T 2 ,T 4 ,T 5 ] that differs from the previously considered query Q 1 [T 1 ,T 2 ,T 3 ,T 4 ] in that it does not include the search term T 3 , but rather includes some other search term T 5 instead. Again, the searching server 116 looks through the posting lists corresponding to the search terms, this time the posting lists P 1 , P 2 , P 4 , P 5 corresponding to search terms T 1 , T 2 , T 4 , T 5 of the query Q 2 . (In FIG. 5 this is shown in a second image of the indexing database 122 , denoted 22 ( 2 ).) Illustratively, the same document D 1 is again found in each of the posting lists; hence D 1 is included in the search result list R(Q 2 ) for query Q 2 . However, this time the result list R(Q 2 ) contains too many other documents of presumably higher relevance to the user U 2 , for the document D 1 to be even shown to them. This is illustratively depicted on FIG. 5 by placing D 1 in a lower position within the list R(Q 2 ).
[0106] In according to conventional use of click-through data, however, the query server 118 (not shown on FIG. 5 ), before presenting the result list R(Q 2 ) to the user U 2 , looks up in the query database 124 , and finds there (amongst probably other information) the previously stored record <D 1 ;Q 1 ,[T 1 ,T 2 ,T 3 ,T 4 ]> showing that the document D 1 had been clicked through in one of the previous queries, namely in the query Q 1 [T 1 ,T 2 ,T 3 ,T 4 ] that differs from the then present query Q 2 [T 1 ,T 2 ,T 4 ,T 5 ] by just one of their four search terms. Considering that the fact that it had been clicked through brings some additional value to D 1 , the query server 118 now upgrades the document D 1 to a higher position in the list R(Q 2 ), as shown by a dotted-arc arrow on FIG. 5 , such that D 1 will now be presented to user U 2 .
[0107] FIGS. 7A, 7B, and 7C show a SERP 200 A of the Yandex™ search engine system for the search query “home gym”, via the Yandex Search app for iOS running on an Apple™ iPhone™ smartphone. The SERP 200 A was generated in accordance with the procedure set forth above, which, for purposes of brevity, will not be repeated here. The search results are listed in QSR order, as the query server 118 has determined (via information stored in Query database 124 ) that, because the search results are being accessed via a smartphone app, the probable user search result interaction sequence is the QSR.
[0108] Thus, starting from the top of the SERP 200 A, the first listed search result 201 A is URL stronglifts.com/home-gym equipment . . . 211 , along with the title of the resource that is found at URL 211 , and a textual snippet of the information provided by the resource. The second listed search result 202 A is URL home-gym-bodybuilding.com/my-home . . . 212 , along with the title of the resource that is found at URL 212 , and a textual snippet of the information provided by the resource. The third listed search result 203 A is URL www.reddit.com/r/homegym/ 213 , along with the title of the resource that is found at URL 213 , and a textual snippet of the information provided by the resource. The fourth listed search result 204 A is an image selector widget 214 . The fifth listed search result 205 A, is a URL decoist.com/2013-11-30/home-gym . . . 215 , along with the title of the resource that is found at URL 215 , and a textual snippet of the information provided by the resource. The sixth listed search result 206 A, is a URL homedesignlover.com/ . . . cool-home-gym . . . 216 , along with the title of the resource that is found at URL 216 , and a textual snippet of the information provided by the resource. The seventh listed search result 207 A is a video selector widget 217 . The eighth listed search result 208 A is a URL www.t-nation.com/ . . . home-gym, along with the title of the resource that is found at URL 218 , and a textual snippet of the information provided by the resource. The ninth listed search result 209 A is a URL www.facebook.com/ . . . , along with the title of the resource that is found at URL 219 , and a textual snippet of the information provided by the resource.
[0109] FIG. 8 , by contrast, shows a SERP 200 B of the Yandex™ search engine system for the search query “home gym”, via a desktop web browser at the URL www.yandex.com. The SERP 200 B was generated in accordance with the procedure set forth above, which again, for purposes of brevity, will not be repeated here. The difference between SERP 200 B and SERP 200 A, which are for identical search terms, is that query server 118 has determined (via information stored in Query database 124 ) that, because the search results are being accessed on a desktop browser, probable user search result interaction sequence is not the QSR. Therefore, the query server 118 has provided instructions to display the search results in not in accordance the QSR, but in accordance with the probable user interaction sequence. This results in SERP 200 B being visually configured differently from SERP 200 A.
[0110] Starting from the top starting from the top of the SERP 200 B, the first listed search result 201 B is URL home-gym-bodybuilding.com/my-home . . . 212 , along with the title of the resource that is found at URL 212 , and a textual snippet of the information provided by the resource. As can been seen in FIGS. 7A-C , however, URL 212 is actually the second search result in terms of QSR.
[0111] The second listed search result 202 B is URL stronglifts.com/home-gym equipment . . . 211 , along with the title of the resource that is found at URL 211 , and a textual snippet of the information provided by the resource. As can been seen in FIGS. 7A-C , however, URL 211 is actually the first search result in terms of QSR.
[0112] The third listed search result 203 B is URL www.reddit.com/r/homegym/ 213 , along with the title of the resource that is found at URL 213 , and a textual snippet of the information provided by the resource. As can been seen in FIGS. 7A-C , URL 213 is also the third search result in terms of QSR.
[0113] The fourth listed search result 204 B is an image selector widget 214 . As can been seen in FIGS. 7A-C , image selector widget 214 is also the fourth search result in terms of QSR.
[0114] The fifth listed search result 205 B is a video selector widget 217 . As can been seen in FIGS. 7A-C , however, video selector widget 217 is actually the seventh search result in terms of QSR.
[0115] The sixth listed search result 206 B, is a URL decoist.com/ 2013 - 11 - 30 /home-gym . . . 215 , along with the title of the resource that is found at URL 215 , and a textual snippet of the information provided by the resource.
[0116] The seventh listed search result 207 B, is a URL homedesignlover.com/ . . . cool-home-gym . . . 216 , along with the title of the resource that is found at URL 216 , and a textual snippet of the information provided by the resource. As can been seen in FIGS. 7A-C , however, URL 216 is actually the sixth search result in terms of QSR.
[0117] The eighth listed search result 208 B is a URL www.t-nation.com/ . . . , home-gym, along with the title of the resource that is found at URL 218 , and a textual snippet of the information provided by the resource. As can been seen in FIGS. 7A-C , URL 218 is also the eighth search result in terms of QSR.
[0118] The ninth listed search result 209 B is a URL www.facebook.com/ . . . , along with the title of the resource that is found at URL 219 , and a textual snippet of the information provided by the resource. As can been seen in FIGS. 7A-C , URL 219 is also the ninth search result in terms of QSR.
[0119] Thus, Query server 118 has derived based on previous user interactions with search results that a probable user interaction sequence with the SERP 200 B is first looking at the second listed search result 202 B, then next looking at the first listed search result 201 B, then next looking at the third listed search result 203 B, then next looking at the fourth listed search result 204 B, then next looking at the sixth listed search result 206 B, then next looking at the seventh listed search result 207 B, then next looking at the fifth listed search result 205 B, then next looking at the eighth listed search result 208 B, and finally looking at the ninth listed search result 209 B. Thus the search results in terms of QSR are actually visually configured on the page in terms of that probable user interaction sequence.
[0120] Modifications and improvements to the above-described implementations of the present technology may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present technology is therefore intended to be limited solely by the scope of the appended claims. | Method of furnishing search engine system search results, comprising: Receiving a search query including information indicative of a property of an application originating the search query. Effecting a search of posting lists to determine search results in respect of the search query, the search results having a relevance rank order. Determining a probable user search result interaction sequence based on information related to previous user interactions with search results having been provided by the system and based on the information indicative of the property of the application originating the search query. The probable user search result interaction sequence being different from the relevance rank order of the search results. Sending the search results, including information allowing for visual configuration of the search results provided to the user by the application originating the search query according to the probable user search result interaction sequence, while maintaining the relevance rank order. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to a hair-cutting system, and more particularly to a hair-cutting system or hair clipper with a visualization capability.
BACKGROUND OF THE INVENTION
[0002] Electric hair clippers or trimmer are commonly used by stylists, barbers, or individuals for styling the hair of others. However, it is needed to provide a hair-cutting system or clipper (interchangeable here) designed specifically for self-cutting. One such self-cutting electric hair-cutting clipper (e.g., commonly-assigned U.S. Pat. No. 7,281,461, to McCambridge et al, issued on Oct. 16, 2007, and incorporated by reference herein) provides effective guiding of hair into or retaining of hairs in a cutting zone of a bladeset and easy holding capability of a hair clippers. However, '461 patent does not provide visualization capability. Although with helping of mirror a person can see partially his or her hair during self-cutting process, it is difficult to cut and style his or her hair on the backside and the top of his or her head. To address this problem, this is a need for improving visualization capability of a hair-cutting clipper.
SUMMARY OF THE INVENTION
[0003] To address the needs described above, the present invention disclosed a hair-cutting system with a visualization device that includes a video camera and a lighting device attached to an electrical hair-cutting clipper. More specifically, said hair-cutting system includes at least one video camera, at least one display device, at least one hair-cutting clipper, at least one video-device-holder which holds said video camera and said hair-cutting clipper together. Such hair-cutting systems are designed for use by an individual in cutting his or her own hair, and also for use by one person to cut the hair of another.
[0004] One can use the hair-cutting system proposed in present disclosure during his/her self haircutting, as shown in FIG. 1 , especially cutting the hair he/she usually cannot see from a mirror such as the hair on the backside or the top of his/her head. For example, one activates the video camera and the display in present disclosure by plugging them into electrical power outlets and then connects the video camera with the display so that the pictures taken by the video camera can be shown on the display. When he or she is cutting his or her hair, the video camera is taking video or pictures at the same time. He/she can see the video or pictures from the display in his/her front, which can help him/her to create hairstyle that he/she wants.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows an example how to use the present hair-cutting system.
[0006] FIG. 2 is the present hair-cutting system includes a video device, an illumination device, a hair-cutting clipper, video-device-holder which holds said video device and said hair-cutting clipper, and a display.
[0007] FIG. 3 shows the present hair-cutting system that includes: a video device; a video-device-holder which uses velcro to hold the video device; the video-device-holder comprising a adjustable arm; an illumination device; a hair-cutting clipper; a computer or a laptop comprising at least one display device.
[0008] FIG. 4 is the present hair-cutting system includes a video device; a hair-cutting clipper; a video-device-holder which holds said video device and said hair-cutting clipper together; an illumination device; a computer or a laptop comprising at least one display device. Said video-device-holder comprising a fixed arm that is preferably located the bottom area of said hair-cutting clipper.
[0009] FIG. 5 is the present hair-cutting system includes a video device; a hair-cutting clipper; a video-device-holder which holds said video device and said hair-cutting clipper together; an illumination device; a computer or a laptop comprising at least one display device. Said video-device-holder comprising a fixed arm that is preferably located the top area of said hair-cutting clipper.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] Hair-cutting systems with visualization devices are disclosed. One can use the hair-cutting systems to cuts his/her own hair. He or she can use the visualization devices to watch a video or pictures in the area where usually cannot be seen when he or she cuts his/her own hair such as the backside or the top of his or her head. It is very helpful for a person who wants to get hair cut and to create any hairstyle by his or her own and improve hair cut quality. It is also useful for a customer to monitor his/her hairstyle when he or she gets a hair cut from a barber.
[0011] FIG. 1 is a schematic for using a haircutting system. One can use the haircutting system proposed in present disclosure to cut his/her own hair, especially cutting the hair he or she cannot see from a mirror such as the hair on the backside or the top of his or her head. For example, one connects the video camera with a display so that the video or pictures taken by the video camera can be shown on the display. When he/she is cutting his/her own hair, the video camera takes video or pictures at the same time. He/she can see the video or pictures from the display in his/her front, which can help him/her to create hairstyle that he/she wants or improve hair cut quality.
[0012] As shown in FIG. 2 , in one embodiment, a hair-cutting system includes a video device of 101 , an illumination device of 102 , a video-device-holder of 103 which holds both said video device, a hair-cutting device of 106 , and a display of 107 . A cable 101 a connecting said video and said display device. The video-device-holder of 103 holds the video device of 101 at one end and holds the hair-cutting device of 106 at another end. The video-device-holder 103 comprises, in one embodiment, an adjustable arm of 103 and a screw 104 that is used to adjust the angle 108 by loosing and tightening the screw 104 . One embodiment, by adjusting the angle of 108 the video device 101 and illumination device 102 preferably focus on the area where the hair is being cutting. In another embodiment, the video-device-holder 103 is foldable.
[0013] In one embodiment, during a process of a hair cutting, the video device 101 takes video or pictures of the area where the hair is being cutting and transmits the video or pictures to the display 107 . In another embodiment, during a process of a hair cutting, the video device 101 takes video or pictures of the area where the hair is being cutting and transmits the video or pictures to a computer and then to the display 107 . In one embodiment, a screw 105 on the video-device-holder 103 is used to mount the video-device-holder 103 to the hair-cutting device 106 .
[0014] In another embodiment, shown in FIG. 3 , a hair-cutting system includes: a video device 201 ; a video-device-holder 202 which in one embodiment uses velcro to hold the video device; a cable 203 for video device; a holder 204 for holding the cable 203 ; a plug 205 of video device 201 to connect the computer 212 ; the video-device-holder 202 comprising a adjustable arm 206 ; an adjustable angle 208 in the adjustable arm 206 ; a screw 207 used to adjust the angle of 208 ; a mounting screw 209 in the video-device-holder 202 ; an illumination device 210 ; a hair-cutting device 211 ; a computer or a laptop 212 comprising at least one display device; a keyboard 213 of the computer or laptop (in dashed line or covered by the cover of 214 ); keyboard cover 214 ; and a computer mouse 215 .
[0015] In yet another embodiment, shown in FIG. 4 , a hair-cutting system includes: a video device 301 ; a video-device-holder 302 which in one embodiment uses velcro to hold the video device; a cable 303 for video device; a holder 304 for holding the cable 303 ; a plug 305 of video device 301 to connect the computer 309 ; an illumination device 307 ; a hair-cutting device 308 ; a computer or a laptop 309 comprising at least one display device; a keyboard 310 of the computer or laptop (in dashed line or covered by the cover 311 ); and a keyboard cover 311 . The video-device-holder 302 comprising a fixed arm 306 that is preferably located the bottom area 320 of the hair-cutting device 308 .
[0016] In further another embodiment, shown in FIG. 5 , a haircutting system includes: a video device 401 ; a video-device-holder 402 ; a cable of the video device 403 ; a holder 404 of cable 203 ; a plug 405 of video device 401 to a computer 409 ; a supporting arm 406 of the video-device-holder; an illumination device 407 ; a hair-cutting device 408 ; a display device and computer 409 ; a keyboard 410 of a computer or laptop (in dashed line or, covered by the cover 411 ); a keyboard cover 411 to protect the computer or laptop keyboard 410 during haircut; a bottom part 420 of the hair-cutting device 408 ; and a top part 421 of the hair-cutting device 408 . The video-device-holder 402 comprising a fixed arm 406 that is preferably located the top area 421 of the hair-cutting device 408 . | Hair-cutting systems with a visualization device are disclosed in present invention. The air-cutting systems include a video camera and a lighting device attached to an electrical hair-cutting clipper. Such hair-cutting systems are designed for use by an individual in cutting his or her own hair, and also for use by one person to cut the hair of another. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to drying of traveling webs and, more particularly, the drying of a newly formed paper web on a papermaking machine.
Prior dryer arrangements pertaining to double felts, impingement drying (moving hot air against the wet surface) or through air drying (blowing heated air through the web) either guide the bare web onto the dryer shell without support or sandwich it between two felts while carrying it on the dryer roll. Sometimes, a single felt is used in combination with an impingement and/or vacuum arrangement to promote removable of moisture.
All of these arrangements have deficiencies and inefficiencies which become especially troublesome when it is desired to operate at or near the fastest speed the machine is designed for. Such inefficiencies are usually manifested by the web billowing off the dryer roll surface or edge flutter, both of which contribute to web breaks, or simply a decrease in the drying rate as the web passes over the dryers. When speeds increase, the rate of drying must also increase in order to keep the web dryness at the end of the machine within predetermined limits. Double felted air impingement dryers have sometimes required a special, endless belt-like arrangement in addition to the top felt in order to keep the web from fluttering under the force of the impinging air. On configurations wherein both felts track over conventional dryer shell surfaces, web billowing is suppressed, but so is the rate of moisture removal. Furthermore, additional equipment must then be used to remove moisture from the felts in the gaps between dryer rolls. On through air drying arrangements wherein the web is carried on a single felt or belt, the web stability due to edge flutter is impaired as it must travel between dryers without support on one or both sides.
In summary, prior art arrangements have tended to sacrifice drying capacity and efficiency for speed and vice versa.
SUMMARY OF THE INVENTION
This dryer arrangement utilizes the web stabilizing characteristics of a double felt while combining it with hot air drying through the web and one felt for more efficient drying. Since the impinging hot air only travels through the web and one felt, less fan power is required and it is easier to remove the water by either evaporation or physically blowing the water droplets out of the permeable web.
Initially, the web is received and held between two felts and guided onto the surface of a dryer whereupon the uppermost felt is drawn away leaving the exposed web and lowermost felt positioned and supported on the surface of the foraminous dryer roll shell. The upper felt is guided back onto the web and lower felt just prior to the point where they are all removed from the dryer and directed to the next dryer where the procedure is repeated.
A hot air impingement blower is positioned above the periphery of a portion of each dryer roll to direct hot air onto and through the web and single felt while they are on its surface, and a vacuum chamber is positioned within each dryer roll shell opposite the blower to hold the web onto the dryer and promote travel of hot air through the web.
An object of the invention is to provide a web dryer arrangement having positive control of the web throughout the length of the dryer section.
Another object of the invention is to provide a double felted dryer having improved web drying effectiveness.
Still another object of the invention is to provide a double felted web dryer arrangement which utilizes forced hot air and a corresponding air receiving chamber within each dryer unit.
A feature and advantage of the invention is that two identical felts can be used and neither special felt moisture removal equipment nor web hold down belts is required.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic side elevational view of a papermachine dryer section illustrating the path of travel of the felts and web.
FIG. 2 is a plan view of the bottom wall of the hot air blower plenum chamber showing the holes which serve as the air impingement nozzles.
FIG. 3 is a sectional view of a dryer roll shell showing the web and felt positioned thereon and the perforations through which air is received into the vacuum chamber within the dryer roll.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment is described in conjunction with a paper web as produced on a papermaking machine and the dryers are rotatable rolls positioned in the staggered array commonly used in the paper industry. However, it is anticipated that other kinds of webs, such as textiles, could also be dried well with this apparatus. Also, it is contemplated that arcuate, non-rotatable, foraminous support surfaces could be used instead of rotatable rolls. In that case the felts would slide over the support surfaces.
As shown in FIG. 1, a paper web 8 is received between a first, upper felt 10 and a second, lower felt 12 which are traveling in the direction indicated by the arrowheads. A plurality of guide rollers 16-16u are mounted on framework (not shown) above and below the dryers 18-18e to move the felts and web into position onto and about the dryers.
In the drawings, lettered postscripts are used to designate multiple items of identical equipment or corresponding positions on separate items.
The web is held between the felts until they contact the surface of dryer roll 18 at point 22 where, or shortly thereafter, the outermost (upper) first felt 10 is guided away from the surface of dryer roll 18, about rollers 16, 16a and back onto the web at point 24 whereupon, or shortly thereafter, the two felts with the web in between are guided off dryer 18 and onto dryer 18a at point 22a. The web travel continues in the same manner along a serpentine path sequentially from dryer 18 to dryer 18e and the outermost felt is guided away from the web, over the guide rollers, and back onto the web before traveling to the next dryer.
Dryers 18-18e are shown arranged in upper and lower tiers with their corresponding upper and lower axes 26-26b, 28-28b, respectively, parallel and coplaner as is commonly done in the paper industry. However, the dryer rolls could be positioned in other arrangements with the axes of the dryers in the upper and lower tiers not necessarily coplaner.
The dryer rolls are rotatably mounted in the frame (not shown) and have an outer shell made foraminous, such as by perforating it with evenly spaced drilled holes or constructing it of an open, grid-like honeycomb fabrication. A cross section of a portion of a dryer roll outer shell 19 is shown in FIG. 3 which illustrates air flowing against the web 8, through felt 12 and holes 36 in the shell 19. Within each dryer roll shell, a chamber 20-20e is positioned to be between the points 22-22e, 24-24e where the double felts contact and leave the roll shell surface, respectively. A vacuum pump 30-30e is operatively connected to each chamber 20-20e, respectively, to receive and remove air and water vapor from the web and contiguous felt as well as to urge and maintain them against the roll shell surface.
Mounted about the periphery of each roll over that portion covered by the web and innermost felt (relative to the dryer shelf surface) is a hot air blower 15-15e. A plenum chamber 14-14e therein has a wall 32-32e, having openings, such as perferations 34-34e, which arcuately conforms to the roll shell surface as shown in FIGS. 2 and 3, to direct hot air against the web covered dryer roll surface.
In operation, when the felts having the web held therebetween arrive at point 22 on roll 18, the first felt 10, being the outermost felt on roll 18, is guided up and over hot air blower 15. This permits hot air to be blown directly onto the now exposed web 8. The vacuum chamber 20, which extends arcuately beneath the shell substantially from point 22 to point 24, urges the web onto the second felt 12 and roll surface to discourage billowing of the web off the surface. Such web billowing, if not eliminated, would either result in a web break or require reduced speed to prevent a web break, both of which are uneconomical and highly undesirable.
The removal of the outermost felt from the web opposite the vacuum chamber reduces the layers of material which the blower must push hot air through. This and the fact that the web surface is exposed to the hot air greatly increases the efficiency and effectiveness of the drying operation.
When the first felt again rejoins the web 8 and second felt 12 at point 24, the web is now positively supported by a felt on either side in the gap between successive dryers. When the felts and web bear on any of the lower tier dryers (having axes 28-28b), the first felt 10 becomes the innermost felt and the second felt 12 becomes the outermost felt. These "inner" and "outer" felt designations, with respect to the first and second felts, are reversed when referring to the upper tier dryers (axes 26-26b).
Thus, as the web travels from upper to lower dryers 18, 18a, 18b, 18c, 18d, 18e, the first and second felts alternate being adjacent the roll shell surface and being guided away from the roll and around the hot air blowers. Thus, both felts 10, 12, are utilized equally and are of identical construction, although they need not be. Furthermore, it is contemplated that both felts could be the open weave, fabric type to facilitate movement of air and water therethrough. Such fabrics are now sometimes made of plastic or fiberglass.
As the endless felts 10, 12 and web emerge from the late dryer contact point 24e, the felts are guided around rollers 16u, 16l 16m, back to the first dryer and the now dry web is guided away in the direction shown by the arrow.
At all times during the travel through the dryer section, web billowing over the dryer surface and edge flutter in the span along the path of travel between successive dryers is controlled and stabilized by either vacuum pressure or by virtue of being supported on both sides in the open span between dryer rolls. In addition, by temporarily removing the outer felt during the time the web is beneath the hot air blower, the insulating effect of the felts to heat transfer is greatly reduced, thus allowing greater drying effectiveness and efficiency. Also, each side of the web is alternately exposed to the hot, drying air. Less power is required to blow hot air, water vapor and particles out of the web, into and through the lower felt. This water vapor is then driven through the foraminous roll shell and into the vacuum chamber, which assists in removing it from the web and lower felt, where it is removed by the vacuum pump. Such a configuration results in an increase in drying effectiveness of 40-60% over an arrangement wherein both felts remain in contact with the web throughout its travel through the dryer section 18-18e. | A double felted dryer arrangement wherein a web to be dried is held between the felts and guided onto the surface of a foraminous dryer roll whereupon the outermost felt is guided away from the dryer and directed over a hot air blower mounted over the now exposed web carried on the innermost felt on the dryer shell surface. The hot air blowing on the web is complimented by an opposed vacuum chamber within the roll shell to promote improved through air drying web and web stabilization. | 3 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made without the support of the Federal Government.
FIELD OF THE INVENTION
The present invention relates generally to a portable device for heating the ends of plastic tubing to temporarily enlarge the diameter and increase the flexibility of the tubing to more easily connect with various fittings.
BACKGROUND OF THE INVENTION
In the following discussion, certain devices and methods will be described for background and introductory purposes. Nothing contained herein is to be construed as an “admission” of prior art. Applicant expressly reserves the right to demonstrate, where appropriate, that the articles and methods referenced herein do not constitute prior art under the applicable statutory provisions.
Methods in many, varied industries utilize plastic tubing for transporting liquids, with the plastic tubing connected to various fittings to allow, e.g., two lengths of tubing to be connected, or for one length of tubing to be connected to a valve or spigot. In many instances, the fitting comprises an elongated cylindrically-shaped body with at least one frustoconically-shaped tail portion that tapers from a larger size at the body of the fitting to a smaller-sized end over which the tubing is slid. The contact between the tubing and the tapered end of the fitting must be tight for the connection to be leak-proof.
In many applications, the slide-on connection between the tubing and the fitting is impeded by the diameter of the tubing and its lack of flexibility. One specific example is in the harvesting of maple syrup, where sap is harvested from a maple tree forest and a polyethylene tubing system is utilized to transfer sap from the tree to a container. The current method requires a scissor-like, hand-held tool with tubing clamps plus a significant amount of force to make the semi-rigid tubing slide over the fitting and complete a usable connection.
What has not been available until now is a portable device for heating the tubing ends to temporarily increase the diameter and flexibility of the tubing so desired connections can be more easily made by hand and tool free. The present invention meets this unmet need.
SUMMARY OF THE INVENTION
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the claimed subject matter will be apparent from the following written Detailed Description including those aspects illustrated in the accompanying drawings and defined in the appended claims.
The present invention relates generally to a portable device for heating the ends of plastic tubing so that the diameter of the heated portion increases slightly and the tubing becomes more flexible. The tubing thus heated requires significantly less effort to slide over a fitting in the process of making a connection. While cooling, the tubing diameter tends to contract back to its original dimension, compressing around the fitting and making a strong, leak-proof connection. The portability particularly is desired in locations not served by electricity.
In some embodiments, the present invention provides a portable device for heating tubing comprising: a portable device for heating tubing comprising: a power source; a thermostatically-controlled heating chamber connected to the power source, wherein the heating chamber holds and heats fluid to a working temperature; and a carrier for carrying the power source and heating chamber. In some aspects, the power source comprises means to adjust the temperature. In some aspects, the carrier is belt-mounted, and in some aspects the carrier comprises a shoulder strap. In some aspects, the power supply and heating chamber are secured in the carrier so that they remain securely in place while being carried and in operation, and in some aspects the carrier is designed to be free standing in an upright position. In preferred aspects of this embodiment of the invention, the heating chamber further comprises a leak-resistant cap, and in preferred aspects, the heating chamber is insulated to resist heat loss.
In some aspects of this embodiment of the invention the carrier further comprises a vessel containing the fluid that is used in the heating chamber, where the fluid has a boiling point above the desired temperature, and preferably is non-toxic to humans and inhibits microbe growth. In some aspects, the heating chamber is configured to heat tubing one inch or less in diameter, and in some aspects, the heating chamber is configured to heat tubing one-half inch or less in diameter. In some aspects, the heating chamber is configured to heat a length of the tubing substantially equal to the length of the receptor portion of the fitting.
In yet another embodiment, the invention provides a portable device for reshaping tubing comprising: a power source; a thermostatically-controlled, fuse-protected insulated heating chamber for holding fluid configured to heat tubing to a desired length; and a carrier for carrying the power source and heating chamber.
DESCRIPTION OF THE FIGURES
So that the manner in which the features, advantages and objects of the present invention described herein are attained and can be understood in detail, a more particular description may be had by reference to the embodiment illustrated in the appended Figure. It is to be noted, however, that the appended Figure illustrates only one embodiment of the invention, and therefore is not to be limiting to its scope, for the present invention may admit to other equally effective embodiments and industrial applications.
FIG. 1 is an illustration showing the device of the present invention according to one embodiment of the present invention.
FIG. 2 is an illustration of the heating chamber portion of the device.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous specific details are set forth to provide a more thorough understanding of the present invention. However, it will be apparent to one of skill in the art that the present invention may be practiced without one or more of these specific details. In other instances, well-known features and procedures well known to those skilled in the art have not been described in order to avoid obscuring the invention.
The present invention relates to a portable device for heating the end portion of plastic tubing to temporarily increase the diameter and flexibility of the tubing so that the tubing more readily slides onto fittings, and then contracts as it cools to provide a tight and secure coupling. The portability particularly is desired in locations not served by electricity such as outdoor environments. The portability and wearability of the device is particularly desired when hands-free work combined with mobility is important.
FIG. 1 is an illustration showing a device 100 of the present invention according to one embodiment of the present invention. Device 100 as shown comprises a belt 102 , buckle 104 , power source 106 , a cover 108 for power source 106 , attachments 110 that attach the pouch or holder 112 of fluid bottle 114 and carrier 116 (holding power source 106 and heating chamber 118 where the tubing (not shown) is inserted and heated) to belt 102 , and a cap 120 for heating chamber 118 . FIG. 2 is an illustration of the heating chamber portion 218 of the device, showing the leak-resistant cap 220 .
The tubing that may be heated by the device may be any type of plastic or polymer tubing, where heating will affect both the diameter and flexibility of the tubing sufficiently to enhance the connection process. The type of tubing used depends on the particular industry and application and is selected by its particular properties, including the amount of flexibility desired, the temperature to which it must be heated to affect connection to a fitting, and cost.
The material used for the carrier housing the power supply and heating chamber in preferred embodiments is any durable material that resists wear, stands up well to the elements and provides support for the power supply and chamber, and in more preferred embodiments, the material is water-resistant or waterproof, including materials such as Kevlar®, nylon, polyurethane, or natural or synthetic fabrics that are laminated to or coated with a waterproofing material such as rubber, polyvinyl chloride, polyurethane, silicone elastomer, fluoropolymers, and wax. If a belt or strap is employed, the belt or strap may be made out of any common material such as nylon or the waterproof fabrics listed above. As an alternative to a belt or strap, the power supply and heating chamber may be carried in a tote bag or backpack, although the belt and strap embodiments allow one to have the heating chamber at the ready in a “hands free” configuration.
The power source used can be any power source that is portable (the lighter the better) and of sufficient power to rapidly heat and keep heated the fluid in the heating chamber for from a few to preferably several hours. Preferably the power supply is rechargeable and in some embodiments the amount of power supplied may be adjustable. Power sources of particular use include rechargeable, sealed batteries used in the collection, storage and release of solar and wind-generated electricity; e.g., sealed lead acid and lithium batteries.
The heating chamber may be made of any material that is preferably highly conductive of heat and is resistant to corrosion by the fluid(s) used to heat the tubing. The heating chamber may comprise several materials and layers. For example, the fluid reservoir of the heating chamber may be made of copper with the components (heating tape, thermostat and fuse) held in place by a high-temperature silicone-based tape. The fluid reservoir is then covered with a high-temperature insulation layer such as that used to insulate copper pipe such as Armacell™. The dimensions of the heating chamber depend on the size of the tubing used. The fluid reservoir must have an opening adequate to accommodate the tubing and hold enough fluid to thoroughly and uniformly heat the tubing. Additionally, the reservoir will have a depth sufficient to accommodate the length of tubing desired to be heated (e.g., a length substantially equal to the length of the receptor portion of the fitting). Typically the tubing will have a diameter of less than three inches, less than two inches, less than one inch, and more typically will have a diameter of about a half inch or less.
Fluids used for heating the tubing include any fluid that has a boiling point higher and preferably significantly higher than the temperature needed to reshape the tubing selected, and, in the context of the food or medical industries, is non-toxic and, preferably, resists microbial growth. One preferred liquid for use with the polyethylene tubing is glycerol, a naturally-occurring compound often used as a food additive. The boiling point of glycerol (290° C.) is well above the ideal connecting temperature for polyethylene tubing (approximately 80-110° C.). Glycerol leaves very little residue on the tubing after heating and has natural bactericidal and bacteriostatic properties.
The preceding merely illustrates the principles of the invention. It will 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 included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended to aid the reader in understanding the principles of the invention and the concepts contributed by the inventors to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure. The scope of the present invention, therefore, is not intended to be limited to the exemplary embodiments shown and described herein. Rather, the scope and spirit of present invention is embodied by the appended claims. In the claims that follow, unless the term “means” is used, none of the features or elements recited therein should be construed as means-plus-function limitations pursuant to 35 U.S.C. §112, ¶6. | The present invention relates generally to a portable device for heating the ends of plastic tubing to enlarge the diameter and increase the flexibility of the tubing to more easily connect with various fittings. | 5 |
FIELD OF THE INVENTION
[0001] The invention relates to blade distance ratio as a factor in the grading ability of dozers. More specifically, it relates to a system and method for dynamically adjusting the blade distance ratio on a four track articulated dozer.
BACKGROUND OF THE INVENTION
[0002] Current market trends indicate that crawler operators are using their machines for more finish grading work than has historically been done. Thus the need for dozers that can competently grade is growing. To support this trend, manufacturers continue to improve the machines ability to perform this work to the operators expectations.
[0003] Key contributors of the dozers finish grading capability include such factors as machine balance, weight distribution, track length on ground, machine rigidity, and the location of the blade relative to the track. Locating the blade closer to the tracks increases the machine stability, and makes the machine easier to operate. The ability to minimize this distance is limited on dozers that have the ability to angle their blade because the blade must have adequate clearance to the tracks in all positions.
[0004] The blade distance ratio is commonly used as an indicator of a dozers grading ability. The blade distance ratio is determined by dividing the distance from the rear track roller to the blade (RTBD) by the effective track length on ground (ETL), i.e. Blade Distance Ratio=RTBD/ETL.
SUMMARY OF THE INVENTION
[0005] The exemplary embodiment of the invention described herein is applied to a crawler dozer with 4 independent tracks. In this configuration, the tracks are mounted such that they can move in a way that they can follow the contour of the ground. Each of the tracks pivots about a drive wheel. The blade distance ratio in this case would be best described as the (distance between the rear track pivot and the blade) divided by the (distance between the front and rear track pivots). In the case of a wheeled dozer, the latter term would be the wheel base.
[0006] In order to have a uniform ground pressure for the tracks of the exemplary embodiment, the pivot to the frame is located near the fore-aft center of the track. The negative consequence of this arrangement is that the distance from the blade to the center of the front weight bearing member is greater than would be achieved with a conventional crawler.
[0007] The invention improves the machine performance, i.e., the machine's ability to grade, by reducing the distance between the blade and the center of force under the front track system. This is accomplished by adding a hydraulic cylinder between the track frame and the track mounting frame which can increase the down-force on the front of the track frame. The cylinder is hydraulically connected to an accumulator and pressure regulating system so that the track can rotationally move around its mounting pivot and maintain contact with the ground.
[0008] This system can be actuated by the operator from the operators station when desired. When this system is activated, the cylinder exerts a torque on the track frame that creates an increased downward force at the front of the track, and a reduced force at the rear of the track. This subsequently causes an increased ground pressure on the front of the track, and a reduced ground pressure at the rear of the track. The amount of force is approximately proportional to the hydraulic cylinder force which can be adjustably controlled by the operator, or preset by the manufacturer.
[0009] An additional benefit of this system is that it enables the operator to artificially increase the downforce at the front of the track. In certain soil conditions, this can increase the tractive effort of the machine by forcing the track lug into the ground deeper than would be achieved without this feature enabled. The remainder of the track would then have a packed track to run in. This increased soil density under the track would enable the track to exert higher pull forces than would be otherwise achievable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side view of a work vehicle in which the invention may be used;
[0011] FIG. 2 is an elevated oblique view of a rear of the vehicle illustrated in FIG. 1 ;
[0012] FIG. 3 is a schematic of a front track drive illustrated in FIG. 1 ;
[0013] FIG. 4 illustrates the track length for calculating the blade ratio without the activation of the invention; and
[0014] FIG. 5 illustrates the track length for calculating the blade ration when the invention is activated.
DETAILED DESCRIPTION
[0015] FIGS. 1 and 2 illustrate a vehicle in which the invention may be used. The particular vehicle illustrated in FIGS. 1 and 2 is a four track articulated dozer 10 having a front portion 20 a rear portion 30 ; an articulation mechanism 40 between the front portion 20 and the rear portion 30 ; first track systems 50 , 60 ; and second track systems 70 , 80 . The front portion 20 includes a blade 22 and a blade mounting frame 23 as well as an operator cab 21 .
[0016] FIG. 3 is a schematic of an exemplary embodiment of the invention. Included is an exemplary embodiment of the track system 50 which includes a track assembly 50 ′ and a hydraulic circuit 50 ″. The track assembly 50 is as illustrated in FIG. 3 . A track frame 50 d is pivotally mounted at track frame mounting pivot 50 d ′ to a mounting frame 200 . A drive wheel 50 a is also pivotally mounted to the mounting frame 200 at drive wheel pivot 50 a ′. A first main idler 50 b is pivotally attached to tension link 50 e at first main idler pivot 50 b ′ and the tension link 50 e is pivotally attached to the track frame 50 d on a first side of the track frame mounting pivot 50 d ′ at tension link pivot 50 b ″. A second main idler 50 c is pivotally attached to the track frame 50 d on a second side of the track frame mounting pivot 50 d ′ at second main idler pivot 50 c ′. A tensioning cylinder 57 is pivotally connected to the track frame 50 d at tensioning cylinder pivot 57 ′ and pivotally connected to the tensioning link at cylinder link pivot 57 ″. A biasing cylinder 56 is pivotally mounted to the mounting frame 200 at biasing cylinder mounting pivot 56 ′ and pivotally mounted to the track frame 50 d at track frame biasing pivot 56 ″.
[0017] Minor idler rollers 50 g and 50 h are pivotally connected to minor rocker beam 50 k at minor roller pivots 50 g ′ and 50 h ′ respectively. The minor rocker beam 50 k is pivotally mounted to the track frame 50 d at rocker beam mounting pivot 50 f . As illustrated in FIG. 3 , the minor roller pivots 50 g ′ and 50 h ′ are mounted on first and second sides of rocker beam mounting pivot 50 f , respectively.
[0018] A first side of a track 50 m contacts the drive wheel 50 a , the first main idler 50 b , the second main idler 50 c , the first minor idler 50 g and the second minor idler 50 h . A second side of the track contacts the ground for purposes of vehicle propulsion. As illustrated in FIG. 3 , the track 50 m assumes a triangular appearance as the first side contacts and conforms to the drive wheel 50 a and the first and second main idlers 50 b and 50 c on front and rear portions of the track assembly, respectively.
[0019] Controlling the biasing cylinder 56 is exemplary hydraulic circuit 50 ″ which includes: a hydraulic pump 51 ; a load sense actuating valve 52 ; a pressure reducing valve 53 in communication with the hydraulic pump 51 and fluid reservoir 59 ; a check valve 52 ′ in communication with the pressure reducing valve 53 ; an electrically adjustable pressure relief valve 54 in communication with the pressure reducing valve 53 ; a first gas charge accumulator 55 in communication with the biasing cylinder 56 as well as in communication with the adjustable pressure relief valve 54 and the pressure reducing valve 53 .
[0020] The pressure relief valve 54 is adjustable. In this particular embodiment, it is adjustable from 70 bar to 140 bar. The pressure relief valve 54 , in practice, is set 10 bar above the setting of the pressure reducing valve 53 . The pressure reducing valve 53 and the pressure relief valve 54 may be adjusted from the operator's cab 21 via a switch control 53 ″ and a controller 53 ′.
[0021] The biasing cylinder 56 is actuated when a signal from the controller 53 ′, prompted by a manipulation from the switch control 53 ″ activates the pump load sense valve 52 and shifts the pressure reducing valve 53 from position (1) to position (2), thus exposing the pressure relief valve 54 , the accumulator 55 and the biasing cylinder 56 to pressurized fluid from the pump 51 . The pump 51 is driven by conventional means well known in the art.
[0022] The blade ratio is improved as it decreases and moves toward a value of 1. FIG. 4 illustrates distances for blade distance ratio calculations for the vehicle of FIG. 1 without the invention activated and FIG. 5 illustrates distances for blade distance ratio calculations for the vehicle of FIG. 1 after the invention is activated. As is clearly illustrated the effective track length (ETL) increases by at least a distance between the track frame pivot 50 d ″ and pivot 50 b ′ for the first main idler 50 b when the biasing cylinder 56 is actuated. The maximum increase in distance (ΔDmax) is illustrated in FIG. 5 . The increase in distance (ΔD) depends upon the fluid pressure applied to the biasing cylinder 56 . Such changes increase the grading ability of the dozer 10 . Activation of the invention tends to shift the weight seen by the track assembly 50 ′ toward the first main idler 50 b the load seen by the ground is more concentrated which results in a greater amount of packing of the dirt under the track 50 m and, consequently, greater traction.
[0023] Having described the illustrated embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. | The blade ratio of an articulated work vehicle with multiple tracks is adjusted by shifting a load from the weight of the vehicle toward the front or rear of one or more of the tracks. The load may be shifted through the actuation of a hydraulic cylinder that applies a biasing load between a frame on which a track frame is mounted and a front or rear portion of the track frame. | 4 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/979,182 filed Feb. 25, 2002, now abandoned which is a U.S. national filing of PCT Application No. PCT/IL00/00284, filed May 19, 2000. This application is also a continuation in part of PCT application No. PCT/IL99/00479, filed Sep. 5, 1999, now U.S. application Ser. No. 09/926,547, filed on Mar. 5, 2002 now U.S. Pat. No. 7,194,139, the disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to optical methods and apparatus for performing computations and in particular to transforming a first data set into a second data set by a linear transformation and determining the phase of data elements in the second data set.
BACKGROUND OF THE INVENTION
Optical data processing can often be used to process data more rapidly and efficiently than conventional computational methods. In particular, optical methods can be used to perform linear transformations of data sets rapidly and efficiently.
For example, it is well known that converging lenses can be used to substantially “instantaneously” transform a first image into a second image that is a Fourier transform of the first image. It is to be noted that the Fourier transform is a relationship between the complex amplitudes of light in the images and not between the intensities of light in the images. The same is generally true with respect to other transformations of images, the transformation is a transformation of complex amplitudes of light and not intensities of light. It is therefore to be understood that when a second image is said to be a Fourier, or other, transform of a first image, what is meant is that the spatial pattern of the complex amplitude of light in the second image is the Fourier, or other, transform of the spatial pattern of the complex amplitude of light in the first image.
If the first image is coded with data, the second image is coded with data that is the Fourier transform of the data in the first image. A suitable optical processor can therefore provide substantial advantages in comparison to a conventional data processor when a spectral analysis of a data set is desired. However, a Fourier transform of a data set in general involves complex numbers, even if the data set comprises only real numbers. Therefore, in order to properly detect an “optical” Fourier transform of a data set, phase as well as intensity of light of an image representing the Fourier transform must be detected. While this can be accomplished, most light detectors are generally sensitive only to light intensity and are not responsive to phase.
It is therefore generally more convenient to determine values for data represented by an image from only the intensity of light in the image. Consequently, it is usually advantageous to process data optically using methods that generate only real numbers from the data.
For example, it is often preferable to optically process data coded in an image in accordance with a cosine transform to perform a spectral analysis of the data rather than a Fourier transform. The cosine transform of a real data set generates real values. However, whereas a cosine transform of a real data set does not generate complex numbers it does, usually, generate both positive and negative numbers. Therefore, while most of the information in an optical cosine transform of an image can be acquired from measurements of intensity of light in the image, sign information is not preserved in the intensity measurements. As a result, an optical processor that transforms an input image into an output image that represents the cosine transform of the input image requires a means for determining which of the numbers represented by the output image are positive and which are negative.
K. W. Wong et al, in an article entitled “Optical cosine transform using microlens array and phase-conjugate mirror ”, Jpn J. Appl. Phys. vol. 31, 1672-1676, the disclosure of which is incorporated herein by reference, describes a method of distinguishing positive and negative data in a cosine transform of an image.
The problem of distinguishing the sign of numbers represented by an image when only the intensity of light in the image is measured is of course not limited to the case of data optically generated by a cosine transform. The problem affects all real linear transforms, such as for example the sine and discrete sine transforms and the Hartley transform, when the transforms are executed optically and only their intensities are sensed, if they generate both positive and negative values from a real data set.
SUMMARY OF THE INVENTION
An aspect of some embodiments of the present invention relates to providing a method for determining the sign of data encoded in an output image of a linear optical processor using measurements of intensity of light in the output image, hereinafter referred to as a “data output image”. The data output image is assumed to be generated by the processor responsive to an input image, a “data input image”, encoded with input data that is real. The input data is either all positive or all negative. For clarity of presentation it is assumed that the input data is all positive.
According to an aspect of some embodiments of the present invention, a reference input image is defined for the optical processor. Magnitude and phase of amplitude of a “reference” output image generated by the processor responsive to the input reference image are used to determine the sign of data represented by the data output image.
The operation of a linear optical processor may be described by the equation F(u,v)=O(u,v:x,y)f(x,y). In the equation f(x,y) is a complex amplitude of light in an input image, i.e. a data input image, that represents input data, which data input image is located on an input plane of the processor, and x and y are coordinates of the input plane. Similarly, F(u,v) is a complex amplitude of light in a data output image that the processor generates responsive to f(x,y). The data output image is located on an output plane of the processor having position coordinates u and v corresponding respectively to position coordinates x and y of the input plane. Intensity of light in the data input image is equal to |f(x,y)| 2 and intensity of light in the data output image is equal to |F(u,v)| 2 .
O(u,v:x,y) represents any continuous or discrete linear operator that transforms a first real data set into a second real data set. O(u,v:x,y) may for example represent the continuous or discrete sine or cosine transform or the Hartley transform. For continuous linear transformations u, v, x and y are continuous and multiplication in the equation representing operation of the processor represents integration over the x, y coordinates. For discrete linear operators u, v, x, and y are discrete coordinates and multiplication represents summation over the x, y coordinates.
Since, in accordance with embodiments of the present invention, the input data is assumed to be real and positive, the phase of f(x,y) is constant and input data is represented by the magnitude of f(x,y). F(u,v) also represents a real data set. However F(u,v) may have both positive and negative data. Data having positive values are represented by values of F(u,v) having a same first phase. Data having negative values are represented by values of F(u,v) having a same second phase 180° different from the first phase.
Let the reference input image and its corresponding reference output image be represented by r(x,y) and R(u,v). Both r(x,y) R(u,v), and intensity of light in the reference output image |R(u,v)| 2 are known. It is to be noted that it is possible to define and synthesize any predefined reference function r(x,y) and use it for sign reconstruction in accordance with embodiments of the present invention. Whereas descriptions of the present invention assume that r(x,y) is real the invention is not limited to the reference image being real. Magnitude and phase of R(u,v) are known from the transform that the optical processor executes and can be checked experimentally using methods known in the art. Preferably, r(x,y) is real. Therefore R(u,v) preferably corresponds to a real data set. In some embodiments of the present invention R(u,v) is a real data set comprising values all of which have a same sign. In some embodiments of the present invention the data set comprises one of or a combination of positive, negative and complex values.
In accordance with an embodiment of the present invention, to determine both the magnitude and sign of F(u,v) the intensity of the data output image |F(u,v| 2 is measured. In addition, in accordance with an embodiment of the present invention, a combined input image c(x,y)=f(x,y)+r(x,y) are processed by the processor to provide a combined output image C(u,v)=F(u,v)+R(u,v). Intensity of light in the combined output image, which is equal to |C(u,v)| 2 =|F(u,v)| 2 +|R(u,v)| 2 +2F(u,v)R(u,v), is measured. Since |F(u,v)| 2 , |R(u,v)| 2 and R(u,v) are known, the sign of F(u,v) can be determined from the “interference” term 2F(u,v)R(u,v).
It is to be noted that not only sign of F(u,v) can be determined from |C(u,v)| 2 , |F(u,v)| 2 , |R(u,v)| 2 and R(u,v). In general, (|C(u,v)| 2 −|F(u,v)| 2 −|R(u,v)| 2 )/2R(u,v) provides a magnitude and a phase for F(u,v). In some cases the phase is known to within an ambiguity, for example, a symmetry ambiguity or a 180°. In some embodiments of the invention the ambiguity is removed and the phase extracted by determining a combined image C(u,v) for two or more different reference images r(x,y). The phase can be extracted for example by solving for F(u,v) using the two combined and reference images.
In some embodiments of the present invention the reference image is chosen so that |R(u,v)|≧|F(u,v)| for all values of u and v for which R(u,v) and F(u,v) have opposite signs. For these embodiments of the present invention only the combined input image c(x,y)=f(x,y)+r(x,y) is processed by the processor to determine both the magnitude and sign of F(u,v). If the intensity of light in the combined image minus the intensity light in the reference image at a point (u,v) in the output plane of the processor is greater than zero, the signs F(u,v) and R(u,v) are the same at the point. If on the other hand the difference is less than zero, the signs of F(u,v) and R(u,v) are opposite. Since the sign of R(u,v) is known, the sign of F(u,v) is known. The magnitude of F(u,v) at the point can be determined from the intensity |C(u,v)| 2 and the known magnitude and sign of R(u,v) by solving a quadratic equation.
An aspect of some embodiments of the present invention relates to providing an improved method for generating a cosine transform of an “input” image using an optical processor that generates a Fourier transformed output image from an input image.
In accordance with an embodiment of the present invention, a first Fourier image that is a Fourier transform of the input image is generated by the optical processor and the intensity of the Fourier image measured and stored. A second Fourier image is generated by the optical processor from the input image plus a known first reference image and the intensity of the second Fourier image is measured and stored. The input image is parity transformed to generate a second input image, referred to as a “parity image”. A third Fourier image, which is a Fourier transform of the parity image is generated and its intensity measured and stored. A fourth Fourier image is generated which is a Fourier transform of the parity image plus a known second reference image. The intensities of the four Fourier images and the amplitudes of the known reference images are used to determine the cosine transform of the input image. In some embodiments of the present invention the first and second reference images are the same.
There is thus provided in accordance with an exemplary embodiment of the invention, a method of optical data processing, comprising:
providing a first data set to be optically transformed using a transform; combining a reference data set with said first data set to generate a combined data set; optically transforming said combined data set into a transformed combined data set; and extracting a second data set that represents a transform of said first data set, from an amplitude portion of said transformed combined data set, using said reference image to extract a phase of at least one element of said second data set. Optionally, said transformed combined data set is detected using a power detector. Alternatively or additionally, said transformed combined data set is encoded using incoherent light.
In an exemplary embodiment of the invention, said transformed combined data set is a discrete data set. Alternatively or additionally, said first data set comprises a one-dimensional data set. Alternatively, said first data set comprises a two-dimensional data set. Optionally, said first data set comprises an image.
In an exemplary embodiment of the invention, said first data set comprises at least one positive value. Alternatively or additionally, said first data set comprises at least one negative value. Alternatively or additionally, said first data set comprises at least one complex value.
In an exemplary embodiment of the invention, extracting comprises extracting using electronic processing.
In an exemplary embodiment of the invention, combining a reference data set comprises adding at least one additional value to an existing element of said first data set. Alternatively or additionally, combining a reference data set comprises replacing at least one existing element of said first data set with an element from a second data set. Optionally, the method comprises compensating for an effect of said replaced value after said extraction. Optionally, said compensating comprises compensating using electronic processing.
In an exemplary embodiment of the invention, combining a reference data set comprises adding at least one additional value alongside existing elements of said first data set. Optionally, said at least one additional value is arranged at a corner of a matrix layout of said first data set.
In an exemplary embodiment of the invention, the method comprises selecting said reference image to create a desired offset in said transformed combined data set. Optionally, said selecting takes into account system imperfections. Alternatively or additionally, said offset is substantially uniform. Alternatively, said offset is substantially non-uniform.
In an exemplary embodiment of the invention, said reference data is at least one delta-function. Optionally, said reference data comprises a plurality of delta-functions. Alternatively or additionally, said at least one delta function has an amplitude substantially greater than that of any of the data elements of said first data set.
In an exemplary embodiment of the invention, said at least one delta function has an amplitude substantially greater than that of any of the data elements of said first data set that have a certain phase.
In an exemplary embodiment of the invention, said at least one delta function has an amplitude substantially greater than an amplitude of a component of any of the data elements of said first data set that fit in a certain phase range.
In an exemplary embodiment of the invention, said at least one delta function has an amplitude not greater than that of any of the data elements of said first data set.
Optionally, said amplitudes are measured as amplitudes of transform elements.
In an exemplary embodiment of the invention, combining comprises combining electronically and generating a combined modulated light beam.
Alternatively, combining comprises combining optically. Optionally, combining comprises creating said reference image optically. Optionally, said reference image is created using a refractive optical element. Alternatively, said reference image is created using a dedicated light source.
In an exemplary embodiment of the invention, said transform is a Fourier-derived transform.
In an exemplary embodiment of the invention, said transform is a DCT transform.
In an exemplary embodiment of the invention, extracting a phase comprises extracting only a sign.
BRIEF DESCRIPTION OF FIGURES
A description of exemplary embodiments of the present invention follows. In the figures, identical structures, elements or parts that appear in more than one figure are generally labeled with the same numeral in all the figures in which they appear. Dimensions of components and features shown in the figures are chosen for convenience and clarity of presentation and are not necessarily shown to scale. The figures are listed below.
FIG. 1 schematically shows an optical processor generating a Fourier transform of an image according to prior art;
FIG. 2 schematically shows the optical processor shown in FIG. 1 generating a cosine transform of an image in accordance with prior art;
FIGS. 3A and 3B schematically show an optical processor generating a cosine transform of an image in accordance with an embodiment of the present invention;
FIG. 4A schematically shows an optical processor that generates a reference image that is a delta function, in accordance with an embodiment of the present invention;
FIG. 4B schematically shows a lens system for generating a delta function reference image, in accordance with an embodiment of the present invention; and
FIGS. 5A-5D schematically illustrate a method of generating a cosine transform of an image, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
In the following discussion an embodiment of the present invention is described in which a real linear transform performed by an optical processor is a cosine transform. The optical processor uses the Fourier transform properties of converging lenses whereby a converging lens transforms an image into its Fourier transform, to generate a cosine transform of an image. The Fourier transform properties of lenses are described in “Introduction to Fourier Optics” by J. W. Goodman, McGraw Hill-Hill Companies, second edition Copyright 1996.
FIG. 1 schematically shows an optical processor 20 that functions to transform images into their Fourier transforms according to prior art. Optical processor 20 comprises a converging lens 22 , an input plane 24 and an output plane 26 . Input and output planes 24 and 26 are coincident with focal planes of lens 22 . It is well known that lens 22 can be used to generate an image on output plane 26 that is a Fourier transform of an image on input plane 24 .
For example, assume that a spatial light modulator 30 having pixels 32 is located at input plane 24 and that the spatial light modulator is illuminated with collimated coherent light, represented by wavy arrows 34 , from a suitable light source. Pixels 32 have transmittances as a function of position that are proportional to a desired function. Spatial light modulator 30 may, for example, be a photographic transparency, a printed half tone image, a liquid crystal array or a multiple quantum well (MQW) modulator. In FIG. 1 , by way of example, the transmittances are determined so that when spatial light modulator 30 is illuminated by light 34 a happy face 36 is formed at input plane 24 . Lens 22 will form an image (not shown) on output plane 26 that is the Fourier transform of the happy face 36 on input plane 24 .
Given a function f(x,y), the Fourier transform of the function (1/4)[f(x,y)+f(−x,y)+f(x,−y)+f(−x,−y)] is the cosine transform of f(x,y). Each ofthe functions in the square brackets is a parity transform, or a one dimensional reflection in the x or y axis, of the other functions in the brackets. It is therefore seen that the cosine transform of a two dimensional function can be generated by Fourier transforming all possible parity transforms of the function.
FIG. 2 illustrates how optical processor 20 shown in FIG. 1 can be used to generate a cosine transform of an image 40 in accordance with prior art by Fourier transforming all of the image's parity transforms. Image 40 may, by way of example, be an 8 by 8 block of pixels from an image that is to be compressed according to the JPEG standard using a discrete cosine transform.
Let positions on input plane 24 and spatial light modulator 30 be defined by coordinates along x and y axes indicated on the spatial light modulator and positions on output plane 26 by coordinates along u and v axes indicated on the output plane. Let respective origins 25 and 27 of the x, y coordinates and the u, v coordinates be the intersections of the optic axis (not shown) of lens 22 with input and output planes 24 and 26 respectively.
Image 40 is formed on the upper right quadrant of spatial light modulator 32 and reflections 42 and 44 of image 40 in the x and y axes are respectively formed in the lower right and upper left quadrants of the spatial light modulator. A reflection 46 of image 40 along a 45° diagonal (not shown) to the x axis through the origin is formed in the lower left quadrant of spatial light modulator 30 . Let the amplitude of light in image 40 be represented by f(x,y). Let the amplitude of light in the image formed on input plane 24 comprising image 40 and its parity reflections be f′(x,y). Then f′(x,y)=(1/4)[f(x,y)+f(−x,y)+f(x,−y)+f(−x,−y)]. (The decrease in amplitude by 75%, i.e. the factor 1/4, which is not necessary, can of course be achieved by proper control of spatial light modulator 30 ). If the amplitude of light in an image formed on output plane 26 by lens 22 responsive to f′(x,y) is represented by F(u,v) then F(u,v) is the Fourier transform of f′(x,y). Because of the symmetry of the image on input plane 24 , F(u,v) is also the cosine transform of f(x,y). If F.T. represents the operation of the Fourier transform and C.T. represents the operation of the cosine transform then the relationships between F(u,v), f′(x,y) and f(x,y) is expressed by the equation F(u,v)=F.T. {f′(x,y)}=C.T.{f(x,y)}.
It is to be noted that f(x,y) and f′(x,y) represent data that is either all positive or all negative. For clarity of presentation data represented by f(x,y) is assumed to be positive. Further, since the cosine transform performed by optical processor 20 is a real linear transform, as noted above, F(u,v) also represents real data. However, F(u,v) may have both positive and negative data. Therefore, the cosine transform of image f(x,y) cannot be determined from the image on output plane 26 by measuring only the intensity |F(u,v)| 2 .
FIGS. 3A and 3B schematically show an optical processor 50 being used to determine the sign and magnitude of the cosine transform F(u,v) of image 40 , i.e. f(x,y), in accordance with an embodiment of the present invention.
Optical processor 50 is similar to optical processor 20 and comprises a lens 22 , input and output planes 24 and 26 . At output plane 26 , processor 50 preferably comprises an array 52 of rows and columns of photosensors 54 . Each photosensor 54 generates a signal responsive to an intensity of light in an image on output plane 26 at a position determined by the row and column of array 52 in which the photosensor 54 is located and a pitch of array 52 . Photosensors 52 sample intensity of light at “discrete” positions (u,v) in output plane 26 . Preferably, the number of photosensors 52 is equal to the number of pixels 32 in spatial light modulator 30 and the locations of photosensors 52 are homologous with the locations of pixels 32 .
In FIG. 3A , in accordance with an embodiment of the present invention, spatial light modulator 30 generates a first image at input plane 24 comprising image 40 and its parity reflections 42 , 44 and 46 . The image is the same as the image comprising image 40 and its reflections shown in FIG. 2 . Lens 22 forms an image at output plane 26 having amplitude F(u,v). Photosensors 54 generate signals responsive to intensity IF(u,v) of light in the image, where IF=|F(u,v)| 2 , at their respective locations u,v.
In FIG. 3B , in accordance with an embodiment of the present invention, spatial light modulator 30 generates a second “combined” image at input plane 24 that comprises the image shown on the input plane in FIG. 3A with the addition of a reference image 60 having a known amplitude r(x,y). Preferably r(x,y) is chosen so that its Fourier transform is real, i.e. it has a symmetry with respect to the origin of axes x and y which results in its Fourier transform being real. By way of example, in FIG. 3B , reference image 60 is formed by controlling central pixels 61 , 62 , 63 and 64 located at the origin of coordinates of input plane 24 to transmit light and appear bright.
If c(x,y)=(f′(x,y)+r(x,y)) then lens 22 forms an image (not shown) on output plane 26 that is the Fourier transform of c(x,y) and photosensors 54 generate signals responsive to intensity, IC(u,v), of light in the image. If C(u,v) represents the Fourier transform of c(x,y), then the amplitude of light in the image is C(u,v)and IC(u,v)=|C(u,v)| 2 .
In accordance with some embodiments of the present invention IF(u,v), IC(u,v) and the known Fourier transform of r(x,y) are used to determine the magnitude and sign of F(u,v) and thereby the cosine transform of f(x,y).
C(u,v)=F.T.{c(x,y)}=F.T.{f′(x,y)+r(x,y)}=F.T.{f′(x,y)}+F.T.{r(x,y)}=F(u,v)+R(u,v), where R(u,v) is the known and/or measured Fourier transform of r(x,y). Therefore, IC(u,v)=[|F(u,v)| 2 +|R(u,v)| 2 +2F(u,v)R(u,v)]=IF(u,v)+IR(u,v)+2F(u,v)R(u,v), where IR(u,v)=|R(u,v)| 2 . IR(u,v) can be calculated from the known Fourier transform of r(x,y) or measured experimentally. In some embodiments of the present invention the sign and magnitude of F(u,v) are determined from the equation F(u,v)=[IC(u,v)−IF(u,v)−IR(u,v)]/2R(u,v).
In some embodiments of the present invention the magnitude of F(u,v) is determined from the square root of IF(u,v). The sign of F(u,v) can be determined by comparing IF(u,v) and IR(u,v) with IC(u,v). If IF(u,v) >IC(u,v) or IR(u,v) >IC(u,v) then R(u,v) and F(u,v) have opposite sign. Otherwise they have the same sign. Since the sign of R(u,v) is known the sign of F(u,v) is known.
Whereas, in FIGS. 3A and 3B reference image 60 is a symmetric image located at the center of origin of the (x,y) coordinates other reference images are possible and can be used in the practice of the present invention. For example, pixels 32 at the corners of spatial light modulator 30 can be used to generate useful reference images. In some embodiments of the present invention pixels 32 only in certain regions of spatial light modulator 30 are used to represent data. Pixels that are not needed for data are used, in some embodiments of the present invention, to generate reference images. In some embodiments, some data pixels are canceled or provided elsewhere n the image, for example as pixels in overlapping blocks. In other examples extra pixels are provided for the reference image, for example by inserting one or more rows or columns per block. For example “data” pixels may be restricted to alternate rows or columns of pixels. Or each data pixel may be surrounded by four pixels that are not used for data. In an exemplary embodiment, 9×9 blocks of data are used for an 8×8 block transform, with at least some of the extra pixels being used as a reference image. Alternatively or additionally, the effect of missing pixels may be corrected using an electronic or optical post processing step.
It should also be noted that dark pixels, pixels that are “turned off”, that do not transmit light can function to generate reference images. For example, if an image on spatial light modulator 30 has bright pixels at the origin of coordinates (i.e. pixels 61 , 62 , 63 and 64 in FIG. 3B ) a reference image can be generated by “turning off” the pixels. Turning off pixels in an image is of course equivalent to adding a reference image to the image for which light at the turned off pixels has a phase opposite to that of the light in the image.
In some embodiments of the present invention, reference image f(x,y) is chosen so that |R(u,v)|≧|F(u,v)| for all values of u and v for which R(u,v) and F(u,v) have opposite signs. For these embodiments of the present invention it is not necessary to determine IF(u,v) and only the operation shown in FIG. 3B in which IC(u,v) is measured is required to determine the magnitude and phase of F(u,v). If at a point (u,v), IC(u,v)−IR(u,v) >0 then the signs F(u,v) and R(u,v) are the same at the point otherwise the signs are opposite. The magnitude of F(u,v) at the point can be determined from IC(u,v) by solving the quadratic equation IC(u,v)=[|F(u,v)| 2 +|R(u,v)| 2 +2F(u,v)R(u,v)] for F(u,v).
FIG. 4A schematically shows a side view of an optical processor 70 , in accordance with an embodiment of the present invention, that generates a reference field for which |R(u,v)|>|F(u,v)| for all values of u and v for which R(u,v) and F(u,v) have opposite signs.
Optical processor 70 comprises a “Fourier” lens 22 having an output plane 26 coincident with a focal plane of lens 22 , a spatial light modulator 72 and a “beam partitioner” 74 . A detector array 76 is located at output plane 26 and measures intensity of light at the output plane. Spatial light modulator 72 defines an input plane for Fourier lens 22 and may be located at substantially any position to the left of output plane 26 . In optical processor 70 spatial light modulator 72 is located by way of example adjacent to lens 22 .
Beam partitioner 74 preferably receives an incident beam 78 of coherent collimated light generated by an appropriate source (not shown) and focuses a portion of the light to a point 80 and transmits a portion of the light as a transmitted beam of light 82 parallel to the incident beam. Light from transmitted beam 82 illuminates and is transmitted through spatial light modulator 72 and is focused by lens 22 to form a Fourier transform F(u,v) of a transmittance pattern f(x,y) formed on the spatial light modulator. It is assumed that the transmittance pattern has an appropriate symmetry so that the Fourier transform is a cosine transform of a desired image.
Point 80 functions substantially as a point source of light and provides a reference image r(x,y) for f(x,y) that is substantially a delta function Aδ(x,y), where A is proportional to an intensity of light focused to point 80 . A Fourier image, R(u,v), of light from point 80 is also formed on output plane 26 by lens 22 . Since r(x,y) is substantially a delta function, R(u,v) is substantially constant and equal to A.
The magnitude of F(u,v) at a point (u,v) is of course proportional to the intensity of light in transmitted beam 82 . In accordance with an embodiment of the present invention beam partitioner 74 is designed so that the relative portions of light focused to point 80 and transmitted in transmitted beam 82 beam are such that A=|R(u,v| is greater than |F(u,v)| for all values of u and v for which R(u,v) and F(u,v) have opposite signs.
In some embodiments of the present invention beam partitioner 74 is a diffractive optical element such as a Fresnel zone plate having reduced efficiency. In some embodiments of the present invention, beam partitioner 74 comprises an optical system 90 of a type shown in a side view in FIG. 4B . Optical system 90 comprises a positive lens 92 and a weak negative lens 94 . Positive lens 94 is preferably coated with an antireflective coating using methods known in the art to minimize reflections. Weak negative lens 92 is treated so that at its surfaces light is reflected with a reflectivity α. Light from incident beam 78 , represented by arrowed lines 96 , that is transmitted through both positive lens 92 and negative lens 94 without reflections is focused to produce the point reference light source A.delta(x,y) at point 80 . If the intensity of light in light beam 78 is “I” the amount of light focused to point 80 is substantially equal to I(1−.alpha.).sup.2. Light that undergoes internal reflection twice in negative lens 94 is transmitted as transmitted beam of light 82 substantially parallel to incident beam 78 . The amount of energy in transmitted beam 82 is substantially equal to I(1−.alpha.).sup.2.alpha.sup.2. The ratio of energy focused to point 80 to that contained in transmitted beam 78 is therefore equal to I/.alpha.sup.2.
In accordance with an embodiment of the present invention R can be chosen so that A =|R(u,v| is greater than |F(u,v)| for all values of u and v for which R(u,v) and F(u,v) have opposite signs.
Given a function f(x,y) it can be shown that the cosine transform C.T.f(x,y)=1/2[ReF.T.{f(x,y)}+ReF.T.{f(x,−y)}]=1/2[ReF p (u,v)+ReF m (u,v)] where Re indicates the real part of a complex number and F p (u,v) and F m (u,v) are the Fourier transforms of f(x,y) and f(x,−y) respectively.
Let c p (x,y)=f(x,y)+A p δ(x,y) and c m (x,y)=f(x,−y)+A m δ(x,y). The Fourier transform, C p (u,v), of c p (x,y) may be written C p (u,v)=[F p (u,v)+A]=[ReF p (u,v)+Im F p (u,v)+A p ], where Im indicates the imaginary part of a complex number and A p is assumed to be real. Similarly the Fourier transform of c m (x,y) may be written C m (u,v)=[F m (u,v)+A m ]=[ReF m (u,v)+Im F m (u,v)+A m ].
If the “intensities” of the Fourier transforms F p (u,v) and C p (u,v) are written as IF p (u,v) and IC p (u,v) respectively so that IF p (u,v)=|F p (u,v)| 2 and IC p (u,v)=|C p (u,v)| 2 then it can be shown that ReF p (u,v)=[IC p (u,v)−IF p (u,v)−A p 2 ]/2A p . Similarly, ReF m (u,v) =[IC m (u,v)−IF m (u,v)−A m 2 ]/2A m where IF m (u,v)=|F m (u,v)| 2 and IC m (u,v)=|C m (u,v)| 2 .
Therefore the cosine transform of f(x,y) can be determined from the intensities IF p (u,v), IC p (u,v) and A p and IF m (u,v), IC m (u,v) and A m . It should be noted that whereas a delta function has been added as a reference field for f(x,y) and f(x,−y) in the above calculations, similar results can obtain for other reference functions r(x,y). FIGS. 5A-5D illustrate a method, in accordance with an embodiment of the present invention by which the functions IF p (u,v), IC p (u,v) and A p and IF m (u,v), IC m (u,v) and A m are evaluated using an optical processor 100 to generate a cosine transform of a function f(x,y). Optical processor 100 is similar to optical processors 50 and 70 and comprises a Fourier lens 22 , a photosensor array 52 at an output plane 26 , which is located at a focal plane of lens 22 and a spatial light modulator 30 .
Referring to FIG. 5A assume that function f(x,y) is represented by an image 40 formed by spatial light modulator 30 . Optical modulator 100 generates the Fourier transform F(u,v) of f(x,y) and acquires values for IF p (u,v). In FIG. 5B , a point light source 102 generates a delta function reference A p δ(x,y) image which is added to f(x,y) to form an image c p (x,y)=f(x,y) +A p δ(x,y). Processor 100 Fourier transforms c p (x,y) and acquires IC p (u,v). Point light source may be provided using any methods known in the art. In some embodiments of the present invention point light source is provided by methods and apparatus that are similar to those described in the discussion of FIGS. 4A and 4B .
In FIG. 5C , spatial light modulator 30 forms an image f(x,−y) and acquires IF m (u,v). In FIG. 5D a delta function reference function A m δ(x,y) is added to f(x,−y) and IC m (u,v) is acquired. A suitable processor (not shown) receives the acquired data and uses it to determine ReF p (u,v) and ReF m (u,v) from which the cosine transform of f(x,y) may be determined as shown above.
The present application is related to the following four PCT applications, all filed on May 19, 2000: PCT/IL00/00282 published as WO 00/72105, which especially describes matching of discrete and continuous optical elements, PCT/IL00/00285 published as WO 00/72107 which especially describes reflective and incoherent optical processor designs, PCT/IL00/00283 published as WO 00/72104 which especially describes various architectures for non-imaging or diffractive based optical processing, and PCT/IL00/00286 published as WO 00/72108 which especially describes a method of processing by separating a data set into bit-planes and/or using feedback. The disclosures of all of these applications are incorporated herein by reference.
In the description and claims of the present application, each of the verbs, “comprise” “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements or parts of the subject or subjects of the verb.
The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons of the art. The scope of the invention is limited only by the following claims. | A method of optical data processing, comprising:
providing a first data set to be optically transformed using a transform; combining a reference data set with said first data set to generate coherent light, encoding a combined data set; optically and coherently transforming said light that encodes the combined data set, into coherent light that encodes a transformed combined data set; obtaining a transformed reference data set by determining the effect said optical transform has on light encoding said reference data set; and extracting a second data set that represents a transform of said first data set, from an intensity portion of light encoding said transformed combined data set, using said transformed reference data set to extract a phase of at least one element of said second data set. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved method of removing a blockage in a false twist spinning unit.
In its more particular aspects the method of the present invention contemplates removal of a blockage in a false twist spinning unit, in particular in a suction drawing-in portion or suction portion forming part of the false twist spinning unit, wherein a yarn monitoring device is arranged downstream of the false twist spinning unit with respect to the direction of travel or movement of the yarn or thread or the like.
A number of false twist spinning units are already known to the art in which at each spinning position a fiber sliver delivered from a sliver can is drafted in a drafting mechanism, spun into a yarn in a false twist spinning unit and thereafter the produced yarn is wound up in a winding unit.
Between the false twist spinning unit and the winding unit there is usually arranged a yarn monitoring device which indicates either the presence of so-called thick places in the yarn or the absence of the yarn.
Upon the occurrence of these so-called thick places, yarn production is immediately stopped and the yarn portion or section having the thick place is removed. Thereafter, spinning is restarted.
The entire operation can either be carried out manually or by means of a controlled device.
Upon indication of the absence of the yarn, the yarn production is also immediately stopped in order to establish the reason for the absence of the yarn.
When there is employed a pneumatic suction drawing-in portion or suction portion for the purpose of receiving the fiber aggregation delivered by the drafting mechanism, then, in many cases, the danger exists that a blockage forms in the suction portion. This blockage may arise, for example, if there are present in the fiber aggregation foreign bodies or fiber tufts which do not pass through an orifice or constriction terminating the suction portion.
In such cases fiber material present in the suction portion must be manually cleared with the aid of an appropriate tool in order to thereafter carry out restarting of the spinning operation.
This manual clearing of such blockage has the disadvantage, however, that there exists the danger of damage to the suction portion by the attendant or operator, so that blockages, for example due to retention of fibers on rough surfaces, tend to occur more frequently than before. Furthermore, manual removal of the disturbance is labor-intensive and is associated with the undesirable need to wait for the attendant.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind it is a primary object of the present invention to provide an improved method of removing a blockage in a false twist spinning unit in a manner not afflicted with the aforementioned shortcomings and drawbacks of the prior art proposals.
It is another important object of the present invention to devise an improved method of avoiding or at least minimizing blockage in a false twist spinning unit by avoiding the aforedescribed damage and which enables again placing the spinning position into an operational condition in a speedy and rational manner.
Now in order to achieve the aforementioned objects and others which will become more readily apparent as the description proceeds, the method of the present development is manifested by the features that there are accomplished the following automatically controlled steps:
(a) sensing a blockage existing in the false twist spinning unit,
(b) opening the false twist spinning unit,
(c) inserting a cleaning device into the suction portion in a direction corresponding to the direction of yarn or thread travel and thereby removing the blockage,
(d) removal of the cleaning device,
(e) closing the false twist spinning unit, and
(f) restarting spinning.
According to a further embodiment of the present invention there can be carried out the method steps of:
(a) sensing a blockage existing in the false twist spinning unit,
(b) opening the false twist spinning unit,
(c) removing the suction portion,
(d) inserting a replacement suction portion in an operational condition,
(e) closing the false twist spinning unit, and
(f) restarting spinning.
According to still further embodiment of the present invention there can be accomplished the following method steps:
(a) sensing a blockage existing in the false twist spinning unit,
(b) opening the false twist spinning unit,
(c) moving the suction portion out of the false twist spinning unit into a predetermined cleaning position,
(d) cleaning the suction portion,
(e) checking the suction portion,
(f) replacing the suction portion in a predetermined operating position in the false twist spinning unit, and
(g) restarting spinning.
Some of the more notable advantages achieved by the present invention substantially reside in the fact that the suction portions are cleaned with certainty and without damage, and furthermore, the spinning position is again placed into its operating condition or state in the shortest amount of time.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein throughout the various figures of the drawings there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 shows a schematic representation of a spinning process;
FIG. 2 shows the spinning process of FIG. 1 in a cleaning phase;
FIG. 3 shows a schematic representation of a modification of the process of FIG. 1;
FIG. 4 shows a schematic representation of a further process in the cleaning phase;
FIG. 5 shows schematically a further process also illustrated in the cleaning phase; and
FIG. 6 shows a modification of the process of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing how the drawings, it will be understood that in a so-called false twist spinning method a fiber sliver 1 is removed from a fiber sliver can 2 and fed to a suitable drafting mechanism 3.
Arranged after the drafting mechanism 3, viewed with respect to the direction of travel of the fiber sliver 1, is a so-called false twist spinning unit 4 which comprises a suction drawing-in portion or suction portion 5, one or more twist-imparting elements 6 adjoining the suction portion 5 and a withdrawal roll pair 7. In the following description, only the single twist-imparting element 6 is discussed, but it is to be specifically understood that such is equally representative of an arrangement constituting a plurality of such twist-imparting elements.
A yarn monitoring device 9 is provided at the yarn travel path or along the yarn direction of travel between the withdrawal roll pair 7 and a wind-up unit or winder 8.
The fiber aggregation 10 delivered by the drafting mechanism 3 is received by the suction portion 5 and delivered to the twist-imparting element or twisting element 6. A spun yarn 11 is formed by the operation of the twist-imparting element 6. This spun yarn 11 is received by the withdrawal roll pair 7 and is passed via the yarn monitoring device 9 to the yarn wind-up unit 8.
The suction portion 5 is connected by means of a connection or connecting line 12 to a suitable suction device 13. The suction portion 5 can, however, operate without the suction device 13 provided that the subsequently arranged twist-imparting element 6 is a pneumatic twist-imparting element possessing a suction effect which is coupled directly to the suction portion 5.
The entire arrangement, that is from the fiber sliver can 2 to the yarn wind-up unit 8, is called a spinning position.
FIG. 2 shows the condition of a cleaning phase in which the yarn production at the spinning position is interrupted as a result of a blockage in the suction portion 5. After the yarn end has left the yarn monitoring device 9, the spinning position is caused to stop, or else the fiber sliver infeed is interrupted.
In order to deal with this undesirable condition or state, the suction portion 5 and its immediate surroundings are freed of the blockage by means of a suitable cleaning element or device 14 (which has been conveniently schematically illustrated as an arrow to simplify the illustration of the drawings). Thereafter, spinning is re-started.
Depending upon the system or design of the suction portion 5, the suction action prevailing in its infeed portion also can be maintained in operation during the cleaning process, that is the suction action does not have to be interrupted during cleaning of the suction portion 5.
If the restart of spinning is a failure, then the aforedescribed cleaning operation can be repeated by means of the cleaning element or device 14.
After a number of unsuccessful attempts at restart of spinning have occurred, the spinning position is left inoperable and then must be checked by the operating personnel.
FIG. 3 shows a modified procedure wherein for the cleaning of the suction portion 5 the latter is lifted or pivoted out of the operational position (indicated with broken lines) into a cleaning position (indicated in full lines).
The lifting or the pivoting out of and the return of such suction portion 5 into the operating position is effected either manually or by any suitable removal or displacement device 15 which is associated with each spinning position or is associated with a travelling cleaning robot.
This variant embodiment offers the advantage that the cleaning process does not have to be carried out within the operating arrangement of the elements.
After re-positioning of the suction portion 5 in the operating position, the procedure for re-starting spinning is carried out.
Also with this variant technique the cleaning operation can be repeated if the spinning re-start procedure proves unsuccessful.
Depending upon the cleaning device or element which is actually used, the connection 12 to the suction device 13 can be interrupted or not, as deemed appropriate, for cleaning of the suction portion 5.
FIG. 4 shows a further variant method of the present invention in which, upon blockage of the suction portion 5, the latter is moved by means of a suitable removal or displacement device 16 into an ejection position (illustrated with broken lines) for exchange of the suction portion 5. In this broken line depicted ejection position the suction portion 5 is removed from the spinning position as indicated diagrammatically with the arrow E.
Thereafter, in the same position, or as indicated in FIG. 4 with chain-dotted lines in another position, a replacement suction portion 5.1 which has previously been placed in an operationally ready condition or state is grasped, as indicated diagrammatically with the arrow F, and is then brought into the operating position (indicated with full lines), so that the procedure for restarting spinning can be effected.
The removal of the blocked suction portion 5 and the grasping of the operationally ready suction portion 5.1 can be carried out manually or automatically by means of the aforementioned removal or displacement device 16.
Operational and blocked suction portions can be stored in a compartmented magazine or in any other suitable storage area.
After the aforedescribed removal of the suction portion 5 this part can be cleaned in a separate operation and placed in an operationally ready or stand-by position from where this cleaned suction portion can be again extracted at the appropriate time by accomplishing the movement schematically indicated with the arrow F.
FIGS. 5 and 6 show a combination of method steps as previously discussed with respect to the embodiments of FIGS. 3 and 4.
In this method, particularly as depicted in FIG. 5, the suction portion 5 is cleaned while, following removal by the removal or displacement device 16, it is located in its removed or extracted position (indicated with broken lines) by means of the cleaning element or device 14. This cleaned suction portion 5 is thereafter checked to determine whether or not it possesses the requisite degree of cleanliness by a monitoring element 17, and thereafter if this is found to be the case such properly cleaned suction portion 5 is reset in the operating position (indicated in full lines), so that the procedure for restarting spinning can thereafter be carried out.
The method according to FIG. 6 includes the additional step that after unsuccessful cleaning of the suction portion 5 the latter, as indicated by the arrow E, is removed and thereafter a new operational suction portion 5.1 is grasped, as indicated by the arrow F, and is moved into the operational position (indicated in full lines).
Thereafter, the procedure for restarting spinning can be carried out again.
It is to be clearly understood that the just described technique of checking the suction portion 5, after its cleaning by the cleaning element or device 14, can also be used for the cleaning processes previously described with reference to FIGS. 2 and 3.
It is also to be understood that in the methods described with reference to FIGS. 5 and 6 the connection 12 between the suction portion 5 and the suction device 13 can be interrupted during cleaning of the suction portion 5.
Furthermore, the twist-imparting element or twisting element 6 can be a pneumatic or a mechanical twisting element. During restart of spinning, when employing a mechanical twisting element, those possible steps conventionally employed for taking up fiber material delivered by the suction portion to the twisting element do not form part of this invention and since such steps are unimportant thereto they will not be here further considered.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. | In a false twist spinning unit a fiber sliver is removed from a fiber sliver can and fed into a drafting mechanism. The fiber aggregation delivered by the drafting mechanism is received by a suction portion of a spinning unit and is passed to a twist-imparting element which produces a spun yarn. The spun yarn is withdrawn by a roller pair and passes via a yarn monitoring device to a winding unit. The suction pressure required for the suction portion is produced by a suction device. In the event of blockage of the suction portion, a cleaning element or device is activated. After cleaning of the suction portion is completed, spinning is restarted. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to rain gutters which are commonly mounted upon the fascia of a building and positioned beneath the lowermost extremity of a sloped roof.
Rain gutters are intended to receive rain water from the roof and direct the water to a downspout which conducts the water away from the foundation of the building. In the course of time however, leaves and other airborne debris accumulate within the gutters to impair their functionality. The removal of debris from the gutter is generally a difficult task involving accident risks inherent in working at precarious heights.
Numerous expedients have been disclosed for preventing entrance of debris into the gutter, or simplifying the removal of accumulated debris. For example, strainer-like devices have been disclosed for emplacement upon the open upper extremity of the trough to prevent entrance of debris. However, such devices themselves become clogged with debris, thereby reducing their effectiveness. Shield devices have been utilized wherein water is conducted around a forwardly directed nose projection that rejects debris. Although relatively low water volumes will travel around such nose projections into an underlying gutter, large flow volumes fail to follow the nose projections and fall directly to the ground as though no gutter were present. Furthermore, many shield devices are of a fragile construction incapable of surviving the weight of a ladder and worker when access to the roof or gutter is sought for periodic maintenance.
Gutter systems have been disclosed wherein gutters of reasonably standard design are pivotably supported by brackets attached to the fascia in a manner permitting controlled inversion of the gutter with consequent dumping of its contents. However, the inversion of such gutters and restoration to their upright functional position generally requires difficult manipulations using a long pole from a location beneath the gutter and in the path of the dumped debris.
It is accordingly an object of this invention to provide an eaves rain gutter which can be easily cleaned of accumulated debris.
It is another object of this invention to provide a gutter as in the foregoing object which permits dumping of accumulated debris without requiring the operator to utilize upward reaching tools or be positioned beneath the gutter.
It is a further object of the present invention to provide a rain gutter of the aforesaid nature of rugged and durable construction amenable to low cost manufacture.
These objects and other objects and advantages of the invention will be apparent from the following description.
SUMMARY OF THE INVENTION
The above and other beneficial objects and advantages are accomplished in accordance with the present invention by an eaves rain gutter for mounting upon the fascia of a building comprising:
(a) an elongated flexible trough having first and second parallel stiffened edge extremities, the first edge extremity being held in fixed horizontal position, and the second edge extremity being movably held in a horizontally disposed water-holding state at an elevation adjacent said first edge extremity and causing said trough to have a sling-like configuration, said second edge extremity being capable of falling freely by gravity to a dumped state wherein the trough is disposed as a vertically oriented substantially flat sheet pendantly supported by said first edge extremity,
(b) a plurality of supporting brackets attachable to said fascia and configured to hold said first edge extremity in a fixed horizontal position, and hold said second edge extremity in a releasible horizontal position,
(c) a plurality of tether lines interactive with said second edge extremity at horizontally spaced sites thereof and adapted to raise said second edge extremity from its position in the dumped state to its position in the water-holding state,
(d) anchoring means for maintaining said tether lines in a fixed position in the water-holding state of the rain gutter, and
(e) guide means which slidably engage said tether lines in a manner causing an angular directional change of the tether lines permitting movement of said tether lines in horizontal and substantially vertical directions, whereby
(f) force applied to said tether lines in their horizontal directions causes said second edge extremity to be raised from said dumped state to said water-holding state.
In preferred embodiments, the gutter trough is comprised of a single strip of a flexible material such as a sheet of rubber, elastomeric synthetic polymer or fabric which is rendered water-impermeable by virtue of associated polymer material. The edge extremities may be stiffened by attachment to rigid rods or tubes.
The guides are preferably associated with the supporting brackets. Bracing means may be associated with said brackets in a manner to cause shaping abutment of the trough sheet in its water-holding state.
In certain embodiments, the tether lines, in their region of horizontal movement, are gathered as a bundle extending toward one lateral extremity of the gutter trough. In other embodiments the plurality of tether lines may be connected to a single horizontally directed cable.
The first edge extremity is preferably forwardly spaced from the fascia while the second edge extremity is positioned rearwardly from said first edge extremity and closely adjacent the fascia.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings forming a part of this specification and in which similar numerals of reference indicate corresponding parts in all the figures of the drawing:
FIG. 1 is a fragmentary perspective view of an embodiment of the rain gutter of this invention, shown in the water-holding state.
FIG. 2 is a sectional view taken along the line 2--2 of FIG. 1 and showing in phantom outline the dumped state of the gutter.
FIG. 3 is a top view of the embodiment of FIG. 1.
FIG. 4 is a front view of a supporting bracket component of the rain gutter of FIG. 1.
FIG. 5 is an enlarged fragmentary sectional view of an alternative edge construction useful in the rain gutter of FIG. 1.
FIG. 6 is an enlarged side view of a joining bracket component of the rain gutter of FIG. 1.
FIG. 7 is a perspective view of the joining bracket of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an embodiment of the rain gutter 10 of the present invention is shown attached to the fascia 11 of a building and positioned below the lowermost edge 12 of roof 13. The intervening space between said edge 12 and fascia 11 is generally referred to as the eaves of the roof structure.
Rain gutter 10 is comprised of flexible elongated trough 14, and a plurality of supporting brackets 15, tether lines 16, and guide means 17. Trough 14 of the exemplified embodiment is fabricated of an integral piece of thin sheet-like material such as rubber, neoprene, polyurethane, silicone, and the like having resistance to weathering, while retaining strength and flexibility over wide temperature extremes. In alternative embodiments however, the trough may be fabricated of two or more rigid elongated panels pivotably interconnected at their long edges to provide a trough of controlled flexibility in the direction normal to the long axes of the panels.
As best shown in FIG. 2, the trough has first and second parallel edge extremities 18 and 19, respectively, engaged by rigid tubular holding clips 20 and 40, respectively, of generally C-shaped cross-section having spring-like characteristics with respect to the width of downwardly disposed slot 21. Each edge extremity of the trough is inserted into said slot and retentively gripped thereby. To enhance the gripping effect, two vertically disposed facing shoulders 22 extend from slot 21 into the interior of holding clips 20 and 40. In the embodiment exemplified in FIG. 5, the edges of the trough are of enlarged cross-sectional configuration, thereby permitting the trough edges to be slid horizontally onto the holding clip, and obviating the need for spring-like characteristics in the clip. Still other alternative expedients may be employed to cause the edge extremities of the trough to be retained within or by the elongated rigid members.
The exemplified embodiment of supporting bracket 15 has a flat mounting plate 23 having apertures 24 adapted to permit penetration of screws for attachment to fascia 11. Upper and lower bent metal rods 25 and 26, respectively, are affixed to the front face 27 of plate 23 by way of spot welding or equivalent means. Upper rod 25 is comprised of a straight support arm portion 28 disposed horizontally and normal to plate 23, and a hook-shaped guide portion 29 laterally displaced below arm portion 28 and adjacent plate 23.
Lower rod 26 is comprised of extension arm portion 30 disposed below arm portion 28 of the upper rod and welded thereto, and brace portion 31 disposed below said extension arm portion and attached to the front face of plate 23. The forwardmost extremity 32 of extension arm portion 30 extends forwardly of support arm portion 28, and is provided with a threaded section 33 and retaining nut 34. In alternative embodiments, the supporting bracket may be of integral molded construction.
Threaded section 33 is adapted to pass through apertures 35 of paired attachment clamps 36 which embrace holding clip 20 at spaced intervals. As shown in FIG. 2, trough 14 is pendantly supported by said paired attachment clamps when the trough is in its dumped state.
Said paired attachment clamps 36 additionally embrace holding clip 40 at spaced intervals beneath guide portion 29 of each supporting bracket 15. Retainer collars 41 are utilized to hold selected paired halves of attachment clamps 36 together. A tether line 16 is fastened to said selected paired attachment clamps 36 by tied engagement through apertures 35. The tether line extends over the top of guide portion 29 and thence horizontally toward a lateral extremity of the trough. The tether lines may be separate in their extension from the holding clip and thence horizontally to a lateral extremity of the trough, or the several tether lines may join with a single horizontally disposed main trunk line 16a as shown in FIG. 1. When a main trunk tether line is used, the separate tether lengths which attach to clamps 36 may be referred to as primary tether lines. Joinder of the tether lines may be achieved by way of joining brackets 42 or by knotting or alternative equivalent means.
A preferred type of joining bracket, illustrated in FIGS. 6 and 7, is shown comprised of an integral piece of bent and machined flat metal stock. Slots 48 and guide wings 49 aid in inserting, locating and adjustably fixing the joining bracket upon a single horizontally directed tether cable 16a. Apertures 50 permit the attachment by knotting of the primary tethers 16.
When the tether lines are horizontally drawn, by manual or motorized means, the second edge extremity is elevated from its pendant location to an upper location adjacent mounting plate 23, as shown in FIGS. 1 and 2. To assist in horizontally moving the tether lines, a pulley sheave 37 may be positioned adjacent a lateral extremity of the trough and adopted to rotate in a vertical plane parallel to fascia 11. Tether lines may travel 90 degrees about said sheave and thence downwardly to a location near the base of the building, thereby permitting the operator to pull downwardly upon the tether lines to raise the second edge extremity.
When the second edge extremity is in its raised location, the tether lines may be secured by way of a loop 38 and interactive hook 39 attached to the building. In said manner, the second edge extremity will be held in place. When it is desired to dump the contents of the trough, the tether lines are merely released from engagement with hook 39, and the weight of the trough 14 and holding clip 40 will cause its descent. Alternative means may however be utilized to achieve the desired anchoring of the tether lines with attendant securement of edge extremity 19 in its uppermost position. In the dumped or descended state, the rain gutter system can be further cleaned by a spray of water from a garden hose.
An end cap 43 is associated with each lateral extremity of the trough. The end cap is comprised of a vertically oriented side panel 44 having a rear groove 45 to permit entrance of holding clip 40, a front groove 48 which accommodates holding clip 20, a mounting plate 46 for attachment to the fascia, and a contoured bottom plate 47 against which the trough abuts from below. Appropriate constructions may be readily designed to enable the trough to accommodate outside and inside corners and downspouts.
While particular examples of the present invention have been shown and described, it is apparent that changes and modifications may be made therein without departing from the invention in its broadest aspects. The aim of the appended claims, therefore, is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A rain gutter adapted to be mounted upon the fascia of a building beneath the lowermost extremity of a sloped roof is designed in a manner to easily discharge any accumulated wind-borne debris. The gutter is comprised of a flexible trough having first and second parallel stiffened edge extremities. The first edge extremity is held in fixed position and the second edge extremity is adapted to fall, causing dumping of the contents of the trough. Tether lines control the positioning of the second edge extremity. | 4 |
FIELD OF THE INVENTION
[0001] This invention relates to coronary bypass grafting surgery and more particularly to instruments and method to facilitate performing an aortotomy and proximal anastomosis, for example, associated with coronary artery bypass grafting surgery.
BACKGROUND OF THE INVENTION
[0002] Contemporary coronary artery bypass grafting surgery is performed on a beating heart to obviate complications commonly associated with prior surgical practices of transitioning a patient onto and off of a heart-lung machine that maintained circulation while the heart was in quiescent condition during construction of a coronary arterial bypass. However, performing an aortotomy and a proximal anastomosis on the aorta that is perfused with blood under pressure contribute to substantial losses of blood in the absence of temporary measures taken to curtail blood flow through the aortic hole. Side-bite and surface-oriented clamping mechanisms have been used to diminish loss of blood during the surgical procedures of punching the aortic hole and anastomosing the graft vessel, but such temporary occlusions damage the endothelium and dislodge emboli that may migrate through the circulatory system. Alternative schemes for performing an aortotomy and limiting loss of blood during the period of anastomosing a bypass graft include introducing a plug or seal at the site of the aortotomy, but such schemes commonly inhibit convenient and rapid completion of the graft anastomosis, and present other complications to be resolved following the grafting procedure.
SUMMARY OF THE INVENTION
[0003] In accordance with the method and instrumentation of the present invention, an aorto-coronary bypass graft is performed using an aortic punch including a corkscrew instrument and a hemostatic sheath that selectively delivers and positions a seal within the punched aortic hole for retention against the aortic wall under tension established by an external structure. The suture anastomosis is performed with the hemostatic seal in place and with a central stem of the seal residing near the location of the last placed stitch. A tubular removal instrument is positioned about the protruding stem to remove the seal as a tear-away strip that is pulled through the tubular removal instrument.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is a pictorial illustration of the corkscrew aortic punch disposed for insertion into the aorta through a hemostatic sheath in accordance with one embodiment of the present invention;
[0005] [0005]FIG. 2 is a pictorial illustration of the hemostatic sheath penetrated through the aortic wall;
[0006] [0006]FIG. 3 is a pictorial illustration of the hemostatic sheath positioned within the aorta as the aortic punch is removed;
[0007] [0007]FIGS. 4 and 5 are pictorial illustrations of a seal-positioning mechanism for insertion through the hemostatic sheath into the aorta;
[0008] [0008]FIG. 6 is a pictorial illustration of the hemostatic seal mechanism deployed from the interior end of the hemostatic sheath;
[0009] [0009]FIG. 7 is a pictorial illustration of the hemostatic seal mechanism manually positioned within the punched aortic hole as the hemostatic sheath and hemostatic seal-positioning mechanism are withdrawn;
[0010] [0010]FIG. 8 is a pictorial illustration of the hemostatic seal retained in place at the punched aortic hole via an external tensioning mechanism;
[0011] [0011]FIG. 9 is a pictorial illustration of suture anastomosis performed about the hemostatic seal;
[0012] [0012]FIG. 10 is a pictorial frontal illustration of the suture anastomosis substantially completed with the stem of the hemostatic seal positioned near the last stitches;
[0013] [0013]FIG. 11 is a pictorial frontal illustration of the tubular removal instrument disposed over the stem of the hemostatic seal in preparation for removal from the graft site;
[0014] [0014]FIG. 12 is a pictorial frontal illustration of the hemostatic seal dissembled through the tubular removal instrument;
[0015] [0015]FIG. 13 is a pictorial frontal illustration of the anastomosis completed upon removal of the tubular removal instrument and tying off of the suture ends about the segment of the anastomosis from which the tubular removal instrument is withdrawn.
[0016] [0016]FIG. 14 is an exploded view of the aortic punch and hemostatic sheath in accordance with one embodiment of the present invention;
[0017] [0017]FIG. 15 is a frontal view of the assembled aortic punch and hemostatic sheath prepared for performing an aortotomy according to the present invention;
[0018] [0018]FIG. 16 is an exploded view of the hemostatic seal positioning mechanism that illustrates the hemostatic seal and tensioning structure in deployed condition and in confined condition;
[0019] [0019]FIG. 17 is a pictorial illustration of the formation of a hemostatic seal in accordance with one embodiment of the present invention;
[0020] [0020]FIG. 18 is a pictorial exploded illustration of a hemostatic seal removal instrument according to one embodiment of the present invention;
[0021] [0021]FIG. 19 is a flow chart illustrating an embodiment of the surgical process according to the present invention; and
[0022] [0022]FIG. 20 is a pictorial illustration of a sterile kit of the instruments for performing the surgical process according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring now to FIGS. 1, 2 and 3 , there are shown pictorial views of the aortic punch 9 configured for penetrating the aorta 17 of a patient in preparation for a proximal anastomosis of a bypass vessel to the aorta of the patient. Specifically, an outer hemostatic sheath 11 is coaxially disposed over the lower elongated segment 13 of the aortic punch which supports a corkscrew-type auger 15 , as shown in FIGS. 14 and 15. The punch and auger 15 are rotated into a wall of the aorta 17 and the plunger 19 can then be depressed to penetrate the sharpened edge of the lower elongated segment 13 through the aorta wall. The punched-out segment of aorta wall remains captivated on the cork screw 15 , and the hemostatic sheath 11 is positioned within the punched hole through the aorta wall. The plunger mechanism 19 and attached elongated lower segment is removed from the hemostatic sheath 11 that remains in position through the aorta wall, as shown in FIG. 3. A fluid-tight seal is included within the hemostatic sheath 11 to inhibit outflow of blood under pressure from the aorta 17 in which it is positioned.
[0024] Referring now to the pictorial illustration of FIG. 4, there is shown a seal-insertion instrument 21 that includes a sheath 23 of outer diameter sized to slide within the hemostatic sheath 11 , and a plunger 25 that is disposed to slide axially within the sheath 23 for selectively ejecting the hemostatic seal structure 27 from its confinement within the sheath 23 . The hemostatic seal structure 27 , as later described herein with reference to FIG. 16, includes resilient members that are confined within the sheath 23 in preparation for positioning and expansion into sealing engagement with the aorta wall, as later descried herein.
[0025] Referring now to the pictorial illustrations of FIGS. 5 and 6, the seal-insertion instrument 21 is inserted into the hemostatic sheath 11 through the fluid-tight seal therein, and the plunger 25 is depressed to eject a portion of the hemostatic seal structure 27 , within the aorta 17 . The plunger 25 includes an axial lumen therethrough to pass a length of line 28 that is attached to the hemostatic seal structure 27 . The proximal end of plunger 25 may also include a hemostatic seal 100 through which the length of line 28 passes.
[0026] As illustrated in FIGS. 6, 7, 16 and 17 , a convex or mushroom-shaped sealing element 29 of the hemostatic seal structure 27 is deployed and manually restrained within the aorta 17 covering the punched aortic hole as the hemostatic sheath 11 and the seal-insertion instrument 21 are removed together from the aorta 17 . The hemostatic seal structure 27 is thereby liberated from confinement within the seal-insertion instrument 21 to expand into sealing engagement with the aorta wall inside the punched aortic hole.
[0027] Referring now to FIG. 16, the hemostatic seal structure 27 includes the convex or mushroom-shaped sealing element 29 , and this sealing element 29 includes an integral central stem 30 that is attached via a suture tether 32 to a resilient frame 34 which tensions the suture tether 32 . The resilient frame 34 is attached to the length of line 28 that passes through an axial lumen through the plunger 25 as the entire structure is packed in confined configuration within the hollow sheath 23 of the seal-insertion instrument 21 . When ejected from the hemostatic sheath 23 upon depression of the plunger 25 , the resilient frame 34 expands to tension the suture tether 32 . Manual positioning by the surgeon's finger, as shown in FIG. 7, promotes proper sealing of the hole in the aorta as the resilient frame 34 expands to tension the suture tether 32 . As thus positioned in this configuration, the resilient frame 34 maintains tension on the suture tether 32 that, in turn, supports the sealing element 29 from outside the aorta to provide outwardly-directed resilient biasing force on the sealing element 29 . This resilient force establishes firm sealing engagement of the sealing element 29 against the inside wall of the aorta. In addition, the suture tether 32 greatly facilitates removal of the resilient frame 34 , as later described herein, upon simply cutting one or both ends of the suture tether 32 away from the resilient frame 34 for removal from the sealing element 29 . In one embodiment the suture-tether 32 may pass through the convex segment of the sealing element 29 to the concave side thereof on both sides of the central stem 30 . In another embodiment, the suture tether 32 may be tied to the central stem 30 closely adjacent the concave surface of the sealing element 29 .
[0028] The sealing element 29 is formed in accordance with one embodiment of the present invention, as illustrated in FIG. 17. Specifically, a hollow tube 33 of flexible material such as polyvinyl chloride, PEBAX, or other polymer material may be extruded about a looped suture 35 or wire or other tensile member for improved tensile strength. Alternatively, a solid, flexible rod of similar material having sufficient tensile strength may be used. The hollow tube (or solid rod) 33 may be helically or spirally wound into the configuration of the mushroom-shaped sealing member 29 , with the central stem 30 integrally formed thereon. The adjacent convolutes of the spirally-wound tube 33 with suture 35 or other tensile member disposed therein (or solid rod) may be lightly adhered together through the application of heat and pressure to a thermoplastic material, or through other suitable adhesive attachments to form the substantially fluid-impervious sealing element 29 that is flexible and resilient for confined packing within the hollow sheath 23 of the seal-insertion instrument 21 . Light adhesion between adjacent convolutes of the spirally-wound tube 33 with a suture therein (or solid rod) promotes disassembly of the sealing element 29 as by tearing along the boundary between adjacent convolutes under tension applied to the central stem 30 , as later described herein. It should be noted that the central stem 30 is an integral and continuous portion of the spiral convolutes (or other meandering pattern) that extend continuously from the central stem portion 30 to the outer perimeter of the mushroom-shaped portion of the sealing element 29 . This assures substantially uniform high tensile strength of the hollow tube 33 with suture 35 disposed therein (or solid rod) over the entire continuous length of the tube 33 to assure complete removal from the aorta in the manner as later described herein. In one embodiment, the sealing element 29 may be formed by winding the hollow tube 33 (or solid rod) around a mandrel that includes separable flanges which are axially spaced apart by about the diameter dimension of the tube 33 (or solid rod), and that includes a central hollow support to house the portion that forms the central stem 30 . Heat and pressure applied between such flanges causes thermoplastic flow and adhesion between adjacent convolutes in the mushroom-shaped portion and to the stem 30 in the central portion of the fluid-impervious sealing element 29 thus formed. Alternatively, bioinert adhesive may be applied to the convolutes and central stem 30 to retain the shape of the fluid-impervious sealing element 29 thus formed.
[0029] Referring now to the pictorial illustration of FIG. 8, the sealing element 29 is shown disposed in sealing position inside the punched aortic hole with the integral stem 30 protruding through the hole, and with suture loop 35 protruding from the proximal end of the stem 30 . It should be noted that the resilient frame 34 and the suture tether 32 are positioned on the outer wall of the aorta to exert an outwardly-directed force on the sealing element 29 to retain it in sealing engagement with the inner aortic wall, and to prevent inadvertent expulsion of the sealing element 29 from the hole or loss of the sealing element 29 into the aorta. The sealing element 29 is thus maintained in sealing position over the hole in the aorta during formation of the proximal anastomosis by suturing the graft vessel 37 onto the aorta 17 , as shown in FIGS. 9 - 11 . The stem 30 is flexible and can be gently pushed out of the way of sutures that are stitched about the hole in the aorta and into the proximal end of the graft vessel 37 . In this way, the stem 30 is left protruding through the anastomosis at a position thereon near the last stitch (or between any adjacent stitches).
[0030] Referring now to FIGS. 10 - 12 and 18 , a seal-removal instrument 41 includes an outer tube 43 with an inner core 45 that is slidable within the outer tube 43 and that carries a hook 47 at its distal end. The assembly of inner core 45 disposed within the outer tube 43 is positioned over the stem 30 of the sealing element 29 with the hook 47 engaged in the suture loop 35 . The outer tube 43 is positioned onto the stem 30 down to the root of its attachment to the mushroom-shaped spiral-wound sealing element 29 , and the inner core 45 is then withdrawn from the outer tube 43 . These motions cause the spirally-wound convolutes of the sealing element 29 to tear and otherwise disassemble for convenient removal as a continuous strand 29 ′, as shown in FIG. 12, of the material from which the spirally-wound sealing element 29 was formed. Thereafter, the outer tube 43 may be withdrawn and the sutures tied off near where outer tube 43 was positioned to complete the proximal anastomosis, as shown in FIG. 13.
[0031] Alternatively, the central stem 30 may be formed as an integral part of the mushroom-shaped portion of the sealing element 29 with sufficient length to extend through the outer tube 43 adequately to permit finger gripping of the stem 30 for manual tensioning and removal of the continuous strand 29 ′ through the outer tube 43 without the need for the hooked inner core 45 and associated suture loop 35 .
[0032] Referring now to the flow chart of FIG. 19, an embodiment of the surgical procedure performed according to the present invention includes forming an aperture 51 in the aorta wall, as illustrated in FIGS. 1 and 2. The hemostatic seal structure in confined configuration within the hemostatic sheath is then introduced 53 into the aorta through the hole in the wall thereof. The sealing element resiliently expands 55 inside the aorta to form a fluid-tight seal over the hole in the wall, and is supported 57 on a tensioned tether from the outside of the aorta. A central stem portion of the sealing element is sufficiently flexible to be pushed away from the locations on the aorta at which suture stitches are inserted during substantial completion 59 of anastomosing the graft vessel to the aorta over the hole in the wall thereof. The central stem portion of the sealing element thus protrudes through the anastomosis between adjacent stitches and is accessible to facilitate removal of the sealing element disposed within the aorta beneath the anastomosis. The sealing element is removed through a tube that is positioned over the central stem portion by applying tensile force to the central stem portion relative to the tube. This disassembles or unravels the sealing element into a single strand 61 that is removed through the tube 63 , as shown in FIG. 12. The ends of the suture adjacent to the location on the anastomosis through which the strand was removed may then be tied off to complete the anastomosis 65 .
[0033] Referring now to FIG. 20, there is shown a pictorial illustration of a kit of instruments and components suitable for performing the surgical procedure according to the present invention, as previously described herein. Specifically, at least the seal-insertion instrument 21 and seal removal tube 43 are packaged within a sealed enclosure 67 that preserves a sterile environment and facilitates convenient shipping and handling of these components without contamination or damage. Additionally, a hemostatic sheath 11 may be included within the enclosure 67 for use with a punch (separately available to a surgeon) in the manner as previously described herein with reference to FIGS. 1 and 2.
[0034] Therefore, the surgical devices and procedures for forming a temporary aortic seal during proximal anastomosis of a graft vessel to the aorta greatly facilitates removal of the temporary seal with negligible risk of any residual debris being created thereby to circulate in blood flowing in the aorta or in the graft vessel. Additionally, the sealing element of the present invention promotes self sealing of an aortotomy during formation of the vessel graft, aided by a resilient frame that is disposed outside the aorta to support the sealing element during formation of the anastomosis. The resilient frame is easily removed at a convenient stage in the procedure. The sealing element thus positioned to seal off the aortotomy during formation of the anastomosis can be conveniently dissembled into a continuous strand that is pulled from the surgical site with minimal additional trauma or complication of the surgical procedure. | Forming a proximal anastomosis on an aortic wall includes method and instrumentation and apparatus for forming an aortic puncture and inserting a fluid-impervious sealing element with a lateral flange and central stem into the vessel through the puncture. An anastomosis of a graft vessel over the puncture is partially completed with the central stem of the sealing element protruding through the partial anastomosis. A removal instrument attaches to the central stem and retrieves the sealing element that disassembles in helical disassociation of the flange and stem into a continuous strand that is withdrawn from the partial anastomosis prior to completion of the procedure. | 0 |
REFERENCE TO RELATED APPLICATIONS
This Application is a Continuation-in-Part of patent application Ser. No. 11/335,073, filed 18 Jan. 2006, now U.S. Pat. No. 7,237,550.
BACKGROUND OF THE INVENTION
The present invention relates to a complex respirator, especially to a complex respirator with replaceable filter so that the storage of the respirator is easier and the filter is selectable with various pore sizes for filtering different kinds of gas.
The problem of air pollution is getting worse nowadays. No matter whether the pollution is from a dust storm, heavy smoke discharged from the factory, vehicle exhaust emission, or even smoke from waste combustion, all include toxic gas or granules harmful to human bodies, both are health risk factors. For the sake of protection and prevention, people wear respirators all the time so as to avoid inhalation of toxic gas and harmful granules while going out. Thus, the use rate of the respirator has risen. Most of the conventional respirators are disposable and have charcoal or “filtering fiber as filter media. Referring to FIG. 1 , the fiber shown is disclosed in U.S. Pat. No. 6,234,171, B1—MOLDED RESPIRATOR CONTAINING SORBENT PARTICLES. The respirator is disposed with fiber 1 attached with sorbent particles 12 . Because a unit area of the fiber 1 only adheres a certain amount of the sorbent particles 12 , the sorbent particles 12 are easily saturated and are then unable to absorb any more toxic or harmful material.
Furthermore, the conventional flat respirator can't attach on a user's face tightly, so that a gap is formed between the edge of the respirator and the face skin. While wearing the flat respirator, part of the air with toxic gas or granules may flow through the gap and the gas enters the user's body. Thus a respirator 20 with a cartridge 22 in FIG. 2 was developed. The traditional cartridge is filled with an adsorbent material as a filter media for filtering the air. Generally, the absorbent material is charcoal to absorb organic solvents and granules. However, the breathing area of the respirator 20 with the cartridge 22 is limited inside the cartridge 22 and includes pores with a small diameter. Therefore, such a respirator makes breathing difficult. In order to get more air flow, people need to breathe more heavily. Although the purpose of avoiding toxic gas or harmful materials is achieved, people feel uncomfortable while breathing. Thus people would not like to wear that kind of respirator while going out to areas with polluted air.
With either the conventional flat respirator or the respirator with the cartridge, the whole respirator needs to be thrown away when the filter is saturated and unable to be used anymore. This causes a kind of waste. Not only do those working in special locations, such as hospitals, use respirators, but also ordinary people do as well. Thus, there is a need to improve the way used filter material is replaced.
Due to a worsening environment, air pollution has become a pressing problem of public health. Thus, the present invention provides a complex respirator that not only protects people from inhaling toxic gas and harmful granules, but also allows users to breathe more smoothly. Moreover, only the filter layer of the respirator needs to be changed and the service time of the respirator is thereby extended.
SUMMARY OF THE INVENTION
Therefore it is a primary object of the present invention to provide a complex respirator that includes a replaceable first filter layer so that users can choose material of the first filter layer depending on places they intend to go. Thus toxic gas or harmful granules in the air people have inhaled will have been filtered.
It is another object of the present invention to provide a complex respirator that includes two filter layers made from different materials with a different area and pore size, so as to filter different granules. Thus, users won't inhale toxic gas or harmful granules in the air.
It is a further object of the present invention to provide a complex respirator with a replaceable filter layer, where the used filter layer is able to be replaced with a new filter layer directly. Thus, the service life of the respirator is extended.
It is a further object of the present invention to provide a complex respirator that includes a chamber therein for buffering pressure coming from air-breathing, so that people using this respirator can breathe smoothly and comfortably.
A complex respirator according to the present invention includes at least a first filter layer, a first shell, and a second filter layer. The first shell is disposed on inner side of the first filter layer while the second filter layer is arranged on the inner side of the first shell. The material of the first filter layer can be changed according to the user's needs. The first filter layer has a larger pore size than that of the second filter layer, while the second filter layer has a larger area than that of the first filter layer. An air chamber is formed between the second filter layer and the first shell so as to make air inhaled or exhaled flow through the first filter layer and the second filter layer uniformly. The present invention further includes a second shell arranged on outer side of the first filter layer for preventing the first filter layer from exposure to water. Moreover, the second shell and the first shell together form an open space facing downwards allowing the inhaled or external air to flow therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, wherein
FIG. 1 is schematic drawing showing fiber of conventional flat respirators;
FIG. 2 is schematic drawing showing a traditional respirator with a cartridge;
FIG. 3 is a schematic drawing of an embodiment according to the present invention;
FIG. 4A is a schematic drawing showing air flow of an embodiment according to the present invention;
FIG. 4B is a schematic drawing showing air flow of an embodiment according to the present invention;
FIG. 5A is a schematic drawing showing filter layers of another embodiment according to the present invention;
FIG. 5B is a schematic drawing showing filter layers of another embodiment according to the present invention;
FIG. 6 is a schematic drawing showing structure of a further embodiment according to the present invention;
FIG. 7 is a schematic drawing showing structure of a further embodiment according to the present invention;
FIG. 8A is a schematic drawing showing the replacement of the filter layer;
FIG. 8B is a schematic drawing showing structure of a further embodiment according to the present invention;
FIG. 9A is a schematic drawing showing air flow of a further embodiment according to the present invention;
FIG. 9B is a schematic drawing showing air flow of a further embodiment according to the present invention;
FIG. 10 is a schematic drawing showing structure of a further embodiment according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 3 , a complex respirator 30 according to the present invention consists of a first shell 32 , at least a first filter layer 34 and a second filter layer 36 . The first filter layer 34 is disposed on an outer side of the first shell 32 and a plurality of first air holes 322 is arranged in a central (that is, non-peripheral) portion of the first shell 32 corresponding to the position of the first filter layer 34 . The second filter layer 36 is disposed on an inner side of the first shell 32 . The second filter layer 36 is made of a material with smaller pore diameter than that of the material of the first filter layer 34 . The first filter layer 34 is used to filter organic gas or microorganisms in the air while the second filter layer 36 is for filtering air with material that can't be filtered by the first filter layer 34 such as dust. The first shell 32 is made from a material impermeable to gas, so that the gas intake or exhaust can only passes through the first filter layer 34 and the second filter layer 36 via the first air holes 322 .
The filter area of the first filter layer 34 is smaller than that of the second filter layer 36 . The first filter layer 34 includes at least a layer of a first filter and a plurality of first microgranular filter media. The first microgranular filter media is distributed uniformly in a plane and is disposed in combination with the first filter, with a mixture setting so that gas passes through the first filter layer 34 uniformly. The second filter layer 36 consists of at least a layer of a second filter and a plurality of second microgranular filter media. The second microgranular filter media is distributed evenly in a plane and is disposed in combination with the second filter, with a mixture setting so that gas passes through the second filter layer 36 uniformly. An air chamber is formed between the second filter layer 36 and the first shell 32 so that intake gas through the first filter layer 34 and the exhaust gas pass the second filter layer 36 uniformly.
Refer to FIG. 4A , there is shown use a complex respirator 30 according to the present invention to inhale air from outside. Because the first shell 32 is made from a gas impermeable material, outside air can't flow through the first shell 32 and is only able to pass through the first filter layer 34 . Then the air passes through the second filter layer 36 uniformly. As shown in FIG. 4B , air exhausted through the complex respirator 30 according to the present invention diffuses uniformly through the second filter layer 36 . Yet the gas through the second filter layer 36 can't flow through the first shell 32 , it can only pass through the first filter layer 34 . Thus, the air inhaled and the air exhausted only pass through the first filter layer 34 and the second filter layer 36 . Therefore, the efficiency of the complex respirator 30 for filtering gas is improved.
As shown in FIG. 5A & FIG. 5B , the first filter layer 34 includes a plurality of layers of first filter 342 , 344 , 346 and a plurality of layers of first microgranular filter media 348 , 350 while the second filter layer 36 includes a plurality of layers of second filter 362 , 364 , 366 and a plurality of layers of second microgranular filter media 368 , 370 . Both the first microgranular filter media layers 348 , 350 and the second microgranular filter media layers 368 , 370 have a plurality of microgranular filter media so as to make gas impassable along fixed paths through the first filter layer 34 and the second filter layer 36 , respectively. Also, by means of a chamber located between the second filter layer 36 and the first shell 32 , gas inhaled or exhaled diffuses uniformly through the second filter layer 36 . Thus, the lifetime of the first filter layer 34 as well as the second filter layer 36 of the complex respirator 30 , of the present invention, is extended.
Referring to FIG. 3 , a chamber between the second filter layer 36 and the first shell 34 provides a buffering space for pressure from gas so that people don't need to breath hard to get air in while breathing, and pressure coming from breathing won't cause deformation of the complex respirator 30 . While wearing the respirator 30 , breathing won't become difficult.
Moreover, the complex respirator 30 further includes a first fixing member 40 and a second fixing member 42 . The first fixing member 40 is disposed on edge of the first shell 32 for fixing a user's mouth and nose inside the covering area of the first shell 32 . The second fixing member 42 includes two circular threads, respectively connected with right and left sides of the first fixing member 40 for preventing the complex respirator 30 of the present invention from falling or loosening from the face of the user. Therefore, the complex respirator 30 according to the present invention goes over the nose and mouth completely without a gap between the respirator and the face of a user, so as to prevent dirty air flowing into the inner space covered by the first shell 32 .
The complex respirator 30 according to the present invention totally separates the nose and mouse from air outside and buffers pressure generated during breathing by the air chamber. Thus people are able to make use the complex respirator 30 to obtain clean air easily and breathe comfortably.
Refer to FIG. 6 , the difference between the embodiment in this figure and the embodiment in FIG. 3 is that in FIG. 3 , a plurality of first air holes 322 is arranged on the first shell 32 corresponding to the position of the first filter layer 34 , while in FIG. 6 , a first air vent 522 is disposed on the first shell 52 corresponding to the position of the first filter layer 54 . Moreover, the first filter layer 54 and the second filter layer 56 both include a plurality of layers of a beehive filter and a plurality of layers of an anti-bacteria, bacteriostatic and deodorization layer. The beehive filter consists of a plenty of beehive cells and each of the beehive cells is contains a microgranular filter media therein. A complex respirator 50 according to the present invention includes the first vent 522 arranged on the first shell 52 so that air inhaled and exhaled air pass through the large area of first filter layer 54 .
In this embodiment, the first filter layer 54 is composed of three layers of first beehive filter 542 , 544 , 546 and two layers of first bacteriostatic and deodorization layer 548 , 550 , that are made from bacteriostatic and deodorization fiber material. The second filter layer 56 consists of three layers of second beehive filter 562 , 564 , 566 and two layers of second bacteriostatic and deodorization layer 568 , 570 , that are made from bacteriostatic and deodorization fiber material. When air flows through the first filter layer 54 and the second filter layer 56 , it can't pass in a fixed path due to the beehive filter. By means of an air chamber formed between the second filter layer 56 and the first shell 52 , air inhaled or exhaled through the complex respirator 50 passes uniformly through the first filter layer 54 as well as the second filter layer 56 . The lifetime of the filter layer 54 and the second filter layer of the complex respirator 50 according to the present invention is extended.
Furthermore, when the first filter layer 54 can't filter the air continuingly, it can be replaced by another new piece of the first filter layer 54 that had not been used yet. Thus the complex respirator 50 according to the present invention reduces the amount of garbage from respirators. Because the first filter layer 54 is replaceable, users can choose the first filter layer 54 from those made from various materials depending on the place they intend to go. For example, if the destination is hospital, the first filter layer 54 chosen would be made from anti-bacteria or bactericidal material. If the place is a construction site, the first filter layer 54 chosen would be a material for filtering dust. If the place is a chemical factory, the first filter layer 54 chosen would be made from material that filter chemicals.
Refer to FIG. 7 , the difference between the embodiment in FIG. 7 and the embodiment in FIG. 3 is that the embodiment in this figure includes a first shell 72 that connects with a cap 74 having air holes 742 for fixing a first filter layer 76 on the first shell 72 and a second shell 84 for protecting the first filter layer 76 from being exposed to drops of water. The cap 74 and the second shell 84 are arranged on the outer side of the first shell 72 . The top side, and edges on right and left sides of the second shell 84 connect with the first shell 72 so as to form an open space having an opening facing downwards. Thus, air passes in and out through the opening of the open space without separation of the second shell 84 . The second shell 84 is also made from impermeable material so that water drops can't pass. Thus the deformation or malfunction of microgranular filter media caused by influence of the water drops is avoided.
The first filter layer 76 is fixed in a slot 722 of the first shell 72 by the cap 74 that is arranged on the outer side of the slot 722 , corresponding to the opening of the open space for convenience of replacing the used first filter layer 76 . As shown in FIG. 8A , when the first filter layer 76 no longer filters the air inhaled or exhaled, the cap 74 is opened for replacing the first filter layer 76 with a new first filter layer 86 that has not been used yet. After the new first filter layer 86 is disposed inside the slot 722 of the first shell 72 , the cap 74 secures the first filter layer 86 , as shown in FIG. 8B .
Refer to FIG. 9A , while people using the complex respirator 70 of the present invention to inhale air, air outside firstly flows into the open space that has on opening facing downwards and is located between the first shell 72 and the second shell 84 , because the first shell 72 is impermeable and air can't pass through it. Then, the air passes through the first filter layer 76 . Next, the air passes through and diffuses uniformly through the second filter layer 78 . Referring to FIG. 9B , when people use the complex respirator 70 of the present invention to exhale air, the exhausted air diffuses through the second filter layer 78 uniformly. However, the air that has passed therethrough can't flow through the first shell 72 . Instead, it can only pass through the first filter layer 76 into the open space and flow out through the opening thereof facing downwards. Therefore, the second shell 84 has no influence on the breathing of users.
Refer to FIG. 10 , the difference between the embodiment in FIG. 3 ( 7 ) and the embodiment in FIG. 10 is that the first filter layer 76 of the embodiment in the FIG. 3 ( 7 ) includes three layers of the first filter 762 , 764 , 766 , while a first filter layer 96 of the embodiment in the FIG. 10 includes three layers of a positioning plate 962 , 964 , 966 . A complex respirator 90 of the present invention fixes two layers of the first microgranular filter media 968 , 970 by means of the three layers of the positioning plate 962 , 964 , 966 . The two layers of the first microgranular filter media 968 , 970 are arranged between two of the three layers of positioning plate 962 , 964 , 966 to form two spaces for air flow so that the flow path of the air inhaled or exhaled is not fixed. By means of an air chamber between a first filter layer 96 and a second filter layer 98 , the complex respirator 90 causes air to uniformly pass through the first filter layer 96 as well as the second filter layer 98 . Thus, the lifetime of the first filter layer 96 , as well as the second filter layer 98 , of the complex respirator 90 is extended.
In addition, a complex respirator is not only for healthy people but also for patients. Patients who use such respirators can prevent droplet-transmitted bacteria or viruses from spreading to neighboring areas. The second filter layer made from bactericidal or anti-bacteria filter material filters bacteria or viruses to prevent infections such as flu or Severe Acute Respiratory Syndrome (SARS) from spreading rapidly.
In summary, the present invention provides a complex respirator that includes a first shell, a second shell, at least a first filter layer and a second filter layer. The first shell is disposed on inner side of the first filter layer while the second filter layer is arranged on inner side of the first shell. A slot is formed between the first shell and the second filter layer. The first filter layer is arranged in the slot and the second filter layer is set on inner side of the first shell. The air inhaled firstly passes through the first filter layer and then through the second filter layer. While the air exhaled flows through the second filter layer and then through the first filter layer. For the inhaled air, the first filter layer is for filtering particles of dust and the second filter layer is for filtering granules of a smaller diameter. As to the exhaled air, the second filter layer filters bacteria or other impurities. Use of the complex respirator by healthy people avoids the inhalation of toxic gas or harmful granules. If patients use the complex respirators, the respirator prevents micro-organisms carried by patients from spreading to surrounding areas.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A complex respirator is provided that includes a first shell, at least a first filter layer and a second filter layer. The first filter layer is replaceable and arranged on an outer side of the first shell while the first shell is disposed on an outer side of the second filter layer. A slot is formed on an outer side of the first shell for accommodating the first filter layer. The filtering area of the first filter layer is smaller than that of the second filter layer while pore size of the first filter layer is larger than that of the second filter layer. The second filter layer filters the gas that the first filter layer is unable to filter. Moreover, the type of first filter media of the first filter layer may be chosen based on the location that the complex respirator is to be used. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. application Ser. No. 09/472,274, filed Dec. 27, 1999, now abandoned which is a continuation-in-part of U.S. application Ser. No. 08/659,644, filed Jun. 6, 1996, now U.S. Pat. No. 6,090,266, all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
It is recognized that additional sources of energy are needed for sustained industrial growth. There exists an ever present danger in depending too heavily on fossil fuels. Fossil fuels (hydrocarbons) represent a limited supply of stored energy which are typically released during a combustion process. By burning hydrocarbons mankind has spewed billions of tons of toxic pollutants into the atmosphere. It therefore makes sense from both an environmental and economic standpoint to develop alternative sources of renewable fuels.
Hydrogen is a fuel which does not produce pollutants, water being its only combustion product. Hydrogen has many industrial uses in the production of fertilizers, dyes, drugs, plastics, hydrogenated oils and fats and methanol and is used in many industries. It is also used as a rocket fuel and in this invention as a minus-emissions fuel that allows ordinary engines to clean the air.
1. Field of the Invention
This invention relates to a process for the production of hydrogen from anaerobically decomposed organic materials, including materials such as those found in landfill materials and sewage sludge, by applying an electric potential to and thereby creating a current through the anaerobically decomposed organic material and thereby forming hydrogen.
2. Description of Related Art
The established processes for producing commercially significant amounts of hydrogen are: (1) steam reforming of hydrocarbons, (2) partial oxidation of coal, (3) electrolysis of water, and (4) direct use of solar radiation (photovoltaic method).
Steam-reformation of hydrocarbons and partial oxidation of coal are disadvantageous in that fossil hydrocarbon fuels are consumed. Production of hydrogen by electrolysis of water, a relatively simple and non-polluting process, is costly and therefore economically disadvantageous for most industrial applications because the amount of energy needed for electrolysis of water exceeds the energy obtained from the combustion of the resulting hydrogen. Photovoltaic methods of hydrogen production have inherent inadequacy related to access to solar radiation for much of the world's population.
Unlike the methods for production of hydrogen outlined above, the process of the present invention does not depend on fossil fuels or the somewhat random appearance of sunlight to produce hydrogen. The present process converts what are typically waste materials into hydrogen, while simultaneously reducing the mass of said materials and/or reducing the treatment time of such materials by application of a relatively small and/or intermittent electric potential to said materials. The process of this invention uses raw materials typically found in, among other places, municipal waste sites and sewage treatment plants and produces more energy, in the form of the chemically stored potential energy of hydrogen, than the electric energy required to produce the hydrogen.
A method of producing hydrogen from sugars is discussed in Energy and the Environment , Proceedings of the 1st World Renewable Energy Congress, Reading, UK Sep. 23–28, 1990. S. Roychowdhury and D. Cox (“Roychowdhury”). This method involves the production of hydrogen from pure sugars such as glucose or maltose.
Roychowdhury reports the initial production of hydrogen upon inoculation of a sugar solution with so-called “landfill inocula”. To obtain landfill inocula, materials were obtained from various depths in a landfill, dried, ground (to obtain “landfill powder”) and then incubated in situ. The incubated culture medium was observed to produce carbon dioxide and methane, primarily, and little else, indicating the presence of highly methanogenic flora in the inoculum. The supernatant from this culture medium, or in some cases the landfill powder, were used as inocula.
Previously, Roychowdhury disclosed that upon inoculation of various sugar solutions with the landfill supernatant or landfill powder, the sugar solution produced hydrogen and carbon dioxide, and no methane or oxygen; indicating the presence of hydrogen-producing bacteria present in the landfill inoculum and/or landfill hydrogen. Hydrogen production decreased with increasing acidity.
It is another object of this invention to provide a method of hydrogen production which does not require the use of fossil fuels.
It is an object of the invention to serve communities that have relatively undeveloped electricity distribution and other energy infrastructures with a system that provides useful energy from collected wastes.
It is an object of the present invention to separate carbon dioxide, nitrogen and other gases from produced hydrogen.
SUMMARY OF THE INVENTION
This invention relates generally to a process which produces hydrogen from anaerobically decomposed organic materials such as anaerobically composted cellulosic materials and anaerobically digested sewage sludge. This process decreases the time required to treat anaerobically composed cellulosic materials and anaerobically digested sewage sludge. More specifically, the invention relates to an embodiment wherein a relatively low electric potential is applied to anaerobically decomposed organic materials such as anaerobically composted cellulosic waste materials and anaerobically digested sewage sludge which, as a result of anaerobic decomposition, have been fermented into “volatile” carboxylic acids such as acetic acid and bicarbonates of ammonia. The electric current resulting from the application of an electric potential is believed to hydrolyze the acetic acids, other volatile carboxylic acids, and bicarbonates of ammonia within the decomposed materials, thereby producing hydrogen. Formation of methane is suppressed, Organic mass, such as solids contained within sewage sludge is reduced at an increased rate, and the time required to treat waste materials such as sewage sludge is thereby reduced.
In another embodiment the time of application of electropotential is intermittent and the duty cycle of voltage application is adaptively adjusted to minimize electric power consumption while maximizing hydrogen production. In application it is believed that the activities of microorganisms that produce enzymes that release hydrogen from the ferment is greatly encouraged and that activities of microorganisms that produce enzymes favoring methane production are depressed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart showing both production of hydrogen and suppression of methaneogenesis from anaerobically decomposed organic materials in the presence of an applied electropotential, and methanogenesis from anaerobically decomposed organic materials in the absence of an applied electropotential.
FIG. 2 is a flow chart showing a process for production of hydrogen which includes on-site anaerobic decomposition of organic material.
FIG. 3 is a bar graph representation of the information in Table 1.
FIG. 4 is a bar graph representation of the information in Table 3.
FIG. 5 is a bar graph representation of the information in Table 3.
FIG. 6 is a bar graph representation of the information in Table 5.
FIG. 7 is a bar graph representation of the information in Table 6.
FIG. 8 is a bar graph representation of the information in Table 8.
FIG. 9 is a bar graph representation of the information in Table 9.
FIG. 10 is a bar graph representation of the information in Table 10.
FIG. 11 is a schematic illustration of an embodiment that adaptively controls application of intermittently applied voltage to maximize hydrogen production while minimizing methane production.
FIG. 12 is a schematically illustrated embodiment showing generation of voltage for practicing the principles of the invention.
FIG. 13 is a schematic illustrating the principles of another embodiment of the invention.
FIG. 14 is a schematic illustrating the principles of another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention may typically be practiced at any large municipal landfill or sewage treatment facility, but can be practiced on a smaller scale wherever anaerobically decomposed organics such as anaerobically composted cellulosic materials or anaerobically digested sewage sludge are found or may be generated.
Anaerobically composted cellulosic materials are typically found in landfill materials. Anaerobically digested sewage sludge typically comprises sludge found at municipal sewage treatment plants. Landfill materials generally consist of approximately 70% cellulosic materials and have a moisture content of 36% to 46%. Sewage sludge is primarily liquid, contains volatile acids such as acetic acid, and includes 2–3% solids. Both landfill materials and sewage sludge naturally contain methane-producing abacterial species and hydrogen-producing bacterial species.
The invention may be practiced by applying an electric potential of between 1 and 7 volts, preferably between 3 and 6 volts, most preferably between 3.0 and 4.5 volts to, and thereby passing an electric current through, anaerobically decomposed organic materials such as landfill materials or sewage sludge. This electric potential is applied through electrodes which are preferably made from lead, copper, steel, brass or carbon, more preferably from cast iron bars, and most preferable from metal impregnated or otherwise electrically conductive graphite.
Anaerobic decomposition, specifically anaerobic composting and anaerobic digestion, refers to a process where organic compounds, typically but not limited to compounds of the general formula C n H 2n O n , decompose in the absence of an oxygen-donor environment. Volatile acids such as acetic acid are typically formed by such anaerobic decomposition. Although anaerobic decomposition may in some instances be preceded by aerobic decomposition, aerobic decomposition is not a prerequisite to anaerobic decomposition and electrodes can be placed within the organic materials prior to the commencement of anaerobic decomposition.
As described above, both landfill materials comprising anaerobically composted cellulosic materials and anaerobically digested sewage sludge contain relatively high amounts of volatile acids such as acetic acid. These acids are known to act as electrolytes. In practicing the invention, one or more sets of electrodes may be placed within landfill material or sewage sludge in such a way that an electric potential is applied, and according to the principles of the invention resulting in an electrical current with low polarization and ohmic losses. Electrode distance and placement along with the program of voltage control including occasional reversal of polarity may be adjusted to achieve these conditions. The voltage, average spacing of electrodes and number of electrodes will vary depending upon the size and composition of the landfill material or sewage sludge sought to be used to produce hydrogen. Electrode sets, may be of any suitable shape, e.g. plates, bars, grids, etc.
In a preferred embodiment of the invention, each individual electrode is placed into landfill materials and is surrounded by an inert “cage” which effectively ensures that the moisture component of the landfill materials, and not a component which might interfere with electrical activity, is immediately adjacent each electrode. Place of the electrodes in a suitable position within the landfill material may require some trial and error.
When an electric potential is applied, hydrogen production begins and production of hydrogen increases to from 70% to 75% by volume of the total gases produced. The level of methane produced decreases from a high of approximately 70% by volume of the total gases produced, when the electric current is first applied, to greatly diminished trace levels. Carbon dioxide and nitrogen production remain relatively constant and do not vary significantly with methane or hydrogen production.
Without being bound by theory, it is believed that the essence of the electrochemistry of this invention is the enzyme facilitated production and decomposition of low molecular weight volatile acids such as acetic acid produced by bacterial breakdown of carbohydrates and other nutrients. Because oxygen production is not observed, it is believed that electrolysis of water is not a source of hydrogen. It is further believed that hydrogen gas produced by the electrolysis of volatiles present in the sludge and in landfill materials, inhibits the subdivision, growth, and activity of methanogenic species.
In a preferred embodiment, cellulosic materials and/or sewage sludge are made to decompose “on-site”, i.e. in a localized bin or chamber, rather than at a centralized landfill or sewage treatment facility. The anaerobically composted cellulosic waste materials and/or the anaerobically digested sewage sludge are then optionally taken to a transfer station equipped with electrodes as previously described to produce hydrogen, or alternatively made to produce hydrogen “on-site” by application of electric potential at or near the on-site bin or chamber. In this alternate embodiment, hydrogen could then be stored or used on-sites as a energy source to produce useful forms of energy including the relatively minor amount used to practice the principles of the invention.
EXAMPLES: ELECTRODES
Electrodes were cast iron bars, 300 mm long, 25 mm wide and 2.5 mm thick. Other metallic electrodes were used including lead, copper, steel, brass and others. pair of copper impregnated graphite electrodes of the same size was used. Degradation of the graphite electrode was not very noticeable.
Landfill Materials
Samples of landfill material were obtained from a sanitary landfill at Staten Island N.Y. from a depth of between 30 to 50 feet. The landfill materials naturally produce methane and carbon dioxide as primary gases (in 55:35 proportions) through methanogenesis.
Sludge
Sludge samples were taken from a primary digester of a sewage treatment plant at Brooklyn, N.Y. Sewage sludge produces methane and carbon dioxide (in 65:30 proportions) by methanogenesis.
Special Apparatus
A series of experiments were set up to determine whether the production of hydrogen would take place when voltage was applied through either sewage sludge or through landfill materials. The pH of the sludge was 7.0–7.5 and the pH of the landfill material was 6.5–7.0. Apparatus included on 800 ml flask with a three hole rubber stopper. Two of those holes were fitted with electrodes and the third hole had a glass delivery tube. The electrodes and the third hole had a glass delivery tube. The electrodes were connected across two 1.5 volt batteries in series, resulting in an applied potential of about 3.0 volts. The apparatus was placed in an incubator set either at 37° C. and later at 55° C. Other apparatus included a New Brunswick Fermenter using a 6–8 liter glass vessel where the temperature, and rotating stirrer and a cooling system could be controlled at a desired setting.
Experimental Data
Example 1
As an experimental control, freshly obtained sewage sludge in an 800 ml flask was placed at 37° C. in an incubator gases, including primarily methane, were produced as described at Table 1 and depicted at FIG. 3 .
TABLE 1
Production of CH 4 and CO 2
DAYS
% CH 4
% CO 2
% N 2
1
65
30
5
2
70
25
5
3
70
25
5
4
65
30
4
5
60
35
4
6
55
40
5
Example 2
Sewage sludge from the primary digester was placed in an 800 ml flask which was then placed in a preheated incubator at 37° C. Methane gas was generated. As soon as optimum production of methane was achieved, a current was passed through the liquid in the flask. The production of methane gas declined gradually and hydrogen and carbon dioxide were produced. Methane was completely suppressed when production of hydrogen reached its peak, as described at Table 2 and depicted at FIG. 4 .
TABLE 2
Production of H 2 and Suppression of CH 4
DAYS
% CH 4
% CO 2
% H 2
1
60
35
—
2
70
25
—
3*
45
25
20
4
25
28
46
5
5
30
60
6
TR
30
68
Example 3
Sewage sludge from the primary digester was placed in an 800 ml flask which was then placed in an incubator at 37° C. A current was passed through the sludge, applying 3 volts, using the two 1.5 volt batteries in series. Very little methane was produced at the beginning. Within 3 days, production of hydrogen reached its peak and methane gas was virtually totally suppressed, as described at Table 3 and depicted at FIG. 5 .
TABLE 3
Production of H 2 and CO 2 When Voltage Was
Applied From the Start
DAYS
% H 2
% CO 2
% N 2
% CH 4
1
65
25
2
8
2
70
25
2
TR
3
70
18
8
TR
4
70
20
8
—
5
68
25
4
—
Example 4
A sewage sludge sample was placed in a five liter flask in the New Brunswick Fermenter and 4 electrodes were introduced. Electrical current was passed through (2.5 volts and 0.05 to 0.07 Amps). In the beginning only methane and carbon dioxide were produced with very little hydrogen. As soon as the voltage was increased to 4.0–4.5, and current to 0.11–0.15 Amps, methane was gradually suppressed and hydrogen was produced as described at Table 4.
TABLE 4
Production of H 2 and CO 2 , From
Sludge in 5 liter Container
DAYS
% H 2
% CO 2
% N 2
% CH 4
1
—
30
12
50
2
5
35
8
46
3
4
30
6
60
5
25
30
5
40
6
48
25
5
20
7
60
20
2
8
9
70
25
4
TR
Example 5
It is of particular interest to treat landfill materials because these materials present municipalities around the world with ubiquitous problems of vector (rodents, roaches, and communicable disease germs) breeding places along with sources of greenhouse gases and groundwater contamination due to production of poisonous leachate. The present invention provides for carbon sequestration from landfills including those that are depositories for sewage sludge.
Landfill materials collected by random borings were provided for determination of the least energy expenditures per energy production. Experiments were set up with landfill materials (composted municipal solid wastes) in two 800 ml flasks, (1) with landfill materials only, (2) with landfill materials where electrodes were dipped in. The results are described at Tables 5 and 6, and depicted at FIGS. 6 and 7 .
TABLE 5
Production of Gases From Landfill Materials
DAYS
% H 2
% CO 2
% N 2
% CH 4
1
—
—
—
—
2
—
3
10
—
3
—
20
8
10
5
—
40
6
50
6
—
30
5
63
7
—
30
5
60
8
—
35
4
60
9
—
35
5
62
TABLE 6
Production of Gases From Landfill
Materials in Presence of Applied Voltage
DAYS
% H 2
% CO 2
% N 2
% CH 4
Total CC
1
53
—
All
—
95
2
72
8
13
—
302
3
76
17
6
—
500
4
75
18
6
—
600
5
72
18
6
—
450
7
79
18
6
—
600
9
65
18
14
—
500
Example 6
Example 5 was repeated: (1) with sludge only, (2) with sludge having operating electrodes. The results are described at Tables 7 and 8, and depicted FIG. 8 .
TABLE 7
Production of Gases From Sludge
in Absence of Applied Voltage
DAYS
% H 2
% CO 2
% N 2
% CH 4
Total CC
2
—
20
14
65
50
3
—
14
10
70
125
4
—
19
4
72
225
5
—
22
4
66
258
6
—
18
8
70
200
TABLE 8
Production of Gases From Sludge
in Presence of Applied Voltage
DAYS
% H 2
% CO 2
% N 2
% CH 4
Total CC
2
65
28
4
8
85
3
70
20
2
TR
200
4
70
18
8
TR
310
5
70
20
2
—
330
6
68
22
4
—
258
Example 7
An experiment was set up with landfill materials in a 6 liter vessel with electrodes. A current was created through the landfill materials by applying an electric potential of 3.5 V. The results are described at Table 9 and depicted at FIG. 9 .
TABLE 9
Production of Gases From Landfill Materials
in 6 Liter Vessel With Applied Voltage
DAYS
% H 2
% CO 2
% N 2
% CH 4
TOTAL
1
75
TR
12
—
100
2
70
5
10
—
1020
4
75
7
15
—
850
6
75
8
17
—
750
8
70
5
20
—
600
Example 8
Landfill materials in a 6 liter vessel were placed in a preheated incubator at 55° C. After 4 days electrodes were connected to 3.5 volt terminals. The results are described at Table 10, and depicted at FIG. 10 .
Similar results are achieved by mixing a relatively small amount of inoculum of human sewage sludge with farm manure and/or crop wastes. After an incubation period in which anaerobic conditions were established, methane and carbon dioxide were produced with very little hydrogen. Upon presentation of voltage at 2.0 to 5.0 volts to cause current to reach 0.10 to 0.20 Amps, methane production was depressed and hydrogen was again produced as summarized in Table 10. Similar results are achieved by use of inoculum from previous runs of Example 4 and provide improvements in the efficiency of conversion of chemical energy potential of organic substances 25 into hydrogen.
TABLE 10
Production of Gas from landfill Materials
in Two Different Environments In the Same Set-Up
DAYS
% H 2
% CO 2
% N 2
% CH 4
TOTAL
1
—
5
All
—
20
2
—
20
35
125
3
—
35
55
200
4
5*
—
30
20
150
7
25
31
7
150
8
60
35
TR
250
9
68
31
—
285
10
65
30
—
200
FIG. 11 shows an embodiment 200 in which suitable electrodes such as concentric electrodes 202 and 204 receive intermittently applied voltage to influence the solvated organic waste between the electrodes to produce hydrogen more or less according to the data shown in Tables 8, 9, and 10. In operation, voltage is applied by voltage source 216 according to a duty cycle controlled by relay 212 that is constantly adjusted by controller 210 to facilitate hydrogen generation and to prevent substantial methane production.
Feedback information from gas detector 206 / 208 is provided to controller 210 . If trace amounts of methane are detected a voltage is applied between electrodes 202 and 204 for a recorded time period until methane production is depressed. The time until methane traces are detected again is noted by controller 210 and a duty cycle of applying voltage across electrodes 202 and 204 for a time interval slightly longer than the time noted for depressing methane production followed by neutral electrode operation for a time period slightly less than the time noted previously for traces of methane to be detected.
This duty cycle is adaptively changed to shorten the time of voltage application and to extend the time between voltage application for purposes of minimizing methane production while maximizing hydrogen production with least application of voltage to electrodes 202 and 204 . Voltage level is reduced to provide another variable and adaptively adjusted with respect to the time of voltage application to minimize energy expenditure. This adaptive control algorithm rapidly adjusts for changes in organic waste composition, moisture content, temperature, and other variables.
FIG. 12 shows an embodiment in which the fuel gas produced by the process of the invention in the presence of electrodes 230 and 232 is in part made available for energy conversion in 240 to electricity by a fuel cell or engine-generator set. Adaptively controlled application of voltage to electrodes 230 and 232 is provided by controller 236 and relay 234 as shown for purposes of minimizing energy consumption per therm of hydrogen produced.
Moreover, adaptive controller 236 provides a control algorithm to minimize methane production while facilitating maximum hydrogen production. Solenoid operated valve 238 controls delivery of fuel gas by line 242 to energy conversion unit 240 as needed to meet adaptively adjusted duty cycle and to meet other demands for electricity as delivered by insulated cables 244 . Suitable power for pumping water, providing a heat-pump cycle, or production of electricity at 240 may be by a heat engine and generator, a fuel cell, a thermoelectric generator, or other devices that convert fuel potential energy into electricity.
In many applications, it is preferred to utilize a piston engine and generator in which the engine is fueled with a SmartPlug combination fuel injector and ignition system to facilitate extremely robust operation. SmartPlug operation is disclosed in U.S. Pat. Nos. 5,394,852 and 5,343,699. This enables the raw mixture of hydrogen and carbon dioxide to be used as a very low grade fuel without further conditioning while producing very high thermal efficiency and full rated power in comparison with engine operation on gasoline or diesel fuel. This is a particularly important advantage for remote operation and to bring fuel and power to depressed economies where it is prohibitive to import fossil-based fuels.
Preferential production of hydrogen provides thermodynamic advantages based on faster fuel combustion, wider air/fuel ratio combustion limits, and with SmartPlug operation the engine operates essentially without throttle losses. These thermodynamic advantages provide much higher brake mean effective pressure or “BMEP” for the same heat release in comparisons with gasoline or diesel fuel.
As shown in Table 11, it is possible to actually clean the air with an engine generator running on hydrogen-characterized fuel produced from landfill or sewage organic wastes. The ambient air was cleaned by operation of an engine that is compared in operation between hydrogen and gasoline.
TABLE 11
TEST RESULTS
AMBIENT AIR
29 ppm HC
0.00 ppm CO
1.0 ppm NO
TEST:
(hydrocarbons)
(Carbon Monoxide)
(Nitrogen
Monoxide)
ENGINE WITH HYDROGEN OPERATION
Idle:
18 ppm HC
0.00 ppm CO
1.0 ppm NO
Full Power:
6 ppm HC
0.00 ppm CO
2.0 ppm NO
USING GASOLINE AS FUEL IN THE SAME ENGINE:
Idle:
190 ppm HC
25,000 ppm CO
390 ppm NO
Full Power:
196 ppm HC
7,000 ppm CO
95 ppm NO
Substantial amounts of carbon dioxide are produced along with hydrogen by operation of electro-conditioned anaerobic digestion of organic wastes. Economical separation of hydrogen from the carbon dioxide is needed for fuel cell applications, for increasing the storage density of hydrogen, and for increasing the value of hydrogen produced. Such separation is provided by the embodiment of FIG. 13 . This embodiment also serves the purpose of providing for utilization 25 of the carbon dioxide for various purposes including use in greenhouses or hydroponics and is an important aspect of the invention.
The solubility of carbon dioxide in water is about 21.6 volumes of gas per volume of water at 25 atmospheres pressure and 12° C. (54° F.). Increasing the pressure or decreasing the temperature increases the amount of carbon dioxide dissolved per volume of water. Lowering the pressure or increasing the temperature releases dissolved carbon dioxide. In most areas of the Earth, the ground water is maintained at a temperature that is equal to the mean annual air temperature plus one degree (F) for each 80′ of overburden to the saturated zone.
FIG. 13 shows a system for separating carbon dioxide from hydrogen by differential absorption of carbon dioxide within a suitable medium such as water or a hindered amine. In operation, mixed gases consisting of hydrogen, carbon dioxide, and lesser amounts of nitrogen and other gases are forced into the bottom of a column of water 302 approximately 1,000′ or higher.
It is generally preferred to use a column of water that is developed by placing a well approximately 1000′ below the saturated zone of the local groundwater. This provides the extremely large heat sink benefit of the sub soil including the ground water in the saturated zone where the temperature is generally constant at the desired temperature of 4° C. to 16° C. (40° F. to 60° F.) for most climate zones throughout the year. Water columns that are elevated along mountain slopes are also feasible but may suffer freezing conditions in the winter and unfavorable warming in the summer season.
Mixed gases are delivered to the bottom of tube 304 by a suitable pump (not shown). Mixed gases enter into a suitable scrubber zone such as the helical fin 306 that is attached to tube 304 with a higher elevation at the point of attachment than any other point on the element of rotation that describes the helical surface as shown. Gases thus tend to be buoyed towards tube 304 as they are scrubbed by the absorbing fluid. Carbon dioxide readily enters into solution at the pressure and temperature conditions maintained. Hydrogen exits at the top of the helix into tube 308 and is delivered to the surface for various uses.
Carbon-dioxide rich water is ducted to the surface by coaxial tube 310 as shown. As the head pressure lessens, carbon dioxide bubbles develop and escape upward and create a lower density mixture that is buoyantly lifted to the gas separator section 312 where denser water 25 that has lost the ability to retain carbon dioxide is returned to annular space 302 and sinks the bottom to replace the upward travelling inventory of water that is lifted within tube 310 . Carbon dioxide is collected at the top of 310 by tube 314 for various useful purposes.
FIG. 14 shows an embodiment in which energy used to pressurize the hydrogen and carbon dioxide is regeneratively recovered by an expansion engine. Embodiment 400 shows an extremely rugged and simple energy conversion system that combines various renewable resources such as sewage, garbage, and farm wastes with solar energy to supply electricity, hydrogen, and carbon dioxide.
In many situations and applications it is preferred to pressurize water in a suitable vessel 402 to provide for the separation by solubility differences as desired to purify hydrogen. In operation, mixtures of hydrogen and carbon dioxide are forced through tube 404 into pressure vessel 402 at the nominal pressure of 450 PSI. It is preferred to utilize a spiral mixer consisting of a helical fin 406 that causes the mixture of gases to scrub along the surface and form high surface-to-volume ratios. The mixed gases follow an extended path through the water as carbon dioxide is absorbed to allow the hydrogen to be collected at the top of spiral scrubber 406 by tube 408 as shown. Carbon dioxide is absorbed into the water while hydrogen is collected at the top of separator 406 as shown.
Hydrogen is delivered by conduit 408 for immediate use in an engine or fuel cell or it may be stored for future use as needed. Carbon dioxide saturated water is taken from absorber vessel 402 by tube 410 to valve manifold 426 which provides control valves to time the flow of carbon dioxide rich water into each of a group of heat exchangers such as 414 , 416 , 418 , 420 , 422 , and 424 as shown. Each heat exchanger is provided with an exit a nozzle that is aimed at the blades or buckets of an adjacent fluid motor rotor such as 430 , 432 , 434 , 436 , 438 , and 440 which deliver work to a common output shaft as shown.
An inventory of water and carbon dioxide solution under pressure is suddenly forced into a preheated heat exchanger such as 414 by briefly opening the control valve that serves 414 . As the fluid is heated the temperature and pressure of the fluid increases and it vaporizes and is expelled with very high momentum to power motor 430 . Each of the other heat exchanger chambers receives a charge of fluid on a timed basis so that the shaft power from the group of motors shown can be considered to have multiple phase torquing such as six phase if each heat exchanger receives flow at a different times or three phase if two heat exchangers are filled simultaneously. A suitable application of the output of the fluid motor is generator 428 or other useful loads as needed.
It is preferred to provide concentrated radiation to the heat exchangers by a suitable solar collector such as a field of heliostats or a parabolic dish 442 as shown. At times that solar energy is insufficient to meet energy conversion needs, supplemental heat may be applied by combustion from a suitable burner 448 . For such supplemental heating it is preferred to use mixtures of carbon dioxide and hydrogen and/or other combustible gases released by anaerobic digestion of organic matter.
After undergoing heating and expansion to a suitably low pressure, carbon dioxide is collected by tube 458 and taken to a suitable application. Water is condensed and collected in reservoir 450 which is cooled by countercurrent heat exchanger 456 by circulation of a suitable heat exchange fluid from 446 to 456 and then through 448 to a suitable cogeneration application. Cooled water is pressurized by pump 454 and returned to pressure vessel 402 to complete the novel carbon dioxide removal and energy conversion cycle.
SUMMARY OF THE INVENTION
Method and apparatus for utilization of intermittently applied voltage for depression of methane production while maximizing hydrogen generation from organic landfill and sewage wastes is provided along with a rational control regime for minimizing the energy expenditure to do so. Renewable biomass and solar resources are combined in a unique energy conversion regime. Production of electricity from an engine operated on hydrogen sourced by the invention is integrated in a synergistic combination that provides regenerative separation of carbon dioxide from fuel gas air and cleaning with carbon sequestration.
The time to dispose of organic materials is preferably reduced by anaerobically digesting such materials in a reaction zone and applying art electric potential across the zone thereby producing hydrogen and carbon dioxide. It is preferred to apply the electric potential occasionally after periods without application of said electric potential.
It is preferred to apply the electric potential at a frequency and for a period to maximize the quantity of hydrogen produced per the amount of electricity consumed. It is preferred to separate carbon dioxide and fuel produced by pressurizing a fluid to a state that provides preferential absorption of carbon dioxide, mixing the fuel and carbon dioxide with the pressurized fluid, and collecting the fuel that remains after preferential absorption of carbon dioxide. Energy conversion efficiency is increased by adding heat to the fluid after preferential absorption of carbon dioxide for the purpose of increasing the amount of work produced by a motor that expands the pressurized fluid, releasing the carbon dioxide in conjunction with the expanding process, and cooling the fluid before the pressurizing step.
The preferred source of such heat is selected from the group including solar energy, heat released by combustion of a portion of the fuel produced, concentrated solar energy, and a combination of solar energy along with heat produced by combustion of a portion of the hydrogen.
An energy conversion process is provided by the steps of anaerobically digesting organic materials to produce carbon dioxide and fuel selected from the group including hydrogen, methane, and mixtures of hydrogen and methane, separating the carbon dioxide from the fuel. The preferred method of separation is comprised of pressurizing a fluid to a state that provides preferential absorption of carbon dioxide, mixing the carbon dioxide and fuel with the fluid, collecting the fuel that remains after said preferential absorption of carbon dioxide, adding heat to the fluid after preferential absorption of carbon dioxide for the purpose of increasing the amount of work produced by a motor that expands pressurized fluid, releasing carbon dioxide in conjunction with the expanding process, and cooling the fluid before the pressurizing step.
In instances that it is preferred to utilize anaerobic digestion to produce hydrogen instead of methane, feedstock organic materials are placed in a reaction zone and an electric potential or voltage is applied across the materials thereby producing hydrogen and carbon dioxide. It is preferred to provide application of intermittent voltage for purposes selected from the group including depression of microorganismal activity that produces methane, enhancement of microorganismal activity that produces hydrogen, and creation of an atmosphere within organic materials that is maintained rich in hydrogen. The process intermittent application of voltage is optimized by feedback information from a gas detector as provided to a controller means. If trace amounts of methane are detected, the voltage is applied for a recorded time period until methane production is depressed, the time until methane traces are detected again is noted by the controller and a duty cycle is provided for applying voltage for a time interval slightly longer than the time noted for depressing methane production followed by neutral electrode operation for a time period slightly less than the time noted previously for traces of methane to be detected In this process, the voltage level is variably reduced to provide an adaptively adjusted control with respect to the time of said voltage application to minimize energy expenditure. | A process for the production of hydrogen from anaerobically decomposed organic materials by applying an electric potential to the anaerobically decomposed organic materials, including landfill materials and sewage, to form hydrogen, and for decreasing the time required to treat these anaerobically decomposed organic materials. The organic materials decompose to volatile acids such as acetic acid, which may be hydrolyzed by electric current to form hydrogen. The process may be continuously run in sewage digestion tanks with the continuous feed of sewage, at landfill sites, or at any site having a supply of anaerobically decomposed or decomposable organic materials. | 2 |
TECHNICAL FIELD OF INVENTION
The present invention deals with backpack devices which possess a flexible enclosure for containing a load to be supported and carried by a wearer. The load exerted upon the wearer of the backpack is now capable of being more comfortably carried as shock absorbing elements are provided between the backpack and the hips of the wearer.
BACKGROUND OF THE INVENTION
Great strides have been made since the introduction of the ladder or H-type backpack frame. Initially, such frames were employed to be supported by one's back to which was lashed articles to be carried. Such frames consisted of generally vertically extending metal, wood, plastic or similar materials possessing a pair of forwardly extending shoulder straps, each strap forming a loop with the rear frame. A belt was also employed to maintain the bottom of the frame against the lower back of the user. The result of all of this was to require the wearer to lean forward while wearing the backpack in order to shift the pack's center of gravity, all of which resulted in making its wearing uncomfortable and tiring.
Devices such as those disclosed in U.S. Pat. No. 4,219,998 entails the use of various support members which cause the center of gravity of the backpack to shift forward relieving its wearer of experiencing the off-balance pulled back sensation previously experienced.
It was also recognized that advantages in backpack comfort could be realized by removing the backpack load from the shoulder straps and transferring it to the hip area well below the backpack's center of gravity. Such devices are shown, for example, in U.S. Pat. No. 4,369,903.
As backpack devices have become more elaborate, there has further been a recognition that an improved product could be configured by providing independent movement between the user and the load renderers. For example, U.S. Pat. No. 4,189,076 provides a device whereby a belt is adapted to be disposed about the waist of the user, the belt including downward extending load support panel which is adapted to be coupled to the load at a point which is substantially below the waist. A rigid support member or yoke is coupled to the lower portions of the supporting which extends about the rear of the user. The pack frame is taught to be pivotally coupled to the yoke in a manner which will permit the user to have normal rotational hip action without being unduly retarded by the load being carried.
Although one can track various improved designs through time, there is yet to be developed a backpack device which is capable of not only shifting the load of the pack to the hip or waist area but also which is capable of absorbing shocks which are normally present during routine movement of the user wearing the backpack.
The present invention can be more readily visualized when considering the following disclosure and appended drawing wherein the sole figure is a side view of the backpack device of the present invention shown on the silhouette of a wearer.
SUMMARY OF THE INVENTION
The present invention is to a backpack device comprising of flexible enclosure for containing a load to be supported and carried by a wearer of said device. A frame for supporting the flexible enclosure is provided which includes a pair of vertically extending tubular struts located at the sides of the flexible enclosure. A waist belt means for encircling the waist of the wearer is provided which is also connected to the flexible enclosure. Sliding connector means adapted to slide along each of the vertically extending tubular struts are, in turn, pivotally connected to shock absorbing means which, themselves, are pivotally connected to the waist belt means. The shock absorbing means are provided to absorb shock between the flexible enclosure and the wearer.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the invention wherein the shock absorbing element includes a spring element.
FIG. 2 is a partially schematic view of another embodiment of the invention wherein the shock absorbing element includes a hydraulic fluid cylinder.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, backpack device 10 is shown being supported by wearer 11. Flexible enclosure 12 typically is composed of a number of subparts containing such items as portable tents, sleeping bags and eating utensils which traditionally make up the contents of a backpack. These various subsections are usually held firmly in place through the use of adjustable straps 13, 14 and 15, the Configuration and positioning of which constituting no part of the present invention.
Although a shoulder harness can be used in conjunction with the device depicted in the appended figure, it has not been shown for the sake of illustrating the present invention with clarity. In wearing backpack 12, wearer 11 generally experiences vertical and horizontal force vectors 26 and 27, respectively, which are shifted off their vertical and horizontal axes as the wearer leans forward. Nevertheless, as wearer 11 walks or performs other movements while wearing backpack 12, the pack's weight exerts horizontal and vertical force vectors which must be dealt with.
Although waist belt 24 helps to support the weight of pack 12 at the hip region of wearer 11, each time a step is taken the wearer experiences a shock as a result of the momentum of pack 12 along vectors 26 and 27. The present invention is intended to substantially reduce the shock by providing shock absorber 16 as illustrated. Shock absorber 16 is pivotally connected to sliding connector 29 by pin or bolt 20 at one extreme and at the waist belt 24 at connector 21. The shock absorber element can be typically telescoping tubes 16A and 16B containing spring means 25 for absorbing shock between movement of said tubes. Alternatively, shock absorbing element 16 can comprise a fluid cylinder means whereby hydraulic fluid is employed for absorbing shock between movement of cylinders. As shock absorbers, both designs are quite conventional and well known in other environments.
It is readily apparent that shock absorber 16 represents the hypotenuse of a right angle triangle whose base is force vector 27 and whose vertical axis is force vector 26. As such, as shock absorbing element 16 expands and contracts in response to the relative motion between backpack 12 and wearer 11, both vertical and horizontal forces are absorbed providing a much more comfortable product capable of being worn for extended lengths of time without fatigue.
It is noted that sliding connector means 29 is capable of movement along vertically extending tubular strut 19. Although not shown, a corresponding strut and sliding connector means are provided on the other side of the pack to support a corresponding shock absorber means 16. Sliding connector means 29 is held in position by strap 17 whose length can be adjusted along vertically extending tubular strut 19 via adjustment buckle 18.
The adjustability of sliding connector 29 through the use of strap 17 and buckle 18 further enhances the practical utility of the present invention. More specifically, by varying the position of sliding connector 29, one can change the angle of shock absorber 16 to vectors 27 and 26, thus changing the positioning of the backpack 12 with respect to user 11. During long hikes, an occasional shift in position can act to relieve muscles of the user. In addition, most human torsos are not perfectly symmetrical and having separate adjustments for the left and right sides of the pack enables the wearer to "fine tune" the present device for a specific torso configuration.
The bottom of the backpack is generally provided with support fabric 28 which is employed as a connector for strap 22 and adjustment buckle 23. These elements act to transmit the forces of vector 27 while force vector 26 is transmitted along vertically extending tubular strut 19.
FIG. 2 illustrates still another embodiment of the invention. The shock absorbing element 16' has a cylinder 16a' filled fluid 25' and designed to be pivotally attached at connector 21' to the waist-belt means 24 (see FIG. 1). Shock absorbing element 16' is further pivotally attached to the sliding connector 29' by pin 20' such that element 16' is further pivotally attached to the sliding connector 29' by pin 20' such that element 16' may be slideably moved along the vertically extending strut 19'.
The invention has been described with specific reference to certain specific embodiments; however, it is to be understood that applicant's invention is not intended to be so limited and it is intended that applicant's invention is only to be limited by the following claims. | A backpack device including a flexible enclosure for containing a load to be supported and carried by a wearer and a frame for supporting the flexible enclosure. Shock absorbers are pivotally connected to the frame and to a waist belt for absorbing shock between the flexible enclosure and the wearer. | 0 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to a Communications Assistance for Law Enforcement Act (CALEA) device and, more particularly, to facilitating an Advanced Intelligent Network (AIN)-CALEA in VoIP network to capture call data and call content using a virtual primary rate interface (PRI) connection.
[0003] 2. Related Information
[0004] The purpose of this invention is to provide lawful intercept of calls. In these modern times, it is unfortunate that public communications have become a conduit by which unlawful activities coordinate. The need to address this problem became apparent with the implementation of digital technology and wireless services, which have almost outpaced the ability of law enforcement officials to conduct authorized electronic surveillance.
[0005] In order to combat this, the US Congress in 1994 passed the Communications Assistance for Law Enforcement Act (CALEA), which provides that carriers shall implement procedures and equipment to assist law enforcement agencies, primarily the Federal Communications Commission, to carry out their lawful interception and monitoring of telecommunication calls. Specifically, CALEA requires telecommunications Carriers to ensure that their equipment, facilities, and services are able to comply with authorized electronic surveillance.
[0006] From the carrier perspective, the CALEA implementations are burdensome. The entire cost for implementing these provisions are left up to the Carriers, leaving the carriers holding the bag. Thus, Carriers need to comply with these enforcement provisions with the least amount of cost burden to their overhead.
[0007] Moreover, implementing the CALEA provisions for the various types of networks is difficult to say the least. In the packet world, for example, redirecting calls is not a trivial undertaking, especially when one considers that packets are only portions of data calls that are whizzing around the network universe.
[0008] It would be an advantage if one could redirect calls within the packet world particularly for CALEA applications. This would allow the CALEA application to be placed anywhere.
[0009] What is needed is a CALEA application that is cost effective for carriers to implement. What is further needed is a means by which carriers can redirect packets. It would be advantageous to be able to place the CALEA device anywhere in the network. Heretofore, there has not been provided any such means that resolves these problems.
OBJECTS & SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a virtual CALEA device.
[0011] An object of the present invention is to provide a virtual PRI facilitating an Advanced Intelligent Network (AIN) that implements CALEA.
[0012] Yet another object of the invention is to redirect packets in a packet network.
[0013] Still another object of the invention is to place the CALEA device anywhere in the network.
[0014] In accordance with the present invention there is provided an apparatus for effecting a governmental regulation for monitoring a call in a telecommunications network. An application for executing commands that effect the governmental regulation. A primary rate interface (PRI) is coupled to the application for redirecting calls to be monitored according to the governmental regulation. A telephony protocol encapsulating the PRI for transporting signals relating to the call over a packetized network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The following figures illustrate the present invention in particular detail, and it shall be considered that the figures are merely examples:
[0016] [0016]FIG. 1 is a block diagram illustrating SIGTRAN encapsulating PRI;
[0017] [0017]FIG. 2 is a block diagram of the protocol stack of the present invention; and
[0018] [0018]FIG. 3 is a system diagram of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] [0019]FIG. 1 shows how a typical network 100 with SIGTRAN PRI (Signaling Transport Primary Rate Interface) incorporated therein is modified to include the virtual CALEA device 102 of the present invention.
[0020] As shown in the figure, there are a number of PBX (private branch exchange) telephone systems connected through various means, each PBX within an enterprise for switching calls between enterprise users on local lines while allowing all users to share a certain number of external phone lines. The main purpose of this configuration is to save the cost of requiring a line for each user to the telephone company's central office.
[0021] There is shown, for example, PBX 102 for connecting the individual users 104 through a media gateway 106 that uses a Primary Rate Interface (PRI) to channel calls through the network 100 . Similarly, a PBX 108 couples calls from users 110 through a media gateway 112 .
[0022] A PBX 114 encapsulates PRI using SIGTRAN in the form of customer premises equipment and another media gateway 116 . Similarly, another PBX 118 encapsulates PRI using SIGTRAN and is connected to the network 100 through a media gateway 120 .
[0023] Media gateway controllers 122 , 124 control the media gateways 106 , 112 , 116 and 120 and exchange the data from the PBX networks via a router 126 according to, for example, Integrated Services Digital Network User Part (E-ISUP) signaling.
[0024] A brief word regarding SIGTRAN is perhaps in order. SIGTRAN is the standard telephony protocol used to transport Signaling System 7 (SS7) signals over the Internet. SS7 signals consist of special commands for handling a telephone call. Internet telephony uses the Internet Protocol's packet-switched connections to exchange voice, fax, and other forms of information that have traditionally been carried over the dedicated circuit switched connections of the public switched telephone network (PSTN).
[0025] Calls transmitted over the Internet travel as packets of data on shared lines, avoiding the tolls of PSTN. A telephone company switch transmits SS7 signals to a signaling gateway. The gateway, in turn, converts the signals into SIGTRAN packets for transmission over IP to either the next signaling gateway or, if the packet destination is not another PSTN, to a soft switch.
[0026] [0026]FIG. 2 shows the protocol stack 200 , a hierarchy of protocols which work together to provide the services on a communications network. The SIGTRAN protocol is made up of several such components. Its protocol stack comprises a standard IP, a common signaling transport protocol (used to ensure that the data required for signaling is delivered properly), such as the Stream Control Transport Protocol (SCTP), and an adaptation protocol that supports “primitives” (a basic interface or segment of code that can be used to build more sophisticated program elements or interfaces) that are required by another protocol.
[0027] For this invention, the protocol stack is reflected in FIG. 2. The Service Switching Point (SSP) 202 is the switch where the surveillance subject line resides. The SSP is coupled to the Signaling and Media Gateway (SG/MG) component 204 via PRI (physically T1/E1). In addition, the SG/MG component 204 is coupled to the media gateway controller (MGC) call agent 206 via IP-signaling protocol (standard or proprietary). The MGC call agent 206 is coupled to the CALEA device 209 over IP network 208 using SIGTRAN-PRI protocol. The physical connections of Signaling and Media Gateway (SG/MG) 204 , media gateway controller (MGC) call agent 206 and CALEA device 209 to the IP-network 208 are well-known within the art of telecommunications engineering.
[0028] In FIG. 3, there is shown a virtual primary rate interface (PRI) device encapsulated by SIGTRAN for facilitating AIN-CALEA 300 . The present invention is advantageous because it allows CALEA applications to interact easily with a packet network, yet while maintaining the Time Division Multiplex (TDM) infrastructure of the resident network. By encapsulating the PRI in a device which has SIGTRANPRI-Capablity, the invention provides a virtual interface by which CALEA application can be implemented in the IP network. By encapsulating PRI-protocol (layer 2 & layer 3) in the packet world the physical connection becomes virtual.
[0029] PRI is an important protocol for large ISDN users. In comparison with the Basic Rate Interface (BRI), the other ISDN protocol which is intended for personal or small enterprises, PRI is intended for use with high speed connections. In general, both BRI and PRI include a number of B-channels and a D-channel. Each B-Channel carries data, voice, and other services. The D-Channel carries control and signaling information and data.
[0030] However, with PRIs 23 B-channels and one 64 Kpbs D-channel using a T-1 line or 30 B-channels and 1 D-channel using an E1/T1 line, PRI is the hands down winner for commercial applications. For that matter, a Primary Rate Interface user on a T-1 line can have up to 1.544 Mbps service or up to 2.048 Mbps service on an E1 line. The 23 (or 30) B-channels can be used flexibly and reassigned when necessary to meet special needs such as videoconferences. The Primary Rate user may be hooked up directly to the telephone company central office.
[0031] In a given ISDN connection, such as PRI, the ISDN protocol demands that each end of the connection assumes one of the two roles of communication. The roles are defined as network-side and user-side. Based on the role, the two ends perform different tasks in particular with regards to authentication of the origination (calling) or termination (called) party/number. In either case, both the calling number and the called numbers are included within the calling information as part of the set-up of an ISDN phone call. This information is provided to the switches as part of the call routing and authentication, and in the case of the called party, the calling party's number is typically displayed within the called party's ISDN device.
[0032] If the role of network-side is assumed, the calling party's number (but not the called party's number) may be subject to authentication, and the call may be rejected if the authentication is not provided. The authenticated call shall be routed or terminated based on the called number. If the role of user-side is assumed, then authentication of the calling number is not typically performed and the call is routed or terminated based on the called number.
[0033] As one example, this authentication is illustrated in a configuration where a PBX is connected to a PSTN. Calls originated from PBX (assuming user-side) towards PSTN (assuming network-side) are mainly subject of authentication in the PSTN switch based on the calling number. This is done based on the fact that PSTN has a database of all subscribers (or groups of subscribers) within the PBX. A call with an unauthorized calling number will be rejected. If the calling number is not presented at the stage of initiation, then PSTN may insert a default calling number defined for that PBX. In a TDM environment, there are situations where two PSTNs may wish to connect to each other through a PRI interface. In this case, each shall accept one of the two roles (network-side or user-side).
[0034] The advantage of the PRI access is its capability to be set to carry any calling ID and called ID and the network will accept the delivery of the call. This is different than other access types such as a regular telephone. By carrying any calling ID and called ID, the CALEA subject does not sense the redirection of the call. This assumes a special configuration in the switch to recognize the PRI-Box as a network-side PRI. This provides the CALEA-device the capability to originate a call with any calling number.
[0035] As shown in FIG. 3, a PRI-Device 302 is provided to assist a CALEA application 304 . When the CALEA subject 306 initiates a call, for example, through a network 308 to a destination 310 , the call is forwarded by the switch (eg.g using AIN termination_attempt trigger or plain call forwarding feature) to the PRI device where the call is managed by the PRI device 302 . The network 308 may be any type of network, including A PSTN or IP network. Each call offered to this device uses the B-channel 312 . That is, the voice is conveyed over the B-channel 312 and is captured. The call data is conveyed on the D-channel 314 , for example, User-User Information (UUI) as supplementary data.
[0036] Using the call data, the invention originates a call and loops the B-Channel 312 to the destination 310 . The call data 314 is forwarded by the PRI device 302 to the CALEA operator 316 and the voice signal may be forwarded to a remote location (not shown) which may terminate in a terminal, such as a recorder or head set for example.
[0037] The network 308 determines whether to forward the call to the CALEA device with the assistance, for example, of a Service Control Point (SCP) 316 .
[0038] The SCP 316 determines how to handle the traffic, i.e., whether to redirect the call to the CALEA device 304 , also called a CALEA facility, that provides the CALEA functionality.
[0039] The PRI device 302 in one aspect may be a PRI card. The PRI card may be installed in a computer, such as a personal computer (PC), where the CALEA application 304 is running. Further, the PRI device 302 may be connected through a gateway 318 to another network 320 , such as an IP network.
[0040] A virtual PRI-Software-protocol-Application 322 is further provided to assist a CALEA application 324 . When a second CALEA subject 326 initiates a call, for example, through the network 320 to a destination 328 , the call is managed by the PRI device 322 .
[0041] The network 320 may be any type of network, including A PSTN or IP network. Each call offered to this device uses the B-channel 330 . That is, the voice is conveyed over the B-channel 330 and is captured. The call data is conveyed on the D-channel 332 , for example, User-User Information (UUI) as supplementary data, calling party ID, called party ID, nature of address . . . etc.
[0042] Using the call data, the invention originates a call and loops the B-Channel 332 to the destination 328 . The call data 334 is forwarded by the PRI device 322 to a CALEA operator and the voice signal may be forwarded to a remote location 336 which may terminate in a terminal, such as a recorder or head set for example.
[0043] The network 320 determines whether to forward the call to the CALEA device with the assistance, for example, of a Service Control Point (SCP). The SCP determines how to handle the traffic, i.e., whether to redirect the call to the CALEA device 324 , also called a CALEA facility, that provides the CALEA functionality.
[0044] The PRI-Software-protocol-Application 322 may be installed in a computer, such as a personal computer (PC), where the CALEA application 324 is running. Further, the PRI-Software-protocol-Application 322 may be connected through a gateway 318 to another network 308 .
[0045] In the present invention, the virtual PRI-Software-protocol-Application 322 is composed of an IP-Interface encapsulated in a SIGTRAN (software component) 340 . The primary rate access (PRI) interface is provided in the TDM world. To move forward to a packet network, we need additional protocol (SIGTRAN) to be able to use a PRI interface inside a packet network. The whole sense of having a virtual CALEA device in a packet network is to provide lawful intercept for packet calls without having to leave the packet world. The object of this invention is not necessarily the feature richness of such device, but nevertheless is worth mentioning that realization of such device may ease realization of many features. For example, the benefit of using the virtual CALEA device is depicted in FIG. 1. As will be appreciated therefrom, the CALEA premise could be realized anywhere inside the packet network, where the law enforcement premises LEI-CPE could be located anywhere within the packet world and based on the subject, intercepted data (or call content) can be forwarded to a specific LEI-CPE (e.g. a LEI-CPE may be a SIP phone).
[0046] While the present invention has been described with reference to a CALEA device, the invention is not limited to a particular ratification of CALEA, and covers assisting law enforcement regulation, either government agency or statutory promulgated, of communications in general.
[0047] The invention also relates to a method 200 for establishing a CALEA functionality using a PRI device as shown in FIG. 2. In step 202 , the SCP decides whether CALEA is to be applied to the call, if yes then the call is redirected toward the CALEA device. In step 204 , the call is converted and forwarded to IP-network. In step 206 , the call is converted and embedded in SIGTRAN protocol and delivered to 209 where the call data is passed over the D-Channel and the process ends.
[0048] The present invention has, thus, been described with reference to the detailed figures, and it shall be appreciated that the invention is not so limited to the particular aspects or embodiments shown, but encompasses the broader invention contemplated herein. | Law enforcement regulation of calls in a telecommunications network is provided. A law enforcement application executes commands that effect the law enforcement regulation. A primary rate interface (PRI) coupled to the law enforcement application redirects calls to be regulated by law enforcement regulation. A method for effecting a law enforcement regulation in a telecommunications network provides a law enforcement application is that regulates calls and a primary rate interface (PRI) for redirecting the calls to be regulated by law enforcement regulation. A telephony protocol encapsulates the PRI for transporting signals relating to the call over a packetized network. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Powered roller drum type soil and pavement compactors. In particular, having the axle ends recessed; permitting the roller to work adjacent to walls and the like without being offset by the roller supports, hubs, and bearings.
[0003] 2. Description of Related Art
[0004] Roller compactors currently have at least one heavy roller supported by framework with axial bearings attached to the ends of a roller drum. The framework and bearings extend beyond the end of the roller, thus preventing the roller edge from working closely against barriers such as walls, poles, posts, curbs, and other barriers rising as high as the roller carrier structures.
[0005] To permit close working, one prior art method has the roller divided in the center so a framework can be attached to the Axle interiorly from the drum edges. This leaves a gap, which causes the operator to make a redundant pass over the un-compacted ridge left by the gap, or to employ additional rollers leading or following the gapped roller. U.S. Pat. No. 4,964,753, by Michael Ciminelli is of this type. Ciminelli's compactor uses a single non-steerable front roller and a pair rear rollers with recessed hubs. The front roller is used to flatten the un-compacted ridge left by the back rollers. Steering is accomplished by independent control of the forward and backward rotation of the rear rollers. The Ciminelli drawings suggest that his compactor possibly may work in zero clearance situations, although he does not state or suggest using it in that manner.
[0006] Another method for supporting and controlling a roller without the frame being beyond the ends of the roller drum is shown in U.S. Pat. No. 4,231,678, by Frederick Carternock. Carternock supports the roller externally by a C section carrying a plurality of wheels spaced around the drum, thereby capturing drum with a ring of external wheels. This requires a high, heavy, frame to hold the C section over the compactor drum.
[0007] The present invention places three compaction rollers on adjacent, parallel, offset axes. Thus compaction occurs over contiguous collinear ground engaging surfaces at the bottoms of the drums. The result is no ridges left that would require additional passes or tandem rollers for removing ridges.
[0008] 3. Objects of the Invention
[0009] It is an object of the invention to provide a roller type compactor where the compacting drum can work adjacent to a vertical barrier such as a wall, pole, post, and the like without leaving an un-compacted strip adjacent to the barrier.
BRIEF SUMMARY OF THE INVENTION
[0010] A roller compactor is a heavy 2 axle machine where at least one axle carries roller for compressing materials as the machine travels. The other axle may have another compacting roller, rubber tires, or a caterpillar tread. Steering is usually accomplished by pivoting one of the axles.
[0011] The prior art frame and bearing systems have been described as lacking the ability to work closely against walls, poles, curbs, etc. The invention described herein overcomes this problem.
[0012] The main roller is divided into three adjacent, independent, ground contacting roller sections on parallel axles. The rollers are designated as a central, and left and right outer rollers. The central and outer rollers are supported from downwardly extending plates of a suspension frame over the middle roller. The central roller axle is journaled to the plates by bearings at each end. The outer rollers are journaled on separate axles extending outwardly from the plates. The outer rollers have a larger diameter than the central roller and all three are in alignment on the ground, thus the axles of the outer rollers are parallel with, but attached to the plate above the center roller axle.
[0013] The bottom (ground contacting) surfaces of all the roller drums are co-planer, but the tops of the outer rollers extend above the upper surface of the center roller drum, thereby leaving a space for the supporting frame, to pass through and extend downward to the roller axles.
[0014] Bearings of suitable size and shape are attached to the rollers and axles.
BRIEF DESCRIPTION OF THE FIGURES
[0015] FIG. 1 is an isometric view showing the 3 section roller assembly on a compacting machine.
[0016] FIG. 2 is an frontal view of the preferred embodiment of the 3 drum roller assembly.
[0017] FIG. 3 is an end view of the drum assembly of the preferred embodiment.
[0018] FIG. 4 is a cut away view of the 3 roller drums cut along sectioning line A-A.
[0019] FIG. 5 is a view showing the essential parts of the roller suspension frame.
[0020] FIG. 6 is an end view of an embodiment of the drum assembly where the outer roller drums have a smaller diameter than the center roller drum.
[0021] FIG. 7 is a view showing the essential parts of the roller suspension frame adapted for use when the outer rollers are smaller than the central drum.
TABLE OF IDENTIFIED DETAILS
[0000]
1 . The roller drum compactor fitted with the described 3 section roller.
2 . The Primary Drum
3 , 3 a , 3 b . The secondary outside drums
4 . Steering Trunnion
5 . Drum support frame(from trunnion to axle)
6 . Primary (center) drum axle
7 . Outer drum axle( 2 )
8 . Ground contacting area of the drums
9 . Unassigned
10 . Outer Drum Wheel Disks
11 . Outer Drum Axle Bearing Assembly
12 . Center Drum Axle Bearing Assembly
13 . Center Drum Wheel Disks
14 . Drive motor, chain, sprockets, etc
15 . Drum Shield Ring
16 . Journaling mount for central roller axle
DETAILED DESCRIPTION OF THE INVENTION
[0038] FIG. 1 illustrates a soil or pavement compactor 1 fitted with the present invention. The primary roller comprising three independent, adjacent rolling drums. The center roller 2 is driven by an hydraulic motor 14 . The outer rollers 3 a , 3 b are on independent axles 12 attached to a frame 5 at a position above the center roller axle 6 . The preferred diameter of the center roller 2 is 30 inches, and the preferred diameter of the outer rollers is 36 inches. The axles are positioned to have the lower, ground contacting, surfaces of the drums aligned co-planarly. Thus there is a gap diametrically opposite (at the top of the drums) through which the axle supporting frame 5 is passed. The frame also carries at its center a pivot trunnion 4 for pivoting the roller assembly about a vertical axis to steer the machine. The pivot trunnion is operatively attached to an operator controlled steering mechanism.
[0039] FIG. 2 is an exterior frontal view showing the three rollers 2 , 3 a , 3 b , part of the axle supporting frame 5 , and the steering trunnion 4 . Since the axles are at the centers of the rollers, the axle offset is implied. The relationship of the top and ground contacting edges are illustrated.
[0040] With the ground contacting portions of the three drums being aligned co-linearly, the three drums accomplish compacting and smoothing operations nearly identically as if they were one longer roller.
[0041] FIG. 3 as an end view of the rollers. The cut-line for FIG. 4 is illustrated.
[0042] Referring to FIG. 4 , The structure of the rollers, axles, and the bearings are illustrated. The two outer drums are generally identical, and the identified features apply to both.
[0043] The three drums are similarly constructed comprising an outer cylinder 2 , 3 , and at least two spaced apart interior wheels 10 , 13 which extend between the axles or axle bearings and the outer cylinders.
[0044] The center roller has one of the wheels moved inward to make space for the chain drive assembly. At least one of the outer rollers has one wheel moved outwardly enough to make space for the hydraulic drive motor and associated drive parts 14 . The wheels 13 for the center roller and the chain drive sprocket are securely attached to the center axle 6 . Thus, power from motor 14 is passed through the chain and sprocket to the axle 6 , then through wheels 13 , and finally to the center roller cylinder 2 to drive the machine forwards and backwards.
[0045] The wheels of the outer rollers extend between the roller cylinder 3 and a bearing hub 11 . Roller or ball bearings permit the outer rollers to rotate freely.
[0046] Access holes through the wheels are provided to gain admittance into the interior of the roller drums for cleaning, repair, assembly, disassembly, greasing, and general maintenance.
[0047] Bearing details such as mounting, type, design, etc, and hub capping are conventional, and not described in detail.
[0048] In addition, each open end of each roller drum has a shield ring 15 welded to the cylinder for both strengthening and to serve as partial end walls to keep most if not all loose gravel, dirt, asphalt, etc from entering the cylinders. This is especially required for the adjacent roller ends. Debris in there would not be easily expelled and could even wedge in the scissors-like spaces where the rollers of different diameters converge toward bottom. The preferred ring width is 1¼ inch, but may be much larger for the outer rim of the outer rollers and for both ends of the center roller. The width of the rings 15 at the inner edges of the outer rollers 3 must be small enough to leave an adequate gap at the top for the supporting frame 5 to pass between the outer rollers and the center roller.
[0049] The prime mover (engine), hydraulic, and steering systems are conventional for machinery of this class, thus does not need to be described.
Alternative Embodiments and Variations of the Invention
[0050] The foregoing description utilizes the composite roller assembly as one of the rollers on a conventional tandem roller riding compactor comprising a chassis supporting a prime mover and associate machinery, an operator's station, and operator's controls for steering and movement. The claimed invention is intended to be mountable on other forms such as a walk-behind machine similar to the general form described by Ciminelli U.S. Pat. No. 4,964,753, multiple axle roller compactors, and rollers towed or pushed by tractors, graders, trucks, hoes, loaders, dozers, and other construction machinery.
[0051] The invention may be practiced with only one outer roller having the claimed recessed hub.
[0052] FIG. 1 illustrates the back of the compactor machine being supported on a single transverse roller. However, the second support may be another of the presently described roller assembly, rubber tires, or a crawler track.
[0053] The rollers are generally smooth for making flat surfaces, but may optionally be equipped with knobs, bars, sheep's-foot like projections, etc for deeper compactions operations or to increase traction.
[0054] The dimensions presented are for a preferred size of compacting machine. Obviously, the compactor may be scaled up or down to fit particular applications.
[0055] The description of the preferred embodiment has the outer rollers having diameters larger than the center roller. The invention may be configured where the outer rollers have a smaller diameter than the center roller. FIGS. 6 and 7 show the modifications to the preferred embodiment to utilize smaller outer rollers. The supporting frame has a retro bend extending through the gap under the central roller at least far enough to clear the inner edge of the outer rollers. There is enough space within the outer rollers to accommodate the hubs and bearings of the central roller axle. Alternatively, the retro-portion may be extended inwardly enough to keep the entire central axle assembly within the central roller. Obviously, this will necessitate an heavier structure in the zone of the retro-bend and inward extension to carry the load of the chassis and engine.
How to Use the Invention
[0056] The compactor machine is controlled by an on-board operator who may run the compactor against curbs, walls, poles, etc.
[0057] The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention as defined by the claims which follow.
[0058] The embodiments of the invention in which an exclusive property right or privilege is claimed are defined as follows: | A roller type asphalt pad and/or soil compactor adapted to compact asphalt paving and sub-grading closely adjacent to building walls, poles, edgings, curbs, and barriers. The roller comprises at least one end having an axially offset cylindrical extension having a recessed hub, or no hub, which allows the extension to compress the paving without having a hub or similar end attachment that prevents the roller assembly from working snugly against a wall or barrier. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to the connection of a flat brake disk to the wheel flange of a vehicle and particularly relates to an elastic connection.
BACKGROUND OF THE INVENTION
[0002] Flat brake disks are being used to an increasing extent in the automotive field. One reason for their use is the desire to reduce the problem of so-called “brake judder”. “Brake judder” is a comfort problem which expresses itself in the form of unwanted noise during braking, some vibrations starting in components lying outside the brake.
[0003] DE 197 51 522 C1 discloses a flat brake disk, which is connected to the wheel flange by a connecting part. The design of the connecting part prevents radially pre-loading the brake disk. A further problem of the disclosed arrangement lies in the fact that, during cornering, the wheel flange bends elastically as a result of the load due to the moment of tilt, which load is introduced through the rim. The brake disk is mounted directly on the wheel flange and it also tilts accordingly. This causes the brake disk to press against one brake pad and wear under unbraked cornering. This may cause displacement between the brake caliper and the brake disk.
OBJECT OF THE INVENTION
[0004] The object of the invention is to connect a wheel bearing flange to a flat brake disk so that the brake disk in all operating conditions of the vehicle may align itself elastically between the brake pads, thus avoiding unwanted constraining forces.
DESCRIPTION OF THE INVENTION
[0005] The primary feature of the invention is an elastic connecting element arranged between the radial interior of the flat brake disk and the axial extension of the periphery of the wheel bearing flange, around which the interior of the disk is displaced. The elastic connecting element can compensate for the displacements (radial, axial and/or in a circumferential direction) between the flat brake disk and the brake caliper. These displacements substantially occur upon temperature differences between the brake disk and the wheel bearing flange and under cornering due to the loads being effected from the wheel which loads cause elastic deformation of the wheel bearing flange. The elastic connecting element compensates for these movements. The movements to be equalized between the axial extension of the flange and the receptacle for the brake disk are generally under 1 mm.
[0006] The connecting element has a further advantage in that it separates the different materials of the brake disk and the wheel flange. As a result, no corrosion processes take place between the two.
[0007] The elastic connecting element additionally compensates for the production tolerances of the adjacent components.
[0008] A further advantage of the connecting element is that it can be manufactured as a single part. As a result, only one part need be handled and installed.
[0009] The brake disk is advantageously pre-loaded in the circumferential direction. As a result, no bumps occur when a braking torque is introduced between the brake disk and the projecting parts on the axial extension at the periphery of the flange where the brake disk is disposed. In the area of the circumferential direction flanks of the projections radially outward from the flange, the elastic connecting element pre-loads the projections against correspondingly shaped recesses in the interior of the brake disk.
[0010] The elasticity is achieved through radial flutes formed in the connecting element. The material of the connecting element is optimally exploited by these flutes, and the elasticity of that element is established in a simple manner by production technology.
[0011] A radially outwardly directed edge is incorporated on the connecting element. This edge is positioned against the lateral side of the brake disk, so that the edge has a damping effect on the disk in an axial direction. The edge is positioned on the side facing away from the direction of installation i.e., the side of the axial extension toward which the brake disk is moved as it is installed in the axial direction onto the axial extension. The brake disk is axially pre-loaded together with the axial retaining element. As a result, displacements between the axial extension of the wheel bearing flange and the brake disk can be compensated for.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 shows a wheel bearing flange with an axial extension.
[0013] [0013]FIG. 2 shows the wheel bearing flange of FIG. 1 with the connecting element arranged in place.
[0014] [0014]FIGS. 3 a , 3 b show the flange of FIG. 2 with a flat brake disk installed from the outward and inward sides, respectively.
[0015] [0015]FIG. 4 shows the flange of FIG. 3 with an axial retaining element.
[0016] [0016]FIG. 5 shows a section of FIG. 4.
DETAILED DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 shows the wheel bearing flange 1 in perspective. A rolling bearing lies within the wheel bearing flange 1 as seen in FIG. 5. There are fastening bores 2 of the rim. An axial extension 3 at the periphery of the wheel flange 1 extends axially to be radially underneath the flat brake disk 6 shown in FIG. 3.
[0018] Radially outwardly directed projections 4 are for mounting the brake disk and are illustrated in the area of the axial extension 3 . The flanks of the projections transfer the braking torque to the disk 6 . The brake disk 6 (FIG. 3 a ) is radially centered on the surface 5 of the axial extension 3 . The meander form between the receptacle of the brake disk 12 and the receptacle of the wheel rim 111 is shown in FIG. 15. Axial extension and rim receptacle therefore alternate with each other.
[0019] [0019]FIG. 2 shows the flange of FIG. 1 with an elastic connecting element 7 installed. This comprises a corrugated metal connecting element 7 a . The corrugated form is preferred to achieve the necessary elasticity in the connecting element. Other forms having surface bumps or stamped undulations may be used. Because of the arrangement of the connecting element 7 a , for which non-rusting metal sheet is a preferred material, the materials of the brake disk and the opposing axial extension 3 are completely isolated, which prevents formation of rust between the different materials. In the area of the circumferential side flanks 4 a of the projections 4 , the connecting element 7 is formed in an angle such that the brake disk is pre-loaded in the circumferential direction. In the area of the flanks 4 a , e.g. surface bumps can also be incorporated in order to achieve this pre-load in the connecting element. Surface bumps are not shown.
[0020] A radially outwardly directed edge 7 b of the connecting element 7 is positioned lightly against the brake disk when it is installed on the flange, achieving the effect of a diaphragm spring when the brake disk is fully installed and fastened. In FIG. 5, an installation direction 13 from the rim is suggested for the brake disk. The radially-directed edge 7 b is therefore incorporated on the opposing side of the connecting element toward which the brake disk is moved as it is installed on the flange. A possible reversal of the installation direction is not illustrated.
[0021] [0021]FIG. 3 a and FIG. 3 b show the wheel bearing flange and connecting element and the installed flat brake disk 6 . In this case, the brake disk 6 has been installed from the direction of the rim receptacle 2 . After installation, the brake disk is pre-loaded both in a radial direction and in a circumferential direction with regard to the axial extension 3 . The recesses 6 a in the inward side of the brake disk transfer the braking torque via the elastic connecting element 7 onto the flanks 4 a of the projections 4 in the axial extension 3 of the wheel bearing flange 1 .
[0022] [0022]FIG. 4 shows the range of FIGS. 3 a / 3 b after installation of an axial retaining element 8 . The retaining element 8 presses the brake disk 6 against the radial edge 7 b of the connecting element 7 and thus pre-loads the brake disk. The brake disk 8 is therefore attached in a manner which allows displacement of the brake disk 8 in an axial direction in relation to the axial extension 3 of the wheel bearing flange 1 . In this example, the axial retaining element 8 is secured by springs 8 a , wherein the springs engage in recesses in the axial extension 3 of the wheel bearing flange.
[0023] [0023]FIG. 5 is a sectional and perspective illustration of the complete unit. The stationary wheel bearing flange 9 or fastening flange and the rolling bearing 10 are seen. The rotating wheel bearing flange 1 and the axial extension 3 are shown in section. The elastic connecting element 7 is between the axial extension 3 and the flat brake disk. The radially outwardly directed damping edge 7 b axially pre-loads the brake disk and the retaining element 8 . The installation direction of the flat brake disk 6 of the connecting element 7 and the metal retaining plate 8 is from the direction of the rim receptacle in this arrangement. The meander design of the wheel bearing flange 1 and the axial extension 3 comprised of first level rim receptacle 11 , second level 12 centering surface areas 5 for the brake disk 6 , which are offset with respect to the first level, is a pre-condition for this installation direction 13 .
[0024] Although the present invention has been described in relation to a particular embodiment thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims. | A wheel bearing flange with a periphery having axial extensions for the mounting of a flat annular brake disk thereon. An isolating connecting element between the axial extensions and the brake disk. The axial extensions have radially outwardly directed projections which engage in radially inward recesses with the interior of the brake disk. The connecting element elastically pre-loads the brake disk relative to the axial extensions to elastically compensate for displacements of the brake disk while driving. | 5 |
RELATED APPLICATION
[0001] This application claims the benefit of provisional application Ser. No. 61/704,744 filed Sep. 24, 2012 entitled “Speed loader for large caliber multi-shot weapon,” inventors David G. Kent, James W. Teetzel, and Mark J. Celona. The foregoing provisional application is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present disclosure relates generally to man-portable, large caliber multi-shot weapons and, more particularly, to a speed loader which provides fast and reliable loading of ammunition rounds. Although the present invention will be described herein primarily by way of reference to a speed loader for a grenade launcher, it will be recognized that the present invention herein can be adapted for use with all manner of weapons and projectiles, including without limitation anti-riot rounds, less than lethal rounds, flares, pyrotechnics, tear gas or like irritant canisters, and the like.
[0003] Large-caliber, multi-shot weapons employing a revolver-style magazine are generally known, such as the Milkor Multiple Grenade Launcher (MGL). These weapons offer an advantage over traditional single-shot weapons in that multiple rounds can rapidly be brought to bear on a target. However, the rounds must be manually loaded into the chambers 164 of the magazine 162 of a weapon 160 one at a time, as illustrated in FIG. 8 , a time consuming process. Because time is of the essence in military, combat, law enforcement and like situations, it would be desirable to provide a loading device for large caliber weapon that substantially reduces the time required for a user to load rounds into the weapon. Although speed loader devices exist for small-caliber firearm revolvers, there still exists a need for a speed loader for the rapid loading and reloading of multi-shot grenade launchers and other large-caliber multi-shot weapons.
SUMMARY
[0004] Apparatus and methods are provided for fast loading a plurality of cartridges into a magazine for holding cartridges.
[0005] An embodiment of the invention is an apparatus for fast loading a plurality of cartridges into a magazine. The apparatus includes a cartridge receptacle having cavities for accommodating the plurality of cartridges such that the cavities surround a central area. A retention wheel has a shaft extending from the rearward facing side of the wheel and inserted through an opening in the central area, wherein the shaft defines an axis for rotation of the wheel. A knob is rotatably attached to the rearward facing side of the receptacle by a fastener engaging the shaft, such that the knob is movable and has a locked and an unlocked position. In the locked position, the cartridges placed in the receptacle are engaged by the retention wheel, and in the unlocked position, the cartridges are released from the retention wheel. For example, the magazine is a part of a large caliber multi-shot weapon; a machine for shooting flares, tear gas or like irritants, or other projectiles.
[0006] In related embodiments of the invention, the retention wheel has a plurality of projections extending radially outward, the projections capable of engaging the plurality of cartridges. Embodiments of the invention include an apparatus in which the projections of the shaft are capable of engaging the cartridges through a rim at the base of the cartridge. In other related embodiments, the fastener engages a complementary receptacle on the shaft. For example, the fastener is threaded and is capable of engaging a complementary threaded receptacle in the shaft. In further, more limited embodiments, the end of the shaft engaging with the fastener has a shape that fits into a complementary or keyed receptacle formed on the inward facing surface of the knob.
[0007] According to other embodiments of the invention, the retention wheel is received in the central area of the cartridge receptacle.
[0008] In various embodiments of the invention, the knob is notched, fluted, knurled, or otherwise textured to enhance the user's grip while rotating the knob.
[0009] In other related embodiments, the cartridge receptacle has an upstanding boss on its rearward facing side, which is received within a like sized cavity on the forward facing side of the knob. For example, the boss has a central opening for receiving the shaft, and a plurality of openings surrounding the central opening.
[0010] Other related embodiments of the invention include a plurality of springs, such that each spring has a proximal and a distal end, and is received into one of the plurality of openings in the boss through the proximal end.
[0011] Related embodiments of the invention further include a detent attached to the distal end of each spring of the plurality of springs, and, for each spring, a pair of complementary recesses on the knob, the pair comprising first and second complementary recesses corresponding to each detent. For example, in the locked position of the knob each spring detent is received in the first complementary recess and the plurality of projections of the retention wheel engage the plurality of cartridges. Also, for example, in the unlocked position of the knob, each spring detent is received in the second complementary recess and the projections of the retention wheel occupy a position between the cavities of the cartridge receptacle, and are thereby moved out of engagement with the cartridges. In related embodiments, the detents and the complementary recesses are rounded to facilitate the movement of the detents in and out of the recesses.
[0012] In a related embodiment of the invention, the apparatus includes a stopping mechanism for limiting the degree of rotation of the knob relative to the cartridge receptacle, the stopping mechanism having at least one pin on the forward facing side of the knob which runs in a corresponding arcuate groove or channel on the rearward facing side of the cartridge receptacle.
[0013] In various embodiments of the invention, the number of cavities in the cartridge receptacle of the apparatus is in the range of 2-12.
[0014] In preferred embodiments of the invention, the cavities of the cartridge receptacle are capable of accommodating cartridges that hold ammunition rounds having a caliber of about 30-40 millimeter, although other caliber ammunition rounds are also contemplated.
[0015] Other embodiments of the invention are methods of using the apparatus of any of the embodiments above for fast loading a plurality of cartridges into a magazine. The method includes inserting a plurality of cartridges into the cartridge receptacle and turning the knob to a locked position thereby engaging the plurality of cartridges with the plurality of projections of the retention wheel. The plurality of cartridges is aligned with a corresponding plurality of chambers in the magazine and the plurality of cartridges is slidably inserted into the corresponding aligned chamber of the magazine drum of the weapon. The knob is turned to an unlocked position to disengage each of the plurality of cartridges from the plurality of projections of the retention wheel. The cartridge receptacle is moved away from the weapon, thereby fast loading the cartridges into the weapon. In related embodiments of the invention, the magazine is part of a large caliber multi-shot weapon.
[0016] In related embodiments, turning the knob into the locked position further includes receiving the detent on the distal end of each of the plurality of springs in the first complementary recesses provided on the knob. Also, turning the knob into the unlocked position further comprises receiving the detent on the distal end of each of the plurality of springs in second complementary recesses provided on the knob.
[0017] Another embodiment of the invention is a method for fast loading a plurality of cartridges into a magazine, the method including inserting a plurality of cartridges into the cavities of a cartridge receptacle disposed between a turning knob and a rotating wheel. Each cartridge has a base end and a tip end, the base end leading the tip end during insertion, such that the retention wheel is capable of engaging the base end of the cartridge. The knob is turned to a locked position, thereby engaging the plurality of cartridges by the retention wheel. The plurality of cartridges is aligned with a corresponding plurality of chambers in the magazine and the plurality of cartridges is slidably inserted into the corresponding aligned chamber of the magazine drum of the weapon. The knob is turned to an unlocked position to disengage each of the plurality of cartridges from the plurality of projections of the retention wheel. The cartridge receptacle is moved away from the weapon, thereby fast loading the cartridges into the weapon. In related embodiments of the invention, the magazine is part of a large caliber multi-shot weapon. In other related embodiment of the invention, engaging the plurality of cartridges by the retention wheel includes engaging the rim present at the base end of each cartridge of the plurality of cartridges by one of a plurality of projections extending radially outward from the retention wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.
[0019] FIG. 1 is an isometric view of an exemplary speed loader embodiment, taken generally from the rear.
[0020] FIG. 2 is an isometric view of the embodiment appearing in FIG. 1 , taken generally from the front.
[0021] FIG. 3 is an exploded isometric view of the embodiment shown in FIG. 1 , taken generally from the front and side.
[0022] FIG. 4 is an exploded isometric view of the embodiment shown in FIG. 1 , taken generally from the side and rear.
[0023] FIG. 5 is an isometric view of the speed loader embodiment appearing in FIG. 1 , with rounds loaded and secured therein.
[0024] FIGS. 6A , 6 B, and 6 C illustrate the speed loader embodiment of FIG. 1 with a round locked, unlocked, and removed from the speed loader, respectively.
[0025] FIGS. 7A-7D illustrate the sequence of steps for loading a magazine of a weapon using the speed loader embodiment appearing in FIG. 1 .
[0026] FIG. 8 is a photograph illustrating the manual loading of a multi-shot grenade launcher.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring now to FIGS. 1-4 , there is shown an exemplary speed loader 100 , which includes a cartridge receptacle member A, a retention wheel member B, and a knob member C. As used herein, the terms “front” and “forward” refer to the forward direction relative to the direction of travel of the projectile to be fired and the terms “rear” and “rearward” refer to the rearward direction relative to the direction of travel of the projectile to be fired.
[0028] The cartridge receptacle A includes a plurality of cylindrical cavities 102 on the forward facing side of the cartridge receptacle A for receiving the base ends 106 of the grenade cartridges 104 or other projectiles to be fired. In preferred embodiments, the rounds are preferably in the range of 30-40 millimeter caliber rounds, although other round calibers are also contemplated. The depicted embodiment illustrates a speed loader embodiment for use with a Milkor MGL, which has a six round cylinder or magazine. A “magazine” or “cylinder” as used herein refers to a rotating, revolver style cylinder or drum having a number of chambers for receiving munitions cartridges. Although the present invention will be described by way of reference to a six-chamber magazine, it will be recognized that the speed loader herein could be adapted for a weapon magazine having any other number of rounds, including 2, 3, 4, 5, 7, 8, 9, 10, 11, 12, and other numbers of chambers.
[0029] The cavities 102 surround a central area 110 receiving the cartridge retention wheel B. The retention wheel B includes a shaft 112 defining an axis of rotation and a plurality of projections 114 extending radially outward therefrom. The shaft 112 extends through a central opening 116 in the cartridge receptacle member A.
[0030] The knob C is rotatably attached on the rearward facing side of the cartridge receptacle A by a threaded fastener 120 engaging a complementary threaded receptacle 122 on the shaft 112 . The distal end of the shaft 124 has a shape that mates with a complementary or keyed receptacle 126 formed on the inward facing surface of the knob C. In this manner, rotation of the knob C relative to the cartridge receptacle A serves to rotate the retention member B. The knob C may be notched, fluted, knurled, or otherwise textured to enhance the user's grip when manually rotating the knob C.
[0031] An upstanding boss 130 on the outward facing surface of the receptacle A is received within a like sized cavity 132 on the inward facing surface of the knob C. The boss 130 includes a central opening 134 receiving the shaft 112 and a plurality of openings 136 for receiving proximal ends of springs 140 . A detent 142 is attached to the distal end of each spring 140 . Four springs are shown in the illustrated embodiment, although other numbers of springs could be employed.
[0032] For each spring biased detent 142 on the boss 130 , there is a corresponding pair of complementary recesses 144 a , 144 b . When knob C is turned such that each spring detent 142 is received in the corresponding recess 144 a , the spokes 114 of the retention wheel B engage the rim 108 formed at the base end 106 of the munitions cartridge 104 , such that the cartridges 104 will be locked into position within the receptacle A. FIGS. 5 and 6A illustrate the speed loader 100 herein with the spokes 114 engaging the rims 108 of the munitions rounds 104 and securing them within the unit 100 .
[0033] When the knob C is turned such that each spring detent 142 is received in the corresponding recess 144 b , the spokes 114 of the retention wheel B are moved to a position midway between the cartridge receptacles 102 , such that the spokes 114 move out of engagement with the rims 108 of the munitions cartridges 104 , to release the cartridges 104 from the receptacle A. FIGS. 6B and 6C illustrate the speed loader 100 herein with the spokes 114 moved to a position disengaging from the rims 108 of the munitions rounds 104 to release them from the unit 100 . By providing spring biased detents 142 and complementary depressions 144 a , 144 b , the knob C will click solidly into the desired locked or unlocked position. In preferred embodiments, rounded detents 150 and complementary rounded depressions are employed to facilitate the movement of the detents 150 out of and into engagement with the depressions 144 a , 144 b.
[0034] A mechanical stop limiting the degree of rotation of the knob C relative to the cartridge receptacle member A is provided by pins 150 carried on the knob 130 and corresponding, aligned arcuate grooves or channels 152 formed on the cartridge receptacle A. The pins 150 run in the corresponding aligned grooves 152 to limit the movement of the knob C.
[0035] The operation of the speed loader 100 is illustrated by the sequence outlined in FIGS. 7A-7D . In operation, the knob C is rotated until the spokes 114 are at a position intermediate the receptacle 102 and cartridges are placed in each receptacle 102 . The knob C is then turned until the spokes 114 engage the rims 108 of the corresponding aligned cartridges 104 , retaining them in the receptacles 102 . When the spokes 114 engage the cartridge rims 108 , each of the detents 142 is aligned with the corresponding one of the depressions 144 a . The bias of the springs 140 urges the detents 142 into the complementary depressions 144 a to secure the knob C in the locked position.
[0036] As shown in FIG. 7A , the unit 100 with attached rounds 104 is then lined up with the magazine drum or cylinder 162 of the weapon 160 (see FIG. 8 ). The cartridges 104 with the speed loader attached are then inserted into the munitions chambers 164 of the magazine 162 (see FIG. 7B ). The knob C is then manually rotated relative to the cartridge receptacle member A (see FIG. 7C ) and the munitions rounds 104 are released into the respective chambers of the magazine 162 . When the knob C is moved into the unlocked position, the spokes 114 are moved to a position intermediate the receptacles 102 and out of engagement with the cartridges 104 . The bias of the springs 140 urges the detents 142 into the complementary depressions 144 b to secure the knob C in the unlocked position. The speed loader assembly 100 is then removed from the magazine 162 ( FIG. 7D ).
[0037] The description above should not be construed as limiting the scope of the invention, but as merely providing illustrations to some of the presently preferred embodiments of this invention. In light of the above description and examples, various other modifications and variations will now become apparent to those skilled in the art without departing from the spirit and scope of the present invention. | Apparatus and methods are provided for fast loading a plurality of cartridges into a magazine for holding cartridges, such as the magazine of a large caliber multi-shot weapon. In various embodiments, the apparatus includes a cartridge receptacle disposed between a retention wheel and a knob. The knob is rotatably attached to the cartridge receptacle and fastened to the retention wheel. The knob has a locked and an unlocked position. In the locked position, the cartridges placed in the receptacle are engaged by the retention wheel. In the unlocked position, the cartridges are released from the retention wheel. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a vibratory pump applicable to pump liquids.
A vibratory pump is known, which includes a housing of synthetic material and formed of a lower part and an upper part linked to each other by means of a connection which is formed in the lower part, an axial oscillating member and a static electric bobbin covered with resin and acting on a movable electric bobbin, which is placed in the axial oscillating member. The middle region of the oscillating member is supported and slides in a bearing and has a flexible membrane, which is disposed near the periphery of the housing in which the axial oscillating member is positioned. The latter supports a cupped glass element which is in cooperation with the flexible membrane. A part of the housing defines a variable volume chamber which communicates with the exterior through an admission valve and with an outer tube. The valve is constituted by a central chamber, which communicates with the variable volume chamber, through a movement of the cupped glass element positioned in the extremity of the axial member, and with the exterior through the opening. A second cupped glass is positioned on the wall of the valve.
In the conventional structure of the pump, the fixed electric bobbin is placed in the interior of the housing and covered with resin; under these conditions the bobbin warms up to the level which is above optimal level.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved vibratory pump.
This and other objects of the invention are attained by a pump in which the static part of the bobbin is positioned in a water refrigeration chamber which ensures the maintenance of the temperature of the bobbin within the acceptable limits.
In the conventional pump of the foregoing type the adjacent extremities of the housing are linked to each other by the connection of external flanges to each other. This solution requires, however, an enormous number of screws to be tightened and untightened each time it is necessary to open or close the pump in the maintenance work and the like; such operation is considered to be annoying and should be eliminated.
Furthermore, the main membrane in the conventional pump is formed by an extension that projects from the lower part of the water chamber to a connection region between the upper and lower parts of the housing, where a flange is coupled to a profiled tooth of the upper part and a flange of the bearing of the central oscillating member, which is interconnected between the flanges of the parts of the housing.
It is another object of the invention to substantially simplify maintenance operations for the vibratory pump.
These and other objects of the invention are attained by a vibratory pump, comprising a housing being substantially cylindrical, said housing including an upper part and a lower part connected to each other; connection means for connecting said lower and upper part to each other; a static electric bobbin covered with resin; a movable electric bobbin on which said static electric bobbin acts; an axial oscillating member supporting said movable bobbin; a bearing supporting said oscillating member; a main membrane supported on said oscillating member and having a periphery set close to an internal face of the housing and in cooperation with the housing defining a variable volume chamber, said lower part of the housing having a cooling chamber filled with water and accomodating said static electric bobbin; an admission central valve connected to said chamber and also to means which provides the cooling chamber with water; a stainless steel membrane having a periphery set in an internal face of said lower part of the housing and positioned between the static electric bobbin and the movable electric bobbin, said lower part having openings which are in communication with the said cooling chamber and with an exterior of the pump, said connection means including a flange region formed in the lower part of the housing and a flange formed on the upper part of the housing, said flange region being spaced from a wall of the upper part by an annular space, a profiled ring accomodated in said space near said flange and coupled to the said flange region by thread means and said ring having on a face thereof a plurality of circular grooves; and a plurality of radial triangular wings circumferentially spaced from each other.
The main membrane may have a profiled flange which is fixed between a tooth formed on the upper part of the housing and a ring which is disposed on the bearing of the oscillating member.
The static electric bobbin may have a cover fixed in the lower part of the housing by ultrasonic soldering.
The admission valve may include an assembly ring provided with a screw thread screwed in an internal surface of the upper part of the housing and a flexible rubber ring having an internal rim, said assembly ring having an external rim on which is set the internal rim of a flexible rubber ring, said upper part having openings for water entry to said chamber, said rubber ring being adapted to cover said openings.
The assembly ring may have an internal rim and an elongated cup-shaped portion co-axial to the assembly ring and having a central opening, and further including a rubber cup-shaped membrane and a pin received in said opening, said membrane being received and adjusted in an internal part of the cup-shaped portion of the assembly ring; said membrane having a lateral wall which covers a wall of the portion of the assembly ring, through which water contained in the chamber flows to an outlet of the pump.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a top plan view of the pump;
FIG. 2 is an axial sectional view through the pump;
FIG. 3 is a plan view of a detail of connection means between two housing parts;
FIG. 4 shows a section B--B of FIG. 3 and illustrates connection means between the parts of the housing in further detail;
FIG. 5 shows a view from arrow C of FIG. 4;
FIG. 6 is a sectional view of the admission and emission valve of the vibratory pump with separated parts; and
FIG. 7 is a sectional view of the valve in the assembled condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, a vibratory pump of this invention includes an essentially cylindrical housing made of synthetic material or the like and having a lower part 1 and an upper part 2 connected to each other by means of connection 3. Housing 1, 2 accommodates in its lower part 1, a static electric bobbin 4 covered with synthetic resin 5. Bobbin 4 acts on a movable bobbin 6 positioned in the interior extremity of an oscillating member 7. The latter is disposed axially in the housing 1, 2. Oscillating member 7 is capable of sliding in a bearing 8 supported between parts 1 and 2 of the housing. The oscillating member 7 is supported by a main membrane 9 which limits, in cooperation with the upper part of the housing, a chamber of variable volume 10 which communicates with a central admission valve 11 and with a duct 12; the admission valve has a chamber communicating through opening 14 with the chamber of variable volume 10 in which a flexible cupped glass element 13 is positioned. A second upper cupped glass element 15 which acts on the opening 14 is positioned on the wall defining the admission valve chamber.
The first embodiment of the vibratory pump includes a refrigeration chamber 16. The lower part 1 of the housing is divided by a stainless steel membrane 17 which is disposed between the static electric bobbin 4 and the movable electric bobbin 6. Membrane 17 separates an upper region or chamber from refrigeration chamber 16. The latter is filled with water which surrounds the static electric bobbin 4 and communicates with exterior by means 19.
The connection 3 between the lower part 1 of the housing and its upper part of 2 is formed by a relatively short portion 20 of the lower part 1 in which an external flange 21 of the upper part of the housing is fitted. Flange 21 is formed so that a space is formed between the external surface of the upper part 2 of the housing near the flange and the internal surface of the portion 2. A ring 22 is received in this space. Flange 20 is coupled to ring 22 by a screw thread 23. Connection 3 can alternatively be formed by radial pins 25 (FIG. 4) which are projections extending from the ring external face. Pins 25 are engaged in corresponding grooves 26 formed in the internal face of the portion 20. These grooves 26 have the "L" shape and have each a portion extending in longitudinal direction of the pump and a perpendicular region 27 in the circumferential part of the housing.
The profiled ring (22) is provided with grooves 28 (FIGS. 1, 4) and has radial triangular vanes 29 responsible for the ring movement in the opening and closing operations.
The vibratory pump further includes a main membrane 9 which is formed with a profiled flange 30-31 which is clamped between a tooth formed on a part 33 of the upper part 2 of the housing and a ring 34 which is positioned on a bearing of the oscillating member 7.
The resin cover 5 of the static electric bobbin 4 is connected to housing parts 1, 2 by ultrasound soldering or other means 35 and it can be substituted by electrostatic covering to enlarge the refrigeration area. Membrane 17 as well as other structural parts are fixed in the housing, for example by auto-gluing means 36.
The admission valve 11 may be formed as valve 37 (FIGS. 6 and 7). Valve 37 has a ring 38 which is provided with a screw thread 39 that is screwed in a corresponding screw thread 40 formed in an outlet portion 12 of the housing part 2. The ring 38 has an external rim 41 on which in assembly is positioned an internal rim 42 of a membrane 43 of a flexible rubber ring type. Openings 44 in the upper housing part serve for the entry of water into the variable volume chamber 10.
An internal rim 45 is provided on ring 38. A cup-shaped region 46 co-axial to the assembly ring 38 has a projection 47 which has a central opening 48 in which a pin 49 of a cup-shaped flexible rubber membrane 50 is received. Pin 49 is adjusted in the internal region of portion 46 of the assembly ring 38; the flexible rubber membrane 50 has a peripheral wall 51 which covers openings 52 which are formed in the wall 53 of the cup-shaped portion 46 of the assembly ring 38, through which openings water contained in the chamber 10 passes to the outlet of the pump.
When the axial oscillating member 7 of the pump is lowered it enlarges the volume of chamber 10 and causes a depression in the internal part of the chamber, which in turn causes the flexible rubber ring 43 to open the openings 44 and the consequent entry of a portion of water into the chamber 10 and simultaneously, causes the compression of wall 51 of flexible rubber membrane 50, which wall meets the outlet openings 52 of the water chamber 10, and closes those openings.
When the axial member 7 ascends it reduces the capacity of the chamber and causes the compression of the flexible rubber ring 43 which meets the openings 44 which are closed, and simultaneously causes the compression of the flexible rubber ring 50 which opens the openings 52 through which a part of water of the chamber 10 passes to the outlet or duct 12.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of vibratory pumps differing from the types described above.
While the invention has been illustrated and described as embodied in a vibratory pump, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A vibratory pump comprises a skeleton composed by an interior part and an exterior part interlinked by a connection with a movable static bobbin covered with resin that acts on a main membrane that in cooperation with a skeleton delimits a variable volume repression chamber communication with the exterior part through an admission central valve and also acts with a repression duct. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 10/528,515, which has an assigned filing date of Oct. 26, 2005, which was the National Stage of International Application No. PCT/US2003/029302, filed Sep. 19, 2003, and which claims the benefit of U.S. Provisional Application No. 60/412,125, filed Sep. 19, 2002. This application is also a continuation-in-part of U.S. patent application Ser. No. 10/470,372, which has an assigned filing date of Jul. 25, 2003, now U.S. Pat. No. 6,990,866 which was the National Stage of International Application No. PCT/US02/03920, filed Jan. 28, 2002, and which claims the benefit of U.S. Provisional Application No. 60/264,877, filed Jan. 29, 2001.
BACKGROUND OF THE INVENTION
This invention relates to load indicating fasteners that are “thread-forming” (also referred to as “thread-rolling” or “self-tapping” fasteners), methods for making load indicating thread-forming fasteners, and methods for measuring the load in thread-forming fasteners.
Thread-forming fasteners are well known in many industries, such as in high-volume automotive assembly. Examples of such fasteners are described in U.S. Pat. No. 5,242,253 (Fulmer), issued Sep. 7, 1993, for example. Such fasteners are also marketed commercially, for example, by Reminc, Research Engineering and Manufacturing Inc., Middletown, R.I., USA, under the trademark “Taptite” and “Taptite 2000”, and a description of such fasteners can be found in their product literature, entitled “Taptite 2000 Thread Rolling Fasteners”.
The major advantage of thread-forming fasteners is that they can be installed directly into a drilled hole, eliminating the cost of tapping the hole. Additionally, the thread formed by a thread-forming fastener has very tight tolerance since it is formed by the fastener itself and therefore forms a better nut.
Although thread-forming fasteners have been used in numerous applications in the automotive and aerospace industries to reduce cost, such fasteners are generally restricted to non-critical or less-critical applications. The difficulty in controlling the tightening process prevents their use in critical applications.
The primary reason for this is that the thread-forming process requires torque, in addition to the tightening torque, and this thread-forming torque varies significantly with hole tolerance, material, friction conditions, etc. As a result, the precise tightening of a thread-forming fastener to a specified torque into a blind hole, where the thread is still being formed as the bolt is being tightened, will result in a 3 sigma load scatter of typically +/−50%, which is unacceptable in critical applications.
SUMMARY OF THE INVENTION
For some time, ultrasonics has been used to accurately measure the load in bolts. Initially, removable ultrasonic devices were the most commonly used. More recently, low-cost permanent ultrasonic transducers, which can be permanently attached to one end of the fastener, have come to be used. Permanent fasteners of this type are described, for example, in U.S. Pat. No. 4,846,001 (Kibblewhite), issued Jul. 11, 1989, U.S. Pat. No. 5,131,276 (Kibblewhite), issued Jul. 21, 1992, U.S. Provisional Patent Application No. 60/264,877 (Kibblewhite), filed Jan. 29, 2001, and International Application No. PCT/US02/03920 (Kibblewhite), filed May 17, 2002, the subject matter of which is incorporated by reference herein.
In accordance with the present invention, it has been determined that such ultrasonics can be mated with an otherwise conventional thread-forming fastener to provide a load indicating thread-forming fastener that can be used for precise and reliable assembly of critical bolted joints, such as those in automobile engines (e.g., cylinder heads, connecting rods, main bearings, etc.), drive trains, steering, brakes, suspensions, and a variety of other applications, including aerospace applications.
Steps can then be taken, using equipment and methods that are otherwise known and conventional, to accurately measure and control the load in the thread-forming fastener during tightening, and to inspect the load in the thread-forming fastener after assembly.
For further detail regarding preferred embodiments for implementing the improvements of the present invention, reference is made to the description which is provided below, together with the following illustrations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of a typical load indicating thread-forming fastener which is produced in accordance with the present invention.
FIGS. 2 and 3 are graphs showing typical load and torque characteristics plotted against the angle of rotation of the load indicating thread-forming fastener of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a typical embodiment of a load indicating thread-forming fastener which is produced in accordance with the present invention. In this illustrative example, the load indicating thread-forming fastener has been implemented in conjunction with an otherwise conventional “Taptite” fastener, which is commercially available from Reminc, Research Engineering and Manufacturing Inc., Middletown, R.I., USA. It is to be understood, however, that this embodiment is shown only for purposes of illustration, and that the load indicating thread-forming fastener of the present invention can also be implemented using any of a variety of known and available load indicating devices, coupled or combined with any of a variety of known and available thread-forming fasteners.
In the illustrative embodiment of FIG. 1 , the load indicating thread-forming fastener 10 generally includes a fastener 12 (e.g., the above-mentioned “Taptite” fastener) and a permanent piezoelectric polymer film transducer 14 (e.g., of the type disclosed in the above-mentioned U.S. Pat. No. 4,846,001, issued to Kibblewhite) attached to one end. The fastener 12 includes a head 16 , which can be suitably engaged by a tool (not shown) for applying torque to the fastener 12 , and a thread-forming body portion 18 .
A suitable identifying element is applied to the thread-forming fastener which can be read and used to determine ultrasonic measurement parameters specific to the thread-forming fastener in order to provide more precise and more reliable load measurements by compensating for differences resulting from manufacturing variations in individual thread-forming fasteners.
For example, as disclosed in U.S. Provisional Patent Application No. 60/264,877 (Kibblewhite) and International Application No. PCT/US02/03920 (Kibblewhite), the transducer 14 can further include a permanent mark such as a two-dimensional high-density bar code (not shown) or some other encodable medium, applied to the top electrode 20 of the transducer 14 for purposes of facilitating subsequent steps taken to obtain an indication of tensile load, stress, elongation or other characteristic of the fastener 12 during a tightening operation, or at various other times during the service life of the fastener 12 , as will be discussed more fully below.
As an alternative, the permanent mark can be applied directly to the thread-forming fastener, and the ultrasonic transducer can then be applied on top of the mark in such a way that the mark can be detected through the transducer. As an example, the bar code can be marked on an end surface of the fastener and the ultrasonic transducer can then be provided on the surface with the bar code in such a manner that the bar code can be read through the transducer. In one such embodiment, the transducer layers are translucent or transparent, allowing the bar code to be read through the piezoelectric and conductive layers of the transducer. In another embodiment, the bar code is marked using an indentation technique, such as dot peening, so that the indentations are detectable, and the bar code is made readable, after application of the transducer.
As a further alternative, a non-volatile memory device can be applied to the thread-forming fastener for purposes of storing desired information. Such memory devices can be powered, written to and read from serially through a single input/output connection and an AC coupled return through the capacitance of the ultrasonic transducer. Such devices are capable of storing data such as unique identification, ultrasonic measurement parameters, tightening and inspection data for use in a manner similar to that of the above-described use of a permanent mark for the storage of information.
In one such embodiment, the previously described top electrode 20 is replaced with the non-volatile memory device, and portions of the top exposed surface of the memory device are made conductive by providing the surface with an electrical contact. This top conductive surface is then electrically connected to a conductive layer on the bottom of the memory device, adjacent to the active piezoelectric polymer film transducer 14 , to provide a suitable electrode for the ultrasonic transducer. The top conductive surface is also electrically connected to the non-volatile memory device for purposes of writing information to and reading information from the memory device.
In another embodiment, the foregoing non-volatile memory device can be a radio frequency identification (RFID) chip or tag coupled with the transducer 14 for purposes of storing desired information. This can be accomplished with known RFID devices, such as the MetalSentinel (13.56 MHz) device available from Interactive Mobile Systems, Inc., Port Townsend, Wash., USA, which are capable of storing data such as unique identification, ultrasonic measurement parameters, and tightening and inspection data.
In such an embodiment, the previously described top electrode 20 is replaced with the RFID device, and portions of the top exposed surface of the RFID device are made conductive by providing the exposed surface with an electrical contact. This top conductive surface is then electrically connected to a conductive layer on the bottom of the RFID device, adjacent to the active, piezoelectric polymer film transducer 14 , to provide a suitable electrode for the transducer 14 . The piezoelectric polymer film transducer 14 is an electrical insulator and further functions as an isolator for the antenna associated with the RFID device for purposes of RF transmission.
The size, shape and location of the conductive portions of the top exposed surface of the RFID device can vary to suit the particular RFID device which is used. For example, the conductive portions of the top exposed surface can be placed along the periphery of the RFID device, leaving the central portions of the top exposed surface open to accommodate the antenna normally associated with the RFID device. The conductive portions of the top exposed surface should preferably cover as much of the top surface of the RFID device as is possible, while leaving sufficient open space to accommodate the function of the antenna. The conductive layer on the bottom of the RFID device preferably covers the entire bottom surface, to maximize contact with the transducer 14 .
Various different couplings are used with RFID devices, including electromagnetic, capacitive and inductive couplings, with different coupling antennas. The antenna can be provided adjacent to non-conductive portions of the top exposed surface. Alternatively, the conductive portions of the top and bottom surfaces of the RFID device can be constructed in such a way as to function as the antenna for the transponder associated with the RFID device which is used. It will further be appreciated that non-contact inductive or capacitive couplings used for RFID transponder communication in the above described embodiments can also be used to couple the excitation signal to the ultrasonic transducer. Additionally, the RF communication frequency can be selected to correspond to a preferred ultrasonic transducer excitation frequency. This then eliminates the need for an electrically conductive top surface for electrical contact with the transducer for load measurement, allowing both the reading of information stored in the RFID device and the measurement of load to be performed even when the transducer is covered with paint or other protective coating.
As an example, the transducer 14 can be implemented using a thin piezoelectric polymer sensor (e.g., a 9 micron thick, polyvinylidene fluoride copolymer film, of the type manufactured by Measurement Specialties Inc., Valley Forge, Pa., USA) permanently, mechanically and acoustically attached to an end surface 22 of the fastener 12 . The top electrode 20 of the transducer 14 can be implemented as a thin metallic foil (e.g., an approximately 50 micron thick, type 316, full-hard, dull or matte finished stainless steel) which has been treated to provide a black oxide finish, which is then preferably provided with a black oxide treatment to provide an extremely thin, durable, corrosion resistant and electrically conductive, black coating. A high-resolution bar code can be marked on the resulting surface by removing selected areas of the coating (e.g., by conventional laser ablation techniques), or by some other process, to provide a high contrast mark easily read with conventional, commercially available optical readers. As an alternative, a non-volatile memory device, such as an RFID device, can be applied to the transducer 14 to provide data storage which can similarly be read with conventional, commercially available readers.
It is again to be understood that such implementations are described only for purposes of illustration, and that any of a variety of transducer configurations can be used to implement the transducer 14 applied to the fastener 12 , as desired. For example, the ultrasonic transducer 14 can be implemented as an oriented piezoelectric thin film, vapor deposited directly on the head of the fastener 12 , as is described in U.S. Pat. No. 5,131,276 (Kibblewhite), issued Jul. 21, 1992. As a further alternative, the ultrasonic transducer 14 can be implemented as a piezoelectric polymer film, chemically grafted on the head of the fastener 12 , as is described in U.S. Provisional Patent Application No. 60/264,877 (Kibblewhite), filed Jan. 29, 2001, and International Application No. PCT/US02/03920 (Kibblewhite), filed May 17, 2002. It will be readily understood that other alternative implementations are also possible.
In the embodiment illustrated in FIG. 1 , the ultrasonic transducer 14 is permanently attached to the head 16 of the fastener 12 , as described in the above-referenced patents issued to Kibblewhite. An essentially flat, or spherically radiused surface 24 is provided on at least a portion of the threaded end of the fastener to provide an acoustically reflective surface to reflect the ultrasonic wave transmitted by the transducer back to the transducer. Load is then measured using standard, pulse-echo ultrasonic techniques, which are themselves known in the art and described, for example, in the above-referenced patents issued to Kibblewhite. Load control accuracies of +/−3% have been achieved when tightening thread-forming fasteners into blind holes during both the first and subsequent tightenings.
In an alternative embodiment, an essentially flat surface is provided on the head 16 of the thread-forming fastener 12 and a removable ultrasonic transducer is temporarily attached to the fastener for the purpose of making load measurements. The threaded end of the fastener 12 is identical to the previous embodiment with the permanent ultrasonic transducer.
In practice, heat is generated as a result of the thread-forming work that takes place during the thread-forming run-down stage of the installation of a thread-forming fastener. This results in a slight increase in temperature in both the fastener (the bolt) and the resulting joint. This increase in temperature can cause errors in the ultrasonic load measurements to be taken because of thermal expansion effects. For this reason, when using ultrasonics for inspecting the load in a fastener, it is usual to measure the temperature of the fastener or the joint in order to compensate for the effects of thermal expansion.
However, in conjunction with a thread-forming fastener, the average temperature increase due to the heat generated during thread-formation can not be measured directly during the installation process and is subject to variations in material, friction, and heat conduction properties of the joint components. Without compensation, this thermal effect can result in inaccuracies of load measurement on the order of 5% to 20%, depending on the bolt, the joint and the assembly process being used.
FIGS. 2 and 3 show typical load and torque characteristics plotted against the angle of rotation of a typical bolt. FIG. 2 shows the tightening curves for a typical through-hole application, in which the torque reduces after the thread is formed through the entire hole. FIG. 3 shows the tightening curves for a typical blind hole application, in which the thread is still being formed as the bolt is tightened.
Further in accordance with the present invention, more accurate load measurements in the thread-forming load indicating fasteners are provided by eliminating the effects of fastener heating resulting from the thread-forming process. This is achieved by measuring the load (or acoustic time-of-flight) value immediately prior to the load-inducing stage of the assembly process, and by using this measured value as the zero-load reading.
The load-inducing stage of the assembly process can be detected by any one of a variety of methods. For example, an increase in load above a predetermined threshold, a change in the increase in load with time, angle of rotation of the fastener or torque, an increase in torque above a predetermined threshold, or a change in the increase in torque with time, angle or load can be detected. Irrespective of the method used to detect the load-inducing stage of the assembly process, a new zero-load base measurement is taken as a value just prior to the load-inducing assembly stage by selecting or calculating a load measurement prior to the load-inducing stage. This can be achieved by selecting a load measurement corresponding to a fixed time or angle prior to the detection of the commencement of the load-inducing stage, for example. Alternatively, for through-hole applications, the end of the thread-forming phase can be detected by a reduction in torque. It is again to be understood that such methods are only illustrative, and that there are numerous other methods for determining the new zero-load base measurement prior to tightening, from load, time, torque and angle of rotation measurements recorded during assembly operations with hand and powered assembly tools.
The thermal effect of thread forming causes an apparent positive load value at zero load just prior to tightening. An alternative to zeroing the load (or time-of-flight measurement) is to add this load offset, measured prior to the load-inducing stage of the assembly process, to the target load (or target time-of-flight). The result is the same since the increase in measured load is the same.
Yet another alternative is to experimentally determine an average value of load error due to the thread forming and adjust the zero-load measurement or target tightening parameter to compensate for this effect using one of the above-described methods. This approach, however, does not compensate for variations with individual fasteners or joint components and is therefore presently considered less desirable.
The result is that, for the first time, ultrasonic load measurement technology can be used with thread-forming fasteners. Errors in load measurement resulting from the thermal effects of thread-forming can be compensated. This then results in accurate load measurement and tightening control of the thread-forming fasteners.
The above-described method of eliminating the effects of fastener heating resulting from the thread-forming process can also be used with other fastener assembly processes that generate heat prior to the load-inducing tightening stage. Thread-locking bolts and nuts, for example, are manufactured with a prevailing “locking” torque to prevent the fastener from loosening during service. Most often, the thread of either the bolt or nut has an irregular profile causing the threads to elastically deform slightly upon mating. Alternatively, the bolt or nut has an insert or patch of a soft material to provide the prevailing torque or resistance to loosening. The prevailing torque provided by these thread-locking features produces heating of the fastener during rundown in the same manner as the tapping torque does with a thread-forming fastener. Consequently, the above-described method for compensating for thermal-related errors in accordance with the present invention can be used with prevailing torque-locking fasteners to improve the accuracy of ultrasonic load measurement during assembly.
It will be understood that various changes in the details, materials and arrangement of parts which have been herein described and illustrated in order to explain the nature of this invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the following claims. | An ultrasonic load measurement transducer is mated with a thread-forming fastener to provide a load indicating thread-forming fastener that can be used for the precise and reliable assembly of critical bolted joints, such as those in the automobile and aerospace industries, among others. Steps can then be taken to accurately measure and control the load in the thread-forming fastener during tightening, and to inspect the load in the thread-forming fastener after assembly. A similar result can be achieved for a thread-locking fastener by mating an ultrasonic transducer with the thread-locking fastener assembly. | 8 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/907,134, filed Mar. 22, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an automotive vehicle having an onboard apparatus for suppressing a vehicle fire.
[0004] 2. Disclosure Information
[0005] Police vehicles are subject to increased exposure to collisions, particularly high-speed rear-end collisions, arising from the need for police officers to stop on the shoulders, or even in the traffic lanes, of busy highways. Unfortunately, other motorists are known to collide with police vehicles employed in this manner. These accidents can compromise the fuel system on any vehicle and may cause fires. The present system is designed to suppress the spread of, or potentially, to extinguish such a fire. U.S. Pat. No. 5,590,718 discloses an anti-fire system for vehicles in which a number of fixed nozzles are furnished with a fire extinguishing agent in response to an impact sensor. The system of the '718 patent suffers from a problem in that the fixed nozzles are not suited to the delivery of the extinguishing agent at ground level. Also, the '718 patent uses a valving system which could become clogged and therefore inoperable. U.S. Pat. No. 5,762,145 discloses a fuel tank fire protection device including a powdered extinguishing agent panel attached to the fuel tank. In general, powder delivery systems are designed to prevent ignition of fires and are deployed upon impact. As a result, the powder may not be able to follow the post-impact movement of the struck vehicle and may not be able to prevent the delayed ignition or re-ignition of a fire.
[0006] The present fire suppression system provides significant advantages, as compared with prior art vehicular fire suppression systems.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the present invention, an onboard fire suppression system includes at least one fiber reinforced composite reservoir containing a fire suppression agent. A propellant, operatively associated with the reservoir, expels the suppression agent from the reservoir. A propellant may be located either inside the reservoir or externally thereto.
[0008] A discharge port extends through a first wall section of the reservoir. A distribution system receives fire suppression agent expelled from the reservoir and distributes the depressant agent in at least one location external to a vehicle. The distribution system is connected to the discharge port. A retaining system, located within the reservoir, maintains the discharge port in registry with the first wall section. The retaining system includes an anchor incorporated in a second wall section opposing the first wall section, and a tensile member extending through the interior of the reservoir, with the tensile member being attached to the anchor and to the discharge port.
[0009] In a first embodiment, the discharge port, the anchor, and the tensile member all comprise metallic members. These metallic members may be fabricated from either ferrous or non-ferrous metals. The tensile member is preferably pre-tensioned. The tensile member may be configured as a number of separate cable elements, with each of the elements having a first end attached to the anchor and a second end attached to the discharge port.
[0010] According to another aspect of the present invention, the reservoir may include a fill port extending through a third wall section of the reservoir. A secondary anchor incorporated in a fourth wall section opposing the third wall section, and an added tensile member extending through the interior of the reservoir maintain the fill port in proper registry with the third wall section of the reservoir.
[0011] According to another aspect of the present invention, a discharge port includes a flanged inner portion and a threaded outer portion having a threaded fastener attached thereto to serve as an abutment facing the outer surface of the first wall section, through which the discharge port extends.
[0012] According to another aspect of the present invention, a method for constructing an internally reinforced reservoir for an onboard fire suppression system includes forming a reservoir body, including at least one discharge port located in a first wall section of the reservoir body, followed by extending a tensile member from the discharge port to a second wall section of the reservoir body. Then, the tensile member is tensioned and affixed to the second wall section so that the tension member remains in tension during standby operation of the reservoir. As used herein, the term “standby operation” means operation during any period of time in which the onboard fire suppression system is available for service, but waiting for the signal from a controller to activate the propellant, so as to cause discharge of the suppressant agent onto a location in or about a vehicle, including at least one external location.
[0013] Other advantages, as well as features of the present invention will become apparent to the reader of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a ghost perspective view of an automotive vehicle having a fire suppression system according to the present invention.
[0015] FIG. 2 is an exploded perspective view of a portion of a fire suppression system according to the present invention.
[0016] FIG. 3 is a perspective view of a control module used with a system according to the present invention.
[0017] FIG. 4 is a perspective view of a manually activatable switch used with a fire suppression system according to the present invention.
[0018] FIG. 5 illustrates a portion of a wiring harness used with the present system.
[0019] FIG. 6 is a flowchart showing a portion of the logic used to control a system according to the present invention.
[0020] FIG. 7 is a cutaway perspective view of a fire suppression agent reservoir according to one aspect of the present invention.
[0021] FIG. 8 is a perspective view of a variable geometry fire suppression agent nozzle according to one aspect of the present invention.
[0022] FIG. 9 is a block diagram of a fire suppression system and with additional components for occupant restraint according to one aspect of the present invention.
[0023] FIG. 10 is a perspective view of a vehicle having a fire suppression system with an internally reinforced reservoir according to one aspect of the present invention.
[0024] FIG. 11 is a cutaway view of a suppression agent reservoir according to one aspect of the present invention.
[0025] FIG. 12 is a cutaway perspective view of a reservoir having an external propellant according to one aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] As shown in FIG. 1 , vehicle 10 has a passenger airbag restraint 48 and a driver's airbag restraint 50 mounted adjacent steering wheel 52 . A fire suppression system includes controller 66 which is mounted upon floor pan 68 of vehicle 10 , and reservoirs 18 which are mounted under floor pan 68 in the so-called kick-up area adjoining the rear axle of vehicle 10 . Those skilled in the art will appreciate in view of this disclosure that additional passenger restraint devices, such as seat belt pretensioners and side airbags, may be installed in a vehicle and controlled at least in part by, or in conjunction with, controller 66 .
[0027] FIG. 1 shows not only reservoirs 18 but also a portion of right and left side fire suppression conduits 28 , as well as fixed geometry nozzles 30 and variable geometry nozzles 36 . As seen in FIG. 1 , variable geometry nozzles 36 project downwardly to allow fire suppression agent to be expelled from reservoirs 18 and placed at a low angle to the ground surface the vehicle is operating upon. This mode of operation is possible because variable geometry nozzles 36 are, as shown in FIG. 2 , telescopingly extensible. This telescoping feature, which is shown in greater detail in FIG. 8 , is produced by a sliding spray head, 40 , which is slidingly engaged with conduit 28 such that gas pressure within conduit 28 forces spray head 40 downwardly into its extended position, causing fire suppression agent 22 to be discharged through a number of holes 42 formed in spray head 40 . As shown in FIG. 2 , at least two variable geometry nozzles 36 may be employed with single reservoir 18 , along with at least two fixed nozzles 30 which are spray bars each having a number of orifices 34 . While in their normally closed state, variable geometry nozzles 36 are liquid-tight by virtue of seals 46 , which are interposed between an end of each of spray heads 40 and the corresponding ends of conduits 28 . In a preferred embodiment, seals 46 comprise elastomeric boots attached to an outer surface of conduit 28 . Seals 46 are simply sheared by the deploying spray head 40 when the present system is discharged. Fixed nozzles 30 are also rendered liquid-tight by covers 44 , which are simply blown off when the present system is discharged. The sealing of nozzles 30 and 36 is important, because this prevents the ingress of road splash, which could block the system in sub-freezing weather or cause corrosion or blockage due to mud or other foreign matter.
[0028] Additional details of reservoir 18 are shown in FIG. 7 . Tank 90 contains approximately 1.5 L of fire suppression agent 22 , and a propellant 92 . Propellant 92 includes two squibs (not shown) which are activated simultaneously by controller 66 via lines 91 so as to release a large amount of gas, forcing fire suppressant agent 22 from tank 90 and into distribution system 26 , including conduit 28 and the various fixed and variable geometry nozzles. A preferred propellant, marketed by Primex Aerospace Company as model FS01-40, is a mixture including aminotetrazole, strontium nitrate, and magnesium carbonate. This is described in U.S. Pat. No. 6,702,033, which is hereby incorporated by reference into this specification.
[0029] Those skilled in the art will appreciate in view of this disclosure that other types of propellants could be used in the present system, such as compressed gas canisters and other types of pyrotechnic and chemical devices capable of creating a gas pressure force in a vanishingly small amount of time. Such propellants may be mounted either within a reservoir with the fire suppressant agent, or externally thereto. Moreover, fire suppressant agent 22 , which preferably includes a water-based solution with hydrocarbon surfactants, fluorosurfactants, and organic and inorganic salts sold under the trade name LVS Wet Chemical Agent® by Ansul Incorporated, could comprise other types of agents such as powders or other liquids, or yet other agents known to those skilled in the art and suggested by this disclosure. If two reservoirs 18 are employed with a vehicle, as is shown in FIG. 1 , all four squibs will be deployed simultaneously.
[0030] FIG. 4 shows manually activatable switch 54 for use with the present system. As shown in FIG. 1 , switch 54 may be advantageously located on the headliner of vehicle 10 between the sun visors, or at any other convenient position. To use this switch 54 , hinged clear cover 56 is first opened by pressing on cover 56 . Thereafter, the fire suppression system may be triggered by manually pressing pushbutton 58 . If the vehicle occupants are not disposed to release cover 56 , the system may be triggered by merely sharply depressing cover 56 , thereby closing contacts (not shown) contained within platform 60 .
[0031] Because the present system is intended for use when the vehicle has received a severe impact, controller 66 , which is shown in FIG. 3 , contains a redundant power reserve or supply, which allows operation of the fire suppression system for about nine seconds, even if controller 66 becomes isolated from the vehicle's electrical power supply. Wiring harness 80 , as shown in FIG. 5 , is armored, and has a para-aramid fiber inner sheath, 82 , of about 2 mm in thickness, which helps to shield the conductors within harness 80 from abrasion and cutting during a vehicle impact event. This para-aramid fiber is sold under the trade name KEVLAR® by the DuPont Company. This armoring helps to assure that communication between controller 66 and reservoirs 18 remains in effect during an impact event. Post-impact communications are further aided by redundancy in the control system. Specifically, four independent sets of primary conductors, 79 a - d , extend from controller 66 to reservoirs 18 protected by sheath 82 . Moreover, an H-conductor, shown at 81 in FIG. 5 , extends between reservoirs 18 . Thus, if one or both of the primary conductors 79 a - b , or 79 c - d , extending to one of reservoirs 18 should become severed, H-conductor 81 will be available to carry the initiation signal from the undamaged lines to both of reservoirs 18 .
[0032] As noted above, an important feature of the present invention resides in the fact that the control parameters include not only vehicle impact, as measured by an accelerometer such as that shown at 70 in FIG. 9 , but also vehicle speed, as measured by means of speed sensors 74 , also shown in FIG. 9 . Speed sensors 74 may advantageously be existing sensors used with an anti-lock braking system or vehicle stability system. Alternatively, speed sensors 74 could comprise a global positioning sensor or a radar or optically based ground-sensing system. Accelerometer 70 , as noted above, could be used with a conventional occupant restraint airbag system, thereby maximizing use of existing systems within the vehicle. Advantageously, accelerometer 70 may be an amalgam of two or more accelerometers having differing sensing ranges. Such arrangements are known to those skilled in the art and suggested by this disclosure. At least a portion of the various sensors could either be integrated in controller 66 or distributed about vehicle 10 .
[0033] FIG. 6 shows a sequence which is used according to one aspect of the present invention for activating a release of fire suppressant agent.
[0034] Beginning at block 100 , controller 66 performs various diagnostics on the present system, which are similar to the diagnostics currently employed with supplemental restraint systems. For example, various sensor values and system resistances will be evaluated on a continuous basis. Controller 66 periodically moves to block 102 , wherein the control algorithm will be shifted from a standby mode to an awake mode in the event that a vehicle acceleration, or, in other words, an impact, having a magnitude in excess of a relatively low threshold is sensed by accelerometer 70 . Also, at block 102 a backup timer will be started. If the algorithm is awakened at block 102 , controller 66 disables manually activatable switch 54 at block 104 for a predetermined amount of time, say 150 milliseconds. This serves to prevent switch 54 from inadvertently causing an out-of-sequence release of fire suppression agent. Note that at block 104 , a decision has not yet been made to deploy fire suppression agent 22 as a result of a significant impact.
[0035] At block 106 , controller 66 uses output from accelerometer 70 to determine whether there has been an impact upon vehicle 10 having a severity in excess of a predetermined threshold impact value. Such an impact may be termed a significant, or “trigger”, impact. If an impact is less severe than a trigger impact, the answer at block 106 is “no”, and controller 66 will move to block 105 , wherein an inquiry is made regarding the continuing nature of the impact event. If the event has ended, the routine moves to block 100 and continues with the diagnostics. If the event is proceeding, the answer at block 105 is “yes”, and the routine loops to block 106 .
[0036] If a significant impact is sensed by the sensor system including accelerometer 70 and controller 66 , the answer at block 106 will be “yes.” If such is the case, controller 66 moves to block 108 wherein the status of a backup timer is checked. This timer was started at block 102 .
[0037] Once the timer within controller 66 has counted up to a predetermined, calibratable time on the order of, for example, 5-6 seconds, controller 66 will cause propellant 92 to initiate delivery of fire suppressant agent 22 , provided the agent was not released earlier. Propellant 92 is activated by firing an electrical squib so as to initiate combustion of a pyrotechnic charge. Alternatively, a squib may be used to pierce, or otherwise breach, a pressure vessel. Those skilled in the art will appreciate in view of this disclosure that several additional means are available for generating the gas required to expel fire suppressant agent 22 from tank 90 . Such detail is beyond the scope of this invention. An important redundancy is supplied by having two squibs located within each of tanks 90 . All four squibs are energized simultaneously.
[0038] The velocity of the vehicle 10 is measured at block 110 using speed sensors 74 , and compared with a low velocity threshold. In essence, controller 66 processes the signals from the various wheel speed sensors 74 by entering the greatest absolute value of the several wheel speeds into a register. This register contains both a weighted count of the number of samples below a threshold and a count of the number of samples above the threshold. When the register value crosses a threshold value, the answer at block 110 becomes “yes.” In general, the present inventors have determined that it is desirable to deploy fire suppression agent 22 prior to the vehicle coming to a stop. For example, fire suppression agent 22 could be dispersed when the vehicle slows below about 15 kph.
[0039] At block 112 , controller 66 enters a measured vehicle acceleration value into a second register. Thereafter, once the acceleration register value decays below a predetermined low g threshold, the answer becomes “yes” at block 112 , and the routine moves to block 114 and releases fire suppressant agent 22 . In essence, a sensor fusion method combines all available sensor information to verify that the vehicle is approaching a halt. The routine ends at block 116 . Because the present fire suppression system uses all of the available fire suppression agent 22 in a single deployment, the system cannot be redeployed without replacing at least reservoirs 18 .
[0040] FIG. 6 does not include the activation of occupant restraints 48 and 50 , it being understood that known control sequences, having much different timing constraints, may be employed for this purpose. In point of contrast, the low velocity threshold allows the present system to deliver the fire suppression agent while the vehicle is still moving, albeit at a very low velocity. This prevents the rear wheels of the vehicle from shadowing, or blocking dispersion of fire suppressant agent 22 . Also, in many cases, a vehicular fire may not become well-established until the vehicle comes to a halt.
[0041] As shown in FIG. 10 , vehicle 200 has a controller 204 which operates to discharge suppression agent 216 contained within reservoirs 208 ( FIG. 11 ), through distribution system 220 .
[0042] FIG. 11 shows a fiber-reinforced composite reservoir 208 having a first wall section, 212 , through which a discharge port, 224 , extends. Discharge port 224 has a generally tubular body, 228 , defining a passage, 230 . Generally tubular body 228 also has an internal flange, 232 , which abuts an inner surface of first wall section 210 . A threaded fastener, 236 , is spun down upon threads 234 formed on an external tubular surface of discharge port 224 , so as to provide an abutment for applying the pre-tensioning force provided by cable elements 240 . Cable elements 240 maintain discharge port 224 in registry with first wall section 210 . As further shown in FIG. 11 , cable elements 240 are tensile members which extend through the interior of reservoir 208 from first wall section 210 through second wall section 214 . Cable elements 240 also extend through anchor 218 , which is placed on an exterior surface of second wall section 214 . Each of cable elements 240 has a first end attached to discharge port 224 , and a second end attached to slugs 244 which are crimped upon cables 240 . Slugs 244 keep cable elements 240 from becoming slack during the useful life of reservoir 208 .
[0043] According to another aspect of the present invention, a method for constructing an internally reinforced reservoir for an onboard fire suppression system includes forming reservoir body 208 and extending tensile members 240 from discharge port 224 to second wall section 214 , followed by tensioning of tensile members, in this case elements 240 , so that cable elements 240 remain in tension during standby operation of reservoir 208 .
[0044] Discharge port 24 also includes a burst disk 226 , which prevents discharge of suppressant agent from reservoir 208 before a predetermined minimum threshold pressure has been released upon firing of propellant 212 .
[0045] According to another aspect of the present invention, reservoir 208 may optionally include a fill port, having an internal flange, 262 , an external threaded fastener 266 , and a fill plug 264 . Cable elements 270 extend from fill port 260 , which is located in third wall section 250 of reservoir 208 , through anchor 272 , which is located on fourth wall 254 of reservoir 208 . Slugs 276 maintain cable elements 270 in their standby position.
[0046] Propellant 212 may be optionally replaced by propellant 282 which is located externally of reservoir 208 and which may include a cold gas propellant or other type of propellant, with the gas discharge being controlled by controller 204 and control valve 286 .
[0047] According to another aspect of the present invention, cable elements 240 , discharge port 224 , and anchor 218 may be formed as non-metallic members or metallic members. If metallic, these components may be formed from ferrous metals or non-ferrous metals. Those skilled in the art will appreciate in view of this disclosure that various types of metallic and non-metallic and composite materials may be used for the construction of various components such as discharge port 224 , cable elements 240 , and anchor 218 . Such materials may include combinations of metallic and non-metallic components.
[0048] Although the present invention has been described in connection with particular embodiments thereof, it is to be understood that various modifications, alterations, and adaptations may be made by those skilled in the art without departing from the spirit and scope of the invention set forth in the following claims. | An automotive vehicle includes a vehicle body and at least one reservoir containing a fire suppressant agent. A distribution system receives the fire suppression agent from the reservoir and conducts the agent to at least one location about the vehicle's body in response to the determination by a sensor system and controller that the vehicle has been subjected to a significant impact. The reservoir includes a discharge port which is positioned in part by a tensile member extending through the reservoir to an anchor incorporated in an external wall section of the reservoir. | 0 |
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 14/142,739, filed Dec. 27, 2013 (pending), which claims the benefit of U.S. Provisional Application No. 61/747,180, filed Dec. 28, 2012 (expired), and this application claims the benefit of U.S. Provisional Application No. 62/031,145, filed, Jul. 30, 2014 (pending).
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to golf club and related equipment. More specifically, the present invention relates to a golf club system having interchangeable heads that each can fit onto a single shared shaft.
[0004] 2. Background of the Invention
[0005] A common problem for golfers is transportation of a full set of golf clubs. Heavy and bulky sets of clubs are made heavier and bulkier by flight cases or travel bags. Due to costs associated with renting gold club sets at remote destinations, it is fairly common for golfer to bring their own clubs. Cost is not the only detractor to renting golf clubs at destination locations. Another factor is the quality of rental clubs often varies. In addition, golfers often develop a personal feel for, and comfort level with, their own golf clubs. Therefore, even a high quality rental or demo golf club sets may be unsuitable depending on a specific golfer's needs and/or desires. For example, experienced golfers may prefer to give themselves an advantage by using their own clubs.
[0006] A compact set of golf clubs may appeal to a wide and varied range of golfers. For example, those with cars may have inadequate trunk space for gold clubs. Some common sports cars, such as, for example the Corvette, have trunks that will not accommodate even one full-sized set of golf clubs. As used herein, a full-sized set of golf clubs refers to a set of golf clubs whereby each club comprises a club head fixedly attached to its own full-sized shaft. Many smaller vehicle trunks also have trouble accommodating more than a single set. Those with homes may have inadequate storage space for golf clubs. Cars are not the only place where sets of full size golf clubs can be difficult to manage. Golfers with homes may have inadequate storage space for golf clubs. Thus, there are many uses for sets of golf clubs that can be conveniently stored and transported.
[0007] Full-sized golf club sets are also heavy. As a result, more senior players may have trouble lifting and/or carrying a full-sized set of golf clubs. Full-sized sets of golf clubs may also be bulky, noisy when moved, and awkward to move, among other negative characteristics. When such full-sized golf club sets are placed in a hard-shell flight case the situation is generally exacerbated. Due to the weight of a flight case, flight cases can double the weight of a full-size set of clubs. Flight cases also add considerable bulk. Soft-shell flight cases are generally lighter and less bulky than hard-shell cases. However, soft-shell flight cases do not protect the clubs from the rigors of travel and expose the clubs to the vagaries of baggage handlers.
[0008] Thus, what is needed is a way to reduce the bulk and weight of a golf club set while preserving the playing physics and other desirable characteristics of the clubs.
BRIEF SUMMARY OF THE INVENTION
[0009] Embodiments of the present invention are directed to golf club sets that preserve playing physics while at the same time reduce the weight, bulk, and other undesirable characteristics of a full-sized set of golf clubs. As a result, embodiments allow golfers to enjoy these and other attendant advantages in a compact, easy to use set of golf clubs. Beyond the benefit of increased portability, it is also possible to choose among several shafts for any one club head. The ability to select different shafts for a particular club head expand the game of golf to include a new dimension of performance tuning because shafts vary considerably in stiffness or spring. Thus, embodiments of the present invention can allow all club heads to be matched to the best shaft for the playing situation at hand.
[0010] A number of design alternatives were explored before arriving at the current club and head system. One area of particular concern and experimentation is the coupler for connecting the shaft to the head. Several prototypes were built in an attempt to create a coupler that would satisfy the performance requirements of the high end golfer. While many requirements exist, one overarching requirement is tightness of fit. That is, the club heads and their male coupling pins needed to be held in contact with the coupler in the shaft without discernable wobble.
[0011] One design utilized two floating wedges that could slide out of the way for insertion of the coupling pin and back into position to wedge the pin in place. The wedge design relied on a long cylindrical opening in the coupler and a straight cylindrical coupling pin. The fit of the device depended, in part, on the tolerance of the machining of these two components. Machining long cylindrical sections has inherent difficulties. Machine tools for cutting these components tend to dull as the cut is achieved. Such dulling can be particularly problematic when many cuts are required such as, for example, in mass producing sets. Tool wear can be an issue for both drilled or lathed parts or any other machined parts involving a cutting tool that may wear over time. In the end, tolerances must be selected that are realistic for production. Even in prototype production quantities, parts machined to a tolerance of ±0.001 inches resulted in discernable “play” in the club with this design.
[0012] Another difficulty of this early design was the need for strong springs to force the wedges in place. While strong springs helped the wedges snap into place, the strong springs made the sleeve hard to pull back with thumb and finger. The wedges also were created by multiple machining cuts which made them more expensive than desired.
[0013] The final design involved ball bearings set in a coupler body and squeezed between tracks in the coupler body and tracks in a coupler pull-back sleeve. Released tension and lateral motion of the pull-back sleeve can allow the coupling pin to be inserted. Once inserted, the release of tension on the pull-back sleeve brings force to bear on flat surfaces of the coupler pin. Finally, this force pulls a conical surface on the coupler pin into contact with a mated conical sheath surface in the coupler. These two conical surfaces can be manufactured relatively easily and inexpensively and do not suffer from the many of the machining tolerance issues of the straight cylinder design.
[0014] A potential issue with the final design is loss of friction and fit from vibration during ball and head impact. Despite a tight fit, the spring and ball/race combination may be subject to release during high vibration. A twist lock would be desirable to minimize unintentional separation. There are also a number of alternate methods of locking the coupler. The method described herein is preferred, but other locking methods would be known to those skilled in the art based upon the present disclosure.
[0015] Finally, the components of a compact golf system according to embodiments are stored in a unique bag. The small size and shape of this bag are a direct result of the design of the club system and provides an advantage to users in itself. This unique club head system makes many new bag designs possible.
[0016] According to one exemplary aspect, an embodiment of the present invention includes a coupler for mating a golf shaft handle to a club head comprising a first pin adapted to fit into a handle end of a golf shaft, a second pin adapted to fit into a club head end of a golf shaft, and a coupling sleeve fixedly attached to one of the first pin and the second pin, the coupling sleeve further being reversibly attachable to the other of the first pin and the second pin to allow for mating of the golf shaft handle to the club head when the coupler is in use on a golf club.
[0017] According to another exemplary aspect, an embodiment of the present invention includes A golf club having a detachable head comprising a first shaft segment and a second shaft segment, the first shaft segment having a grip or handle attached thereto and the second shaft segment being fixedly attached to a golf club head, and a coupler affixed to either the first shaft segment or the second shaft segment for reversibly mating the handle to the club head.
[0018] According to a further aspect, the coupler according to an embodiment comprises an inner housing and a pull-back sleeve, whereby the pull-back is sleeve movable with respect to the inner housing to allow for movement of one or more first ball bearings within the coupler such that in a first pull-back sleeve position, the ball bearings allow insertion of an insertion pin during mating of the first and second shaft segments, and in a second pull-back sleeve position, the ball bearings hold the insertion pin axially in place to reversibly secure the first shaft segment to the second shaft segment.
[0019] In another embodiment, a golf club according to an embodiment comprises a grip end having a shaft; and a coupler coupled to the shaft. The coupler comprises a grip end fitting coupled to the shaft, the grip end fitting having a hole into which a post is inserted and a notch; and a pullback sleeve with two ends, the pullback sleeve having a ramp on one end going around the circumference of the pullback sleeve, the ramp extending to a wall, wherein when the pullback sleeve is twisted in one direction, the post rides up the ramp until it becomes too difficult for twisting to continue, and when the pullback sleeve is twisted in the other direction, the post rides down the ramp until it is stopped by the wall such that it is aligned with the notch.
[0020] In another exemplary embodiment, a golf club comprises a grip end having a shaft, a golf club head that is coupled to the shaft, a coupler attached to the shaft to couple the golf club head to the shaft, wherein the coupler comprises a grip end fitting coupled to the shaft, the grip end fitting having a hole, a post (or pin) inserted into the hole in the grip end fitting, and a pullback sleeve with two ends and a slot, the pullback sleeve having a ramp on one end extending a portion of the way around the circumference of the pullback sleeve to a wall, wherein when the pullback sleeve is twisted in one direction, the post rides up the ramp until it becomes too difficult for twisting to continue, and when the pullback sleeve is twisted in the other direction, the post rides down the ramp until it is stopped by the wall such that it is aligned with the slot.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows a shaft with grip and head fitted with the coupler components ready to be connected;
[0022] FIG. 2 shows the pull-back sleeve according to an exemplary embodiment of the present invention in isolation;
[0023] FIG. 3 is a cross sectional view through line 3 - 3 of the coupler of FIG. 2 ;
[0024] FIG. 4 is a cross-sectional schematic view of a coupler according to an exemplary embodiment of the present invention showing a locking mechanism to limit rotational motion of the club head with respect to the shaft when the head is assembled to the shaft;
[0025] FIGS. 5A-5C show three views of the shaft coupler insert with pressed in spring pin retainer for the locking mechanism according to a preferred embodiment of the present invention;
[0026] FIG. 6 shows a spring for use inside the coupler;
[0027] FIG. 7 shows another exemplary embodiment of a coupler having a second set of ball bearing for locking the couple and pin during operation.
[0028] FIGS. 8A-8D are schematic illustrations of a pullback sleeve 800 according to an embodiment.
[0029] FIGS. 9A-9J are schematic illustrations of a coupler body according to an embodiment.
[0030] FIGS. 10A-10F are schematic illustrations of a grip end fitting according to an embodiment.
[0031] FIG. 11A illustrates a coupler assembly in a loose condition according to an embodiment.
[0032] FIG. 11B illustrates a coupler assembly in a tightly coupled condition according to an embodiment.
[0033] FIG. 12 illustrates a fully assembled golf club using two couplers according to an embodiment.
[0034] FIG. 13 illustrates a collar that can be used with a coupler that couples an upper shaft segment to a lower shaft segment.
[0035] FIG. 14 illustrates a tool that can be used to assist in tightening a coupler using a collar as shown in FIG. 13 .
DETAILED DESCRIPTION
[0036] FIG. 1 illustrates an exemplary golf club 10 according to an embodiment. Golf club 10 includes a large shaft segment 100 with a detachable head 500 . Shaft 100 is cut from a standard full-sized shaft to accommodate the shortest club length—usually the putter. Alternatively, shaft segment 100 may be originally manufactured to the desired length, rather than cut from a longer shaft length. Club head 500 , intended for mating with shaft segment 100 , includes a shorter shaft section 102 between a club shaft insert sheath 504 and a head shaft segment coupler pin 106 (see FIG. 3 ).
[0037] The length of shaft section 100 is fixed, while the length of shaft section 102 can vary from club to club and may be used to set the club length optimally for that club. For example, longer clubs such as woods or long irons usually have longer overall shafts than short irons, wedges, and or putters (although some golfers prefer putters having long shaft length). By fixing the length of shaft segment 100 , shaft section 102 can be varied to allow for varying shaft lengths desired for the various clubs in a golfers bag. Large shaft segment 100 is fitted to a coupler mechanism 200 via an insert pin 108 (see FIG. 3 ). Insert pin 108 is pressed and glued into the shaft, but may be affixed by any suitable manner known in the art.
[0038] The diameter of pin 108 is selected optimally to fit the inner diameter of shaft 100 at the shaft length used for the average person, but may also be custom fit to various players' specifications. Modern club shafts are often tapered such that their inner diameter varies along the length of the shaft. Club lengths for players usually vary less than six inches and are typically based on arm length and height of the player, but shaft lengths may be suited to any player's specifications. Because the difference in diameter for a shaft over a six inch section typically is not significant, the diameter of insert pin 108 is set to fit the smallest diameter of shaft 100 in an embodiment of the present invention. This corresponds, for example, to the longest club for the tallest player.
[0039] Pin 108 includes a threaded end 108 a to accept fixed coupler housing 202 . This thread is preferably counter-clockwise for right handed players and clockwise for left handed players. The desire for different threading direction based on handedness is due, in part, to the opposing torque/twists generated by left- and right-handed golfers about the shaft. Coupler housing 202 has internal threads to appropriately match the threaded end 108 a of pin 108 . Coupler housing 202 may also be affixed to shaft 100 in other ways known in the art, for example, using expoxy.
[0040] As seen in FIG. 3 , coupler housing 202 has several features. It has a conical portion 204 to mate with matching conical surface 106 a of the coupler pin 106 affixed to club head 500 . It has multiple ball bearing guide holes 206 to hold ball bearings 300 in place. As seen in FIG. 3 , only one such guide hole 206 is shown in the cross section, but others may be located about the perimeter. In a preferred embodiment, there are three equally spaced guide holes 206 located about a perimeter of coupler housing 202 .
[0041] As seen in FIGS. 2 and 4 , there is a notch 208 to provide a clocking fit to alignment pin 120 in the coupler pin 106 . Pin 120 and notch 208 assure the shaft handle always lines up the same way with all club heads. Another pin 110 is press fit into the side of coupler housing 200 to provide clocking into the “L” shaped guide of the pull back sleeve 202 .
[0042] Head coupling pin 106 is inserted and glued, or otherwise affixed, into the head shaft segments 102 as previously described. These shaft segments 102 vary in length significantly and thus the inside diameter of these shaft segments varies significantly also. In this case, the variation is enough to affect the need for head coupling pins 106 of various diameters. This may or may not be a need in other embodiments since manufacturers may make all parts for a design and simply standardize on an inner diameter of this part. The design described here relies on modification of readily available club components which have variations.
[0043] Housing 200 also includes a press-fit pin 210 to hold a twist to a spring 400 (see FIG. 6 ). As shown in FIGS. 5A-5C , pin 210 and hole 214 work together to hold spring 400 in a position of tension to provide a twisting force for the operation of the locking mechanism. Pin 210 wedges the base of the spring 400 and hole 214 receives a short vertical section 402 at the end of spring 400 . Spring 400 is twisted to latch during assembly. The twist maintains coupler 200 in locked position at all times. The pull back sleeve 202 must be twisted and pulled back by the golfer in order to pull out the head. When the coupler pin is extracted, pin 110 slides into retaining area 212 a to hold it in place until another coupler pin 106 for another head is inserted. This simplifies the hand motions necessary to insert and extract a club while allowing an automatic locking of the coupler.
[0044] The head coupling pin 106 has a pressed in pin 120 for locking fit as previously described. Although other kinds of pins can be used, the use of a press fit pin here, and other places in the invention, is preferred as it reduces cost and complexity of manufacture.
[0045] Coupler 200 also includes a pullback sleeve 202 . In an embodiment, pullback sleeve 202 has a knurled surface 230 which facilitates gripping for hand operation. Although this is shown as a knurled surface, it may be of any surface texture, including being smooth, so long as the sleeve is movable by a user gripping coupler 200 by hand. The sleeve 202 must be pulled and rotated at various times during operation. Sleeve 202 has several surfaces which help make the coupler hold without “play”. The conical, or rounded, surface of the end of coupler pin 106 is slowly sloping to allow easy insertion. This rounded end surface presses on the ball bearings 300 during insertion. The ball bearings 300 alternately push on the surface 216 of the pull back sleeve 202 . The force of insertion is translated by the angles and rotation of the ball bearings into a motion of the pull back sleeve 202 against spring 400 .
[0046] During insertion, the operator pulls sleeve 202 toward the shaft using thumb and index finger. This positions the ball bearings 300 free from surface 216 so they can allow passage of the nose of pin 106 . When the ball bearings 300 pass over the crest of the nose surface on pin 106 they “fall” into contact with surface 116 . When this occurs sleeve 202 can be released coming to rest close to the coupler pin hilt ring 114 . In this position the clocking pin 120 is at rest in the notch 208 and the ball bearing 300 is in contact with surfaces 116 and 216 .
[0047] As sleeve 202 moves in the direction away from club head 500 , locking pin 110 becomes clear of notch 212 . As this occurs, the twisting force of spring 400 causes sleeve 202 to rotate until pin 110 slides into channel 212 a . As pin 106 presses further into the coupler 200 , sleeve 202 continues to move further away from club head 500 . This can be seen as an increasing gap between sleeve 202 and the “hilt” region 114 of coupler pin 106 . When the ball bearings 300 pass over the crest of the surface 116 they “fall” into contact with surface 216 . As this occurs, sleeve 202 changes direction and comes to rest close to the coupler pin hilt ring 114 . In this position, the locking pin 120 is at rest in the notch 208 and the ball bearing 300 is in contact with surfaces 116 and 216 .
[0048] The angle of surface 116 is steep enough to make a force large enough to enable the ball bearing 300 to “climb” up and thus uncouple. Under static conditions, the force necessary to make this uncoupling occur are well beyond those found in golf club operation. The angle of surface 216 should not be so steep, however, that it cannot be uncoupled by hand when the pull-back sleeve 202 is manipulated by the user. For example, in one embodiment of the present invention angle of surface 216 is approximately 12 degrees.
[0049] There is, however, a possibility of vibration assisting this “climb”. To account for this possibility, the locking mechanism described above can be employed. However, the locking mechanism is not necessary for the operation or manufacture of a golf club with interchangeable heads according to embodiments of the present invention.
[0050] Moreover, other locking mechanisms, for example, the use of a ball bearing for locking pin 110 can be used in embodiments of the present invention to assure adequate locking during operation. The mechanism described here was selected to simplify the manual operation of the coupler.
[0051] FIG. 7 shows coupler 1200 with pin 1106 inserted and held in place by ball bearings 1300 and locked by bearings 1350 . Bearings 1350 are held in coupler 1202 by holes 1226 . There are three bearings 1350 oriented 120 degrees apart (similar bearings 1300 ). When these bearings are between surfaces 1140 of pin 1106 and surfaces 1240 of the pull back sleeve 1202 , the coupler 1200 will be locked and can only be released by manual operation. To visualize this, one can imagine ball bearings 1300 climbing surface 1206 and thus causing pull back sleeve 1202 to move towards the shaft 100 (not shown in FIG. 7 ). This would allow pin 1106 to begin to uncouple. Ball bearings 1350 will then wedge against surface 1142 , which is perpendicular to this direction of motion. The combination of surfaces 1140 , 1142 , and 1240 form a sort of box, which is filled by ball bearing 1350 , thus preventing uncoupling.
[0052] Manual uncoupling is possible because the operator moves the pull back sleeve 1202 against spring 1400 , positioning surface 1250 at ball bearing 1350 . In this position, the ball bearings 1350 can move out of the way of the coupling pin 1106 and extraction can occur. Insertion is done in an analogous, but reverse manner.
[0053] While the foregoing embodiments are acceptable in the vast majority of cases, the above-described issues with machine tolerances can result in slight movements between components of the coupler. FIGS. 8A-8D , 9 A- 9 J, 10 A- 10 F, and 11 A- 11 B are schematic diagrams illustrating a coupler that addresses such movements by modifying a grip end fitting and pullback sleeve of the coupler.
[0054] FIGS. 8A-8D are schematic illustrations of a pullback sleeve 800 according to an embodiment. FIG. 8C is a cross-sectional view of pullback sleeve 800 taken at line A-A in FIG. 8B . FIG. 8D is a view looking down into pullback sleeve 800 . In an embodiment, pullback sleeve 800 having a top end 808 and a bottom end 812 . In an embodiment, top end 808 is closer to the handle end of the golf club than bottom end 812 . Pullback sleeve 800 includes a notch or slot 802 , a wall 804 , and a ramp 806 . In an embodiment, ramp 806 extends around a top end 808 of pullback sleeve 800 and ends at wall 804 . As illustrated in FIGS. 8A and 8B , ridges 810 a , 810 b , 810 c , etc. are present in an outer surface of pullback sleeve 800 . Any desired number of ridges can be used in an embodiment.
[0055] FIGS. 9A-9J are schematic illustrations of a coupler body 900 according to an embodiment. FIG. 9C is a view looking down into coupler body 900 . FIG. 9D is a view looking up into the coupler body 900 . FIG. 9F is a cross-sectional view of coupler body 900 taken at line F-F in FIG. 9B . FIG. 9G is a cross-sectional view of coupler body 900 taken at line G-G in FIG. 9B . FIG. 9H is a cross-sectional view of coupler body 900 taken at line H-H in FIG. 9B . FIG. 9I is expanded detail of “I” in FIG. 9F . FIG. 9J is expanded detail of “J” in FIG. 9F . A first set of ball bearings 904 a , 904 b , and 904 c is seated in holes 906 . A second set of ball bearings 902 a , 902 b , and 902 c is seated in holes 908 . For example, in an embodiment, ball bearing 902 a , 902 b , and 902 c correspond to ball bearings 1350 in FIG. 7 , and ball bearing 904 a , 904 b , and 904 c correspond to ball bearings 1300 in FIG. 7 . In an embodiment, coupler body 900 corresponds to coupler body 1202 in FIG. 7 .
[0056] FIGS. 10A-10F are schematic illustrations of a grip end fitting 1000 according to an embodiment. Grip end fitting 1000 fits into the grip end or shaft 100 as a base for the coupler housing, such as the coupler of FIG. 7 . Grip end fitting 1000 includes a hole 1002 . A post or pin 1004 (see FIGS. 11A and 11B ) is inserted into hole 1002 . In an embodiment, such insertion is by press fitting pin or post 1004 into hole 1002 . FIG. 10C is a cross-sectional view of grip end fitting 1000 taken at line C-C in FIG. 10B . FIG. 10D is a view looking down into grip end fitting 1000 . FIG. 10E is a cross-sectional view of grip end fitting 1000 taken at line E-E in FIG. 10B . FIG. 10F is a cross-sectional view of grip end fitting 1000 taken at line F-F in FIG. 10D . As shown in FIGS. 10A , 10 B, and 10 C, grip end fitting has a top end 1006 and a bottom end 1008 . In an embodiment, top end 1006 is positioned closer to the handle of a golf club.
[0057] FIG. 11A illustrates a coupler assembly 1100 in the loose condition according to an embodiment. In the loose condition, slot 802 allows for the pullback sleeve to be pulled back to insert an interchangeable club head. FIG. 11B illustrates a coupler assembly 1100 in a tightly coupled condition according to an embodiment. In an embodiment, section 1102 of coupler assembly 1100 is inserted in a lower shaft segment 1902 of the golf club described in FIG. 12 . In an embodiment, coupler assembly 1100 is coupler 200 as described above with respect to FIG. 3 or coupler 1200 as described above with respect to FIG. 7 .
[0058] No interchangeable club head is shown in FIG. 11A or 11 B. However, in operation, pullback sleeve 800 is pulled back (toward the right in FIG. 11A ), post or pin 1004 moves into notch 802 , and an interchangeable club head is inserted as described above. Once inserted, the user releases pullback sleeve 800 , which moves pin 1004 out of slot 802 . To more tightly couple the coupler components, that is to transition from the configuration in FIG. 11A to FIG. 11B , the user twists pullback sleeve 800 (counterclockwise in the illustration of FIGS. 11A and 11B ), which causes pin or post 1004 to ride up ramp 806 . Eventually, the user will no longer be able to twist pullback sleeve 800 the due to the slope of the ramp and the coupler components being very tightly coupled.
[0059] To uncouple a club head, the user twists pullback sleeve 800 (in the clockwise direction as shown in FIGS. 11A and 11B ) such that the post travels down ramp 806 . Wall 804 stops the travel of post 1004 such that post 1004 is aligned with slot 802 . At this point, the user can pull back pullback sleeve 800 with post or pin 1004 moving into slot 802 , and removes the club head.
[0060] The ramp angle of ramp 806 must be steep enough such that pin or post 1004 will ultimately make twisting pullback sleeve 800 difficult, that is, essentially stopping twisting, but not so steep that twisting pullback sleeve 800 is initially difficult. The ramp also should also prevent twisting prior to the twisting going all the way round to notch 802 . For example, a ramp angle can be chosen that will cause twisting of the pull back sleeve to become too difficult within 270 degrees of rotation. A ramp angle of 6 degrees has been found to be acceptable, and generally results in twisting becoming too difficult within a fairly short distance. Ramp angles may be different for different club head due to the length of shaft segment 102 .
[0061] FIG. 12 illustrates a fully assembled golf club 1900 using two couplers. A first coupler 200 (or coupler 1200 ) couples interchangeable golf club heads to a golf shaft such as described above, and a second coupler 1900 an upper shaft segment 1904 having a grip 1926 to a lower shaft segment 1902 . Such a second coupler is described in U.S. patent application Ser. No. 14/142,739, filed Dec. 27, 2013, published Jul. 3, 2014 as U.S. Pub. No. 2014/0187342, entitled “Golf Club System with Golf Club Bag”, to Brady, which is hereby incorporated by reference in its entirety. In embodiment, coupler 1900 has a collar 1908 that is used to tighten the coupler 1900 to tightly couple the upper shaft segment 1904 and to lower shaft segment 1902 . In an embodiment, coupler 1900 is a screw-type coupler, and collar 1908 facilitates screwing one portion of coupler 1900 to the other. Such a collar 1908 is shown in FIG. 13 . As shown in FIG. 13 , collar 1908 has an aperture 1910 .
[0062] Because some people may not have the strength to twist collar 1908 sufficiently to tightly couple the upper and lower shaft segments, a tightening tool can be employed to assist in tightening the coupler. An exemplary tightening tool 2002 is illustrated in FIG. 14 . Tightening tool 2002 comprises a handle 2004 and a pin 2006 . In operation, pin 2004 fits into an aperture 1910 in collar 1908 as shown in FIG. 13 . Handle 2004 provides leverage to allow coupler collar 1908 to be held in place while the upper shaft segment 1904 or lower shaft segment 1902 is rotated to tightly couple the upper and lower shaft segments.
[0063] The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
[0064] Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention. | A system of interchangeable club heads sharing one or more shafts and golf bag for carrying the club heads and one or more shafts. The club heads contain a shaft segment to set club length and a coupler to interconnect to the shaft and grip. The shaft contains an opposite gender coupler. The system is very lightweight and much more portable than a conventional set of golf clubs. It also creates the opportunity for players to match club heads with shafts with differing performance characteristics. Additionally, it solves a problem for golfers using long shafts on putters. These long shafts can now be disassembled for storage and transport. A ramp on the circumference of one end of a pullback sleeve works in conjunction with a post on a grip end fitting to more tightly couple the club head end to a shaft. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is a 35 U.S.C. §§ 371 national phase conversion of PCT/ES2004/000080, filed 24 Feb. 2004, which claims priority of Spanish Application No. R200300462, filed 26 Feb. 2003. The PCT International Application was published in the Spanish language.
BACKGROUND OF THE INVENTION
This is formed by safety posts with non slip ends which are equipped with rapid connection parts for fencing and with the option of an upper safety part in the form of a jack with a lower, horizontal, inclined extension to be attached to a building's cornice or protuberance which may also include these fencing connection methods. They may be extended in length and include a base which covers the lower part of the same.
It's very simple construction means that it is possible to guarantee the overall protection of workers on outdoor and indoor building sites, preventing accidents with the invention's safety equipment.
This appplication for an Invention Patent consists of, “SAFETY EQUIPMENT FOR BUILDING SITES” as stated in the title which has been constructed, set out and designed to fulfil the purpose fpr which it has specifically geen designed, with maximum degree of safety and effectiveness and providing numerous advantages as shown in this document.
The high rate of accidents in the building industry arising from the high degree of risk in the work carried out (by its very nature and by the nature of the site where it is carried out) is currently a very serious problem. Accidental falls on building sites, particularly falls from a great height, plus being hit by objects, are currently the main risks to workers on a building site.
Awareness about the high degree of risk in the construction industry has been increasing over recent years. A significant degree of effort has been put into protection equipment such as nets and other similar equipment in order to prevent injury. Also access to the building site has to be maintained in a good condition, there have been improvements and increases in signage as well as showing precautions to be taken on the building site. Nevertheless, these safety measures are unfortunately still insufficient to reduce the site accident rates in the industry.
On building sites which use posts before and/or after shuttering the building, after the floors have set, the risk of the worker falling, (perhaps through tripping accidentally on the floor, through, for example, becoming unbalanced after straining too hard, or through fainting, etc) is very high because of the gaps between posts, particularly when this space opens out onto a long drop, creating a significant potential risk. Usually this gap is partially covered with wooden planks, iron bars, nets or it is left without being covered. This is not a solution to the problem at all.
Therefore there is potentially serious danger for builders on a building site because of these gaps between posts. Wooden planks or iron bars which are normally available to cover the space between adjoining posts offer minimal safety on a building site and simply act as ‘reassurance’, that is to say visual symbols for the worker warning him that there is a danger present. These measures are insufficient to prevent accidents on a building site.
To solve this problem this invention proposes safety equipment for building sites which has been specially designed to protect all workers on indoor and outdoor building sites.
SUMMARY OF THE INVENTION
It consists of safety equipment to be used on a building site subsequent to the shuttering stage, after the floor has set. As will be shown later, the advantageous features of the safety equipment in this invention mean that it is also likely to be used for building being renovated as well as during interior decoration work.
The safety equipment in the invention basically comprises of a series of safety posts built from telescopic tubular bodies equipped with supporting surfaces and locking mechanisms to prevent relative movement between the posts after they have placed in position. The layout of the telescopic tubes offers a wide range of heights. It must be remembered that these safety posts do not have the same function as the posts which are usually used on sites. The posts commonly used as supporting parts are specially designed to withstand axial compression loads. Posts are generally used to hold up construction work during maintenance or renovation work. However, safety posts in this invention are designed to support side impacts and not to avoid slide sideways when receiving impacts, vibrations and the possibility cracks in the construction work drying out. Therefore, according to the invention, the upper end of the safety post has non-slip surfaces which in one example may be a rubber or similar material surface on the upper end of the safety post and a rough surface on the lower end or base which allows the safety post to be fixed on the building site. The lower end may be made into a foot with extensions going down to anchor the safety post on to the untreated surface of new building work for example.
On the other hand, the side area on at least one of these pieces of equipment has the means to rapidly connect a fence using the transverse mechanism to join it to the safety posts. This fencing or rail offers the required safety to guarantee protection around the outside of the building site as well as providing access to interior stairways for instance, lift shafts and flat roofs. The layout of the banister as overall protection equipment prevents potentially fatal falls. In order to achieve this, the aforementioned banister as part of the safety equipment is designed to withstand weight and impact from the employees and building equipment present on the site.
In some scenarios it may be necessary to adapt the fencing to different gaps between safety posts. To do this and in accordance with the invention's safety features, the aforementioned fencing comprises a horizontal bar structure and other reinforcing bars, in such a way that these bars may be extended in length to vary the operating length of the fencing.
As an option, the invention may be equipped with an upper safety part which is especially adapted to connect a safety fence in such areas as a house's balcony or similar locations where there are no safety posts. This upper safety part comprises a vertical holding piece with the lower end having a horizontal extension ending in an inclined plane. The aforementioned upper holding piece on the safety equipment includes a horizontal part which moves vertically along it and is equipped with a locking mechanism. The configuration of this vertical holding piece lets a cornice or a protuberance on a building to be captured between the aforementioned horizontal extension and the moveable horizontal part as though it were a chuck. By doing this, the aforementioned inclined plane is properly supported on the upper end of the safety post. Therefore, the vertical holding piece remains fixed throughout the building work. The aforementioned inclined plane, which is in the shape of a disc, may include a rubber safety base between it and the end of the safety post which it can rest on to prevent any of the parts from moving as happens with the aforementioned safety post. The vertical holding piece has rapid connection parts like the transversal fencing in accordance with the other parts of the invention. These connections allow fencing to be located in higher areas of the building work, above the safety posts, on balconies for example. Therefore the invention can become very simply constructed, highly effective dual safety equipment.
The way the equipment has been invented means that the safety fencing includes a base or kick plate covering its lower section. The kick plate is designed to stop objects from falling onto people on the building site or to prevent an employee getting past it and removing the base to get inside the fencing. It is therefore, a part which reinforces the safety equipment's safety.
As previously stated, the invention has locking equipment designed to prevent movement between the aforementioned telescopic tubes on the safety posts. The preferred configuration for this locking equipment will essentially include a tubular part which will fit tightly around the central part of the safety post where it holds together both tubes. This tubular part is threaded on the inside to be able to fit an outer thread on the upper end of the lower tube. In this way turning the tubular part to tighten it moves it vertically toward the upper tube to butt up against a rod located in its opening to prevent the safety post tubes from moving.
Preferably, this tubular part has at least one side opening to house a lever key which has been designed to rotate it. This is a special key which is located inside a container on each floor of the building. This container will be a striking colour so that it can be found easily and therefore may be used on the safety post. Once the key has been used, the operator must return it to the container. This obliges the employee to be aware of the importance of safety on the building site.
In order to simplify the equipment and to make it easy to assemble, the rapid connection devices on the aforementioned fencing are made from hooks designed to be located in the openings on the fencing. A specific example of this would mean that these rapid fencing connection devices are pairs of hooks on the side of each safety post tube which are designed to be put into the respective pairs of holes on the fences forming them into a right angle. Here, each hook in the pairs of hooks is welded to the safety post at different heights to prevent interference between the aforementioned fencing.
The rapid fencing connection devices on the invention are on every tube on each safety post so that the safety post may connect fencing at different heights. This guarantees safety on the building site in any situation and for any type of work being carried out.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the safety equipment in this invention will be evident from the detailed description of its preferred configuration shown below. This is a non-limiting example and includes the attached drawings:
FIG. 1 is a side view of a safety post in the invention equipped with fencing and a vertical holding piece which is also supplied with the fencing;
FIG. 2 is a partial enlarged cross-section of the locking mechanism to prevent movement between the telescopic safety post tubes;
FIG. 3 is a front view of the invention's safety equipment;
FIG. 4 is a front view of the invention fencing safety equipment; and
FIG. 5 is an enlarged side view of the invention's safety post shown without the fencing.
DESCRIPTION OF PREFERRED EMBODIMENTS
The parts used in the preferred configuration of the invention are described below:
( 1 ) Safety post; ( 2 ) Lower tube; ( 3 ) Upper tube; ( 4 ) Safety post locking mechanism; ( 5 ) Fencing rapid connection mechanism; ( 6 ) Fencing; ( 7 ) Upper safety piece; ( 8 ) Vertical holding piece; ( 9 ) Horizontal extension; ( 10 ) Inclined plane disc; ( 11 ) Vertically moving horizontal piece; ( 12 ) Moveable horizontal piece locking mechanism; ( 13 ) Building cornice or protuberance; ( 14 ) Rubber safety base; ( 15 , 16 ) Horizontal fencing bars; ( 17 , 18 , 19 ) vertical fencing bars; ( 20 ) Reinforcing fencing bars; ( 21 ) Kick plate; ( 22 , 23 ) Safety post tube ends; ( 24 ) Non-slip safety post piece; ( 25 ) Safety post locking tube mechanism; ( 26 ) External thread on the upper end of the lower safety post tube; ( 27 ) Rod; ( 27 a ) Rod safety lock; ( 28 ) Upper tube openings; ( 29 , 30 ) Side openings on safety post locking tube mechanism; and ( 31 ) Special lever key.
Safety equipment comprising a series of vertical safety posts will be described. These safety posts ( 1 ) will be separated as illustrated in FIG. 3 attached to this report. This diagram shows two of the aforementioned posts ( 1 ). The safety posts ( 1 ) in the safety equipment in the invention is painted in a striking colour so that it can be easily detected in a danger zone by the operator, for example, fluorescent orange. Each safety post ( 1 ) shown basically comprises of a lower tube ( 2 ) and upper tube ( 3 ) which is held in position by sliding it inside the lower tube ( 2 ) telescopically in order to obtain different heights. In the middle area there are mechanisms ( 4 ) to prevent movement between the tubes ( 2 , 3 ). These mechanisms are described in more detail below.
These safety posts ( 1 ) have mechanisms ( 5 ) for the rapid connection of a fence ( 6 ) in a transversal position in terms of each safety post ( 1 ). In the example, the fence ( 6 ) is up to 3 metres long and its configuration may be clearly seen in FIG. 4 of the drawings. As these drawings show that the rapid fencing connection mechanisms ( 5 ) are made up of hooks (in the example shown). These hooks may be anywhere along the lower tube ( 2 ) and on the upper tube ( 3 ) (or on both) depending on the degree of coverage required by the building site. In every situation the fencing ( 6 ) covers the existing gap between two adjoining safety posts ( 1 ) to great effect. This provides the required safety to guarantee protection around the outside of the building site, stairways, lift shafts and other locations on the building site. The configuration of the fencing ( 6 ) shall be described in greater detail in terms of FIG. 4 of the drawings.
A significant feature of the invention and referring to FIG. 5 of the drawings is the upper end ( 22 ) and lower end ( 23 ) of the safety posts ( 1 ) in the invention. These are equipped with the relevant non-slip surfaces ( 24 ). The lower part of the lower tube ( 2 ) on the safety post ( 1 ) has a metal foot grip or a grooved or rough shoe extending downwards to improve the anchoring of the safety post ( 1 ) onto the ground of the building site. More specifically the upper end ( 22 ) of the safety post ( 1 ) may have a grooved rubber base ( 24 ) while the lower end ( 23 ) of the safety post ( 1 ) may have a grooved rubber foot with thick studs ( 24 ). This configuration makes the invention safer because each safety post ( 1 ) can effectively absorb blows and vibrations, preventing the posts ( 1 ) from sliding sideways on impact and also absorbing possible cracks when the building work dries out.
With particular to FIG. 1 in the drawings, the invented piece of equipment also has the option of an upper safety piece, called ( 7 ) in drawing number 1 . The upper safety piece ( 7 ) comprises a vertical holding piece ( 8 ) at the lower end of which is a horizontal extension ( 9 ) ending in an inclined plane disc ( 10 ). The upper safety piece also has a vertically moveable horizontal piece ( 11 ) and is equipped with mechanisms ( 12 ) to lock this part in a vertical position with regard to this vertical holding piece ( 8 ). As FIG. 1 in the drawings attached to this report shows, the aforementioned upper safety piece ( 7 ) allows the external section of a building's cornice or protuberance ( 13 ) to be trapped between the aforementioned horizontal extension ( 9 ) and the moveable horizontal piece ( 11 ). The trapping of the building's cornice or protuberance ( 13 ) between the horizontal extension ( 9 ) and the vertically moveable horizontal piece ( 11 ) occurs because of downward compressive force exerted by locking mechanisms ( 12 ) onto the vertically moveable horizontal piece ( 11 ) and upward compressive force exerted by locking mechanisms ( 4 ) through upper tube ( 3 ) and rubber safety base ( 14 ) onto the inclined plane disc ( 10 ), and the horizontal extension ( 9 ), such trapping also connecting the upper safety piece ( 7 ) with the safety post ( 1 ). The assembled position shown demonstrates that the lower surface of the inclined plane disc ( 10 ) is supported on the upper end of the safety post ( 1 ) so that the vertical holding piece ( 7 ) remains fixed during the building work due to the locking mechanisms ( 12 ) which, by way of an example may be a screw, (although other equivalent locking mechanisms are possible). The disc ( 10 ) includes a rubber safety base ( 14 ) assembled between the disc itself ( 10 ) on the horizontal extension ( 9 ) and the upper end of the tube ( 3 ) on the safety post ( 1 ) This prevents the relative movement and vibration of the different parts.
As with the upper and lower tubes ( 3 , 2 ) on the safety post ( 1 ), the upper holding piece ( 7 ) also has traversal fencing ( 6 ) and rapid connection mechanisms ( 5 ). This allows fencing ( 6 ) to be located in upper areas of the building work above safety posts ( 1 ) as seen in FIG. 1 .
FIGS. 3 and 4 shows that the traversal fencing ( 6 ) with the safety equipment has a relatively lightweight structure comprising vertical bars ( 17 , 18 , 19 ) and reinforcing bars ( 20 ). Sometimes the fencing might have to be adapted to different gaps between the safety posts ( 1 ) although this is not illustrated. In order for it to be able to do this, it is envisaged that the fencing structure may be extended lengthways to change its operating length. This scenario allows this safety equipment invention to be used on renovation and interior decoration work. By way of an example, the equipment may be effectively used for repairing balcony ceilings, attaching awnings and changing balustrades, etc., where the safety equipment on the upper section of the balcony covers the gap where an employee working above the height of the balcony fencing may fall.
On the lower part of the aforementioned fencing ( 6 ) there is a base or foot ( 21 ) which covers the lower part of the fencing ( 6 ) to prevent objects falling off which may accidentally injure an employee. The base ( 21 ) may be a strip of canvas stretched between the end upright bars on the fencing ( 6 ). This may also be a metal or plastic plate or any other type of suitably strong material. The base ( 21 ) may also be made from a combination of materials, for example, an area of canvas plus a lower band of another suitably rigid material.
As previously stated, the invention also has locking mechanisms ( 4 ) on the safety posts ( 1 ) which prevent the backward movement of the tubular parts ( 2 , 3 ). FIGS. 2 and 5 show that these mechanisms ( 4 ) include a tight fitting tubular piece ( 25 ) which surrounds the central part of the safety post ( 1 ) where the two tubes fit together ( 2 , 3 ) as seen in FIG. 5 . The tube is threaded on the inside ( 25 ) in order for an outer thread ( 26 ) on the upper end of the lower tube ( 2 ) to be screwed onto it as shown in FIG. 2 . Turning the tube ( 25 ) in the tightening direction moves it vertically towards the upper tube ( 3 ) butting up against a rod ( 27 ) (or hiding a locking pin) which is housed in the opening ( 28 ) to prevent the aforementioned tubes ( 2 , 3 ) on the safety posts from moving. The rod ( 27 ) is locked by the safety locking part ( 27 a ) to prevent it from accidentally falling out of the safety post ( 1 ).
As can be seen in FIG. 2 , the tube ( 25 ) has a pair of side openings ( 29 , 30 ) where the special lever keys ( 31 ) are placed. This ( 31 ) key is designed to turn the tube ( 25 )and is to be stored in a container (not shown) on each floor of the building. After the key ( 31 ) has been used, the operator returns it to the aforementioned container so that everyone is aware of the importance of safety on a building site.
Having sufficiently described the details of the safety equipment in this invention using the attached drawings, it is understood that appropriate changes to the details of the invention may be made, whenever the essential features of the summarised invention are not altered. | The invention relates to a construction safety assembly. The inventive assembly comprises: safety posts with non-skid ends, which are provided with means for the rapid connection of a barrier; and, optionally, an upper jack-type safety element having a lower horizontal protrusion along an inclined plane, which is used to brace the cornice or projecting element of a building and which can also comprise the aforementioned barrier connection means. The adjustable-length barrier comprises a base which covers the lower part thereof. In this way, the invention provides a dual safety assembly of very simple construction, which can be used to guarantee the collective safety of labourers performing external and internal construction work and prevent accidents. | 4 |
This application claims the benefit of the U.S. provisional application Ser. No. 60/100,121, filed Sep. 14, 1998.
DETAILED DESCRIPTION OF THE INVENTION
From the earliest time herbal plants have been used to treat and heal or comfort the sick. In recent years the medicinal value of herbs have been rediscovered. Even pharmaceutical companies have renewed their effort to search for potent new drugs in wild tropical plants.
Today display shelves in supermarkets, major drug stores, and health food stores are filled with hundreds of natural or artificially enriched and flavored teas but nutritionally and healthwise none of these can equal banana blossom tea. Rich in vitamins, minerals, amino acids, and other essential nutrients, it is the world's most beneficial tea. It is naturally rich in potassium and magnesium, minerals that have been clinically proven to benefit the heart by reducing high blood pressure, heart attacks, and strokes. It is believed that banana flowers are also rich in antioxidants and tannins. Antioxidants are chemicals known to help prevent cancers and combat aging and tannins have been reported to prevent bladder and urinary tract infections in women. Interestingly, banana flower also contains nutrients that bees convert into royal jelly that are needed by bee colonies to survive. Endowed with these beneficial nutrients and disease fighting chemicals, Banana blossom tea is the greatest tea since the discovery of tea in China over 4000 years ago. Naturally caffein free, not artificially decaffeinated, this pleasant, mildly aromatic tea will complement any meal and is the perfect after dinner and bed time beverage. It is great for people of all ages, from children to senior citizens and is the tea naturally designed for people with glaucoma, hypertension, hyperthyroidism, hypoglycemia, and other illnesses. It is truly the TEA OF THE NEW MILLENNIUM.
South East Asians consider banana flowers a health food and to this day use the flowers to prepare tasty native cuisines. Banana flowers, however, have remained virtually unknown to people living in temperate regions of the world because banana is a tropical plant and, but for some ornamental varieties, does not thrive in cold climate.
Banana is the world's most unique fruit tree. It evolved in a tropical jungle, very likely, during the Mesozoic era when dinosaurs roamed the earth and the continents of Africa, Asia, and Americas were a single mega-continent called Pangaea. It may explain why banana appeared in the jungles of these continents before people began cultivating them. Unlike other fruit trees that bear fruits for many decades, some varieties will bear fruit for well over a hundred years, every banana tree dies after producing just one large magnificent flower that blooms continuously for almost a year producing clusters of fruits on a bunch often weighing over 100 pounds.
Banana was first cultivated in the Land of the Pharoahs several millenniums ago. Very possibly they were the first to use this magnificent and rare flower to brew the sacred tea of the Pharoahs. But such sacred knowledge, had it existed, is lost forever in the dust of antiquity. Today banana is intensively cultivated in Ecuador, the Philippines, and other tropical countries and billions of pounds of the highly nutritious fruits are marketed worldwide.
Five years ago I decided to try converting this exotic flower into tea because most herbal plants have medicinal value and banana is an herbal plant. Besides huge quantities of this valuable resource are being discarded. Fortunately I was able to convert the flowers into a mild, pleasant tasting tea. To continue my research, I had to find a large reliable source and decided on Ecuador because it is the world's largest producer of bananas with annual export exceeding 9 billion pounds. Based on their annual production, I estimate that Ecuador alone produces over 300 million pounds of banana flowers, most of which are left to rot in the field because a significant market for the flowers has not been developed.
Banana is a fruit that does not react kindly to refrigeration, turning black and undesirable when chilled. For this reason green bananas are shipped in containers kept at 57° F. I had samples of banana flowers shipped to me from Ecuador in a similar container. Unfortunately, at 57° F., the temperature was too high and most of the banana flowers rotted during shipment owing to excessive condensation in the container. If banana flowers are chilled to below 40° F. to prevent spoilage, the white heart of the flowers will turn black, also making them undesirable. At ambient temperatures banana flowers will bloom continuously dropping all their petals. For these reasons, even if a large market for fresh banana flowers existed, it will be difficult to export fresh banana flowers from Ecuador and other distant countries.
It is a fortuitous discovery that banana flowers can be converted into tea because banana flowers are produced in countries that can least afford to waste this natural resource.
The banana flower tea is produced by a process of first obtaining fresh banana flowers and trimming, cleaning, and washing same. This is followed by the step of cutting/shredding the flowers wherein said flowers are cut manually or mechanically. The flowers are then dried in a dryer or sun dried followed by roasting. Roasting of the banana flowers takes place in a roaster at 400-450 F. for 5-7 minutes. The roasted flowers may then be milled, blended with desired flavor and aroma materials, and packaged in tea bags and boxes for subsequent brewing to form a banana flower tea beverage. It should be noted that all equipment and machines needed to manufacture the banana flower tea are commercially available and used in the manufacturing of food and drug products.
BRIEF DESCRIPTION OF THE DRAWING
The figure is a flowchart drawing of the process of making the banana flower tea of the instant invention.
SUMMARY
Banana flower tea (Banana blossom tea) is made from the flowers of banana plants (Genus: Musa). The most nutritious herbal flower, it is rich in vitamins, minerals, essential amino acids and other nutrients that are needed to keep our body disease free and healthy. It is believed to be an excellent source of antioxidants and tannins. Antioxidants are chemicals known to help prevent cancers and combat aging and tannins have been reported to prevent bladder and urinary tract infections in women.
In cultivating bananas for their highly nutritious fruits, hundreds of millions of pounds of banana flowers are incidentally produced. Based on Ecuador's annual export of bananas, I have estimated that Ecuador alone produces over 300 million pounds of banana flowers. Unfortunately most of these flowers are unutilized and are generally discarded. For these reasons I investigated ways to utilize this herbal flower and discovered that by using controlled thermal treatment, the flowers can be converted into a pleasant tasting, highly nutritious, caffein free herbal tea. | A tea is made from the flowers of a banana plant from the genus Musa. Also described is the method of making a banana flower tea using steps including cutting, drying, and roasting under certain conditions. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/083,157 filed Apr. 27, 1998.
BACKGROUND OF THE INVENTION
This disclosure relates generally to electrical connectors and specifically to connectors that are intended to be used to introduce one or more electrical conduits into a junction box or electrical enclosure. Typically, these connectors are designed to be attached to junction boxes by insertion into and friction attachment to, the "knock-out" openings typically provided in the walls of the junction box. A traditional part of the design of most connectors is a means for holding or securing the cable or conduit within the connector so as to lessen the force on the connections being made in the junction box and provide safe, secure and reliable electrical service. Typically, the cable or conduit entering the junction box is secured within the connector by an adjustable clamping arrangement. This clamping arrangement will generally take the form of a small metal plate, called a saddle, arched somewhat to conform to the shape of the conduit, attached to an adjustment screw, which when turned, will depress the saddle against the conduit and thereby secure it within the confines of the connector. As force is applied through the saddle to the conduit, a countervailing force is applied to the adjustment screw and its threaded opening, typically in the cap of the connector, which, in turn, manifests itself by elevating a collar element in the cap, which ultimately, secures the connector to the junction box.
DESCRIPTION OF THE PRIOR ART
The connectors of the prior art are presently multi-component plastic or metal devices. A fairly typical example of a connector is depicted in U.S. Design Pat. No. 336, 282 to Guginsky dated Jun. 8, 1993. Many of the elements incorporated in the disclosed connector are present and readily apparent in the Guginsky design; however, the Guginsky connector is not fabricated from a single piece of material and therefore involves costs of assembly and lost parts that are completely obviated by connectors made according to the disclosed design.
SUMMARY OF THE INVENTION
More specifically, what I envision as my invention and contribution to the art is a connector for securing an electrical conduit or cable to a junction box or electrical enclosure, said connector, in single-piece construction, comprising: a housing having a bottom and a plurality of sides; an entry port defined by a hoop attached to the bottom of said housing; a cap attached to said hoop opposite said bottom attachment having a collar mateable with said junction box and a threaded opening for the insertion of an adjustment screw; an exit port defined by a throat attached to said housing opposite said hoop attachment; and a saddle attached to said throat, opposite said housing attachment, said saddle, when configured so as to be beneath and approximately parallel to said cap, can be depressed by tightening an adjustment screw in said threaded opening to secure the placement of conduit within said connector and to impinge said collar against the perimeter of an opening in said junction box to secure the attachment of said connector to said box.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of the disclosed connector with a junction box in cross-section to show the interrelationship of the connector, electrical conduit and said box or enclosure.
FIG. 2 is a side elevational view of the disclosed connector.
FIG. 3 is a front end elevational view of the disclosed connector.
FIG. 4 is a rear end elevational view of the disclosed connector.
FIG. 5 is a side elevational view of the disclosed connector, in full cross-section, taken along line 5--5 of FIG. 3, in combination with a partial view of a junction box, also in full cross-section, and a clamping screw depicting how electrical conduit is held in the connector and the connector is held in the box.
FIG. 6 is a partial top plan view of the connector taken along line 6--6 of FIG. 5 showing only the saddle, throat and throat flange of the disclosed connector.
FIG. 7 is a side elevational view of the saddle, its cleat and its attachment to the throat.
FIG. 8 is an end elevational cross-sectional view of a partial view of the disclosed connector taken along line 8--8 of FIG. 2.
FIG. 9 is a top plan view of the one-piece body and saddle construction of the disclosed connector.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The connector of this disclosure is readily understood by reference to the drawing. In FIG. 1, an elevated side view shows the connector 10 in combination with a cable conduit 46 and a panel wall of a junction box 45. The wires 47 of the cable are presented to the interior of the box ready to be connected with other wires. In FIG. 1, it is also apparent that the connector 10 is securely attached to the panel of the box 45 by having the collar 33 of the cap 31 of the connector snugly positioned within the box 45.
It is important to note at this juncture that the disclosed connector can be used on virtually any style of electrical conduit or cable, e.g., armored cable, type MC cable, flexible metal conduit, E.M.T., non-metallic sheathed cable, and the like. And furthermore, the disclosed connector can also be used in a multitude of various other non-electrical fastening and connection applications, e.g., in the plumbing and automotive industries.
In FIG. 2, additional components of connector 10 become apparent. In this elevated side view, both sides being the same, there is a clearer view of the cap 31 and its collar 33. Additionally, there are the defining members of both the cable entry port 37 and the cable exit port 13. The former is defined by the hoop 35 and the latter by the throat 17. Furthermore, supporting the throat 17 is the throat flange 21. Other details of the connector shown in FIG. 2 are the bumps 27 on the bottom of the housing 25 interior, which are denominated "frog's eyes" and the ridge 41 extending across the exterior bottom of the connector housing 25 for the purpose of assisting in the proper positioning of the connector with a junction box. This positioning is depicted in FIG. 1 where it is clear that the ridge 41 limits the entry of the connector 10 into the box 45.
FIG. 3, providing an elevated front end view of the connector, clearly establishes the relationship among the cable exit port 13, its defining member, the throat 17 and the supporting member for the throat, the throat flange 21. Also apparent in FIG. 3 is the relationship between the throat flange 21 and the saddle 15. Although the saddle 15 itself is not clearly seen in FIG. 3, the saddle hinge 16, originating on the throat flange 21, is seen as it bends rearward to position the saddle 15 generally beneath and parallel to the cap 31.
In a preferred embodiment of the connector 10, the throat 17 is rolled, either inwardly or outwardly to provide a smooth, rounded edge to facilitate pulling wires through the connector and into the junction box. This rolled edge simply involves forming the interior edge of the throat during the manufacturing process and produces a product that does not deviate from the unitary construction of the connector.
In FIG. 4, looking through the connector from the opposite end of FIG. 3, the cable entry port 37 of the connector is prominently featured. Also apparent is the cable exit port 13, which is typically smaller than the cable entry port because the wires are generally stripped of their covering before entering the junction box 45, and the metal armor or other protective jacket ends at a point within the connector 10.
FIG. 5 presents a full cross-sectional view of the connector illustrating the dynamics of the connector. Specifically, FIG. 5 shows the saddle 15 being depressed by the adjustment screw 29. The phantom view of the saddle 15 shows the saddle cleat 23 interacting with the cable covering to aid in gripping the cable and holding it securely in place.
FIG. 5 also depicts the preferred orientation of the adjustment screw 29. When positioned at an angle of somewhat less than 90°, more room for the user's hands and tool is provided, so tightening the screw can be effected without bumping into or interfering with the panel wall 45 of the junction box or electrical panel.
It is also in FIG. 5 that the second dynamic of the integrated saddle 15 can be explained and seen most dramatically. As the adjustment screw 29 is tightened down on the saddle to the point where firm resistance with the cable is encountered, an elevated or upward force will be exerted on the screw 29 which will, in turn, exert an elevating force on the cap 31 of the connector. This force, in opposition to the downward force being applied on the saddle 15, will urge the collar 33 against the periphery of the "knock-out" in the panel of the junction box 45 creating a very firm friction fit. So, as the integrated saddle is depressed against the cable to retain it securely in the connector, the collar 33 of the connector 10 is expanded within the "knock-out" in the junction box to provide a more secure attachment.
A closer look at the integrated saddle 15 is provided by FIG. 6. This view shows its orientation relative to the throat 17 and throat flange 21. The connection between the saddle and the throat flange is provided by a narrow, isthmus-like structure which is called the saddle hinge 16. In addition to making the saddle an integral part of the connector 10, the hinge, of course, functions like a hinge allowing the saddle to be depressed with relative ease. Also apparent in FIG. 6 is a depression 19 on the interior surface of the saddle 15 which serves to confine the action of the adjustment screw 29 to prevent straying or slipping to the side as it tightens down on the saddle.
FIG. 7 provides an additional perspective of the integrated saddle 15. In this view the integrated relationship between the collar flange 21 and the tongue or hinge 16 is especially apparent, and the "grabbing" capability of the cleat 23 can also be readily appreciated.
In FIG. 8, a partial cross-section of the body 25 of the connector, a complete depiction of the aforementioned "frog's eyes" 27 is provided, and, with very little imagination, anyone can see how those bumps or protuberances on the interior surface of the connector body 25 can assist in securely retaining the conduit within the connector.
Finally, a different perspective of the disclosed connector 10 is presented in FIG. 9. Here, the connector is shown in plan view to illustrate the connector's single-piece construction. FIG. 9 depicts, roughly, the configuration of the connector, in the flat, before forming it to its final shape. This unitary construction presents significant cost savings in material and similar savings in labor during both fabrication and use. Clearly, the connector 10, as depicted in FIG. 9 can be easily stamped, molded or cast from a variety of materials and then bent to conform to the desired product.
While the foregoing is a complete and detailed description of the preferred embodiments of the disclosed connector, numerous variations and modifications may also be employed to implement the all-important purposes of the invention without departing from the spirit of the invention; and therefore the elaboration provided should not be assumed to limit, in anyway, the scope of the invention which is fairly defined by the appended claims. | A connector for facilitating the connection of electrical conduit or cable to junction box, which is fashioned from a single piece of material, and features a saddle member and rolled throat that are integral parts of the connector. These integrated features simplify manufacturing and ultimate use of the disclosed connector. | 8 |
BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] This invention relates generally to a steam vacuum cleaner and, more specifically, to a steam vacuum cleaner that also has sterilization function.
[0003] II. Description of the Prior Art
[0004] Heretofore, it is known that a vacuum cleaner can only inhale dust and small particles and is not able to remove heavy stain and stubborn dirt, not to mention the sterilization function, users have to apply mop with water or cleaner to clean the floor after vacuum to maintain floor cleaning; repeat cleaning is very tedious, the remaining chemical cleaner on the floor might considered unhealthy to human body The present invention improves on the heretofore known vacuum cleaner by providing a steam vacuum cleaner. The steam vacuum cleaner can supply high temperature steam for cleaning and sterilization purpose.
SUMMARY OF THE INVENTION
[0005] It is therefore a primary object of the invention to provide a steam vacuum cleaner to inhale dust and small particles and inject high temperature steam to remove heavy stain and stubborn dirt for detailed cleaning and sterilization purpose.
[0006] In order to achieve the objective set forth, a steam vacuum cleaner in accordance with the present invention comprises a dust container with a machinery plate on top to install a vacuum motor; a hose set composed of a hose and at least one hose turning tube made of hard material with definite length and turning angle, one end of the hose is plugged into the hose connector moveably; a nozzle with a dust inlet each on the front and end, a flute formed along the open of said dust inlet; a steam mechanism compromising of a steam generator to generate high temperature steam; a steam output structure to send out the high temperature steam; a steam conveying structure to send high temperature steam to the steam tube connector on said nozzle; several steam spouts located on the bottom center of said nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The accomplishment of the above-mentioned object of the present invention will become apparent from the following description and its accompanying drawings which disclose illustrative an embodiment of the present invention, and are as follows:
[0008] [0008]FIG. 1 is an assembly view of the first application of the present invention;
[0009] [0009]FIG. 2 is a perspective view of the first application of the present invention;
[0010] [0010]FIG. 3 is a bottom view of the nozzle of the first application of the present invention;
[0011] [0011]FIG. 4 is a bottom view of the nozzle of the second application of the present invention;
[0012] [0012]FIG. 5 is a perspective view of the second application of the present invention;
[0013] [0013]FIG. 6 is an assembly view of the steam the present invention;
[0014] [0014]FIG. 7 is a cross-sectional view of FIG. 6 in accordance with the present.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring to FIG. 1 and FIG. 2, the present invention is composed of following:
[0016] a dust container ( 10 ) with a machinery plate ( 11 ) on top to install a vacuum motor ( 12 ); the machinery plate ( 11 ) has a cover ( 13 ) on top to protect all the equipments inside; a hose connector ( 14 ) is on one side of the dust container ( 10 );
[0017] a hose set, as shown in FIG. 1 and FIG. 2, is further composed of a hose ( 15 ) and at least one hose turning tube ( 16 ) made of hard material with definite length and turning angle; one end of the hose ( 15 ) is plugged into the hose connector ( 14 ) moveably;
[0018] a nozzle ( 20 ), as shown in FIG. 2, FIG. 3 and FIG. 4, with a dust inlet ( 21 ), ( 22 ) each on the front and end, a flute ( 211 ), ( 221 ) is formed along the open of the dust inlet ( 21 ), ( 22 ) to increase the vacuum clean area; the dust inlet ( 21 ), ( 22 ) connect to the nozzle hose connector ( 23 ) through internal path inside the nozzle ( 20 ), the nozzle hose connector ( 23 ) moveably connects to the hose turning tube ( 16 ); several wheel ( 24 ) are installed on the sides of the bottom of the nozzle ( 20 ) so that the nozzle ( 20 ) can roll on the floor.
[0019] Based on the structure described above, users can activate the vacuum motor ( 12 ); dust and small particles are sucked in from the dust inlet ( 21 ), ( 22 ) of the nozzle ( 20 ), pass through the hose ( 15 ) and the hose turning tube ( 16 ) finally reaches the dust container ( 10 ). The present invention consists of a steam mechanism; the steam mechanism consists of following:
[0020] a steam generator generates high temperature steam; two applications of the present invention are described below. Referring to FIG. 1 and FIG. 2, the steam generator ( 30 ) of the first application is installed on the machinery plate ( 11 ); the steam generator ( 30 ) further composes of a water tank ( 31 ) with a water inlet on top, the water inlet has a threaded water inlet cover ( 321 ), the water inlet cover ( 321 ) exposes outer the cover ( 13 ) for users to add cleaner or water; a heater ( 33 ) is under the water tank ( 31 ) to heat the fluid in the water tank ( 31 ) to generate high temperature steam; a steam outlet tube ( 34 ) is on near the top of the water tank ( 31 ) for the high temperature steam to go out. Referring to FIG. 5 and FIG. 6, the steam generator ( 40 ) of the second application is installed external to the main body; the main body of the vacuum cleaner described above is on top of a main base ( 41 ), the steam generator ( 40 ) is installed on the other side of the main base ( 41 ). The steam generator ( 40 ) has a water tank ( 42 ) on the main base ( 41 ), fluid is filled from top of the water inlet; a water outlet tube ( 43 ) is on the bottom of the water tank ( 42 ), the water outlet tube ( 43 ) can connect to a water pump (not shown in FIG) to press water into a heater ( 44 ) inside the main base ( 41 ), the heater ( 44 ) heats up the injected fluid into high temperature steam and output the high temperature steam through a steam outlet tube ( 45 ). The steam generator ( 30 ) of the first application boils the water in the water tank ( 31 ) to generate steam, users have to wait for a period of time until the water to heat up for steam cleaning function; users also have to wait till all the water is consumed before more water to fill in. The steam generator ( 40 ) of the second application continuously has water injected from the water tank ( 42 ) into the heater ( 44 ); the steam is generated in no time and continuously, users can fill water anytime to have the steam all the time;
[0021] a steam conveying structure is to send steam from the steam outlet tube ( 34 ), ( 45 ) to the nozzle ( 20 ), the structure has two types: external and internal. The external type (as shown in FIG. 2) is to have the steam outlet tube ( 34 ) run along the hose ( 15 ) and the hose turning tube ( 16 ) externally to the steam tube connector ( 25 ) on the nozzle ( 20 ). The internal type (as shown in FIG. 5, FIG. 6 and FIG. 7) is to have the steam outlet tube ( 45 ) insert into and go along inside the hose ( 15 ), the end of the steam outlet tube ( 45 ) passes through the hose ( 15 ) and connects to the steam tube connector ( 25 );
[0022] a steam output structure (as shown in FIG. 2, FIG. 3 and FIG. 4), is to have a steam tube connector ( 25 ) on the nozzle ( 20 ) for the steam outlet tube ( 34 ), ( 45 ) to connect; several steam spout ( 26 ) are on the bottom center of the nozzle ( 20 ), the steam spout ( 26 ) are connected to the steam tube connector ( 25 ) with the internal channel of the nozzle ( 20 ); two floor scraper ( 27 ), ( 28 ) are installed on two sides of the steam spout ( 26 ) on the bottom of the nozzle ( 20 ), the floor scraper ( 27 ), ( 28 ) can be in blade shape as shown in FIG. 3 or in brush shape as shown in FIG. 4.
[0023] Users can, activate the steam device, the steam generator ( 30 ), ( 40 ) heats up water or cleaner into high temperature steam, the high temperature steam is output from the steam outlet tube ( 34 ), ( 45 ) and pressed through the steam tube connector ( 25 ) on the nozzle ( 20 ), finally injected out from the steam spout ( 26 ).
[0024] The external type steam outlet tube ( 34 ) is fixed to the hose ( 15 ) and the hose turning tube ( 16 ) with several band ( 50 ).
[0025] The internal type steam conveying structure includes:
[0026] an “L” shape connector ( 51 ) (as shown in FIG. 6, FIG. 7) is installed on the end of the hose ( 15 ) where the hose ( 15 ) is inserted into the dust container ( 10 ). An orientation piece ( 511 ) with curve shape can fix the whole structure onto the hose ( 15 ) internally; a thread section ( 512 ) stretching out of the hose ( 15 ) is beneath the orientation piece ( 511 ); a connector ( 513 ) is on top of the structure stretching toward the hose ( 15 ), the connector ( 513 ) connects to a internal steam tube ( 451 ) inside the hose ( 15 ).
[0027] a fixed nut ( 52 ) is designated to attache to the end of the steam outlet tube ( 45 ); the fixed nut ( 52 ) has a holder ( 521 ) on one end bent inward;
[0028] a connecting tube ( 53 ) with at least one ring ( 531 ) on surface for the steam outlet tube ( 45 ) to wrap around, a holding ring ( 532 ) is on one end of the connecting tube ( 53 ) to hold the steam outlet tube ( 45 ) from coming out; the fixed nut ( 52 ) wraps the connecting tube ( 53 ), the holder ( 521 ) reaches and is stopped by the ring ( 531 ), the fixed nut ( 52 ) is then turned and locked into the thread section ( 512 ) of the “L” shape connector ( 51 ), the fixed nut ( 52 ) and the internal steam tube ( 451 ) is fixed firmly together. The internal steam tube ( 451 ) extends inside the hose ( 15 ) and connects to the external steam outlet tube ( 45 ′) with the “L” shape connector ( 51 ) at the end; the external steam outlet tube ( 45 ′) stretches along the hose turning tube ( 16 ) and connects to the steam tube connector ( 25 ) of the nozzle ( 20 ).
[0029] The function of steam mechanism and vacuum cleaner are described below:
[0030] when steam vapor is generated, users can turn on vacuum motor ( 12 ) for cleaning.
[0031] Users can push the nozzle ( 20 ) on the floor back and forth to have the dust inlet ( 21 ), ( 22 ) inhale dust on floor; at the same time, the injected high temperature steam from steam spout ( 26 ) can soft and loose the stubborn stain, the stain along with the condensed water is sucked by the dust inlet ( 21 ), ( 22 ), the high temperature -steam also has sterilization function. The floor scraper ( 27 ), ( 28 ) also helps remove the stubborn dirt.
[0032] The floor scraper ( 27 ), ( 28 ) not only help remove the stubborn stain, they also isolate the steam spout ( 26 ) from the dust inlet ( 21 ), ( 22 ) to prevent the steam from inhaling by the dust inlet ( 21 ), ( 22 ) when the steam is just injected from the steam spout ( 26 ) to let steam has more time to function.
[0033] While a preferred embodiment of the invention has been shown and described in detail, it will be readily understood and appreciated that numerous omissions, changes and additions may be made without departing from the spirit and scope of the invention. | A steam vacuum cleaner comprising a vacuum cleaner and a steam mechanism, the present invention inhales dust and small particles, at the same time injects high temperature steam to soft and loose heavy stain and stubborn dirt for detailed cleaning and sterilization purpose. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to a preservative material and storage method for liquids. More specifically, the invention relates to a preservative material for liquids which is composed of a nanofiber material, and to a method of storing liquids using the same.
BACKGROUND ART
[0002] Liquids that have been placed in containers, such as eye drops, cosmetics, toiletries, beverages and inks, are sometimes used over a relatively long period of time after the container is opened.
[0003] In such cases, to prevent the quality of the liquid from deteriorating during the period of use due to airborne microorganisms and falling microorganisms and fungal spores which enter the container and grow therein, in addition to the ingredients for achieving the intended effects of the contents themselves, use is also generally made of additives such as antibacterial agents and preservatives.
[0004] Synthetic compounds such as synthetic preservatives have often been used as such additives, but because of the rise in the safety consciousness of the consumer in recent years, the preference nowadays is for the use of products of natural origin (see Patent Documents 1 to 4).
[0005] However, additives such as preservatives and antiseptic agents not only lead to a decline in the objects and effects of the contents themselves, various other problems arise, such as an undesirable odor or taste and color, adverse effects on the human body (e.g., chapped skin, discomfort, skin irritation), the extra cost of the additives, and an increase in the elements of quality control.
[0006] For example, when a synthetic compound is added, depending on the physical constitution of the user, this may give rise to a hypersensitivity reaction. When this happens, even if the chief ingredients are harmless in humans, people who develop a hypersensitivity reaction are unable to use the liquid.
[0007] As for products of natural origin, these in themselves sometimes have a distinctive odor or taste and color, which often limits the products in which they can be used.
[0008] Moreover, there are not many types of naturally occurring products which can actually be used.
PRIOR-ART DOCUMENTS
Patent Documents
[0009] Patent Document 1: JP-A 2001-178431
[0010] Patent Document 2: JP-A 2000-229804
[0011] Patent Document 3: JP-A 6-70730
[0012] Patent Document 4: JP-A 2004-59525
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0013] The present invention was arrived at in light of the above circumstances. The objects of the invention are to provide a preservative material for liquids which is capable of preserving a liquid for a relatively long period of time without the addition of additives such as antibacterial agents, and to provide a method of storing liquids using such a material.
Means for Solving the Problems
[0014] The inventors have conducted extensive investigations in order to achieve the above objects. As a result, they have discovered that by bringing a nanofiber material having numerous pores in contact with a liquid, the growth of microorganisms within the liquid is suppressed or microorganisms within the liquid are destroyed. Moreover, they have found that this nanofiber material can be advantageously used as a preservative material for liquids.
[0015] Accordingly, the present invention provides:
[0000] 1. A preservative material for liquids, comprising a nanofiber material having a plurality of pores.
2. A storage method for liquids, comprising the step of contacting the preservative material for liquids of 1 above with a liquid.
3. A storage method for liquids, comprising the step of holding, in a nanofiber material having a plurality of pores, a liquid in an amount not greater than a void volume of the nanofiber material.
4. A storage container for liquids, comprising at least one opening and an interior in which a liquid is placed, wherein a nanofiber material is disposed at the interior in such a way as to contact the liquid.
5. A storage container for liquids, comprising at least one opening and an interior in which a liquid is placed, wherein a filter having at least one layer of a nanofiber material is provided at the opening in such a way as to isolate the interior of the container from the exterior.
6. A liquid-containing nanofiber material comprising a nanofiber material having a plurality of pores and a liquid which is held in at least some portion of the pore voids.
EFFECTS OF THE INVENTION
[0016] This invention enables liquids, such as pharmaceuticals, cosmetics, toiletries, oral hygiene agents, beverages, items of stationery, liquid cultures and liquid manure, to be stored for an extended period of time without the addition of additives such as antibacterial agents. That is, the invention is able, without the use of additives, to suppress microbial toxins, odors and the like which are generated by the growth of microorganisms.
[0017] The preservative material for liquids of the invention renders unnecessary additives such as antibacterial agents that have hitherto been used, thereby making it possible not only to eliminate deterioration in the inherent effects of liquids such as pharmaceutical products and in the odor, taste, color and the like of such liquids, but also to store these liquids in a condition that is safe for the human body.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The invention is described more fully below.
[0019] The preservative material for liquids according to the invention is composed of a nanofiber material having a plurality of pores.
[0020] Here, the shape of nanofiber material is not subject to any particular limitation, provided it has numerous pores. Examples include cotton wool-like, nonwoven fabric-like, felt-like and sponge-like nanofiber materials. In this case, blending or covering with fibers having a fiber diameter of 1 μm or more may be carried out by a known technique.
[0021] The nanofibers account for a proportion (weight ratio) of the nanofiber material which is not subject to any particular limitation but, in order to fully elicit the effects of the invention, is preferably more than 50 wt %, more preferably at least 70 wt %, and even more preferably at least 80 wt %.
[0022] The fibers making up the nanofiber material have an average fiber diameter of at least 1 nm but less than 1,000 nm, preferably from 10 to 800 nm, and more preferably from 50 to 700 nm.
[0023] The basis weight of the nanofiber material, although not subject to any particular limitation, is preferably from about 1 to about 100 g/mm 2 , and especially from about 10 to about 70 g/mm 2 .
[0024] In addition, the diameter of the pores in the nanofiber material, although not subject to any particular limitation, may be set to, for example, from about 0.001 to about 100 μm, preferably from about 0.01 to about 10 μm, and more preferably from about 0.01 to about 5 μm.
[0025] When the above nanofiber material is used as the subsequently described filter, by setting the minimum pore size therein to 0.1 μm or less, preferably from 0.01 to 0.1 μm, and more preferably from 0.01 to 0.08 μm, and by setting the maximum pore size to more than 0.1 μm but not more than 1 μm, preferably more than 0.2 μm but not more than 1 μm, and more preferably from 0.3 to 1 μm, microorganisms and the like present outside of the container can be prevented from entering the interior of the container.
[0026] The starting polymer for the nanofibers is not subject to any particular limitation, provided it is a water-insoluble polymer. Illustrative examples include polyester resins, polyamide resins, polyurethane resins, polyacrylic resins, polyamideimide resins, polyvinyl chloride resins, polystyrene resins, polyimide, polyarylate, polyaniline, polypyrrole, polythiophene, cellulose and cellulose derivatives.
[0027] The nanofibers used in the invention may be obtained by spinning a solution (composition) of the above polymer dissolved in a suitable solvent using any of various spinning processes, such as electrostatic spinning, spunbonding, melt blowing and flash spinning.
[0028] In the practice of the invention, the use of an electrostatic spinning process, which is capable of manufacturing the fibers to a relatively uniform diameter in a range of at least 1 nm but less than 1,000 nm, is especially preferred.
[0029] Electrostatic spinning is a process in which, as an electrically charged electrostatic spinning dope (resin solution) is spun within an electrical field, the dope is broken up by forces of repulsion between the electric charges, resulting in the formation of a very fine fibrous material composed of the resin.
[0030] The basic configuration of the apparatus which carries out electrostatic spinning includes a first electrode which also serves as a nozzle for discharging the dope to be electrostatically spun and which applies to the dope a high voltage of from several thousands to several tens of thousands of volts, and a second electrode which faces the first electrode. The dope which has been ejected or shaken from the first electrode becomes nanofibers due to the high-speed jets and the subsequent folding and expansion of the jets within the electrical field between the two opposed electrodes, and collects on the surface of the second electrode, thereby giving nanofibers (nanofiber material).
[0031] The solvent used in preparing the dope for electrostatic spinning is not subject to any particular limitation, provided it is able to dissolve the polymer. Illustrative examples of suitable solvents include acetone, methanol, ethanol, propanol, isopropanol, toluene, benzene, cyclohexane, cyclohexanone, tetrahydrofuran, dimethylsulfoxide, 1,4-dioxane, carbon tetrachloride, methylene chloride, chloroform, pyridine, trichloroethane, N,N-dimethylformamide, N,N-dimethylacetamide, N-methyl-2-pyrrolidone, ethylene carbonate, diethyl carbonate, propylene carbonate, acetonitrile, and organic acids such as formic acid, lactic acid and acetic acid. These solvents may be used singly or as mixtures of two or more thereof.
[0032] The storage method for liquids according to the invention involves bringing the preservative material for liquids described above into contact with a liquid.
[0033] Here, the preservative material and the liquid may come into contact in any suitable manner; the liquid may come into contact with only part of the surface of the preservative material, or (a portion of) the liquid may be impregnated into and held by at least some portion of the voids of the plurality of pores in the preservative material.
[0034] The amount of preservative material used is not subject to any particular limitation, provided it is an amount that ensures a sufficient probability of contact with microorganisms. Specifically, it is preferable to use at least 1 mg, more preferably at least 5 mg, and even more preferably at least 10 mg, of the preservative material per 500 mL of liquid.
[0035] Moreover, in an embodiment wherein a liquid is held in at least some portion of the voids of the plurality of pores in the nanofiber material making up the preservative material, the liquid may be held in an amount not greater than the void volume of the nanofiber material so as to give a liquid-containing nanofiber material.
[0036] In such a liquid-containing nanofiber material, because deterioration of the liquid held at the interior of the voids does not readily arise, the nanofiber material can be advantageously employed as, for example, sanitizing wipes, wet tissues, make-up puffs and sponges which are used over a relatively long period of time after being opened.
[0037] The liquid which is used for storage is exemplified in particular by liquids composed primarily of water, including pharmaceutical products such as eye drops, medicinal drinks and sprays; cosmetics such as toners, lotions, tonics, shampoos and rinses; liquids used in toiletries; liquids used in stationery, such as India ink and other types of ink; liquid cultures, liquid manure and water placed in vases; and liquids for drinking, such as drinking water, long shelf life water, juices and alcoholic beverages.
[0038] The storage container for liquids according to the present invention is an ordinary liquid storage container having at least one opening and an interior in which a liquid is placed, wherein a nanofiber material is disposed at the interior in such a way as to contact the liquid.
[0039] Here, the place where the nanofiber material is disposed is not subject to any particular limitation, provided it is a position that enables the nanofiber material to come into contact with the liquid. Examples include any place within the container, such as the inside wall or the bottom surface. However, because the liquid placed at the interior decreases with use, to enable constant contact between the liquid and the nanofiber material, when the material is fixed to the container, it is preferable to dispose the material in a manner so as to include the bottom surface of the container. Alternatively, the nanofiber material may be simply immersed or allowed to float in the liquid without being fixed to the container.
[0040] Specific modes of use are exemplified by those in which the nanofiber material is attached to the inside wall and bottom surface of a container such as a PET bottle, glass bottle, vase or eye drop container, or in which the nanofiber material is simply dropped into these containers.
[0041] Also, the inventive storage container for liquids may be one in which a filter having at least one layer of a nanofiber material is provided at the opening of the above ordinary liquid storage container in such a way as to separate the interior of the container from the exterior.
[0042] Here, the liquid and the nanofiber material come into contact when the liquid flows into the interior through the opening and/or when the liquid flows out to the exterior, thereby eliciting the antibacterial or disinfecting effects of the invention. As a result, liquid preserving effects are manifested.
[0043] When the above nanofiber material is used as a filter, as explained above, by adjusting the minimum pore diameter and the maximum pore diameter within specific ranges, the entry of microorganisms from the exterior can be blocked. Therefore, through the synergism of the sterilizing effects on microorganisms in the liquid and the blocking effect against organisms from the exterior, it is possible to preserve liquids for a longer period of time.
[0044] Moreover, it is possible to dispose a nanofiber material at the interior of the container, and also provide a filter which includes a nanofiber material.
[0045] The nanofiber material may be used alone as a filter, or it may be laminated with another nonwoven fabric or porous film or sheet and the resulting laminate used as a filter.
EXAMPLES
[0046] Examples of the invention and Comparative Examples are given below by way of illustration, and not by way of limitation. Tests and measurements in the Examples and Comparative Examples below were carried out by the following methods.
[1] Average Fiber Diameter
[0047] The fiber diameter was measured at 20 places selected at random from a micrograph obtained by capturing an image of the specimen surface at a magnification of 5000× with a scanning electron microscope (S-4800I, manufactured by Hitachi High-Technologies Corporation). The average (n=20) for all the fiber diameters was calculated and treated as the average fiber diameter.
[2] Antibacterial Activity Measuring Test 1 (Cell Count Measurement Method)
[0048] The test was carried out using the following cell count measurement method (JIS L 1902) described in K•kin B•sh• Kak• Seihin no Kak• K•ka Hy•ka Shiken Manyuaru [Manual for Evaluating and Testing the Effects of Treatment in Antibacterial Deodorization-Finished Products] established by the Sen'i Seihin Eisei Kak• Ky•gikai (Japanese Association for the Hygienic Finishing of Textiles).
[0049] A suspension of Staphylococcus aureus as the test organism was initially prepared by culturing this organism in a common bouillon medium and adjusting the concentration to from 10 6 to 10 7 cells/mL. The suspension (0.2 mL) was uniformly inoculated onto 0.4 g of the specimen in a sterilized threaded vial and static cultured at 36 to 38° C. for 18 hours, following which 20 mL of sterile, buffered physiological saline was added to the vessel and the vessel contents were shaken vigorously by hand 25 to 30 times at an amplitude of 30 cm so as to disperse the live cells in the specimen within the liquid. Next, a suitable dilution series was created with sterile, buffered physiological saline, 1 mL of dilution at each stage was placed in two Petri dishes, and about 15 mL of standard agar culture medium was added. Culturing was then carried out at 36 to 38° C. for 24 to 48 hours, following which the number of live colonies was counted and the live cell count in the specimen was computed in accordance with the degree of dilution. In rating the effects, the test was judged to be complete when the growth value exceeded 1.5. The bacteriostatic activity S and the bactericidal activity L were determined from the following formulas.
[0000] Bacteriostatic activity S=B−C
[0000] Bactericidal activity L=A−C
[0000] where A: average common log value of live cell count for three specimens immediately after contacting a standard cloth with test organisms
B: average common log value of live cell count for three specimens after culturing standard cloth for 18 hours
C: average common log value of live cell count for three specimens after culturing antibacterially finished specimen for 18 hours
[3] Antibacterial Activity Measuring Test 2 (Antibacterial Finished Product—Antibacterial Test Method; JIS Z 2801)
[0050] S. aureus, Escherichia coli and Klebsiella pneumoniae as the test organisms were initially cultured on a common agar medium (Nissui Pharmaceutical Co., Ltd.), and the grown colonies were scraped off and suspended in a 1/500 concentration common bouillon medium (Eiken Chemical Co., Ltd.) to give test organism suspensions adjusted to about 10 6 CFU (colony forming units)/mL.
[0051] A 50 mm square reinforced polyethylene film was placed in a sterile Petri dish, and the specimen (40 mm square, 0.1 g) was placed on top thereof. The test organism suspension (0.1 mL) was added dropwise to the specimen, and a 50 mm square reinforced polyethylene film was covered over and brought into close contact with the specimen. This state is one in which an amount of liquid not greater than the void volume of the specimen is held in the specimen. The inoculated specimen was then placed in a closed vessel held at a relative humidity of at least 90% RH and a temperature of 35±1° C., and allowed to act for 24 hours. After 24 hours of action, the specimen was recovered in a sterile stomacher bag, 10 mL of a soybean casein digest broth with lecithin and polysorbate (SCDLP) bouillon medium (Eiken Chemical Co., Ltd.) was added, and the test organisms were washed out. Using the washing as the stock solution, a ten-fold dilution series was prepared. One milliliter each of this sample stock solution and of the dilutions were prepared as pour plates with a standard agar medium (Nissui Pharmaceutical Co., Ltd.) and cultured at 35±1° C. for 48 hours, following which the colonies that grew on the medium were counted and the number of test organisms for each specimen was determined.
[4] Antibacterial Activity Measuring Test 3 (Antibacterial Activity Evaluating Test for Airborne Organisms)
[0052] Using a 1 m 3 test chamber made of polyvinyl chloride, two stirring fans were placed in diagonally opposed corners on the floor surface. A bacterial suspension spraying hole and an airborne bacteria collecting hole were provided at the center of one sidewall of the test chamber, a bacterial suspension spraying device and a filter holder were connected thereto, and an airborne bacteria collecting unit was connected after the filter holder. A glass nebulizer containing a test organism suspension was used as the bacterial suspension spraying device, and a glass midget impinger was used as the airborne bacteria collecting unit.
[0053] S. aureus as the test organism was cultured in tryptic soy agar (TSA medium; available from Difco). The grown colonies were scraped off and suspended in sterile ion-exchanged water to form a test organism suspension adjusted to about 10 9 cells/mL.
[0054] Compressed air was delivered to the bacterial suspension-containing glass nebulizer from a compressor and the test organism suspension was sprayed into the test chamber at a rate of 0.2 mL/min for 10 minutes, thereby suspending the bacteria in air (the airborne cell count was about 2×10 9 cell/1,000 i). The suspended bacteria within the chamber were collected through a specimen (diameter, 49 mm) placed in the filter holder. That is, a glass midget impinger in which 20 mL of sterile physiological saline had been placed was connected after the filter holder, and air within the test chamber was collected each time at a rate of 5 L/min for 10 minutes (=50 L). As a control, the airborne bacteria within the chamber were collected through a filter holder in which a specimen had not been placed.
[0055] Using as the stock solution the sterile physiological saline within the impinger after the test organisms had been collected, a ten-fold dilution series was prepared. One milliliter each of this sample stock solution and of the dilutions were prepared as pour plates with a TSA medium and cultured at 35° C. for 48 hours, following which the grown colonies were counted and the number of organisms that passed through the specimen per 50 L of air was determined.
[0056] At the same time that the attached cells were passed through the specimen in this way, the cells that attached to the specimen were subjected to the subsequently described evaluation as specimen-attached cells. Air within the test chamber containing suspended cells was passed through the specimen placed in the filter holder at a rate of 5 L/min for 10 minutes (=50 L), causing the test organisms to attach to the specimen. The specimen to which test organisms had been made to attach was removed from the filter holder, placed in a closed vessel filled with the vapor of a 1.8 wt % sodium chloride solution (35° C.; relative humidity, 90%), and held for 24 hours.
[0057] The test specimens were then removed, each was placed in a sterile stomacher bag, 10 mL of SCDLP medium (Eiken Chemical Co., Ltd.) was added, and the attached cells were washed out. Using the washing as the stock solution, a ten-fold dilution series was created. One milliliter each of this sample stock solution and of the dilutions were prepared as pour plates with TSA medium and cultured at 35° C. for 48 hours, following which the number of colonies that grew on the medium were counted and the number of attached cells was determined.
[5] Antibacterial Efficacy Measuring Test
[0058] Specimens were placed in amounts of 10 mg, 0.1 g or 0.2 g in a sterilized wide-mouth bottle (mouth diameter, 3 cm), and 500 mL of pre-sterilized drinking water was placed in each bottle so that the drinking water was in contact with all portions of the specimen. These bottles were left to stand uncapped at room temperature for 30 minutes, following which they were capped and held at room temperature for two weeks. After two weeks, 200 μL of each solution was inoculated onto a standard agar medium, incubated at 37° C. for 48 hours, and the colonies that formed were observed. The antibacterial properties were evaluated based on the common bacteria within the solution.
−: no change (no colonies formed) +: changed (colonies formed)
[6] Skin Toner Storage Efficacy Test
[0061] S. aureus and E. coli as the test organisms were initially cultured in a common agar medium (Nissui Pharmaceutical Co., Ltd.), and the grown colonies were scraped off and suspended in a 1/500 concentration common bouillon medium (Eiken Chemical Co., Ltd.) to give test organism suspensions adjusted to about 10 7 CFU (colony forming units)/mL. The test organism suspension (0.1 mL) was added to 100 mL of skin toner (FDR Lotion M, available from Fancl Corporation), and a toner test solution for each organism was prepared to a cell concentration of 10 4 CFU/mL. The toner test solutions were each dispensed in an amount of 30 mL to a 50 mL centrifuge tube and a given amount of the specimen was placed therein, following which the tubes were stored at room temperature for a given number of days (0, 1, 3 or 7 days). The cell counts for the toner test solutions were measured by the pour plate method after the respective number of days of storage had elapsed. As a control, a similar test was carried out on a skin toner test solution in which the specimen was not placed.
[7] Minimum Pore Size and Maximum Pore Size Measurement Test
[0062] The pore sizes were measured and evaluated as described below based on the bubble point method (ASTM F316, JIS K 3832).
[0063] Using a perm porometer (model CFP-1200A manufactured by PMI), dry air was passed through a sample having a measurement diameter of 25 mm and the air flow rate was observed as the air pressure was increased in stages (dry flow rate curve).
[0064] Next, the sample was soaked in Galwick (available from PMI) having a surface tension of 16 dynes/cm, and the soaked sample was pretreated by degassing in a vacuum drier so that no bubbles remained in the sample. Dry air was passed through the pretreated sample, and the air flow rate was observed as the air pressure was increased in stages (wet flow rate curve).
[0065] The minimum pore size and the maximum pore size were determined from these two dry and wet flow rate curves.
[1] Production of Preservative Material for Liquids
Example 1
Polylactic Acid
[0066] Ten parts by weight of polylactic acid resin (LACEA H280, available from Mitsui Chemicals, Inc.) and 45 parts by weight of dimethylformamide (abbreviated below as “DMF”) were mixed and heated to 60° C., thereby dissolving the polylactic acid resin in the DMF and obtaining 55 parts by weight of a polylactic acid-containing solution (solids content, 18 wt %).
[0067] This lactic acid-containing solution (spinning dope) was placed in a syringe and electrostatic spinning was carried out at a discharge tip orifice diameter of 0.4 mm, an applied voltage of 20 KV (at room temperature and atmospheric pressure), and a distance from the discharge tip orifice to the fibrous substance collecting electrode of 15 cm, thereby giving a preservative material for liquids (nanofiber nonwoven fabric).
[0068] The resulting nonwoven fabric had an average fiber diameter of 500 nm, and fibers with a diameter greater than 3 μm were not observed.
Example 2
Nylon 6
[0069] Ten parts by weight of nylon 6 (A1030BRT, produced by Unitika, Ltd.) was dissolved in 57 parts by weight of formic acid at room temperature (25° C.), thereby obtaining 67 parts by weight of a nylon 6-containing solution (solids content, 15 wt %).
[0070] This nylon 6-containing solution (spinning dope) was placed in a syringe and electrostatic spinning was carried out at a discharge tip orifice diameter of 0.4 mm and an applied voltage of 50 KV (at room temperature and atmospheric pressure), thereby giving a preservative material for liquids (nanofiber nonwoven fabric). The resulting nonwoven fabric had an average fiber diameter of 250 nm, and fibers with a diameter greater than 1 μm were not observed.
Example 3
Polyacrylonitrile
[0071] Ten parts by weight of polyacrylonitrile (Barex 1000S; available from Mitsui Chemicals, Inc.) was dissolved in 40 parts by weight of DMF at room temperature (25° C.) to give 50 parts by weight of a polyacrylonitrile-containing solution (solids content, 20 wt %).
[0072] This polyacrylonitrile-containing solution (spinning dope) was placed in a syringe and electrostatic spinning was carried out at a discharge tip orifice diameter of 0.4 mm, an applied voltage of 30 KV (at room temperature and atmospheric pressure), and a distance from the discharge tip orifice to the fibrous substance collecting electrode of 15 cm, thereby giving a preservative material for liquids (nanofiber nonwoven fabric).
[0073] The resulting nonwoven fabric had an average fiber diameter of 100 nm, and fibers with a diameter greater than 1 μm were not observed.
Example 4
Cellulose
[0074] A cuprammonium solution was prepared by weighing out 0.768 g of copper hydroxide (Wako Pure Chemical Industries) into a flask, then adding 17.86 g of a 28% aqueous ammonia solution (Wako Pure Chemical Industries) and 1.372 g of water. One part by weight of absorbent cotton (Hakujuji Co., Ltd.) was added to 20 parts by weight of this solution, thereby giving 21 parts by weight of a cellulose-containing solution (solids content, about 4.8 wt %). The solution was stirred for 18 hours at room temperature, and the starting cotton was confirmed to have completely dissolved.
[0075] This cellulose-containing solution (spinning dope) was placed in a syringe and electrostatic spinning was carried out at a discharge tip orifice diameter of 0.4 mm, an applied voltage of 30 KV (at room temperature and atmospheric pressure), and a distance from the discharge tip orifice to the fibrous substance collecting electrode of 10 cm, thereby giving a nanofiber nonwoven fabric. The resulting nanofiber nonwoven fabric was washed with 0.1 mol/L hydrochloric acid so as to remove the copper ions, thereby giving the target preservative material for liquids (nanofiber nonwoven fabric).
[0076] The resulting nonwoven fabric had an average fiber diameter of 700 nm, and fibers with a diameter greater than 1.5 μm were not observed.
Comparative Example 1
Polylactic Acid
[0077] The same polylactic acid resin as in Example 1 was melt spun at a spinning temperature of 160° C. using monofilament nozzles, thereby giving filaments having an average diameter of 20 μm. The resulting filaments were separated and dispersed, then deposited on a moving conveyer screen-type condenser to form a web. Next, the constituent filaments were united with each other by subjecting the web to a conventional nonwoven fabric-forming operation, thereby giving a nonwoven fabric. The average fiber diameter was 20,000 nm.
Comparative Example 2
Nylon 6
[0078] The same nylon 6 resin as in Example 2 was melted at a spinning temperature of 260° C., and formed into a nonwoven fabric by the same process as in Comparative Example 1. The average fiber diameter was 15,000 nm.
Comparative Example 3
Polyacrylonitrile
[0079] The same polyacrylonitrile resin as in Example 3 was melted at a spinning temperature of 260° C. using a pressure melter-type melt spinning machine, and formed into a nonwoven fabric by the same process as in Comparative Example 1. The average fiber diameter was 30,000 nm.
Comparative Example 4
Cellulose
[0080] The same absorbent cotton (Hakujuji Co., Ltd.) as in Example 4 was used. A web was formed by a conventional wet method, and a nonwoven fabric was obtained by directing a high-pressure stream of water at the cotton to mutually entangle the fibers. The average fiber diameter was 30,000 nm.
[0081] Antibacterial Activity Measuring Tests 1 to 3, the antibacterial efficacy measuring test, the skin toner storage efficacy test (Examples 2 and 3 only), and the minimum pore size and maximum pore size measurement test were carried out on the nonwoven fabrics obtained in Examples 1 to 4 and Comparative Examples 1 to 4. The results of Antibacterial Activity Measuring Test 1 are shown in Table 1, the results of Antibacterial Activity Measuring Test 2 are shown in Table 2, the results of Antibacterial Activity Measuring Test 3 are shown in Table 3 (passed cell count) and Table 4 (antibacterial activity against attached cells), the results of the antibacterial efficacy measuring test are shown in Table 5, the results of the skin toner storage efficacy test are shown in Table 6 ( S. aureus ) and Table 7 ( E. coli ), and results of the minimum pore size and maximum pore size measurement test are shown in Table 8.
[0000]
TABLE 1
Average
Antibacterial tests*
fiber
Live cell
Bacteriostatic
Bactericidal
diameter (nm)
Resin
count
activity
activity
Example
1
500
polylactic acid
<600
>4.1
>1.5
2
250
nylon 6
<600
>4.1
>1.5
3
100
polyacrylonitrile
<600
>4.1
>1.5
4
700
cellulose
<600
>4.1
>1.5
Comparative
1
20,000
polylactic acid
4.5 × 10 7
−0.3
−2.9
Example
2
15,000
nylon 6
7.4 × 10 7
−0.3
−2.5
3
30,000
polyacrylonitrile
7.2 × 10 7
−0.3
−1.8
4
30,000
cellulose
7.9 × 10 7
−0.3
−2.5
*Standard cloth (cotton)
Immediately after inoculation: 1.9 × 10 4
After 18 hours of culturing: 7.9 × 10 6
[0000]
TABLE 2
Average
Live cell count
fiber
Staphylococcus
Klebsiella
Escherichia
diameter (nm)
Resin
aureus
pneumoniae
coli
Example
1
500
polylactic acid
<10
<10
—
2
250
nylon 6
<10
<10
48
3
100
polyacrylonitrile
<10
<10
1,800
4
700
cellulose
<10
<10
<10
Comparative
1
20,000
polylactic acid
380,000
1,500,000
—
Example
2
15,000
nylon 6
400,000
1,400,000
—
3
30,000
polyacrylonitrile
400,000
1,400,000
—
4
30,000
cellulose
420,000
1,600,000
20,000,000
[0000]
TABLE 3
Passed cell count
Average
fiber diameter
Passed cell count
(nm)
Resin
(cells/50 L of air)
Example
1
500
polylactic acid
<10
2
250
nylon 6
<10
3
100
polyacrylonitrile
<10
4
700
cellulose
<10
Comparative
1
20,000
polylactic acid
1,500,000
Example
2
15,000
nylon 6
1,200,000
3
30,000
polyacrylonitrile
1,400,000
4
30,000
cellulose
1,600,000
[0000]
TABLE 4
Antibacterial activity against attached cells
Average
fiber diameter
Attached cell
(nm)
Resin
count
Example
1
500
polylactic acid
<10
2
250
nylon 6
<10
3
100
polyacrylonitrile
<10
4
700
cellulose
<10
Comparative
1
20,000
polylactic acid
3,300,000
Example
2
15,000
nylon 6
2,100,000
3
30,000
polyacrylonitrile
4,200,000
4
30,000
cellulose
4,200,000
[0000]
TABLE 5
Average
Amount of
fiber
preservative material
diameter (nm)
Resin
10 mg
0.1 g
0.2 g
Example
1
500
polylactic acid
−
−
−
2
250
nylon 6
−
−
−
3
100
polyacrylonitrile
−
−
−
4
700
cellulose
−
−
−
Comparative
1
20,000
polylactic acid
+
+
+
Example
2
15,000
nylon 6
+
+
+
3
30,000
polyacrylonitrile
+
+
+
4
30,000
cellulose
+
+
+
Control: distilled water only +
[0000]
TABLE 6
Skin toner storage efficacy test ( S. aureus )
Specimen
S. aureus count
Weight (g)/
After 1
After 3
After 7
30 mL of
day of
days of
days of
Resin
test solution
0 days
storage
storage
storage
Example
2
nylon 6
0.4
—
16,000
2,000
<10
2
nylon 6
0.2
—
19,000
4,000
<10
3
polyacrylonitrile
0.4
—
12,000
<10
<10
3
polyacrylonitrile
0.2
—
12,000
260
<10
Control
—
—
37,000
22,000
14,000
8,400
Control: Skin toner test solution only
[0000]
TABLE 7
Skin toner storage efficacy test ( E. coli )
Specimen
E. coli count
Weight (g)/
After 1
After 3
After 7
30 mL of
day of
days of
days of
Resin
test solution
0 days
storage
storage
storage
Example
2
nylon 6
0.4
—
21,000
7,000
<10
2
nylon 6
0.2
—
26,000
7,600
40
3
polyacrylonitrile
0.4
—
20,000
230
<10
3
polyacrylonitrile
0.2
—
23,000
2,400
<10
Control
—
—
44,000
22,000
22,000
11,000
Control: Skin toner test solution only
[0000]
TABLE 8
Average
fiber
Pore size (μm)
diameter (nm)
Resin
Minimum
Maximum
Example
1
500
polylactic acid
0.0432
0.7070
2
250
nylon 6
0.0176
0.501
3
100
polyacrylonitrile
0.0210
0.8560
4
700
cellulose
0.0500
0.9500
Comparative
1
20,000
polylactic acid
15.0
102.0
Example
2
15,000
nylon 6
9.0
80.5
3
30,000
polyacrylonitrile
19.0
132.3
4
30,000
cellulose
19.0
132.3
[0082] It is apparent from Tables 1 to 4 that the preservative materials obtained in Examples 1 to 4 had antibacterial activities, and it is apparent from Tables 5 to 7 that bacteria did not grow in solutions stored using these preservative materials. Moreover, it is apparent from Table 3 that the preservative materials used in Examples 1 to 4 allowed substantially no bacteria to pass through. | A nanofiber structure having pores is used as a preservative material for a liquid material. A liquid material can be stored for a long period without causing deterioration and without the need of using any additive such as an anti-bacterial agent merely by contacting the liquid material with the preservative material. | 8 |
This invention was made with Government support under Contract No. DE-AC05-84OR21400 awarded by the U.S. Department of Energy to Martin Marietta Energy Systems, Inc. The Government has certain rights in this invention.
BACKGROUND OF INVENTION
1. Field of Invention
The invention is directed to a thin-film battery and a method for making same. More particularly, the invention is directed to a new thin-film lithium battery having a novel electrolyte permitting a battery to be fabricated having greatly enhanced energy density and specific energy over conventionally available batteries. The invention is also directed to a novel cathode permitting a battery to be fabricated having significantly enhanced energy densities over conventionally available batteries.
2. Description of Prior Art
A battery is one of two kinds of electrochemical devices that convert the energy released in a chemical reaction directly into electrical energy. In a battery, the reactants are stored close together within the battery itself, whereas in a fuel cell the reactants are stored externally. The attractiveness of batteries as an efficient source of power is that the conversion of chemical energy to electrical energy is potentially 100% efficient although the loss due to internal resistance is a major limiting factor. This potential efficiency is considerably greater than the conversion of thermal energy to mechanical energy as used in internal combustion engines, which always results in heat transfer losses. Moreover, the additional disadvantages of contaminants emitted into the atmosphere as byproducts of incomplete combustion and dwindling availability of fuel supplies have intensified research into batteries as an alternative source of energy.
One limitation of conventional batteries is that they use toxic materials such as lead, cadmium, mercury and various acid electrolytes that are facing strict regulation or outright banning as manufacturing materials. Another limitation is that the amount of energy stored and/or delivered by the battery is generally directly related to its size and weight. At one end of the development spectrum, automobile batteries produce large amounts of current but have such low energy densities and specific energies due to their size and weight and such relatively lengthy recharge times that their usage as a source of propulsion is impractical. At the other end of the development spectrum, small, light, lithium batteries used to power small electronic appliances and semiconductor devices have much higher energy densities and specific energies but have not had the capability to be scaled up to provide the high energy for high power applications such as use in automobiles. Further, these small, light, lithium batteries have low charge-discharge cycle capability, limited rechargeability and, even where scaled down for microelectronics applications, size that frequently is many times larger than the semiconductor chip on which they are used.
Thin-film battery technology is foreseen as having several advantages over conventional battery technology in that battery cell components can be prepared as thin, e.g. 1 micron, sheets built up in layers using techniques common to the electronics industry according to the desired application. The area of the sheets can be varied from sizes achievable with present lithographic techniques to a few square meters providing a wide range in battery capacity. Deposition of thin films places the anode close to the cathode resulting in high current density, high cell efficiency and a great reduction in the amount of reactants used. This is because the transport of ions is easier and faster in thin film layers since the distance the ions must move is lessened.
Most critical to battery performance is the choice of electrolyte. It is known that the principle limitation on rechargeability of prior batteries is failure of the electrolyte. Battery failure after a number of charge-discharge cycles and the loss of charge on standing is caused by reaction between the anode and the electrolyte, e.g. attack of the lithium anode on the lithium electrolyte in lithium batteries. An extra process step of coating the anode with a protective material adds to the complexity, size and cost of the battery.
The power and energy density of a battery is also dependent upon the nature of the cathode. To achieve optimum performance, the open circuit voltage and current density on discharge should be as high as possible, the recharge rate should be high and the battery should be able to withstand many charge-discharge cycles with no degradation of performance. The vanadium oxide cathode of the present invention has a much higher capacity per mole than the crystalline TiS 2 of prior art cathodes.
The present invention avoids the limitations of present battery design and provides a novel battery having application as a battery used with manufacture of semiconductor components and as a high energy, high current macrobattery with appropriate scale-up of the described processes. The present invention includes a novel electrolyte having a good conductivity but more importantly it has electrochemical stability at high cell potentials and requires no protective layer between it and the anode during battery fabrication or use. The present invention also includes a novel cathode having a microstructure providing excellent charge/discharge properties.
SUMMARY OF THE INVENTION
A primary object of invention is to provide a new thin-film battery and a method for making same.
A second object of invention is to provide a new electrolyte for a thin-film battery in which the electrolyte has good ionic conductivity and is not reactive with the battery anode.
Another object of invention is to provide a method for making an improved electrolyte for a thin-film battery.
A yet further object of invention is to provide a new cathode having improved microstructure for a thin-film battery and a method for making same.
These and other objects are achieved by depositing a pair of current collecting films on a substrate; depositing an amorphous cathode layer on the larger of the two collecting films; depositing an amorphous lithium phosphorus oxynitride electrolyte layer over the cathode; and depositing a metallic anode layer over the electrolyte.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a thin-film battery deposited onto a semiconductor chip package with current leads extending to a semiconductor chip.
FIGS. 2A-2D illustrates the layers in plan view to form a thin-film battery according to the present invention.
FIG. 3 schematically illustrates a cross-sectional view of a thin-film battery made according to the present invention.
FIG. 4A is a micrograph of a vanadium oxide cathode formed by a sputtering process where the target is aged due to prior sputtering and the process gas flow rate is less than about 15 sccm.
FIG. 4B is a micrograph of a vanadium oxide cathode formed by a sputtering process where the target is fresh and the process gas flow rate is greater than about 15 sccm.
FIG. 5 illustrates the charge-discharge performance for a microbattery made according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
There are many possible uses for a thin-film, rechargeable battery as a primary or standby power source for low current electronic devices. A thin-film cell could be fabricated directly onto the semiconductor chip, the chip package or the chip carrier and could be fabricated to any specified size or shape to meet the requirements of a particular application. Referring to FIG. 1, a possible application is shown in which a thin-film cell 10 is deposited onto a semiconductor chip package 12 with current leads 14 extending to the chip 16. A Li-VO x cell about 8 microns thick occupying an area of 1 square centimeter as shown has a capacity of 130 microAmp-hours and could supply a current of up to 100 microAmps at a voltage ranging from 3.7 volts at full charge to about 1.5 volts near the end of its discharge. If a larger battery were deposited over the unused area of the package, the capacity and current density of the battery could of course be increased.
With reference to FIGS. 2A-D, the steps in fabricating such a single cell are shown. Two current collectors, vanadium for example, are deposited as a larger and a smaller 0.5 micron thick film, 18 and 20 respectively, on a substrate 22 such as glass, alumina, sapphire or various semiconductor or polymer materials. The films may be deposited by rf or dc magnetron sputtering or diode sputtering of vanadium in Argon, vacuum evaporation or other such film deposition techniques common to the semiconductor electronics industry. Similarly, an amorphous vanadium-oxide, VO x , cathode 24 is deposited as a 1 micron thick film over the larger current collector 18 by sputtering vanadium in Argon+14%O 2 . An amorphous oxynitride lithium electrolyte film 26 is then deposited over the cathode 24 by sputtering of Li 3 PO 4 , lithium orthophosphate, in 20 milliTorr of N 2 and a total gas flow of 14 sccm. As before, various film deposition techniques may be used for fabrication of the vitreous electrolyte film 26 although reactive DC sputtering is not available when lithium orthophosphate is the target as it is an insulator material and would accumulate charge until the deposition process stopped. Example targets for the described microbattery measured 25 millimeters in diameter by 3 millimeters thick and were prepared by cold pressing lithium orthophosphate powder followed by sintering of the pressed disc in air at 900° C. Deposition of a 1 micron thick film was carried out over a period of 16-21 hours at an average rate of 8-10 Angstroms per minute. The film 26 has the composition Li x PO y N z where x has the approximate value of 2.8; 2y+3z has the approximate value of 7.8; and z has the approximate value of 0.16 to 0.46. Deposition of a film 28 of lithium over the vitreous electrolyte film 26, the intervening substrate 22 and the smaller current collector 20 completes the cell. A typical film thickness for the lithium film 28 is about 5 microns. FIG. 3 is a schematic cross-section view of FIG. 2D.
Example performance characteristics of such a battery as described above are an open circuit voltage of 3.6 to 3.8 volts and, for a 1 micron thick cathode, a capacity of about 130 microAmp-hours per square centimeter for a discharge to 1.5 volts. The battery is capable of producing a discharge current of up to 2 milliAmps per square centimeter and can be recharged at a current of at least 20 microAmps per square centimeter. The battery has been subjected to more than 100 charge/discharge cycles with no degradation in performance and, after the first few cycles, the efficiency of the charge/discharge process was approximately 100%. Further, the vitreous oxynitride lithium electrolyte 26 has demonstrated long-term stability in contact with the lithium anode 28 such that the battery does not require the extra protective film, typically lithium iodide, to prevent reaction of the lithium anode with the electrolyte.
Performance of thin-film batteries has been critically limited by the properties of the chosen electrolyte. For rechargeable lithium batteries, the electrolyte should have a high lithium ion conductivity and it must be chemically stable in contact with lithium. Films deposited by sputtering or evaporation of inorganic compounds onto substrates held at ambient temperatures are usually amorphous. This is advantageous because, for many lithium compounds, the lithium ion conductivity of the amorphous phase is orders of magnitude higher than that of the crystalline phase and the conductance of the amorphous film is often adequate for use an as electrolyte. As many of these amorphous materials have acceptable low electronic conductivities, there is a wide choice of materials available for possible application in thin-film cells which meet the first two requirements. However, instability in contact with lithium eliminates many materials from consideration and has limited development of a thin-film lithium cell. The amorphous lithium phosphorus oxynitride film 26 of the present invention is made by sputtering Li 3 PO 4 in pure N 2 and has both the desired electrical properties and the stability in contact with lithium for fabrication of electrochemical cells.
A comparison of the conductivities at 25° C. for several electrolyte compositions in the lithium phosphosilicate system achieved by sputtering lithium silicates and lithium phosphates in Ar and Ar+O 2 is shown in Table 1. The lithium phosphosilicate listed had the highest conductivity of the films in the Li 2 O:SiO 2 :P 2 O 5 system. Several of the more highly conductive lithium phosphosilicate films with different compositions were investigated as the electrolyte for lithium cells. In each case, the lithium anode 28 reacted with the electrolyte film 26. However, the electrolyte of the present invention was found to be stable in contact with the lithium anode although it contained only about 2 to 6 at. % nitrogen. Moreover, as shown in Table 1, the conductivity is more than 30 times greater than that of the film deposited by sputtering Li 3 PO 4 in 40% O 2 in Argon. Incorporation of nitrogen into the thin films of the present invention increases conductivity at least five times greater than similarly prepared films containing no nitrogen. The increase in conductivity is due to an increase in lithium ion mobility rather than an increase in the number of charge carriers brought about by a change in the structure of the electrolyte. Further, such cells appear to be stable indefinitely, exhibiting only a small voltage loss which is considered to occur due to the electronic conductivity of the electrolyte.
TABLE 1______________________________________Comparison of amorphous lithium phosphate, phosphosilicate,and phosphorus oxynitride electrolyte films. Process Film σ(25° C.) × 10.sup.8 E.sub.2Target Gas Composition (S/cm) (eV)______________________________________Li.sub.3 PO.sub.4 40% O.sub.2 Li.sub.2.7 PO.sub.3.9 7 0.68 in ArLi.sub.3 PO.sub.4 + 40% O.sub.2 Li.sub.4.4 Si.sub.0.23 PO.sub.5.2 20 0.57Li.sub.4 SiO.sub.4 in ArLi.sub.3 PO.sub.4 N.sub.2 Li.sub.3.3 PO.sub.3.8 N.sub.0.22 240 0.56______________________________________
The enhanced conductivity, superior mechanical properties of nitrided glass(e.g. hardness, resistance to fracture) and chemical stability of the oxynitride lithium electrolyte of the present invention could also be used to fabricate enhanced electro-optic devices using electrochromic layers, i.e. so called smart windows, because of the increased resistance to attack from water vapor.
The performance of the lithium microbattery of the present invention is also very dependent on formation of the cathode. Consideration of the microstructure of the cathode is equally as important as consideration of the composition. Typical of prior thin-film batteries is the use cathodes having a characteristic crystalline microstructure. The microstructure is dependent on substrate temperature, extent of the erosion of the target material due to prior sputtering and the pressure and composition of the process gas during deposition. At substrate temperatures of 400° C., vanadium oxide cathodes, for example, consist of crystalline platelets standing on edge while films deposited onto substrates at about 50° C. consist of clusters of crystalline fibrous bundles. With reference to FIG. 4, two distinct types of microstructure are shown for vanadium oxide films deposited by reactive sputtering of vanadium. When deposited from an eroded target, the cathode films 28 were characterized by a high density of micron-sized fibrous clusters in FIG. 4A of crystalline V 2 O 5 . When a fresh target surface is used and the flow rate is increased to about 20 sccm, the microstructure of the cathode 28 has the smooth microstructure shown in FIG. 4B. The advantage achieved with the amorphous structure over the crystalline structure is that at least three times more lithium ions can be inserted into cathode 28 having such amorphous structure, thus resulting in a lithium cell of much higher capacity.
As the sputtering target, e.g. vanadium, ages, the microstructure of the films deposited with higher flow rates gradually evolves to that of the films having fibrous clusters characteristic of deposition at the lower flow rates. This change in the films is evident by a decrease in sputtered target voltage (at constant power) and as much as a 30% decrease in deposition rate.
Lithium cells fabricated with crystalline or amorphous vanadium oxide cathodes had open circuit voltages of 3.6 to 3.7 volts. However, compared with amorphous cathodes, the rates of discharge and charge that the cells with the crystalline cathodes could sustain without excessive polarization are significantly lower, usually less than 3 microAmps per square centimeter. This probably results from poor transport across the interface between the electrolyte 26 and the cathode 28 since the electrolyte 26 does not conformably coat the fibrous clusters of the crystalline cathode 28 but rather covers just the top portion, resulting in a relatively small contact area.
Lithium cells made according to the present invention having the lithium phosphorus oxynitride electrolyte 26 and the smooth amorphous cathode 28 may be discharged at rates of up to 3 milliAmps per square centimeter. With reference to FIG. 5, a set of charge-discharge curves for one cycle of such a cell is shown. The total charge passed through this cell between 3.64 volts and 1.5 volts is about 575 milliCoulombs. The capacity of the cell over this voltage range is 130 microAmp-hours per square centimeter with an energy density of 1.2×10 6 Joules per kilogram based on combined masses of the cathode, electrolyte and anode.
The greatly enhanced energy density achievable with thin-film batteries made according to the present invention may, with suitable scaling of process parameters, permit fabrication of high energy thin-film macrobatteries. For example, according to the present teachings, a 25-kWh thin-film lithium battery could be constructed by connecting in series approximately 46 large-area thin-film cells. Such a battery would have an average voltage of 165 volts, a weight of 67 kilograms, a volume of 36 liters, a specific energy of 370 Watt-hours per kilogram and an energy density of 690 Watt-hours per liter.
While there has been shown and described what is at present considered the preferred embodiment of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. | Described is a thin-film battery, especially a thin-film microbattery, and a method for making same having application as a backup or primary integrated power source for electronic devices. The battery includes a novel electrolyte which is electrochemically stable and does not react with the lithium anode and a novel vanadium oxide cathode Configured as a microbattery, the battery can be fabricated directly onto a semiconductor chip, onto the semiconductor die or onto any portion of the chip carrier. The battery can be fabricated to any specified size or shape to meet the requirements of a particular application. The battery is fabricated of solid state materials and is capable of operation between -15° C. and 150° C. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is the U.S. national phase of International Application No. PCT/EP2016/050606 filed Jan. 14, 2016, which claims priority of German Application No. 10 2015 100 727.4 filed Jan. 20, 2015, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a sample transfer device for reception of a sample, in particular of a sample to be processed and/or to be investigated microscopically, having a transfer rod that is configured for reception of a sample holder, the sample holder to be arranged in a chamber of the sample transfer device for the purpose of transferring the sample to a processing unit or analytical unit.
BACKGROUND OF THE INVENTION
[0003] Sample transfer devices of this kind are utilized in particular in electron microscopy. Samples to be investigated, which contain e.g. cells, enzymes, viruses, or lipid layers, are cryofixed, i.e. the water-containing sample is frozen very quickly to temperatures below −150° C., avoiding the formation of ice crystals. The biological structures can thereby be kept in their natural state. For example, a biological process can be halted at any desired point in time by cryofixation and can be investigated, for example, in a cryo-electron microscope and/or in a light microscope with corresponding sample cooling. Prior to the actual investigation, cryofixed samples can be subjected to further preparation steps in a manner known per se, for example processing using freeze-fracturing, freeze-etching, and/or coating techniques.
[0004] In order not to impair the quality of the frozen samples, it is very important that they be transferred in contamination-free, and optionally cooled, fashion between the processing devices or analytical devices that are being used. “Processing devices” or “processing units” may be understood, for example, as a cryofixation device, a freeze-fracture apparatus, a freeze-etching apparatus, or a coating apparatus, while “analytical devices” or “analytical units” are to be understood, for example, as a cryo-electron microscope or a cooled light microscope.
[0005] So-called sample transfer devices are used for the purpose of conveying or transferring a sample to a processing unit or analytical unit. One such sample transfer device is represented, for example, by the “Leica EM VCT100” vacuum cryotransfer system (manufacturer: Leica Microsystems), which is described in the brochure of the same name that is accessible via the link: http://www.leica-microsystems.com/fileadmin/downloads/Leica%20EM%20VCT100/Brochures/Leica_EM VCT100_Brochure_EN.pdf. This transfer system comprises a transfer rod for detachable mounting of a sample holder, the latter being arranged at the end of the transfer rod. If a very small frozen electron microscopy sample is present on the sample holder, the latter can be picked up by suitable displacement of the transfer rod and by connection to the sample holder, the sample then being arranged, by another (backward) displacement of the transfer rod, in a chamber of the transfer system for the purpose of transferring the sample to a processing unit or analytical unit. In the chamber, the sample is kept under inert gas or under high vacuum and, to the extent necessary, at the low temperature necessary for further cryo-processing or cryo-investigation. The transfer system attachment system is configured in such a way that a high-vacuum connection to the processing unit or analytical unit can thereby be created. The chamber or the sample holder is furthermore in communication with a coolant reservoir, usually a Dewar container, that can be filled with a coolant, typically liquid nitrogen. The sample holder, and the sample present thereon, are thereby cooled.
[0006] A plurality of different sample holders are available depending on the particular processing unit or analytical unit, and are depicted in the aforesaid brochure. After cryofixation of the sample, the latter is loaded into the vacuum transfer system with a suitable sample holder. Transfer to the downstream processing unit or analysis unit then occurs. The transfer is accomplished in a cooled state, so that the sample cannot incipiently or completely thaw and thus become unusable. Contamination, for example upon exposure of the sample to ambient air, is also to be avoided. Sample transfer devices, such as the above-described “Leica EM VCT100” vacuum cryotransfer system, comprise vacuum sliders or slide valves so that the sample can be introduced, for example under vacuum, into the corresponding processing device or analytical device. For example, a slide valve is arranged at the attachment point of the sample transfer device, and a further slide valve at the corresponding attachment point of the processing unit or analytical unit. After attachment of the sample transfer device to the processing unit or analytical unit with the respective slide valves closed, the cavity that is produced is evacuated in the manner of an air lock. The slide valves are then opened, and the sample is then transferred under vacuum to the processing unit or analytical unit. For this, the transfer rod can be displaced linearly and often also rotated around its axis.
[0007] It has been found that changes in the state of the sample during transfer can lead to damage to the sample, and thus misinterpretations or unusable results upon analysis, or can complicate subsequent processing steps or make them entirely impossible. Sample transfer is often accomplished in time-controlled fashion based on empirical values.
SUMMARY AND ADVANTAGES OF THE INVENTION
[0008] The object of the present invention is therefore to further decrease the probability of a sample-damaging change of state, and to detect such a change of state without a long delay.
[0009] To achieve this object, a sample transfer device according to the present invention is proposed. Advantageous embodiments are evident from the description below.
[0010] A sample transfer device according to the present invention comprises a chamber in which a sample holder can be arranged. An inert gas atmosphere, or a vacuum (high vacuum) usually exists in this chamber. Cryogenic temperatures usually exist in the chamber. According to the present invention, at least one measurement device for measuring a physical variable is arranged inside the sample transfer device.
[0011] The invention makes it possible to measure, and optionally also to monitor, physical variables, in particular those that influence a sample present in the chamber.
[0012] Physical variables that can be recited are, in particular, the temperature and the pressure in the chamber of the sample transfer device. Other variables are also conceivable, however, such as the chamber volume, the number of particles in the atmosphere of the chamber, the location and orientation of a sample that is located on a sample holder that in turn is connected to the transfer rod of the sample transfer device. Measurement of the physical variable of time, for example the duration of a transfer of the sample to a processing unit or analytical unit or between processing units and/or analytical units, also represents an important variable.
[0013] What is meant by a “measurement device” in the context of this Application is firstly only the sensor or probe that measures the relevant physical variable so that a corresponding signal (usually a voltage signal or current signal) is generated. It is only in a further sense, which is likewise intended to be encompassed, that a “measurement device” also means a circuit or electronic system that encompasses the aforesaid sensor or probe and generates a signal that can already be conditioned for subsequent further processing.
[0014] It is advantageous if a measurement device for measuring a pressure existing in the chamber is present in the interior of the sample transfer device. Pressure measurement devices are known per se; they encompass, for example, piezoresistive or piezoelectric pressure sensors, capacitive or inductive pressure sensors, etc. Suitable pressure sensors correspondingly exist in the vacuum sector, for example a thermal conductivity vacuum gauge or an ionization vacuum gauge.
[0015] It is furthermore advantageous if a measurement device for measuring a temperature existing in the chamber of the sample transfer device is present. The transfer rod is equipped with a corresponding gripper for reception of a sample holder. Via the transfer rod, the sample holder having the sample arranged thereon is transferred to or from a sample stage arranged in the chamber. The temperature measurement device can be connected, for example, to one of the aforesaid elements, preferably to the sample stage, if that element is thermally conductively connected to the sample holder and to the sample present thereon. For purposes of this Application, the arrangement of a measurement device on an element of this kind connected to the transfer rod of the sample transfer device is to be encompassed by an “arrangement inside the sample transfer device.” It is advantageous to measure the temperature of the sample stage by means of a temperature sensor that is arranged on the sample stage. The sample temperature can thereby be determined to a good approximation, since the sample stage and the sample holder having the sample are thermally conductively connected to one another. Temperature sensors are known per se. To be recited here are, in particular, NTC and PTC thermistors, whose resistance depends on temperature and which can therefore be used for temperature measurement. On the other hand there exist integrated semiconductor temperature sensors that supply a proportional current, a proportional voltage, or in general a temperature-dependent signal as a function of temperature. Other temperature sensors are also known.
[0016] Because previously known sample transfer devices do not possess their own system for measuring physical variables influencing the state of a sample, it was hitherto not possible to measure, for example, the sample temperature and the pressure after closure of the chamber of the sample transfer device. Only after the sample had been transferred into a subsequent processing unit or analytical unit could the sample again be brought into a defined state. A measurement of, for example, the sample temperature and the pressure could only be made in the corresponding processing device or analytical device. The history of the sample state during the transfer was unknown. With the present invention it is now possible to determine the state of the sample, based on the physical variables determining the sample state, by means of the at least one measurement device inside the sample transfer device.
[0017] The measurement of the at least one physical variable can be made before the actual transfer, during the transfer, and/or after the actual transfer. This also depends on whether the measurement devices present in the sample transfer device themselves have a supply of electricity. Be it noted that an independent supply of electricity is not obligatorily necessary. As a rule, the transfer occurs from a loading station to a processing unit, between two processing units, or between a processing unit and an analytical unit, or also between two analytical units, the aforesaid units each possessing a docking station onto which a sample transfer device can be attached. It is possible in principle to implement a supply of electricity to the at least one measurement device inside the sample transfer device via a docking station of this kind, and correspondingly also to perform the measurement and the transfer of measured values into the docking station only after docking, whereupon further processing of the measured values occurs.
[0018] In such a case the aforesaid physical variables, such as temperature and pressure, would be measured at the respective docking stations. In the uncoupled state, i.e. during a transfer, the electrical supply to the at least one measurement device would then be interrupted. The measured values absent during the transfer can then usefully be interpolated.
[0019] A sufficiently accurate description of the history of the sample state is thereby obtained respectively by way of measured values upon docking onto the aforesaid units (loading, processing, and analytical units), and during transfer (by interpolation). This allows identification of sample-damaging changes of state, which can be detected in particular immediately after docking onto one of the aforesaid units. Unusable results or misinterpretations upon subsequent analysis can thus be avoided, or sample states that are unsuitable for further processing can also be detected a priori.
[0020] It is furthermore advantageous if a time measurement device is present inside the sample transfer device. A time measurement device of this kind can, for example, be activated upon removal of the sample transfer device from a docking station and deactivated upon re-docking onto a docking station, so that what is measured as a measured variable is the transfer time. This transfer time can be conveyed and processed, for example, via the docking station of the respective unit. If this transfer time is, for example, greater than a permissible limit value, this can be an indication of a sample-damaging change of state. Alternatively or additionally (for verification) the history of further physical variables, such as temperature and pressure, can be employed in order to identify any sample damage.
[0021] Instead of an interpolation of measured values, it can also be useful and appropriate to measure the respective physical variables continuously, or at least at specific time intervals, during a transfer. A rechargeable battery, in particular, is arranged for this purpose, for example, inside the sample transfer device in order to supply electricity to the at least one measurement device. Other energy suppliers, such as primary batteries or a wireless energy transfer (inductive, capacitive delivery) are also conceivable and possible. A rechargeable battery has the advantage that it can be charged in simple fashion, for example via the docking station upon docking of the sample transfer device. When the rechargeable battery is arranged inside the sample transfer device, attention must be paid to adequate temperature- and/or pressure-insulated encapsulation. In order to avoid this, the rechargeable battery (or other energy supplier) can also be arranged outside, for example on the housing of, the sample transfer device, and can be connected to the at least one measurement device in the interior of the sample transfer device, for example, via corresponding pressure- and/or temperature-resistant connectors.
[0022] It is particularly advantageous if an electronic control system is present, which is operatively connected to the at least one measurement device in such a way that a measurement can be initiated by the relevant measurement device and/or measured values of the relevant measurement device can be received by the electronic control system. The necessary measurement processes, control processes, and other regulation processes can thereby be implemented via an integrated electronic control system. Like the rechargeable battery, the electronic control system can be arranged inside or outside the sample transfer device. The same statements as for the rechargeable battery thus apply here.
[0023] As already mentioned, sample transfer devices usually possess an attachment point to the respective docking stations of subsequent processing devices or analytical devices. It is advantageous if the corresponding attachment system of the sample transfer device comprises an interface by way of which the measured values of the at least one measurement device are transferred to the attached processing unit or analytical unit or to a docking station in communication therewith. It is furthermore advantageous if the at least one measurement device is supplied with electricity by way of this interface as soon as the sample transfer device is docked onto the relevant processing unit or analytical unit. The transferring of the measured values on the one hand, and the supplying of electricity on the other hand, can be effected and controlled in particular via an electronic control system that is present. Lastly, the electronic control system itself can also be exclusively or additionally supplied with electricity via the aforementioned interface.
[0024] If a rechargeable battery is present in or on the sample transfer device, it is advantageous to charge it via the interface by means of an external current source.
[0025] As explained, sample transfer devices comprise a transfer rod at the end of which a sample holder is detachably mounted. The location of the sample holder, and thus also of the sample, can be modified by linear motion of the transfer rod. The orientation of the sample holder, and thus of the sample, can often also be modified by rotating the transfer rod around its axis. The sample transfer device can also comprise, for the purpose of receiving a sample holder, a sample stage that is located at the end of the transfer rod. It is advantageous in this connection if the location of the sample stage or of the sample holder, and/or a corresponding motion (x) of the transfer rod, is detected, and/or if a corresponding rotation (α) of the transfer rod is detected, by means of a further measurement device. It can furthermore be useful to measure the location and orientation of the sample in three dimensions, or to derive them from measured values of the aforesaid measurement device. A history of the sample position during a transfer, or at least before and after a transfer, can thereby be created. The aforesaid measurement device can represent a location sensor and/or motion sensor that is arranged in the interior of the sample transfer device, in particular in the interior of the chamber thereof. Alternatively, it can be useful to measure a motion (x) and/or a rotation (a) by way of corresponding (known) sensors on the transfer rod outside the sample transfer device.
[0026] It can be advantageous if the aforesaid electronic control system generates a warning signal if a measured value of the at least one measurement device exceeds or falls below a predetermined limit value. For example, if the pressure in a vacuum chamber exceeds a maximum permissible limit value, a corresponding warning signal is generated and can be immediately transferred outward (for example, via radio) or can be transferred and displayed (acoustic and/or optical display) immediately upon docking of the sample transfer device onto a docking station. The same applies analogously, for example, to the measured value for the temperature, in particular for cryofixed samples. The same applies in turn to the measured value, explained above, for the duration of a transfer, which should be, for example, below a predefined limit value.
[0027] The invention further relates to a system having a sample transfer device according to the present invention that comprises an interface to a docking station of a processing unit or analytical unit, and having such a docking station. It is advantageous in this context if the interface of the sample transfer device possesses a contact, in particular an electrical contact, further in particular a resilient electrical contact, and if the docking station possesses a corresponding contact, in particular an electrical contact, in particular likewise a resilient electrical contact, those contacts being arranged and configured in such a way that upon a connection of the sample transfer device and the docking station, the aforesaid contacts enter into an operative connection with one another. It is then possible thereby, in particular, for the aforesaid measured values to be transferred to the docking station and/or to the associated processing unit or analytical unit. On the other hand, the at least one measurement device and/or electronic control system of the sample transfer device can be supplied with electricity via the mutually connected contacts.
[0028] Further embodiments and advantages of the system according to the present invention are evident analogously from the description of the sample transfer device according to the present invention.
[0029] Further advantages and embodiments of the invention are evident from the description of the appended drawings.
[0030] It is understood that the features recited above and those yet to be explained below are usable not only in the respective combination indicated but also in other combinations or in isolation, without departing from the scope of the present invention.
[0031] The invention is depicted schematically in the drawings on the basis of an exemplifying embodiment, and will be described below with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWING VIEWS
[0032] FIG. 1 is a schematic cross section through an embodiment of a sample transfer device according to the present invention;
[0033] FIG. 2 is a schematic perspective view of the sample transfer device of FIG. 1 and of a suitable docking station, in two different views ( FIGS. 2A and 2B );
[0034] FIG. 3 shows the sample transfer device and the docking station of FIG. 2 after docking; and
[0035] FIG. 4 shows a possible operative connection among a sample transfer device, docking station, a processing device, a control unit, and a display.
DETAILED DESCRIPTION OF THE INVENTION
[0036] FIG. 1 is a schematic cross section through a sample transfer device 10 . A slide valve 2 , with which a (vacuum) chamber 1 can be closed off, is arranged in a housing of sample transfer device 10 . Flange-mounted onto that chamber is a pressure measurement probe 3 constituting a pressure measurement device. This probe 3 , in the activated state, measures the pressure (p) in chamber 1 . Located in chamber 1 is a sample stage 5 that can be detachably mechanically connected to a sample holder for a sample. By means of a transfer rod 4 , a sample (not depicted) mounted on the sample holder can be linearly (x) displaced, i.e. can be conveyed into a processing unit or analytical unit when slide valve 2 is open. For transfer, for example, from a processing unit into an analytical unit, the sample is brought into the interior of chamber 1 by a corresponding motion of transfer rod 4 , and transferred from the processing unit to the analytical unit at a defined temperature and a defined pressure. Transfer rod 4 is rotatable (α) around its axis. Sample stage 5 is connected via a connecting element 6 to a reservoir vessel 7 . A coolant, typically liquid nitrogen, is present in reservoir vessel 7 . A temperature sensor 8 is present as a second measurement device on sample stage 5 . Said sensor, in the activated state, measures the temperature of sample stage 5 and thus of the sample holder connected thereto, including the sample. The measured values of pressure measurement device 3 and of temperature measurement device 8 are directed to an electronic control system 9 . Alternatively or additionally, the corresponding measurement leads of the measurement devices can also be guided outward through corresponding vacuum-tight connectors in the housing of the sample transfer device, in order to be further processed by an electronic control system located, for example, on the housing of the sample transfer device.
[0037] Sample transfer device 10 possesses an attachment system (end face of the housing) to a docking station 100 (see FIG. 2 ). The attachment system possesses an interface having an electrical contact 11 a . The attachment system furthermore possesses an opening through which a transfer of the sample out of chamber 1 into the corresponding processing unit or analytical unit can occur.
[0038] FIG. 2 shows sample transfer device 10 and a docking station 100 , which as a rule is fixedly connected to the relevant processing device or analytical device. In this exemplifying embodiment, data transfer of the measured values of pressure measurement device 3 and of temperature measurement device 8 , and electrical supply to the sample transfer device, are accomplished via the aforesaid interface, which comprises a resilient electrical contact 11 a on the sample transfer device side. A matching contact 11 b is present on docking station 100 . Sample transfer device 10 is connected in vacuum-tight fashion to docking station 100 via a mechanical positioning system (stop) 12 and an interlock 13 . In this state, spring contacts 11 a and 11 b are positioned in accurately fitted fashion with respect to one another. By way of the interface thereby produced (for example, including an RS-232 interface), electricity is supplied and the measurement devices in the sample transfer device are thus activated (in the present example, the sample transfer device does not have its own electricity supply). Temperature and pressure from the closed vacuum chamber 1 are continuously measured as physical variables, and transferred via the interface to one or more further devices as explained below. Electronic control system 9 can possess a time measurement device that is activated upon undocking and stopped upon re-docking. The transfer duration can thereby be measured. Further measured variables, for example the location and orientation of sample stage 5 or of transfer rod 4 , and the position of slide valve 2 , can additionally be sensed using sensors. Docking usually occurs with slide valve 2 closed, and with a slide valve (not depicted) in docking station 100 correspondingly closed. The resulting cavity is evacuated in the manner of an air lock. The slide valves are then opened, and transfer of the sample can be initiated.
[0039] FIG. 3 shows sample transfer device 10 in the docked state, i.e. mechanically and electrically connected to docking station 100 (and to the subsequent processing unit or analytical unit).
[0040] FIG. 4 shows the corresponding operative connection by way of which measured data of the measurement devices in the interior of sample transfer device 10 can be passed on to external devices. This is accomplished via the previously mentioned interface by way of which measured data can be conveyed to docking station 100 and from there to an attached processing device 200 and/or via a control unit 300 to a display 400 , for example a TFT screen. If the measured data of the corresponding measurement devices are outside permitted limits, this can be correspondingly indicated and evaluated as an indication of a sample-damaging change of state. Subsequent processing or analysis of the sample can then be omitted.
[0041] In the exemplifying embodiment depicted here, the measured data, especially for the pressure and the sample temperature, are acquired upon sample transfer, i.e. in the respectively docked state. In the decoupled state, i.e. during a transfer, the supply of electricity to the sample transfer device is interrupted, and electronic control system 9 as well as measurement devices 3 and 8 are thus deactivated. Electronic control system 9 and measurement devices 3 and 8 are activated after re-docking to the subsequent processing unit or analytical unit 200 has occurred (see FIG. 4 ), and before sample transfer. The current measured data, especially pressure and sample temperature, are acquired. Measured values absent during the transfer can easily be interpolated by the electronic control system. If continuous acquisition, or acquisition occurring over specific time intervals, of measured values during a transfer is necessary or useful, a supply of electricity to electronic control system 9 and to measurement devices 3 and 8 is necessary; this can be effected in simple fashion via a rechargeable battery that can respectively be charged in particular in the docked state.
[0042] The elements depicted in FIG. 4 —sample transfer device 10 , docking station 100 , processing unit 200 , control unit 300 , and display 400 —can also be configured differently. For example, control unit 300 can be integrated into processing unit 200 . Similarly, display 400 can be integrated into control unit 300 and/or into processing unit 200 . With regard to sample transfer device 10 , be it noted once again that electronic control system 9 explained in connection with FIG. 1 can also be arranged externally on the housing of sample transfer device 10 ; the same applies to any rechargeable battery that may be present and/or to any separate display that may be present. In this case the external control unit 300 and display 400 could be replaced by the electronic control system that is present on the housing of sample transfer device 10 and has a correspondingly embodied display, which usefully is likewise arranged on the housing of sample transfer device 10 . With an embodiment of this kind the state of a sample in sample transfer device 10 could be continuously and autonomously monitored, independently of docking onto a docking station 100 , by corresponding measurement, processing of the measured values, and display thereof.
LIST OF REFERENCE CHARACTERS
[0000]
1 Chamber
2 Slide valve
3 Pressure measurement device
4 Transfer rod
5 Sample stage
6 Connecting element
7 Reservoir vessel
8 Temperature measurement device
9 Electronic control system
10 Sample transfer device
11 a Contact
11 b Contact
12 Mechanical positioning system, stop
100 Docking station
200 Processing unit
300 Control unit
400 Display | The invention relates to a sample transfer device ( 10 ) for reception of a sample, having a transfer rod ( 4 ) that is configured for reception of a sample holder, the sample holder to be arranged in a chamber ( 1 ) of the sample transfer device ( 10 ) for the purpose of transferring the sample to a processing unit or analytical unit ( 200 ), at least one measurement device ( 3, 8 ) for measuring a physical variable being arranged inside the sample transfer device ( 10 ). | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of a knot hole beam, for instance a warp beam of a loom, for winding up threads, yarn or other filamentary material or the like, comprising a winding tube or cylinder possesssing at its periphery knot holes, each of the knot holes having an insertion bore serving for the insertion of a bundle of tied together thread or yarn ends and at least one knot arresting opening merging thereat and constructed narrower than the insertion bore.
With prior art knot hole beams, such as disclosed in Schweizerische Technische Zeitschrift, dated Mar. 10, 1949, page 161, and U.S. Pat. No. 785,386, there are proposed two knot arresting openings following the insertion bore which, viewed with respect to the insertion bore, extend in the peripheral direction of the winding tube or cylinder or axially parallel to the winding tube axis and merge with the insertion bore, respectively.
With the first-mentioned course of the knot arresting openings in the peripheral direction the bending strength of the winding tube and its moment of resistance against bending in a direction perpendicular to the axis of the winding tube are relatively markedly reduced. In the presence of more intense traction or tension forces, for instance caused by the warp threads of a loom, which threads are let- or wound-off the knot hole beam (warp beam) during operation, rupture of the winding tube or cylinder can result.
In the case of the second-mentioned course of the knot arresting openings axially parallel to the lengthwise axis of the winding tube, it is indeed so that the bending strength is less affected, however, during operation the knots inserted into the knot arresting opening can slide out relatively easy in the direction of the insertion bore.
SUMMARY OF THE INVENTION
Hence, it is a primary object of the present invention to provide a new and improved construction of knot hole beam, especially a warp beam for looms, which is not associated with the aforementioned drawbacks and limitations of the prior art proposals.
Another specific object of the present invention aims at improving the drawbacks of prior art constructions knot hole beams as related above.
Still a further significant object of the present invention provides a new and improved construction of warp beam for a loom which is relatively simple in construction and design, economical to manufacture, extremely reliable in operation, and not associated with the drawbacks and deficiencies of the prior art structures heretofore considered.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the knot hole beam of this development is manifested by the features that between the insertion bore of the knot arresting opening there is provided at least at one side of the knot hole edge an arresting projection for the inserted knot. This arresting projection protrudes in the direction of a line which is directed axially parallel to the lengthwise axis of the winding tube and which line extends through the center of the insertion bore. The arresting projection is situated closer to such axially parallel line than an outer peripheral portion of the knot arresting opening which is situated furthest from such axially parallel line. The inserted knot then can be particularly securely held in the associated knot arresting opening during operation and it can be drawn or pulled by the tension of the related threads by itself in the direction of the center of the knot arresting opening.
There are possible constructional manifestations with comparatively lesser inclined position of the knot arresting openings relative to the axially parallel or paraxial line, wherein the bending strength of the winding tube is only slightly reduced. In this regard compare the structure of FIG. 4 to that of FIG. 3.
The reason for the reduced weakening or attenuation of the moment of resistance with such type knot arresting openings resides in the fact that the course of the force lines and the taking-up of the bending forces due to the bending load as well as their continuous change in direction during operation, is handled more favorably owing to the rotation of the beam, as will be demonstrated by the description to follow.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a basic view of a knot hole beam constructed according to the teachings of the present invention;
FIG. 2 is an end view thereof;
FIGS. 3 and 4, show for comparative purposes, arrangements of knot holes of prior art knot hole beams; and
FIGS. 5 to 18 respectively show different exemplary embodiments constructed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, upon the winding tube or cylinder 2 of the warp beam for a loom, illustrated in FIG. 1, there is threaded an outer yarn or thread limiting or bounding disk 3 which is fixedly clamped by means of any suitable and therefore not further illustrated clamping device 4, for instance a clamping ring. At the other end of such winding tube or cylinder 2 there is threadably connected an inner boundary or limiting disk 5.
The winding tube or cylinder 2 or equivalent structure contains at its periphery a number of knot holes, which have been generally designated in their entirety, in FIGS. 1 and 2, by reference character 6.
In the knot holes 6 there are inserted the schematically illustrated bundle 8 of warp thread ends 9 and such are held therein. Each thread or yarn bundle 8 and the associated warp thread ends 9 are knotted together by a knot 11 schematically indicated in broken or dotted lines in FIG. 1. The lengthwise axis of the winding tube or cylinder 2 has been designated by reference character 12'.
As shown in FIG. 3, the knot hole 6a contains a substantially circular bore 7 (radius R) for the insertion of a knot 11 and the warp thread ends 9 of a respective thread bundle 8. At the top and bottom of FIG. 3, the insertion bore 7 continues in the form of two slots 13 and 14. The knot 11 inserted into the bore 7 can be shoved beneath one of such slots 13 and 14 and thus arrested against sliding out. With the indicated arrangement of the warp thread ends 9 or warp threads and the rotational direction, according to the arrow 15 (for loom operation=winding-off of the warp beam or let-off motion), or rotational direction according to arrow 15a (for warping operation=winding-up of the warp beam) the knot 11 is to be shoved beneath the arresting slot 13, and with the opposite arrangement the warp threads (in FIG. 2, incoming from below) are to be inserted into the slot 14. With the prior art embodiment of FIG. 3 the knot arresting slots 13 and 14 extend from the insertion bore 7 in the peripheral direction of the winding tube or cylinder 2 generally indicated by the axis 12'. The center M of the insertion bore 7 and the center N of the arresting location of the knot 11 in the arresting slot 13 are located along a connection line E' which, together with a line 12 which is parallel to the tube axis 12' and which so-called axially parallel line 12 extends through the center M, forms an angle F of 90°. The slot 14 is also correspondingly arranged.
During operation, the winding tube or cylinder 2 experiences a tension load or stress (bending load or stress) which is upwardly directed in FIGS. 1 and 2 and thus has exerted thereon a bending moment. The force lines 16 which arise from such tension stress in the material of the winding tube 2 have been shown in FIG. 3. These force lines 16 are markedly bunched or forced together at locations 17, 18 owing to the knot arresting slots 13, 14, so that at such locations load peaks 10 appear in the material of the winding tube 2 and can relatively easily lead to rupture of the winding tube 2.
With the heretofore known prior art embodiment of FIG. 4 the single knot arresting slot 13 extends from the insertion bore 7 in the direction of the axially parallel line 12 (angle between E and 12=0). The spacing (radius R) of the location 17 of maximum deflection of the force lines 16 is appreciably shorter than the corresponding spacing R' of the arrangement of FIG. 3. Therefore, the permissible bending moment is greater for the embodiment of FIG. 4 than that of FIG. 3.
With the embodiment of FIG. 5 the single knot arresting slot 13 again extends substantially parallel to the axially parallel line 12 (angle between E and 12=0). However, there are provided between the insertion bore 7 and the knot arresting slot 13 two arresting projections 21 which extend towards the axially parallel line 12, and to each side of the knot hole edge or flange there is located one such projection. These projections 21 are situated closer to the axially parallel line 12 than the outer peripheral portions 26 of the slot 13 which are furthest removed therefrom, so that there is prevented any sliding-out of the knot 11.
In the embodiment of FIG. 6 there are employed two oppositely situated, knot arresting slots 13 and 14 which are located at an inclination to the axis 12 (angle G between E and 12), and which slots at locations 26 are only guided up to the boundary lines 27 parallel to the axis 12. The force lines are thus not appreciably more strongly bunched or forced together at locations 26 than at locations 20. Owing to the mentioned inclined position, the knots 11 are drawn towards the slot ends during operation. With this embodiment there is provided at each arresting slot 13, 14 an arresting projection 21 only at the side of the flange or edge of the knot hole 6, each such arresting projection being situated closer to the axially parallel line 12 than the associated peripheral portion 26.
In the embodiment of FIG. 7 the inclined positioned slots 13 and 14 (angle G between E and 12) extend in a narrowed or tapered fashion, and specifically, in the reverse sense than with the arrangement of FIG. 5. The knots 11 are held by projection 21 and the inclined position against sliding-out.
With the embodiment of FIG.8 the slots 22 and 23 are flexed or bent as shown at locations 24 and 25, respectively. Slot 22 is flexed in the direction of the warp threads, the slots 23 opposite thereto. The latter should be employed in the case of a reverse thread arrangement.
With the embodiment of FIG. 9 there are provided, apart from the knot arresting slots 13 and 14, two further slots 13a and 14a respectively. By virtue of the foregoing there are present still further possibilities of displacing the inserted parts 11, 9, for instance for the case that the tension forces at the side of the warp threads extend more or less at an inclination to the axis 12.
FIG. 10 corresponds to the arrangement of FIG. 9, however here the knot 11 is inserted into the slot 13a.
With the embodiment of FIG. 11 there are provided only short recesses 22a and 23a corresponding approximately to the slots 22 and 23 of FIG. 8. The parts 11 and 9 are held by the projection 21 and the yarn or thread tension.
With the construction of FIG. 12 the single knot arresting slot 13 continues into a circular recess 31. To prevent sliding back of the knot 11 towards the right there are provided the projections 21, although the slot 13 extends parallel to the axis 12 (angle between E and 12=0).
In the arrangement of FIG. 13 there are provided two substantially circular-shaped knot arresting recesses 33, 34 which are disposed in the direction of the axially parallel line 12 (angle between E and 12=0). By means of the projections 21 it is possible to prevent sliding-out of the knob 11.
With the arrangement of FIG. 14 both of the inclined positioned arresting slots 13, 13a (angle G between E and 12) are arranged at the same side with respect to the axis 12 for the purpose of selection of the insertion of the knot 11.
With the embodiment of FIG. 15 the parallel arresting slot 13b (angle between E and 12=0) is provided at both sides of the flanges or edges of the knot hole with a number of projections 21 to prevent any sliding-out of the knot 11.
With the arrangement of FIG. 16 the slots 13 and 13a, which correspond to the arrangement of FIG. 14, are of tapered configuration, in order to prevent sliding-out of the knot 11 by means of the projections 21.
With the showing of FIG. 17 there is an arrangement having only a substantially circular, inclined positioned recess 13c (angle G between E and 12) for knot arresting purposes, whereas with the arrangement of FIG. 18 there is provided a parallel, but flexed or bent slot 22 (angle G between E and 12).
In all instances of the inventive constructions of the knot holes the angle G between the connection line E of the center M of the insertion bore 7 with the center N of the arresting location of the knot 11 and the axial parallel lines 12 deviates from 90°, preferably amounts to a value of 0° to approximately 30°. Of course, below the center N of the arresting location of the knot 11 there should be understood that there is provided an intermediate region towards the end of the arresting slot, in which there is positioned a fitting knot of the jointed together warp thread ends. Depending upon the size of the knot and the available warp thread material the center N may possess slight positional changes.
The invention can be employed in conjunction with any winding beam, in the first instance for the warp beam of a loom, but also for warp beams of warp knitting machines or other machines employed in finishing work, for instance dyeing plants or the like. Instead of working yarn or threads, there can be wound-up upon the beam also wires, glass fiber material or the like. The insertion bore 7 can be constructed, for instance, also to be many-cornered or many-sided, for instance hexagonal, or have other shapes. What has been indicated heretofore correspondingly is valid also for the arresting slots 13, 14 and so forth, to the extent that at least one arresting projection 21 is provided between the insertion bore and the knot arresting slot.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. | A knot hole beam, for instance a warp beam for looms, for winding-up yarns or the like, comprising a winding tube or cylinder provided at its periphery with knot holes, each knot hole possessing an insertion bore serving for the insertion of a bundle of tied together or knotted yarn or thread ends and at least one, therewith merging knot arresting opening of narrower shape than the insertion bore. Between the insertion bore and the knot arresting opening there is provided at least at one side of the knot hole edges an arresting projection for the inserted knot. Such arresting projection protrudes towards a line which is axially parallel to the lengthwise axis of the tube and extends through the center of the insertion bore. The arresting projection is situated closer to such axially parallel line than an outer peripheral portion of the knot arresting opening which is situated furthest therefrom. | 3 |
BACKGROUND OF THE INVENTION
The invention refers to a method for the transmission of preferably periodically repeated teletext data in a television signal wherein on the transmitter side, complementary data for a respective teletext page is transmitted in addition to the teletext basic data of conventionally constructed teletext pages, and wherein, on the receiver side, the teletext data is separated from the television signal, the data belonging to a particular teletext page is collected and the basic data and the complementary data of a desired teletext page are intermediately stored and processed in such a way that the characters allocated to the basic data are made to appear at those character positions where no complementary data is present, and that the characters allocated to the basic data working in conjunction with the complementary data are made to appear at those character positions where complementary data is present. Such a method is known from "Rundfunktechnische Mitteilungen", vol. 27 (1983), issue 3, pages 116 through 134. The invention also refers to a facility for carrying out the method.
With the conventional teletext system at present in use in Europe (with the exception of France), only the so-called "level 1" of the teletext standard WST (world system teletext) is made use of; the system possesses only a limited basic character set for texts and graphic representations. Special characters, fine textures or color hues cannot be reproduced using this "level 1" system. To avoid these shortcomings the WST standard provides, particularly in its expanded stages "level 2" and "level 3", for the transmission of complementary data in so-called pseudo rows (also called "ghost rows") which have addressable row numbers which are not used by the "level 1" but are kept unoccupied in the transmission format. Several rows with the same row number must be used, as required, for the transmission of the required quantity of complementary data as can be seen in FIG. 1 for row number #26 (cf. also the above-mentioned publication "Rundfunk-technische Mitteilungen").
As the teletext receiver does not receive any information concerning the number of pseudo rows transmitted in association with a particular teletext page (basic data), the decoder does riot "know" whether, which and, if applicable, how many pseudo rows have been broadcast for a teletext page. A correct evaluation can, therefore, only be performed if the desired teletext page and all associated pseudo rows are received in full. Moreover, additional storage capacity for every teletext page which is to be stored, for example, 4 kByte, must be kept permanently available in the decoder which cannot be used otherwise in case no pseudo rows are transmitted.
In view of this, it is the object of the invention to render possible an improved transmission or processing of complementary data with a method or a facility respectively of the aforementioned type while also guaranteeing complete compatibility with existing teletext receivers which work according to "level 1".
SUMMARY OF THE INVENTION
The above object generally is solved according to the invention by a method for the transmission of preferably periodically repeated teletext data in a television signal wherein on the transmitter side, complementary data for a respective teletext page is transmitted in addition to the teletext basic data of conventionally constructed teletext pages with the complementary data for a respective page of teletext being transmitted in the form of one or more associated complementary pages; and wherein, on the receiver side, the teletext data is separated from the television signal, the basic data and the complementary data belonging to a particular teletext page are collected, the complementary page(s) allocated to a desired teletext page is/are intermediately stored separately from the associated teletext page(s), and the basic data and the complementary data of a desired teletext page are processed in such a way that the characters allocated to the basic data are made to appear at those character positions where no complementary data is present, and that the characters allocated to the basic data working in conjunction with the complementary data are made to appear at those character positions where complementary data is present.
As a development of the invention, the complementary data for several or all teletext pages is transmitted in at least one complementary page. The number of complementary pages can, therefore, be advantageously reduced.
According to further advantageous arrangements and developments of the method according to the invention the complementary pages are structured in the format of conventional teletext pages; the complementary pages are provided with page numbers in the hexadecimal system; the page numbers of the complementary pages coded in the hexadecimal system are allocated to page numbers of the associated, conventional teletext pages according to a fixed scheme ordered in the decimal system and preferably selectable using a ten-key number keypad; the complementary data is transmitted in the Viewdata (Prestel) build-up code, and separate decoding is provided for the basic data and the complementary data on the receiver side; separate information about the number of complementary pages for each associated, conventional teletext page is transmitted; information is transmitted as to whether and, if applicable, how many complementary pages will have only page-specific complementary data for each complementary teletext page are contained in the teletext cycle; further, separate information about the number of rows used is transmitted in at least one complementary page; separate information is transmitted in the format of a complementary page; at least that complementary data which applies to several pages is transmitted with an increased error protection when compared with the basic data; the complementary data is transmitted with an error protection greater than that of the basic data; and/or the complementary data represents, at least partly, error protection data for the associated basic data which, on the receiver side, is used for correcting and, if necessary, for substituting associated, disturbed basic data.
The invention is more closely explained by means of the embodiment examples illustrated in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic representation of the known teletext WST standard;
FIG. 2 shows a schematic representation of the invention-type method according to a first embodiment example;
FIG. 3 shows a schematic representation of the invention-type method according to a second embodiment example; and
FIG. 4 shows a block circuit diagram of an embodiment of a circuit arrangement for carrying out the method according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Differently from the teletext WST standard (FIG. 1), so-called complementary pages are transmitted in addition to the usual teletext pages ("basic pages") and the complementary pages are, preferably, structured in the format of the teletext pages.
With the invention-type method according to a first embodiment example (FIG. 2), so-called complementary pages are transmitted in addition to the usual teletext pages ("basic pages") and the complementary pages are, preferably, structured in the format of the teletext pages.
With the invention-type method according to a second embodiment example (FIG. 3), complementary data for several or all teletext pages is transmitted in at least one complementary page.
As FIGS. 2 and 3 show, the complementary page(s) allocated to a certain teletext page contain the missing data ("complementary data") for a higher WSR level (for example, level 2/3).
In FIG. 3 the "level 1" page 100 with the subcode 0000 and the complementary pages 10A 0001 and 10A 0002 is specified as an example in the second embodiment example according to the invention. The first hexadecimal-numbered complementary page 10A 0001 contains a specially marked section containing complementary data which applies not only to the associated "level 1" page 100 0000 but also no other "level 1" pages--for example, the page 104 0001. Therefore, in this example, the complementary data for 104 0001 is composed of the specially marked section of page 10A 0001, which is not sent separately (again), and the associated complementary page 10E 0100.
The same applies for basic pages with page numbers from 200 onwards. For example, complementary page 10E is allocated to basic page; 104, complementary page 1E0 to basic page 109, and complementary page leg to basic page 199.
One essential feature of the invention lies in the fact that complementary data for pages of lower order is transmitted under page numbers of higher-order page numbers. With a known teletext transmission system ("TOP" system), information about each basic page in the cycle and its allocation to other pages is transmitted in a separate teletext page ("basic TOP table") in the form of a page, group, block classification. This classification is used here in order to differentiate between lower- and higher-order pages. Hereby, a precisely defined location (according to columns and rows) for each basic page is provided on the separate page (BT table).
Table I, shown below, specifies, for example, which hexadecimal complementary page numbers are allocated to the individual basic pages between 100 and 199. ##STR1##
The PT table is transmitted as another separate page ("pseudo-table" of PT) according to the same column and row allocation as in the BT table; the coding of this PT table is shown in Table II. The PT table contains, for each basic page (at the position of which there is a certain PT code), data concerning the number of complementary pages and additional information as to whether further complementary data is present in higher-order pages.
TABLE II______________________________________Number of Further complementary data Codecomplementary pages in higher-order pages PT______________________________________0 -- 01 -- 12 -- 23 -- 34 -- 45 -- 56 -- 67 -- 70 yes 81 yes 92 yes A3 yes B4 yes C5 yes D6 yes E7 yes F______________________________________
Table III, supra, shows the computation rule with which, in the case of multiple pages (i.e. basic page plus subpage(s)), the subcode of the complementary pages can be inferred from the subcode of the basic page and the number of complementary pages (Table II). For example, two complementary pages for basic page 0001 have the subcode 0101 and 0102. The subcode for the basic page represents an "expanded page number" so, for example, the subpages of the multiple page No. 120 possess the page numbers 120 0001, 120 0002, ... . The number components 0001, 0002 represent the subcodes.
TABLE III______________________________________ Number of Com-Basic com- plement.page plement. pagesubcode pages subcode Remark______________________________________0000 1 0000 basic page with 1 comp.0000 XX 0001 basic page with XX comp. 0002 . . 00XX0001 1 0100 1st subpage with 1 comp.00YY X YY01 YYnth subpage with XX comp. YY02 . . YYXX______________________________________
The following table, Table IV, shows a cycle according to the invention-type method ("higher level cycle") by means of an example.
TABLE IV__________________________________________________________________________ Code Complementary data from PT following comp. pages (com.)__________________________________________________________________________100 Block A 2 2 com. of 100 110 Group A1 1 1 com. of 110 111 Page A1-1 8 1 com. of 110 112 Page A1-2 9 1 com. of 110+1 com. of 112 120 Group A2 121 Page A2-1200 Block B 8 2 com. of 100 210 Group B1 9 2 com. of 100+1 com. of 210 211 Page B1-1 9 2 com. of 100+1 com. of 210+1 com. of 211 212 Page B1-2 3 3 com. of 212 220 Group B2 221 Page B2-1__________________________________________________________________________
In the cycle illustrated, several pages are combined to form a group and several groups to form a block. A code 1 from Table II indicates, for example, for page 110, that only one complementary page of page 110 and no other complementary pages of the higher-order page 100 are present. Page 111 with PT code 8, on the other hand, indicates that no own complementary pages exist but specially marked sections in the complementary page of page 110 must be taken into account.
On the receiver side (FIG. 4), basic data and complementary data are equally separated from the video signal in a separation stage 10 and assembled into individual teletext pages. Every teletext page is fed via the output line 11 to a grate circuit 30 which then feeds the teletext page fed to it via a reading line 31 to an intermediate memory 40 for the page if a control circuit 50, to be more thoroughly explained later, feeds a release signal to the gate circuit 30 via an output line 51. Moreover, the control circuit 50 effects, via a futher output line 52, an addressing of the intermediate page memory 40 for the read-in process. The read-out process of the intermediate page memory 40 is also performed under the control of the control circuit 50 via a third output line 53.
The page numbers for the teletext pages appearing on the line are fed from a page number decoupling circuit 20 to the control circuit 50 via a line 21. Herefor, the decoupling circuit 20 detects the number of each teletext page fed to it from line 11 via a branch connection 12. Further, the control circuit 50 is connected to the input 70 operated by the user. The desired page number is fed to the control circuit via a line 71. In case a separate page arrives with the page numbers of the basic pages (so-called "basic TOP table") or another separate page (PT table according to Table II) with the information as to whether specially marked sections with complementary data for lower-order pages are included and/or with the number of complementary pages for each corresponding basic page, which appear in the cycle of the teletext pages or, respectively, in a cycle section, then these separate pages are or the separate page concerned is automatically fed to the intermediate page memory 40. The data of these intermediately stored separate pages is transmitted via the data reading line 54 to the control circuit 50 which determines the page numbers and the associated quantity of complementary data for each page number and stores them in a page number memory 60 which is connected via a bidirectional bus 61 with the control circuit 50.
With the receiver-side facililty for carrying out the method according to the first embodiment example, it is now assumed that the user, for example, by operating the keyboard 70, has selected the page #100. The control circuit 50 determines the number and the page numbers of the complementary pages allocated to this chosen page. If, for example, the basic page #100 is supplemented by two complementary pages (FIG. 2), then these two complementary pages have the page number #10A with the subpages #0001 and 0002. By means of a clear, fixed relationship between the basic pages #100 through 899 and the associated complementary pages 10A through 1E9 (which, in the example under consideration, are numbered in hexadecimal form) the page numbers of the complementary pages can be easily calculated or determined by means of special tables. As soon as one of these pages appears in the cycle--the control circuit 50 is informed of this by the decoupling circuit 20--a release signal for the gate circuit 30 appears on the output line 51, whereupon the basic page #100, via line 31, is stored, for example, at storage location #1, complementary page 10A 0001 at storage location #2 and complementary page 10A 0002 at storage location #3 of the intermediate page memory 40. The addressing to the storage locations is performed, as already mentioned, under the control of the control circuit 50 via output line 52. After all three pages under consideration are read in, the control circuit 50 generates, via output line 53, a read-out command for storage location #1 whereupon the basic page #100 is read out, via a line 41, from the intermediate page memory 40 into a decoder for basic data 80. The basic data decoder 80 decodes the page #100 in a suitable manner and transfers the resulting data via line 91 to a processor 90. Apart from that, two read-out commands for storage locations #2 and #3 are provided by the control circuit 50 via output line 53 and the complementary pages 10A 0001 and 10A 0002 are read out successively via line 42 into a decoder for complementary data 81. The complementary data decoder 81 decodes the data of the complementary pages in a suitable manner and transfers the resulting data via line 92 to the processor 90 which presents the decoded data of all three pages together as a video signal with the components R, G, B, and S, for example, on the picture screen of a television receiver.
Let it be assumed that the facility on the receiver side is now so modified that it possesses the means for carrying out the method according to the second embodiment example. For the sake of simplicity, the same designations and references as in the foregoing will be used in the following. It is now assumed that the user, for example, by operating the keyboard 70, has selected the page #111. The control circuit 50 determines the number and the page numbers of the complementary pages allocated to this chosen page. If, for example, the basic page #111 is supplemented by complementary data from the higher-order page 110 (Table II), then this complementary page has the page number #11A. As soon as one of these pages appears in the cycle--the control circuit 50 is informed of this by the decoupling circuit 20--a release signal for the gate circuit 30 appears on the output line 51, whereupon the basic page #111, via line 31, is stored, for example, to storage location #1 and complementary page 11A at storage location #2 of the intermediate page memory 40. The addressing of the storage locations is performed, as already mentioned, under the control of the control circuit 50 via output line 52. After all the two pages under consideration are read in, the control circuit 50 generates, via output line 53, a read-out command for storage location #1 whereupon the basic page #111 is read out, via a line 41, from the intermediate page memory 40 into a decoder for basic data 80. The basic data decoder 80 decodes the page #111 in a suitable manner and transfers the resulting data via line 91 to a processor 90. Apart from that, a read-out command for storage location #2 is provided by the control circuit 50 via output line 53 and the complementary page 11A is read out via line 42 into the decoder for complementary data 81. The complementary data decoder 81 decodes the data in the specially marked section of the complementary page in a suitable manner and transfers the resulting data via line 92 to the processor 90 which presents the decoded data of all three pages together as a video signal with the components R, G, B, and S, for example, on the picture screen of a television receiver.
In a particular embodiment, the basic data decoder 80 consists of a teletext level 1 decoder and the decoder for the complementary data transmitted in a videotext build-up code from a videotext (BTX) decoder.
The control circuit 50 can also, according to the first embodiment example, after a user has selected page #100, automatically fill the remaining storage location #4 of the intermediate page memory 40 with a further page. The next following page number in the page number memory 60 is, for example, page #105. Apart from that, the control circuit 50 determines, for example, that no further complementary page is present for the basic page #105. The page #105 can, therefore, be temporarily stored in storage location #4 in the manner already described after its appearance in the teletext cycle.
By using the invention-type method according to the first embodiment example, the available intermediate page memory 40 can be utilized in an adaptive and, consequently, optimum way because only so many storage locations need to be reserved as actually is required for the presentation of any arbitrary page.
A further advantage of this method consists of the fact that missing rows in the complementary pages can be determined in a simple manner and spoiled rows can be fed to a suitable error correction circuit (not illustrated). The control circuit 50 "knows" from the page number memory 60 whether and, if applicable, how many complementary pages are present in the cycle. As all rows in a complementary page in a non-disturbed case are normally occupied, or with a not fully occupied complementary page a special end-of-data identifier can be provided in the last row, the searching and loading process for the intermediate page memory 40, with incomplete or missing complementary pages, can be correspondingly influenced in such a way that, gradually, a page with all complementary pages is completely and correctly temporarily stored.
The control circuit 50 can also, according to the second embodiment example and after the described user's selection of page #111, automatically fill the remaining two storage locations #3 and #4 of the intermediate page memory 40 with further pages. The next following page number in the page number memory 60 is, for example, page #112. Apart from that, the control circuit 50 determines, for example (Table IV), that the basic page #112 is supplemented by the complementary page #11C and the specially marked section of page 11A already loaded into storage location #2. The pages #112 and 110 can, therefore, be temporarily stored in locations #3 and #4 in the manner already described after their appearance in the teletext system and, upon being called up, be presented on the picture screen together with the general data from memory #2.
By using the invention-type method according to the second embodiment example, the available intermediate page memory 40 can be utilized in an optimum way because the complementary data in the specially marked sections apply to several basic pages and do not need to be reloaded every time.
An advantage of this method consists of the fact that the additional data capacity required for level 3 can be minimized. The complementary data cannot just be defined for one page but, on the contrary, also for higher-order pages (groups), a block or for the entire cycle. Therefore, for example, a new color table for the entire cycle, sports logos for the sports block, and equal headlines for news groups can be agreed. | In order to compatibly transmit teletext data in the form of special characters, fine textures and color hues at higher WST levels, complementary data in the form of one or more associated complementary pages are transmitted for each page of teletext by the broadcaster in addition to the basic teletext data of conventionally structured teletext pages (level 1). The complementary data for some or all teletext pages are transmitted preferably in at least one complementary page. In the receiver, the complementary page(s) associated with a selected teletext page are temporarily stored separately from the corresponding teletext page(s) and processed so that the characters associated with the basic data are displayed in those character positions where there is no complementary data present. The characters associated with the basic data in cooperation with the complementary data are displayed in those character positions where complementary data is present. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a striped dentifrice product and more particularly to a striped toothpaste or gel stored in a container wherein at least a portion of the sidewalls are transparent or translucent so that when viewed by the consumer through the sidewalls the dentifrice is unstriped but when dispensed, the dentifrice is surface striped, as if by magic, by a second dentifrice having a distinguishable color.
2. The Prior Art
Aesthetic effects have been acknowledged to play an important role in consumer acceptance of many products. In many cases ornamental effects have been used to distinguish particular products in the marketplace and identify products having particular distinct properties. In the dentifrice field, toothpastes and gels which have incorporated therein contrasting colored stripes are known. Such stripes provide an aesthetic effect which the consumer finds pleasing and promotes the use of the dentifrice, particularly by children. Although such products have met with consumer approval, it has been found desirable to market a dentifrice having a first color packaged and stored in a collapsible container having at least a transparent portion through which the dentifrice product stored within the container may be viewed wherein the striped effect of a second dentifrice of a different color appears magically upon the surface of the stored dentifrice as it is dispensed from the container.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided an aesthetically pleasing striped dentifrice. The stripe is created when there is dispensed from a container a first unstriped dentifrice which is contacted under pressure with a second dentifrice having a color distinguishable from the first, the second dentifrice being maintained in the container separately from the first dentifrice, the container having sidewalls at least a portion of which are transparent, through which the unstriped first dentifrice can be viewed by the user whereby the second dentifrice is deposited as a surface stripe on the first dentifrice when activated under pressure, the two dentifrices being simultaneously extruded from the container. The extrusion, as viewed by the user, magically creates a distinct striped effect on the second dentifrice, the color of the stripes being distinguishable from the first dentifrice.
The container used in the present invention before pressure is applied thereto appears to the consumer as containing an unstriped dentifrice. When pressure is applied to the container contents, there is unexpectedly extruded from the container, as if by magic, a striped ribbon of dentifrice which is presented to the consumer in a very appealing form. Dentifrice which is magically transformed from an unstriped to a striped form is a particularly appealing form of the product thereby promoting use of the product by consumers, especially children.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The term "transparent" as used herein means having the property of being visible and includes within its meaning bodies which are translucent as well as being visually clear.
The term "different color" includes within its meaning a color which is distinguishable from a first color either by shade, which is lighter or darker than the first color or is dissimilar or contrasting to the first color.
The compositions of the first and second dentifrices with which the transparent container of the present invention is filled are of substantially the same composition except for the fact that the dentifrices contain different colorants abrasive and thickener contents. It is within the scope of the present invention that the first dentifrice may not contain any colorant and may be translucent or visually clear. The colorants used to prepare the individual dentifrice components are pharmacologically and physiologically non-toxic when used in the suggested amounts. The colorants include both pigments an dyes. Pigments useful in the practice of the present invention include non-toxic, water insoluble inorganic pigments such as titanium dioxide and chromium oxide greens, ultramarine blues and pinks and ferric oxides as well as water insoluble dye lakes prepared by extending calcium or aluminum salts of FD&C dyes on alumina such as FD&C Green #1 lake, FD&C Blue #2 lake, FD&C R&D #30 lake and FD&C # Yellow 15 lake. The pigments have a particle size in the range of 5-1000 microns, preferably 250-500 microns. Dentifrices which contain pigments are referred to herein as "pastes".
Dyes used in the practice of the present invention are distributed uniformly throughout the dentifrice and are desirably food color additives presently certified under the Food Drug & Cosmetic Act for use in food and ingested drugs, including dyes such as FD&C Red No. 3 (sodium salt of tetraiodofluorescein), Food Red 17, disodium salt of 6-hydroxy-5-{(2-methoxy-5-methyl-4-sulphophenyl)azo}-2-naphthalenesulfonic acid, Food Yellow 13, sodium salt of a mixture of the mono and disulphonic acids of quinophtalone or 2-(2-quinolyl)indanedione, FD&C Yellow No. 5 (sodium salt of 4-p-sulfophenylazo-1-p-sulfophenyl-5-hydroxypyrazole-3 carboxylic acid), FD&C Yellow No. 6 (sodium salt of p-sulfophenylazo-B-naphtol-6-monosulfonate), FD&C Green No. 3 (disodium salt of 4-{[4-(N-ethyl-p-sulfobenzylamino)-phenyl]-(4-hydroxy-2-sulfoniumphenyl)-methylene}-[1-(N-ethyl-N-p-sulfobenzyl)--3,5-cyclohexadienimine], FD&C Blue No. 1 (disodium salt of dibenzyldiethyl-diaminotriphenylcarbinol trisulfonic acid anhydrite), FD&C Blue No. 2(sodium salt of disulfonic acid of indigotin) and mixtures thereof in various proportions. The concentration of the dye for the most effective result in the present invention is present in the dentifrice in an amount from about 0.05 percent to about 10 percent by weight with respect to the weight of the total composition and preferably present from about 0.1 percent to about 5 percent of the total weight of the composition. Dentifrices which contain dye colorants are referred to herein as "gels".
In the practice of the present invention it is preferred that when a colorant included in the first or base dentifrice packaged in the transparent container be a lake dye or pigment and that colorant included in the second striping dentifrice be a food color dye.
In the preparation of the first and second dentifrice components in accordance with the present invention there is utilized an orally acceptable vehicle, including a water-phase with humectant which is preferably glycerine or sorbitol or an alkylene glycol such as polyethylene glycol or propylene glycol, wherein the water is present typically in amount of about 5 to about 25% by weight and the glycerine, sorbitol and/or the alkylene glycol ingredients typically total about 20 to about 60% by weight of the dentifrice, more typically about 25 to about 50% by weight.
Both dentifrice components typically contain a natural or synthetic thickener or gelling agent in proportions of about 0.0 to about 5% by weight, preferably about 0.2 to about 1% by weight. These proportions of thickeners in the dentifrice compositions of the present invention are sufficient to form an extrudable, shape-retaining product which can be squeezed from a tube onto a toothbrush and will not fall between the bristles of the brush but rather, will substantially maintain its shape thereon. Suitable thickeners or gelling agents useful in the practice of the present invention include Irish moss, iota-carrageenan, gum tragacanth, starch, polyvinylpyrrolidone, hydroxyethylpropyl-cellulose, hydroxybutyl methyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl cellulose and carboxymethyl cellulose.
Polishing agents such as silica, calcined alumina, sodium bicarbonate, calcium carbonate, dicalcium phosphate and calcium pyrophosphate may be included in the dentifrice compositions used in the practice of the present invention. Visually clear dentifrice compositions are obtained by using polishing agents such as collodial silica, such as those sold under the trademark Toxosil 103 or alkali metal aluminosilicate complexes (that is, silica containing alumina combined in its matrix) which have refractive indices close to the refractive indices of gelling agent-liquid (including water and/or humectant) systems used in dentifrice compositions.
The polishing material is generally present in the gel or paste compositions in weight concentrations of about 3% to about 50% by weight.
Surfactants are used in the dentifrice compositions of the present invention to achieve increased prophylactic action and render the instant compositions more cosmetically acceptable. Suitable examples of surfactants include water-soluble salts of higher fatty acid monoglyceride monosulfates, such as the sodium salt of the monsulfated monoglyceride of hydrogenated coconut oil fatty acids, cocamidopropyl betaine, higher alkyl sulfates such as sodium lauryl sulfate, alkyl aryl sulfonates such as sodium dodecyl benzene sulfonate, higher alkyl sulfoacetates, sodium lauryl sulfoacetate, higher fatty acid esters of 1,2-dihydroxy propane sulfonate, and the substantially saturated higher aliphatic acyl amides of lower aliphatic amino carboxylic acid compounds, such as those having 12 to 16 carbons in the fatty acid, alkyl or acyl radicals, and the like. Examples of the last mentioned amides are N-lauroyl sarcosine, and the sodium, potassium, and ethanolamine salts of N-lauroyl, N-myristoyl, or N-palmitoyl sarcosine.
The anionic surfactants are typically present in the dentifrice compositions of the present invention in an amount of about 0.3 to about 5% by weight, preferably about 0.5 to about 2.0% by weight.
The dentifrice compositions of the present invention may also contain a source of fluoride ions as anticaries agent in amount sufficient to supply about 25 ppm to 2500 ppm of fluoride ions and include inorganic fluoride salts, such as soluble alkali metal salts, for example, sodium fluoride, potassium fluoride, sodium monofluorophosphate and mixtures thereof.
Typically, in the case of alkali metal fluorides, these salts are present in an amount up to about 2% by weight, based on the weight of the preparation, and preferably in the amount of about 0.05% to 1%.
In addition to fluoride compounds, there may also be included anticalculus agents such as pyrophosphate salts including dialkali or tetraalkali metal pyrophosphate salts such as Na 4 P 2 O 7 , K 4 P 2 O 7 , Na 2 K 2 P 2 O 7 , Na 2 H 2 P 2 O 7 and K 2 H 2 P 2 O 7 , long chain polyphosphates such as sodium hexametaphosphate and cyclic phosphates such as sodium trimetaphosphate which are included in the dentifrice composition at a concentration of about 1 to 5% by weight.
Sweeteners well known to the art, including natural and artificial sweeteners, may be used. The sweetener may be selected from a wide range of materials including naturally occurring water-soluble sweeteners and artificial water-soluble sweeteners. Artificial water-soluble sweeteners include but are not limited to, soluble saccharin salts, e.g., sodium or calcium saccharin salts and cyclamate salts. Naturally occurring water-soluble sweeteners include, but are not limited to sucrose, sugar alcohols, including sorbitol as 70% sorbitol solution, mannitol, xylitol, maltitol, hydrogenated starch hydrolysates and mixtures thereof. The sweetener is present in the dentifrice at a concentration of about 0.1 to about 5% by weight.
The dentifrice compositions of the present invention may contain a flavoring agent. The flavoring agent is incorporated in the dentifrice composition of the present invention at a concentration of about 0.1 to about 5.0% by weight and preferably about 0.5 to about 1.5% by weight. Flavoring agents which are used in the practice of the present invention include essential oils as well as various flavoring aldehydes, esters, alcohols and similar materials. Examples of the essential oils include oils of spearmint, peppermint, wintergreen, sassafras, clove, sage, eucalyptus, marjoram, cinnamon, lemon, lime, grapefruit and orange. Also useful are such chemicals as menthol, carvone and anethole. Of these, the most commonly employed are the oils of peppermint and spearmint.
Various other materials may be incorporated in the oral preparations of this invention such as antibacterial agents such as triclosan, chlorhexidiene, anionic polymeric carboxylates such as methyl vinyl etherl/maleic anhydride copolymers, desensitizers such as potassium nitrate, vitamins such as panthenol, retinyl palmitate, tocopherol acetate, herbs such as chamomilla recutita, mentha piperita, salvia officinalis, commiphora myrrha, whitening agents such as hydrogen peroxide and urea peroxide, preservatives, silicones, chlorophyll compounds and/or ammoniated materials such as urea, diammonium phosphate, and mixtures thereof. These adjuvants, when present, are incorporated in the dentifrice composition in amounts which do not substantially adversely affect the properties and characteristics desired.
The two dentifrice components of the present invention may be simultaneously dispensed in controlled quantities from a container, such as a pressurized container, pump or collapsible tube by applying pressure on the components which pressure is activated by the user. Containers suitable for such dispensing are known to the art, as for example, as disclosed in U.S. Pat. Nos. 4,687,663 and 4,487,663, the disclosures of which are incorporated herein by reference.
IN THE DRAWINGS
FIG. 1 is a an elevational view of one embodiment of the present invention in which is shown a collapsible tube having transparent sidewalls for dispensing the dual dentifrice components stored therein simultaneously in striped form.
FIG. 2 is a partial central sectional view of the collapsible tube containing the two dentifrice components to be dispensed simultaneously in striped form.
FIG. 3 is a sectional view of a portion of the collapsible tube in which the two portions of the dentifrice are extruded together as an attractive striped product.
Referring now to the embodiment of the invention as illustrated in FIGS. 1 to 3 of the drawings, a collapsible dispensing tube 10 having transparent sidewalls 10a is provided with a threaded head end 11 having a plurality of threads 12 for securing a cap 13 to the head of end of the tube 10 having a sloping forward end 14 and a discharge passageway or port 15.
The tube 10 is formed from a plastic material such as high density polyethylene or polypropylene having sufficiently thin sidewalls as to be capable of being repeatedly flexed to apply pressure to dispense the dentifrice components stored in the tube.
Positioned within the sloping forward end 14 of the tube 10 is a zone under the head end which extends from the threaded head end 11 back into the tube 10 to define first zone 16 which is concealed from view by the opaque skirt 18 of the sloping forward end 14.
The first zone 16 which is enclosed by the sloping forward end 14 and hidden from view by the opaque skirt 18 of the tube 10 is filled with striping gel 19 having a first color. The balance of the tube 10 is filled with a paste 20 of contrasting color and forms the body of the toothpaste to be striped upon compression of the sidewalls 10a of the tube 10, the gel 19 and paste 20 contacting each other in zone 16 along surfaces 22.
In order for the striping gel 19 contained within the zone 16 to be placed as stripes 23 on the extruded ribbon body of the paste 20, at least one and preferably a plurality of striping passages 24 is formed within the insert 25 positioned within the discharge passageway 15 of the head end 11, the insert 25 communicating between the discharge passageway 15 and the second zone 26 of the tube 10 where the paste 20 is stored. In order to produce a colored stripe of a particular width, the width of the striping port 24 must be no wider than the stripe produced. Slight spreading of this stripe may occur as the paste 20 leaves the tube port 15, the extent depending on such factors as, for example, paste viscosity and extrusion pressure. However, for good reproducibility and sharpness of stripe, only slight spreading is permissible. Therefore, the width of the striping port 24 must be the same as or slightly less then the width of the stripe 23 to be produced.
In operation, the tube 10 is filled with the dentifrice components to be dispensed in the form of a striped ribbon 29 by first charging into the tube 10, the dentifrice gel 19 which is to form the stripes. This material is charged into first zone 16 in a quantity such that it does not fill the container beyond the inlet 27 of the insert 24 and above the point 22 where the two different colored dentifrice materials will be in contact within the tube 10. The paste material which is to form the body 20 of the extruded striped ribbon 29 is then charged into the tube 10 to fill the balance of the tube space at least a portion which is visible to the user through the transparent sidewalls 10a. The volume ratio of striping gel 19 to base dentifrice paste 20 is generally in the range of 1:6 to 1:15 and preferably 1:9.
When pressure is applied to the sidewalls 10a of tube 10 to dispense the striped dentifrice ribbon 29, the paste 20 which forms the body of the striped dentifrice 29 is extruded out through the inlet 27 of the insert 25 leading to the discharge port 15 of the tube 10 through discharge passageway 12. At the same time, the pressure applied to the sidewalls 10a of the tube and thereby to the paste material 20 is also transmitted by the paste 20 longitudinally in a forward direction to the striping gel 19 packed in the zone 16 of the tube 10. As a consequence of this pressure, the striping gel 19 is forced through the striping port 24 onto the ribbon of paste material 20 passing through the discharge passageway 28 of the insert 25. In this manner, the striping gel 19 is made part of the paste ribbon 29, and both dentifrices emerge from the discharge port 15 of the tube 10 in the form of a striped ribbon 29 which appears to form magically as the unstriped paste viewed through the transparent sidewalls 10a of the tube 10 is dispensed.
The present invention is illustrated in terms of its preferred embodiments in the accompanying Example. All parts and percentages referred to in this specification and the appended claims are by weight example.
EXAMPLE
______________________________________ Gel Paste (Wt. %) (Wt. %)______________________________________Water 8.85 8.35Glycerin 10.0 10.0Carboxymethylcellulose 0.40 0.40Saccharin 0.30 0.30Polyethylene glycol 600 3.0 3.0Sorbitol 52.2 52.2Sodium fluoride 0.32 0.32Toxosil 103 18.0 18.0Zeodent 165 4.5 4.5Sodium lauryl sulfate 1.5 1.5Color (1% blue dye solution) 0.95 0.95Titanium dioxide -- 0.50______________________________________
In the preparation of the gel and paste compositions a vehicle solution of the glycerine, sorbitol, polyethylene glycol 600 and water was made and subjected to 28-30 lbs applied vacuum and a mixture of saccharin sodium fluoride and carboxymethylcellulose was added thereto. Subsequently, the dye or TiO 2 was blended with the vehicle. The mixture was degassed at 28-30 lbs applied vacuum over a 5 minute period. Then, the Toxosil 103, Zeodent 165 and sodium lauryl sulfate were added after preliminary degassing. The ingredients were mixed. After about 5 minutes mixing, with application of vacuum, the dentifrice preparation was considered to be complete and the gel and paste components were packed into tubes of the type illustrated in the FIGS. 1-2 of the drawing at a volume ratio of 1:9. Only the paste was viewable in the tube 10, the gel component being hidden from view by the opaque skirt 14 affixed to the top end of the tube.
After packaging, the dentifrice product was squeezed from a tube and was extruded as a distinctive striped ribbon product of continuous blue stripes extending the length of surface of the white dentifrice product which stripes appeared spontaneously as if by magic on the white toothpaste being extruded. | A method for forming a striped dentifrice wherein a first dentifrice which appears unstriped when stored in a container having sidewalls at least a portion of which is transparent, is transformed into a striped dentifrice upon extrusion from the container, which method comprises storing the first dentifrice in the container provided with discharge means and striping means within the discharge means, sequentially filling the container with a striping dentifrice having a color which distinguishes the striping dentifrice from the first dentifrice, the striping dentifrice being stored in an area of the container separate from the first dentifrice, followed by filling the container with the first dentifrice, applying pressure on the dentifrices to cause the striping dentifrice to be applied to the first dentifrice within the container area in which the second dentifrice is stored and be simultaneously extruded together from the container, so that upon extrusion, the extruded dentifrice appears to have been magically transformed into a striped body. | 0 |
BACKGROUND OF THE INVENTION
This invention was made in the course of, or under, a contract with the U.S. Energy Research and Development Administration.
This invention relates to the art of joining metal members to form high-strength joints. More particularly, it relates to a method of making a resistance weld and braze joint of compatible metals and a braze metal. The method is particularly useful for making high-strength joints between small tubular members and relatively large plate members, such as for heat exchanger tube connections, connections to liquified gas storage tanks in space vehicles, and vacuum valve connections. It is also useful to provide a means for replacement connections where a high-quality, high-strength metal connection is required.
Heretofore, small diameter tubes have been attached to heavy plate members in industry using resistance welding techniques because resistance welding is easy to control and monitor as a fast, reliable production method. However, connections that are made using conventional resistance welding often leave certain flaws, i.e., internal cervices and other defects that develop a point of stress concentration. Such defects are particularly troublesome where the connection is used under high pressure or high stress conditions or in corrosive environments.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved technique of obtaining high-quality, high-strength metal-to-metal joints to eliminate sources of stress concentration. It is also an object of the invention to provide a combined weld-braze method for making high-strength metal-to-metal connections that substantially reduce weld failures due to internal flaws.
In accordance with the present invention, it has been found that, by using a combined weld-braze technique, high-strength metal joints can be obtained between a first metal member and a second metal member. The first metal member is counterbored to dimensions that will provide an interference fit with a second metal member to be joined thereto. A compatible braze metal is disposed between the bottom of the counterbore and the end of the second metal member. The second member is then placed in position to mate in interference with the counterbore of the first member in a vacuum chamber of a welding apparatus. The chamber is evacuated, force is applied and resistance weld energy is then applied. During the motion of the members, they are resistance welded. Upon contact with the braze metal, the residual heat generated in the resistance weld melts the braze metal to concurrently braze the members as part of a continuous operation. Thus the weld energy is controlled so that the energy generated serves both to provide a combined resistance weld and braze joint between the members.
It has been found that this method of forming a metal joing is particularly useful for connecting metal tubes or metal tubes to steel plates. For example, stainless steel tubes can be joined to metal plates of the same metal using a braze alloy of a metal selected from gold, gold-copper alloy, or gold-nickel alloy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmental cross section of a typical weld-braze connection prior to joining and resistance welding.
FIG. 2 shows a fragmental cross section of the connection of FIG. 1 after completion of the resistance weld-braze.
FIG. 3 is a cross sectional schematic view of one type of apparatus, including a vacuum chamber and fixtures, for performing the resistance weld-braze of the present invention.
FIG. 4 is a graphic representation of electrode motion during the two phases of the resistance weld-braze.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In connection with the following description of the preferred embodiments, unless otherwise stated, the term "resistance weld" is intended to embrace and include the phrase "resistance weld-braze."
With reference now to the exemplary preferred embodiment shown in FIGS. 1 and 2, a connection is illustrated between a plate member 10 and a tubular member 12. The plate member 10 is counterbored 14 by conventional machining techniques to provide interference fit when joined or mated with the machined shoulder 16 of the tubular member 12. A suitable compatible braze metal 18 is disposed between the end of said shoulder 16 and the bottom of said counterbore 14, either in the form of a metal washer or a layer of braze plated onto the end of said shoulder. The foregoing components are then placed in a suitable apparatus, to be described hereinafter in connection with FIG. 3, to supply the energy for the joining and resistance welding steps.
The completed weld-braze connection is illustrated in FIG . 2, wherein the plate member 10 and the tubular member 12 are shown as a high-strength joint that includes a curved area of diffusion bond weld 20 between the walls of the counterbore 14 and the shoulder 16. In addition to the diffusion bond weld 20, there is a continuous layer of braze 22 bonding the end of the tubular member 12 to the bottom of the counterbore 14. This diffusion bond weld 20 and braze 22 combine to provide an unusually high-strength joint of exceptional quality.
It will be recognized by those skilled in the welding arts that a wide variety of resistance welding apparatus can be used to perform the weld-braze herein disclosed. However, for the purpose of illustration, one type of suitable apparatus is shown schematically in FIG. 3. This apparatus comprises a welding fixture with vacuum chamber, a suitable resistance welding power supply and a means for monitoring and controlling the welding parameters. Turning now to the welding apparatus of FIG. 3, a base 30 supports a work support fixture 28 and a bottom ram 32 within vacuum chamber walls 34. Vacuum seal in the lower portion of the welding apparatus is provided by lower O-ring seals 38 and inner O-ring seals 40. The workpiece to be welded, exemplified in this figure by plate member 10 and the tubular member 12 are disposed on the bottom ram 32 while surrounded by a suitable insulating support sleeve 23. A split electrode 24 that is machined to surround the tubular member 12 and rest on shoulder 16 is inserted over the tubular member 12 within the insulating sleeve 23. An upper ram 26, that is supported by the walls of the vacuum chamber 34 and sealed with upper O-rings 36, rests on the electrode 24 in order to provide a means of linear mechanical force to the workpieces 10 and 12. To provide for the efficient flow of welding current, upper ram 26, electrode 24, lower ram 32, and base 30 are constructed of a highly conductive metal, such as copper or a copper alloy. In addition, suitable means, not shown but represented by the force arrows 49 and 50, are provided to establish the mechanical energy required, to be used in combination with the electrical energy, for the resistance weld-braze. The electrical current for the resistance weld-braze is supplied by a conventional welding power supply 48 through a conductor 52 to the upper ram 26. A suitable monitor and control means 54 monitors and controls both the electrical and physical parameters of the welding operation. The electrical parameters monitored and controlled include such conventional items as weld current, voltage, and weld time. Physical parameters, that are required to perform the weld, include the pressure applied to the upper ram 26 and the motion of the electrode during welding. The latter parameter is measured by a transducer on the ram and an inline strain cell measures the applied force. In addition, a high quality weld requires an evacuated system. In the present system, evacuation is performed by a vacuum pump 42 and the vacuum that is established is continuously monitored by a cold cathode ionization gage 44 and a thermocouple gage 46.
In operation, the welding parameters are set for the particular metals to be joined in the above-described monitor and control means 54, and the shoulder 16 of tubular member 12 is positioned over the counterbore 14 of plate member 10 with the braze alloy disposed between the members as described in FIG. 1. The required pressure is applied to the rams 26 and 32 so that the shoulder 16 rests on the counterbore 14 during the initial cold setup and positioning. To facilitate the latter step, the shoulder 16 and counterbore 14 are preferably chamfered. The weld cycle is then started using the predetermined parameters. The weld cycle can best be illustrated with reference to FIG. 4 which shows an example of the electrode (ram) motion with respect to weld time. During the initial portion of the cycle, the weld bond forms progressively through the weld joint by metal upset induced by a combination of weld force and heat. The shoulder 16 seats in the counterbore 14 during the first portion of the cycle and improvement of the bond progresses across the weld interface during the second portion of the weld cycle, viz., after the shoulder 16 is seated in the counterbore 14. At this time, the weld force and heat melt the braze alloy and complete the brazing portion of the cycle. The resulting weld-braze joint has a continuous layer of braze alloy across the bottom with a curved diffusion-bonded interface along the side as shown in FIG. 2.
The metals being joined in the present illustrative embodiment are stainless steel with gold or gold alloy for the braze metal. For these materials, the weld-braze operation was completed in about one-half second and carried out in a vacuum of less than 20 microns. In joining stainless steel components, it has been found that braze metals of elemental gold, an alloy of gold with copper, or gold with nickel make a satisfactory braze. The braze metal may be in the form of a solid washer or piece or may be plated by conventional techniques to the area of the metal members being joined.
It will be apparent to those skilled in the art that different metals and braze alloys will require varying amounts of interference fit and differences in the weld-braze parameters. Also, that the weld-braze must be conducted in a vacuum or other special atmosphere. Hydrostatic tests of weld-braze of stainless steel performed in a vacuum using this technique indicate that an average weld strength of in excess of 150,000 psi can be obtained, whereas a conventional vacuum welded (resistance weld only) joint provided an average weld strength of only 80,000 psi. | High-strength metal joints are formed by a combined weld-braze technique. A hollow cylindrical metal member is forced into an undersized counterbore in another metal member with a suitable braze metal disposed along the bottom of the counterbore. Force and current applied to the members in an evacuated chamber results in the concurrent formation of the weld along the sides of the counterbore and a braze along the bottom of the counterbore in one continuous operation. | 1 |
BACKGROUND OF THE INVENTION
This invention relates generally to gas turbine engines and, more particularly, to apparatus for scavenging lubricating oil from the structure of a bearing during all operating conditions.
Gas turbine engines typically include a core engine having a compressor for compressing air entering the core engine, a combustor where fuel is mixed with the compressed air and then burned to create a high energy gas stream, and a first or high pressure turbine which extracts energy from the gas stream to drive the compressor. In aircraft turbofan engines, a second turbine or low pressure turbine located downstream from the high pressure turbine extracts more energy from the gas stream for driving a fan. The fan provides the main propulsive thrust generated by the engine.
Typically, a rotor shaft is supported within a non-rotating stator by bearings used in the turbine engine to accurately locate and rotatably mount the rotor with respect to the stator. The bearings are typically surrounded by oil sumps which contain lubricating oil which is sprayed onto the bearings. The bearing and sump are isolated from the hot gas path by a seal which prevents oil leakage from the sump and hot gas entry into the sump. The seal is a contact seal, typically a non-metallic brush seal or carbon seal. At low power points in the operation of the engine, lubricating oil tends to seep toward the seal. Any oil accumulation near the contact seal can cause coking or the creation of varnish on the seal surfaces, which can cause deterioration of seal performance.
BRIEF DESCRIPTION OF THE INVENTION
One embodiment of an apparatus for scavenging lubricating oil employs a runner comprising a generally cylindrical forward section and an aft generally frusto-conical section and a generally disk-shaped slinger integrally joined coaxially to the axially aft end of the runner. The runner also comprises a means for blocking oil flow in the forward direction along its outer surface, which in the first embodiment comprises a circumferential groove in the outer surface of said runner between said forward section and said aft section.
In another embodiment of the apparatus as described in the previous paragraph, the means for blocking flow of oil forward along the outer surface of said runner further comprises a radially stepped ring surface downstream of said contact surface.
In another embodiment an apparatus for scavenging lubricating oil comprises a generally cylindrical forward section a frusto-conical aft section tapered radially outwardly integral with a disk-shaped slinger and having means for blocking flow of oil forward along said runner comprising at least one separating wall extending radially outwardly from said frusto-conical aft section of said runner.
In yet another embodiment, an apparatus for scavenging lubricating oil, a means for blocking flow of oil forward along said runner comprises an abradable strip mounted on a generally cylindrical extension of a stationary seal holder oriented parallel to the rotor axis of rotation, for contacting at least one separating wall mounted on a tapered section of a runner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of a gas turbine engine incorporating an apparatus for scavenging lubricating oil;
FIG. 2 is a schematic, partial cross-sectional view of one embodiment of an apparatus for scavenging lubricating oil incorporating an integrated slinger/runner apparatus;
FIG. 3 is a schematic partial cross-sectional illustration of an alternative embodiment of an apparatus for scavenging lubricating oil incorporating an integrated slinger/runner;
FIG. 4 is a schematic, partial cross-sectional illustration of another alternative embodiment of an apparatus for scavenging lubricating oil incorporating an integrated slinger/runner; and
FIG. 5 is a schematic, partial cross-sectional illustration of yet another embodiment of an apparatus for scavenging lubricating oil incorporating an integrated slinger/runner.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 schematically illustrates a gas turbine engine 10 which includes a stationary engine stator structure and a rotor structure mounted for rotation around longitudinal axis 12 . As used herein “forward” refers to the upstream axial direction as shown by arrow 13 and “aft” refers to the downstream axial direction of air flow as shown by arrow 15 . The forward end of the rotor 20 is rotationally supported within stator 18 by forward bearing 14 . An oil sump 16 is defined about the forward bearing 14 , and the oil sump 16 is pressurized by air provided to cavity 24 .
FIG. 2 schematically illustrates a gas turbine bearing structure which includes one embodiment of an integrated slinger/runner. The stator 18 supports the rotor 20 via forward bearing 14 . Oil lubricating the forward bearing 14 within the oil sump 16 is supplied via conduit 17 . A sump seal 22 including generally annular contact brush seal 23 is located forward of the oil sump 16 to seal the forward end of the oil sump 16 . Pressurized air in the cavity 24 provides a positive air pressure on the exterior of the sump seal 22 . Runner 30 comprises a generally cylindrical axially forward section 31 concentric with the axis of rotation of the rotor 20 , having circumferential radially outer contact surface 46 axially aligned with sump seal 22 , and a frusto-conical aft section 36 having radially outwardly tapered exterior surface 34 . A circumferential groove 38 extends around the radially outer surface of runner 30 axially between radially outer contact surface 46 of axially forward section 31 and radially outwardly tapered exterior surface 34 of frusto-conical aft section 36 . Slinger 32 comprises a generally circular disk attached to the axially aft end of frusto-conical aft section 36 of runner 30 to form an integrated slinger/runner. Slinger 32 is generally axially aligned with a plurality of scavenge ports 44 in flow communication with the oil sump 16 .
The stationary seal support structure 26 supports generally annular contact brush seal 23 so that seal surface 33 is axially aligned with radially outer contact surface 46 of runner 30 . O-ring 27 seals the oil sump 16 to block oil leakage out of the sump and hot gas leakage into the oil sump 16 . Stationary seal support structure 26 includes cylindrical sleeve 40 extending axially aftward from stationary seal support structure 26 . The radially exterior surface of cylindrical sleeve 40 is formed as a circumferential scavenger groove 42 and the radially inner circumference thereof includes a circumferential, helical groove 28 in contact with the axially aft portion of radially outer contact surface 46 .
During rotational operation of the gas turbine engine 10 , lubricating oil is provided to the bearing by spray mechanisms (not shown) and pressurized air is applied to the exterior of sump seal 22 to prevent oil leakage through the sump seal 22 . The oil sump 16 is vented to maintain proper pressure balance between the volume exterior to the oil sump 16 and the interior of the oil sump 16 . In scavenging lubricating oil during normal operation of the gas turbine engine, oil from the forward bearing 14 driven by centrifugal force is pumped away from sump seal 22 by rotation of the runner 30 in contact with circumferential, helical groove 28 and radially outwardly tapered exterior surface 34 , and by slinger 32 toward the scavenge ports 44 . During slow speed operation or when engine rotation is stopped, oil is drawn by gravity forwardly along the surface of runner 30 toward the sump seal 22 , but contact of oil with sump seal 22 is blocked by circumferential groove 38 , which scavenges oil from radially outwardly tapered exterior surface 34 and directs it toward the bottom of the runner 30 where it is drawn by gravity along slinger 32 toward the bottom scavenge port. Circumferential scavenger groove 42 collects oil from the stationary seal support structure 26 at all operating conditions and channels it to scavenge ports 44 at the bottom of the annular structure.
FIG. 3 is a detailed partial cross-sectional schematic illustration of a modification of an integrated slinger/runner as shown in FIG. 2 . The axially forward section 31 of runner 30 includes a radially outer contact surface 47 . Axially downstream of radially outer contact surface 47 , runner 30 incorporates a radially outwardly stepped ring 49 having stepped surface 48 projecting radially outwardly from the radially outer contact surface 47 . Circumferential groove 38 is disposed axially between radially outwardly stepped ring 49 and radially outwardly tapered exterior surface 34 which tapers radially outwardly at an angle between one and four degrees in the downstream direction. Stepped surface 48 projects radially outwardly by a height sufficient to block oil from overflowing circumferential groove 38 axially upstream and has a surface roughness sufficient to inhibit flow of oil axially upstream. Slinger 32 is integral with the frusto-conical aft section 36 of runner 30 . During engine operation radially outwardly stepped ring 49 is in contact with circumferential, helical groove 28 and inhibits seepage of oil toward sump seal 22 during rotation of runner 30 . Radially outwardly stepped ring 49 also enhances the effectiveness of circumferential, helical groove 28 in scavenging oil at slow rotation or during static conditions to block oil flow forward along the surface of the runner 30 .
FIG. 4 schematically illustrates another embodiment of an apparatus for scavenging lubricating oil including an integrated slinger/runner. Generally cylindrical runner 100 includes a generally cylindrical forward section 101 and a frusto-conical aft section 102 from which at least one separating wall projects generally radially and perpendicular to the axis of rotation. Although two separating walls 104 , 106 are shown, it will be understood that a single separating wall or several may be used depending on material properties of the wall or walls and expected operating conditions of the engine. The stationary contact seal holder 110 supports the contact seal 112 which engages radially exterior surface 114 of generally cylindrical runner 100 . At its axially aft end, frusto-conical aft section 102 is integrally connected to disk-shaped slinger 108 . The stationary contact seal holder 110 further includes a cylindrical axial extension 116 extending axially aft of the contact seal 112 and supports stationary abradable strip 118 on its radially inner frusto-conical surface 128 . The cylindrical axial extension 116 is tapered radially outwardly relative to the axis of rotation in the downstream direction to align stationary abradable strip 118 with the radially outer tips of separating walls 104 , 106 . The stationary contact seal holder 110 is secured to the stationary seal support structure 120 by welding or other suitably robust technique and O-ring seal 122 prevents air leakage into the sump and oil leakage from the sump. A circumferential groove 124 extends circumferentially around cylindrical axial member 126 . The tapered structure of the frusto-conical aft section 102 in FIG. 4 with multiple separating walls 104 , 106 extends generally perpendicularly to the stationary abradable strip 118 , to pump the oil away from the contact seal 112 to block oil flow axially upstream toward contact seal 112 during engine operation. Most of the oil will be contained inside the sump due to the disc pump action of the disk-shaped slinger 108 . Any residual oil or oil/air mixture passing over the disk-shaped slinger 108 will be centrifuged back to a scavenge port (not shown in FIG. 4 ). The oil/air mixture reaching the tapered surface of stationary abradable strip 118 by whatever mechanism, will contact one of the separating walls 104 , 106 and drain back into the sump. The proposed design provides a near zero oil leakage possibility even under the situations with little or zero pressurization margins. Circumferential groove 124 scavenges oil from the stationary seal support structure 120 at all operating conditions to direct it toward the bottom of the support structure and oil scavenge ports.
FIG. 5 is yet another preferred embodiment of an apparatus for scavenging lubricating oil including an integrated slinger/runner. Runner 200 includes generally cylindrical forward section 201 and a frusto-conical aft section 202 having separating walls 204 , 206 integral with disk-shaped slinger 208 . The FIG. 5 design requires at least one separating wall. Stationary contact seal holder 210 supports contact seal 212 axially aligned to engage radially exterior contact surface 214 of generally cylindrical forward section 201 . Stationary contact seal holder 210 also includes axially extending hollow cylindrical member 216 with abradable strip 218 , covering the radially inner cylindrical surface 226 of axially extending hollow cylindrical member 216 . The axially extending hollow cylindrical member 216 and abradable strip 218 extend axially generally parallel to the rotor axis of rotation. The radial heights of the respective separating walls 204 , 206 are selected to maintain contact with the mating abradable strip 218 . The stationary contact seal holder 210 is attached to stationary seal support structure 220 , and O-ring seal 222 prevents leakage between stationary contact seal holder 210 and stationary seal support structure 220 . An axially extending cylindrical member 228 extends axially from stationary seal support structure 220 and provides circumferential groove 224 to scavenge oil from the support structure during all operating conditions.
The design of FIG. 5 is preferred in turbine engine designs requiring accommodation of significant axial movement of the rotor components relative to stator components due to thermal cycles, rotational speed variation or other operating conditions. The axially extending hollow cylindrical member 216 accommodates axial movement of frusto-conical aft section 202 and separating walls 204 and 206 relative to abradable strip 218 without exerting significant axial load on separating walls 204 , 206 or allowing loss of contact between separating walls 204 , 206 and abradable strip 218 . Air flow which leaks through the contact seal 212 will be diffused in the first separating wall cavity 230 , and the swirling will create resistance to air leakage into the sump. Additionally, use of the abradable strip 218 allows the tighter radial clearances to further reduce the air leakage into the sump. The proposed features eliminate oil collection near the contact seal 212 , and at the same time minimize air flow into the sump. This design also provides the additional feature of continuing to resist lubricating oil leakage even if the primary contact seal 212 failed or the pressurization margins were lost.
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 modification within the spirit and scope of the claims. | An apparatus for scavenging lubricating oil comprises an integrated slinger/runner rotatable with the turbine engine rotor discourages oil seepage out of an oil sump of a forward bearing for a gas turbine engine during all operating conditions of the gas turbine engine from idle to take-off speeds and during static non-operation. The apparatus includes a runner comprising an axially forward section and a frusto-conical aft section, and a slinger joined coaxially integrally to the aft frusto-conical aft section. The apparatus includes a means for blocking flow of oil from the frusto-conical aft section toward the axially forward section. | 5 |
FIELD OF THE INVENTION
This invention relates to attachments for chair arms in general and particularly to trays attachable to chair arms for holding food and beverages.
BACKGROUND OF THE INVENTION
Today's movie theaters and stadiums, as examples of the premier public entertainment attractions, draw a great number of viewers throughout the year. Many spectators find that the pleasure of viewing the event is enhanced by consuming refreshments, such as candy, popcorn, hot dogs, beer and soft drinks of various sizes. These refreshments often comprise a major source of revenue for the event and indeed, the concession sales may be the difference between profit and loss for the event. Often the viewer becomes tired of holding the drinks in his or her hands and may find holding the soft drink cumbersome when also trying to eat popcorn, candy or hot dogs. Thus, the drink must be set down on the floor where it may be accidentally kicked over and spilled, or on the chair arm where it may easily be knocked over. The juggling of these refreshments is often frustrating and may detract from the enjoyment of the film or event, as well as being a potential hazard to adjoining viewers. Additionally, if the viewer had a easy or handy way of carrying more concession goods back to his or her seat, it is believed that the viewer might well buy more goods. It is foreseeable that if the viewer had a tray to carry back food items and drinks, that the viewer might buy sufficient items to fill up the tray.
Because of these conditions, it is desirable to have available to the spectator a tray on which to carry food and beverages and on which the beverage would be held securely and not precariously balanced on the tray. It is also desirable that the tray be secured in some manner to the seat so that it can not easily be knocked over and so that it is available to the spectator and his or her companion. Preferably, the tray is fashioned to accommodate the placement of various sizes of beverage containers, with the tray stable and relatively immobile once mounted to the chair so as to prevent dislodgement by inadvertent movement.
OBJECTS OF THE INVENTION
The principle objects of the present invention are: to provide such a tray which receives various sizes of standard cups; to provide such a tray which maintains various sizes of beverage cups within easy grasp of the chair occupant while maintaining stability of the cup; to provide such a tray which is easily and inexpensively manufactured for disposal or reuse; to provide such a tray which is mountable to a receptacle in a chair arm; to provide such a tray which can be mounted in various positions, such as left, right and center on the chair arm for use by occupants of adjoining seats; to provide such a tray which can sit level on a surface, such as a concession stand counter for loading with food and beverages; to provide such a tray which can be stacked for storage and/or reuse; and to provide such a tray which is relatively simple to use, economical to manufacture and particularly well-adapted for the proposed usages thereof.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings, wherein are set forth by way of illustration and example certain embodiments of this invention.
SUMMARY OF THE INVENTION
A concession tray is comprised of a planar tray having an upper surface for retaining concession goods and including at least one downwardly depending receptacle for receiving and holding a cup. The receptacle extends perpendicularly to the tray and outwardly of the bottom surface of the tray and forms a truncated, conical boss. Preferably, there are three downwardly depending receptacles, left, center and right mounted, which frictionally and rotatably mount into a seat arm cup receptacle in left, center and right positions. The truncated conical cup receiver boss is receivable in a matching configuration conical socket in the chair arm and is joined thereto by a friction fit for toolless ease of connection and disconnection.
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a concession tray embodying the present invention.
FIG. 2 is a bottom plan view of the concession tray.
FIG. 3 is a side elevational view showing two concession trays in stacked relationship.
FIG. 4 is a top plan view showing the concession tray attached to a chair armrest and in a left swung position.
FIG. 5 is a top plan view showing the concession tray in a right swung relationship and attached to a chair arm.
FIG. 6 is a top plan view showing the concession tray attached to a chair arm and in a center position.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Referring to the drawing in more detail:
The reference numeral 1, FIG. 1, generally indicates a concession tray embodying the present invention. The concession tray 1 is generally planar and has an upper surface 2 and a lower surface 3. Referring to FIG. 1, the concession tray 1 has a left or rearward side 5 and a forward side 6 with opposite margins 7 and 8. The tray 1 is generally rectangular in overall configuration with the rearward side 5 forming a radius curve, and corners 9 and 10 between the margins 7 and 8 and the forward side 6 are also radiused curves.
In the example shown in FIGS. 1 and 2, the concession tray 7 has an indented portion 12 with a generally centrally located area 13 providing a logo space. Logo space 13 is generally the area in which a concession operator, stadium operator or a theater operator could place the company's logo by molding, embossing or vinyl or paper overlay. At the corners 9 and 10 are respectively positioned circular indentations 15 and 16 for receiving cups containing beverages. The circular indentations 15 and 16 are shallow, such as 1/8 inch deep relative to the indented portion 12. An upraised rim 17 extends about the periphery of the indented portion 12 and aids in keeping goods from sliding off of the tray 1 or liquid spillage from running off the tray.
Generally at the rearward side 5 are a plurality of downwardly depending cup receptacles extending perpendicularly to the tray 1 and outwardly of the lower surface 3. In the illustrated example, there are three such cup receptacles, including a left receptacle 20, center receptacle 21 and right receptacle 22. Each cup receptacle 20, 21, and 22 defines three coaxial bores: an inner or first bore 24, defined by a first wall 25, a middle bore 27 defined by a middle wall 28, and an outer bore 30 defined by an outer wall 31. The coincidental axis of the bores 24, 27 and 30 passes through the center of the bores and is generally vertical. A closed bottom 33 terminates the inner bore 24 and annular rings 34 and 35 form steps or shoulders between the inner bore 24 and the middle bore 27 and between the middle bore 27 and the outer bore 30. The outer bore 30 has a diameter that is greater than the diameter of the middle bore 27 which in turn has a diameter that is greater than the diameter of the first or inner bore 24, as is evident from the drawings. Thus, various sizes of cups can be accommodated by the cup receptacles 20, 21 and 22. The walls 25, 28 and 31 extend perpendicularly and downwardly of the tray 1 and form truncated, frusto-conical bosses.
In order to increase the surface area of contact between the received cup and either the inner bore 24, middle bore 27 and outer bore 30, the surfaces of the bores 24, 27 and 30 slope toward the center axis. Preferably, the preferred angle of slope is in the range of two to three degrees from the vertical. The desired angle of the slope generally corresponds to an angle of slope prevalent in many beverage cups used in theaters, stadia and the like. It is envisioned that this angle could be varied to conform to a particular slope of subject cups sold at a particular establishment, depending upon the circumstances.
At the top of the receptacles 20, 21, and 22, and at the rearward side 5 of the concession tray 1, is generally a raised land area 37 which extends into the rim 17 at the margins 7 and 8. A wall 38 separates the raised land area from the indented portion 12 and a downturned flange 39 forms the margin at the rearward side 5. On the underside or lower surface 3, FIG. 2, strengthening webs 41 extend between the receptacles 20, 21 and 22 and various other structural elements. Additionally, strengthening rings extend about the receptacles 20, 21 and 22 at the confluence of the wall 31 with the upper surface 3.
Spaced from the rearward side 5 and extending downwardly from adjacently the forward side 6 is a conical leg 44, which in the illustrated example, is molded into the concession tray 1 and is formed with a wall 45 forming an inner conical cavity 46. The cavity 46 accords to the external configuration of the leg 44 for vertical stacking receipt and nesting, FIG. 3. Preferably, the length of the leg 44 is the same as the length of the cup receptacles 20, 21 and 22 so that the concession tray 1 maintains a level relationship when placed on a concession stand counter and loaded with food and beverages.
The concession tray 1 is constructed to nest with like concession trays 1, FIG. 3. Therein, the receptacles 20, 21 and 22 and leg 44 of each tray 1 nest inside the matching cavity formed by the receptacles 20 through 22 and leg 44 of the underlying concession tray 1.
The concession tray is designed to be used in conjunction with a cupholder armrest, such as disclosed in the inventor's U.S. Pat. No. 4,863,134, issued Sep. 5, 1989 and incorporated herein by reference. U.S. Pat. No. 4,863,134 discloses a combination cupholder and armrest for attachment to a chair arm, such as a chair arm in a stadium or theater seat. The cupholder portion of the armrest includes a cupholder receptacle which defines at least two coaxial bores, having two different diameters sized to receive a plurality of different sized cups. The cup receptacles 20, 21 and 22 of the concession tray 1 are sized and matched for snug frictional yet rotatable toolless fit and removal in the cupholder end of the armrest. As disclosed above, the instant concession tray 1 includes the three cupholders 20, 21 and 22, any one of which may fit into the cupholder of the armrest disclosed in the Young et al. ,134 patent. Thus, the concession tray 1 may be positioned so that the left receptacle 20 is mounted in the cupholder end of the armrest 50 so that it is swung to the left of the armrest, FIG. 4. Alternatively, the right cup receptacle 22 can be mounted in the armrest 50 so that it is swung to the right of the armrest 50 and over the lap of the person seated in the right side seat. Finally, the concession tray 1 may be center mounted with the center receptacle mounted in the armrest 50 so that it is substantially equally positioned between side by side seated companions.
It is foreseen that the material of construction may be either plastic with a tray of injection molded plastic or that the tray can be formed of pressed paper stock. In those situations, as in a movie theater, where trays may be collected and washed, it may be preferable to use plastic material. In those situations where it is not practicable to wash and reuse the tray 1, it may be more economical to construct the tray of molded paper stock. Particularly in sports stadia, it may be preferable to form the tray 1 of molded paper stock of low mass and light weight in order to reduce the opportunity for the tray 1 being thrown by unruly fans.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown except insofar as such forms and limitations are included in the following claims. | A concession tray for carrying beverages and snacks from a concession sales area to a stadium or theater seat. The concession tray is made of light, inexpensive paper stock or plastic and includes downwardly extending cup receptacles sized for receipt into a chair arm cupholder. The cup receptacles have multiple internal shoulders for receiving and holding different sizes of cups. The tray cup receptacles preferably include left, center and right receptacles for left, center or right mounting on the chair arm. A downwardly depending leg spaced from the cup receptacles maintains the tray level for loading with concession food and beverages. The tray is configured for stacking with the cup receptacles and legs fitting into matching cavities. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a conversion circuit that may be used in a preamplifier circuit. In particular, the present invention relates to conversion of single-ended to differential signals.
BACKGROUND OF THE INVENTION
[0002] Preamplifier circuits are typically low-noise amplifiers incorporated into disk drives for the purpose of amplifying signals used in the disk drive. In meeting the low-noise requirements of the preamplifier, a single-ended signal may be converted to differential signals in an attempt to reduce or eliminate crosstalk. A single-ended signal is typically a signal defined by one voltage or current. A differential signal is typically a signal defined by the difference of two currents. Crosstalk is an undesired transfer of signals between system components.
[0003] Any noise on the current supply is typically noticeable on a single-ended signal since the current supply affects the single-ended signal without compensation. However, noise on the supply is typically not noticeable on a signal produced by differential signals since the noise is reflected on both the differential signals and therefore the resulting difference of the two signals is preserved. Accordingly, converting a single-ended signal to differential signals typically reduces crosstalk.
[0004] In a preamplifier circuit, there is typically some amplification (often referred to as gain) to a single-ended signal prior to the conversion of the single-ended signal to the differential signals. This single-ended gain may affect the current supply which in turn may affect the single-ended signal through the supply, causing crosstalk. Accordingly, this crosstalk typically limits the single-ended signals that could be passed through the single-ended to differential converter. Due to cross-talk, the current amplification of the preamplifier typically shuts off at high frequencies, since the impedance may become too high for the circuit to carry the high frequency signals.
[0005] Additionally, there may also be some crosstalk due to a current flowing into ground, commonly referred to as ground current. When current flows into ground, the ground may fluctuate. Since signals are measured in relation to ground, fluctuation of ground may cause fluctuation in the signal, causing cross-talk.
[0006] It would be desirable to have a single-ended to differential converter that prevents cross-talk. It would also be desirable for the single-ended to differential converter to process signals at higher frequencies. The present invention addresses such needs.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a conversion circuit that converts a single-ended signal to differential signals. According to an embodiment of the present invention, crosstalk is avoided by insuring that none of the transistors in the conversion circuit are directly connected to ground. By not having a transistor directly connected to ground, ground current is avoided and crosstalk associated with ground current is eliminated.
[0008] Additionally, according to an embodiment of the present invention, the conversion circuit also amplifies the signal by a gain greater than one. Accordingly, the amplification which is typically performed prior to the signal being input into the conversion circuit may now be performed in the conversion circuit. By shifting the amplification from occurring prior to the conversion circuit to occurring in the conversion circuit, crosstalk between the current source and the single-ended input signal may also be avoided.
[0009] A system according to an embodiment of the present invention for converting a single-ended signal to differential signals is presented. The system comprises a first device configured to convert a current to voltage. The system also includes a second device coupled to the first device. The system further includes a third device coupled to the first device and second device, wherein not one of the first, second, and third device is directly connected to ground and wherein the current is amplified by a gain of more than two.
[0010] A method according to an embodiment of the present invention for converting a single-ended signal to differential signals is also presented. The method comprises converting a current to voltage; inputting a differential voltage to a differential pair; and amplifying the current by a gain of more than two, wherein approximately no ground current is produced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a schematic diagram of a conventional single-ended to differential signal conversion circuit.
[0012] [0012]FIG. 2 is a schematic diagram of a single-ended to differential signal conversion circuit according to an embodiment of the present invention.
[0013] [0013]FIG. 3 is another schematic diagram of the single-ended to differential signal conversion circuit according to an embodiment of the present invention.
[0014] [0014]FIG. 4 is a flow diagram of a method according to an embodiment of the present invention of converting a single-ended signal to differential signals.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] The following description is presented to enable one of ordinary skill in the art to make and to use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiments will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein.
[0016] [0016]FIG. 1 is a schematic diagram of an example of a conventional single-ended to differential signal conversion circuit. The conversion circuit 100 is shown to include a current supply 102 , a volt meter 104 , a ground 110 , and transistors 106 and 108 . An example of the type of transistors 106 and 108 is an enhanced n-type metal oxide semiconductor (NMOS). Enhanced NMOS transistors typically have positive threshold voltages.
[0017] An amplified single-ended current is input into the conversion circuit 100 . The input current (I in ) meets impedance caused by transistor 106 . This impedance converts (I in ) into voltage. Transistor 108 sees this voltage as a positive voltage and transistor 106 receives this voltage as a negative voltage. By definition, the amplification of the current through transistor 106 has a gain of one and the current gain of transistor 108 matches the gain of transistor 106 . Accordingly, the current gain of transistor 108 is also one. Differential signals I outP 112 a and I outN 112 b are of the same magnitude. Accordingly, the differential circuit 100 has a current gain of two.
[0018] Since the single-ended signal is typically amplified prior to entering the differential circuit 100 , there may be some crosstalk caused by the single-ended gain affecting the current supply. The effect on the current supply may in turn affect the signal-ended signal. This crosstalk may shut off the current gain of conversion circuit 100 at high frequencies, such as at a frequency of approximately 160 MHz.
[0019] There may also be some crosstalk in the conventional conversion circuit 100 due to a ground current flowing from transistor 108 to ground 110 . As the signal is sent to ground 110 , the ground 110 may fluctuate. Since all the signals are measured in terms of ground 110 , all the signals also fluctuate, causing cross talk.
[0020] It would be desirable to have a single-ended to differential signal conversion circuit that avoids such crosstalk. It would also be desirable for the single-ended to differential converter to process signals at higher frequencies. The present invention addresses such needs.
[0021] [0021]FIG. 2 is a schematic diagram of a single-ended to differential signal conversion circuit according to an embodiment of the present invention. FIG. 2 shows an example of a single-ended to differential signal conversion circuit 200 which is shown to include three transistors 214 , 208 , 206 , a voltage source 204 , a current supply 202 , and a ground 210 . An example of the type of transistors 214 , 208 , 206 to be used are NMOS transistors. The primary function of transistors 208 and 206 are to act as a differential pair. Voltage is input into transistors 208 and 206 and the voltage is converted into current to result in an output of a differential current.
[0022] A current is input (I in ) into the conversion circuit 200 . An example of I in is approximately 0.5 milli-Amps with a signal of approximately 10 micro-Amps or about 1% of I in . Transistor 214 converts I in to voltage. An example of the voltage converted by transistor 214 is approximately 10 milli-Volts at the input. There is a voltage drop at transistor 214 such that the voltage at the common transistor source 216 a , 216 b , and 216 c is ½ V, where V is the input voltage. For example, ½ V at the common transistor source 216 a , 216 b , and 216 c may be 5 milli-Volts. The current flows through transistor 214 , adds to the current at transistor 208 , and flows through source 216 c of transistor 206 to flow out at I out P 212 b . An example of I out P is approximately two milli-Amps of direct current (DC), with approximately forty micro-Amps of signal current.
[0023] To produce I out N , I in flows through transistor 214 , adds to the current at transistor 208 , and is sent out of the circuit as I out N 212 a . I out N and I out P are compliments of each other, accordingly, an example of I out N is approximately two milli-Amps of DC, with approximately forty micro-Amps of signal current. An example of the current at the current source 202 is approximately five milli-Amps. Note that in this conversion circuit 200 , there is no current flowing into ground 210 since no device is directly connected to ground. Accordingly, there is no cross-talk from a ground current.
[0024] A further advantage of this conversion circuit 200 is that a significant current gain may be accomplished. For example, a current gain of eight may be accomplished by setting the ratio of the drain 218 b of transistor 208 and the drain 218 a of transistor 214 at a ratio of four to one, and the ratio of drain 218 c of transistor 206 to the drain 218 a of transistor 214 at a ratio of four to one. If drain 218 b and drain 218 c are set four times higher than drain 218 a , then a current gain of four I occurs at transistor 208 and a current gain of four I occur at transistor 206 , providing a total current gain of eight for the differential signal.
[0025] Accordingly, the single ended signal does not need to be amplified prior to being input into the conversion circuit 200 . Since the single ended signal is not an amplified signal, there is no gain prior to the conversion circuit 200 to cause cross-talk with the current source. Additionally, the conversion circuit 200 is able to process signals at higher frequencies, such as frequencies up to approximately 200 MHz.
[0026] [0026]FIG. 3 is a schematic diagram of an example of the single-ended to differential signal conversion circuit 200 as incorporated into a larger conversion circuit, according to an embodiment of the present invention. An input voltage, such as 2 volts, is input into a conversion circuit 300 . A transistor 302 converts the voltage into current. Transistor 304 passes the alternating current (AC) and transistor 303 balances the direct current (DC) component. An example of the current output of transistor 302 is approximately 1000 micro-Amps DC and 10 micro-Amps AC.
[0027] The current passes through transistor 304 which protects transistor 214 from capacitance. Transistor 304 acts as a cascode device which causes transistor 214 to see very low impedance and low gain. Cascode devices may be common gate transistors that pass current from source to drain with a voltage gain. The cascode devices may provide a low gain and low capacitance at the drains of transistors, such as transistor 214 , an protect the drains of the transistors from an output voltage. Details of the workings of cascode devices are well known in the art. Once the current is input into circuit 200 , events occur as described in conjunction with FIG. 2.
[0028] As previously described, a current is input (I in ) into the conversion circuit 200 . Transistor 214 converts I in to voltage. There is a voltage drop at transistor 214 such that the voltage at the common transistor source 216 a , 216 b , and 216 c is ½ V, where V is the input voltage. The current flows through transistor 214 , adds to the current at transistor 208 , and flows through source 216 c of transistor 206 to flow out at I out P 212 b . To produce I out N , I in flows through transistor 214 , adds to the current at transistor 208 , and is sent out of the circuit as I out N 212 a.
[0029] A transistor 306 may be coupled with circuit 200 in order to balance transistor 214 . The current gain at transistor 206 is the negative of the current gain of transistor 214 . For example, if transistor 214 has a current gain of 1, then transistor 306 has a current gain of −1. When a circuit is balanced, the current on transistors 208 and 206 are equal and the input current operates at the same average current as the current source 202 .
[0030] Transistors 308 - 312 may also be coupled with circuit 200 to protect the output voltage from capacitance for transistors 208 , 206 , and 214 , respectively, by acting as cascode devices which causes transistors 208 , 206 , and 214 to see very low impedance and low gain. Additionally, transistors 308 - 310 may be used as multiplexing switches that can be used to tristate the output into an off state. The use of such a cascode device as a tristate device is also well known in the art.
[0031] [0031]FIG. 4 is a flow diagram of a method according to an embodiment of the present invention for converting a single-ended signal to differential signals. An initial current is converted to a voltage (step 400 ). This voltage is used to create a differential voltage, and the differential voltage is input into a differential pair to produce differential currents (step 402 ). The initial current is also amplified by a gain of more than two, wherein approximately no ground current is produced (step 404 ).
[0032] Although the present invention has been described in accordance with the embodiment shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiment and these variations would be within the spirit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. | The present invention relates to a conversion circuit that converts a single-ended signal to differential signals. According to an embodiment of the present invention, crosstalk is avoided by insuring that none of the transistors in the conversion circuit are directly connected to ground. By not having a transistor directly connected to ground, ground current is avoided and crosstalk associated with ground current is eliminated. | 7 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to umbrellas and parasols that have a center support shaft from which extends a plurality of ribs secured to the top of the shaft. A plurality of deployment ribs are secured to the ribs and slide up and down the shaft extending the ribs which are covered by a water-repellent material.
2. Description of the Prior Art
Prior art devices of this type have been well developed over the years with the basic structural configuration of the umbrella well-defined and well understood by those skilled in the art.
SUMMARY OF THE INVENTION
An umbrella that is configured in the shape of a sport's related headgear when opened, having a conventional umbrella canopy with the addition of a brim canopy extending outwardly from a portion of the lower perimeter of the canopy. Specialized support ribs define the brim canopy without interfering with the working of the conventional portion of the umbrella deployment structure.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan view of a single support rib system and deployment mechanism in open position;
FIG. 2 is a side plan view of a single support rib system and deployment mechanism in closed position;
FIG. 3 is an enlarged view of a portion of the support rib system;
FIG. 4 is a perspective view of the umbrella fully deployed; and
FIG. 5 is a top plan view of the umbrella showing the support rib system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 4 of the drawings, a sport's cap umbrella 10 can be seen having a shaft 11 with a crown 13 on one end and a handle grip 14 on the other end. An umbrella canopy 15 extends from the crown on a generally arcuate configuration downwardly around the shaft 11 being spaced in relation thereto at the canopy's perimeter 16. A brim canopy 15A extends outwardly from a portion of the canopy's perimeter 16 on a horizontal plane defining a curved brim best seen in FIGS. 4 and 5 of the drawings.
Referring now to FIGS. 1 and 2 of the drawings, a portion of the shaft 11 can be seen with the crown 13 having a plurality of canopy support ribs 17 pivotally secured therefrom in spaced radial pattern. Each of the ribs are cross sectionally U-shaped for strength and flexibility which is common in the umbrella support technology. A plurality of deployment arms 18 are pivotally extended from a spool-type sleeve 19 movably positioned on the shaft 11. Each of the deployment arms 18 are pivotally secured at their free end to a respective canopy support rib 17 at a point defined by approximately one-third their overall length from said crown 13. A spring urged lock arm 20 is located in the spool sleeve 19 and is designed to engage an aperture in the shaft 11 adjacent the crown 13 so as to lock the spool sleeve to the shaft at the desired position extending the canopy support ribs 17 into an open position as seen in FIG. 1 of the drawings.
It will be apparent to those skilled in the art that the structure thus described is that of a conventional umbrella and that further elaboration on such a well known structure is not required.
An annular ring 21 is movably positioned on the shaft 11 between the spool-type sleeve 19 and the crown 13. A plurality of brim canopy deployment support arms 22 are pivotally secured to and extend from said annular ring 21. A rib connector fitting 23 best seen in FIGS. 1, 2 and 3 of the drawings has a cross sectionally U-shaped body member 24 with an angularly disposed end portion 25 with enlarged apertured sections defined at end portion 25 and midway along the body member 24.
Each rib connector fitting 23 is pivotally secured to each of the free ends of all of the brim canopy deployment support arms 22 and a select group of the canopy support ribs 17 adjacent the brim canopy deployment support arms 22. This relationship is best seen in FIGS. 1 and 5 of the drawings at A.
A plurality of brim ribs 26 are secured to the free ends of the rib connector fitting 23. At least two of the brim ribs 26 are of a length less than that of the other of said brim ribs. The brim ribs 26 support and define the brim canopy 15A as seen in FIGS. 4 and 5 of the drawings.
In operation, material M is fitted over the ribs 17 as in a conventional umbrella. The brim canopy 15A has a separate material covering which is attached to the bottom perimeter edge of said material M.
Referring now to FIG. 2 of the drawings, the sport's cap umbrella is shown in a closed configuration with the brim ribs 23 pivoted upwardly in a generally vertical alignment parallel the shaft 11. The spool-type sleeve 19 is advanced upwardly on the shaft 11 towards the crown 13. A spring 27 is positioned on the shaft between the annular ring 21 and the sleeve 19 and is moved up the shaft as the sleeve 19 is advanced. The spring 27 eventually engages the annular ring 21 moving the same upwardly which in turn extends the brim ribs 26 pivoting at A. The spring 27 compresses slightly against the annular ring 21 as the lock arm 20 registers in the aperture in the shaft effectively locking the spool type sleeve 19 on the shaft 11 near the crown 13. The canopy support ribs 17 are now in open position as best seen in FIGS. 1, 4 and 5 of the drawings with the material M stretched tightly across the ribs. The canopy brim 15 is also extended as hereinbefore described.
To close the sport's cap umbrella, the above outlined procedure is reversed; unlocking the spool-type sleeve 19 and moving the same downwardly the shaft, collapsing the deployment arms and canopy ribs, etc.
Thus it will be seen that a new and useful improvement to an umbrella has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention. | An umbrella configured in the shape of a cap, having a main canopy from which extends about a portion of the lower perimeter a brim canopy when in opened and extended position. The brim canopy folds upwardly against the main canopy as it is closed. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is Divisional of U.S. patent application Ser. No. 11/648,694 filed Jan. 3, 2007, which is a Divisional of U.S. patent application Ser. No. 11/230,572 filed Sep. 21, 2005, which in turn is a Continuation of International Application No. PCT/JP2004/003928, filed Mar. 23, 2004, which claims priority to Japanese Patent Application No. 2003-83329, filed Mar. 25, 2003. The contents of the aforementioned applications are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an exposure apparatus that exposes a pattern on a substrate via a projection optical system and a liquid in a state wherein the liquid is filled in at least one part of a space between the projection optical system and the substrate; and a device fabrication method that uses this exposure apparatus.
[0004] 2. Description of Related Art
[0005] Semiconductor devices and liquid crystal devices are fabricated by a so-called photolithography technique, wherein a pattern formed on a mask is transferred onto a photosensitive substrate.
[0006] An exposure apparatus used by this photolithographic process includes a mask stage that supports the mask, and a substrate stage that supports the substrate, and transfers the pattern of the mask onto the substrate via a projection optical system while successively moving the mask stage and the substrate stage. There has been demand in recent years for higher resolution projection optical systems in order to handle the much higher levels of integration of device patterns. As the exposure wavelength to be used is shorter, the resolution of the projection optical system becomes higher. As the numerical aperture of the projection optical system is larger, the resolution of the projection optical system becomes higher. Consequently, the exposure wavelength used in exposure apparatuses has shortened year by year, and the numerical aperture of projection optical systems has also increased. Furthermore, the currently mainstream exposure wavelength is the 248 nm KrF excimer laser, but an even shorter wavelength 193 nm ArF excimer laser is also being commercialized. In addition, as well as resolution, the depth of focus (DOF) is also important when performing an exposure. The following equations respectively express the resolution R and the depth of focus δ.
[0000] R=k 1 .λ/NA (1)
[0000] δ=± k 2 ·λ/NA 2 (2)
[0007] Therein, λ is the exposure wavelength, NA is the numerical aperture of the projection optical system, and k 1 and k 2 are the process coefficients. Equations (1) and (2) teach that, when the exposure wavelength λ is shortened and the numerical aperture NA is increased in order to enhance the resolution R, then the depth of focus δ is narrowed.
[0008] If the depth of focus δ becomes excessively narrow, then it will become difficult to align the surface of the substrate with the image plane of the projection optical system, and there will be a risk of insufficient margin during exposure operation. Accordingly, a liquid immersion method has been proposed, as disclosed in, for example, PCT International Publication WO99/49504, as a method to substantially shorten the exposure wavelength and increase the depth of focus. This liquid immersion method fills a liquid, such as water or an organic solvent, between the lower surface of the projection optical system and the surface of the substrate, thus taking advantage of the fact that the wavelength of the exposure light in a liquid is 1/n that of in air (where n is the refractive index of the liquid, normally approximately 1.2-1.6), thereby improving the resolution as well as increasing the depth of focus by approximately n times.
[0009] Incidentally, inside the chamber of a conventional exposure apparatus (an exposure apparatus for dry exposure), the humidity is lowered and an airflow is generated by an air conditioner, which creates an atmosphere in which liquids tend to vaporize. Accordingly, if it is decided to perform immersion exposure in an environment similar to the inside of the chamber of the conventional exposure apparatus, then there is a possibility that the liquid for the immersion exposure will vaporize, making it impossible to maintain the control accuracy of the temperature of that liquid, the projection optical system (a part of the optical elements) in contact with that liquid, or the substrate. In addition, variations in the temperature of the projection optical system degrade the projected image, and variations in the temperature of the substrate deform (expand and contract) the substrate, creating the possibility that the pattern overlay accuracy will degrade.
[0010] The present invention has been made considering such circumstances, and has an object to provide an exposure apparatus and device fabrication method capable of accurately forming the image of a pattern on a substrate when performing the exposure process based on the liquid immersion method. It is another object of the present invention to provide an exposure apparatus and device fabrication method capable of setting and maintaining at a desired temperature the liquid for liquid immersion exposure, and a substrate that is to be exposed.
SUMMARY OF THE INVENTION
[0011] An exposure apparatus of the present invention is an exposure apparatus that fills a liquid in at least one part of a space between a projection optical system and a substrate, projects the image of a pattern via the projection optical system and the liquid onto the substrate, and exposes the substrate, includes a vaporization suppression apparatus that suppresses vaporization of the liquid.
[0012] In addition, the device fabricating method of the present invention uses the exposure apparatus as recited above.
[0013] According to the present invention, the vaporization suppression apparatus suppresses the vaporization of the liquid for immersion exposure, and the desired temperature can therefore be set and maintained by suppressing change in the temperature of the projection optical system, the substrate, or the liquid for immersion exposure due to the vaporization of the liquid. Accordingly, degradation of the projected image of the projection optical system and deformation of the substrate caused by temperature changes can be suppressed, and the image of the pattern can thereby be formed on the substrate with good accuracy.
[0014] An exposure apparatus of the present invention is an exposure apparatus that fills a liquid in at least one part of a space between a projection optical system and a substrate, projects the image of a pattern via the projection optical system and the liquid onto the substrate, and exposes the substrate, includes a member that forms a closed space that surrounds the portion that contacts the liquid; and a vapor pressure adjusting-device to adjust the vapor pressure of the interior of that closed space higher than the vapor pressure of the exterior of that closed space.
[0015] In addition, the device fabricating method of the present invention uses the exposure apparatus as recited above.
[0016] According to the present invention, because of the high vapor pressure of the closed space, which includes the portion that contacts the liquid, the change in the temperature of the portion such as the projection optical system or the substrate that contacts the liquid, due to the vaporization of the liquid, is suppressed. Accordingly, the image of the pattern can thereby be formed on the substrate with good accuracy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic diagram that depicts the first embodiment of an exposure apparatus according to the present invention.
[0018] FIG. 2 is an enlarged view of the principal parts in the vicinity of a projection optical system.
[0019] FIG. 3 is a view that depicts an exemplary arrangement of supply nozzles and collection nozzles.
[0020] FIG. 4 is a view that depicts an exemplary arrangement of supply nozzles and collection nozzles.
[0021] FIG. 5 is an enlarged view of the principal parts of the second embodiment of the exposure apparatus according to the present invention.
[0022] FIG. 6 is a flow chart that depicts one example of a semiconductor device fabrication process.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The following explains the preferred embodiments of the present invention, referencing the drawings. However, the present invention is not limited to the embodiments below, e.g., the constituent elements of these embodiments may be mutually combined in a suitable manner, and other well-known configurations may be supplemented or substituted.
[0024] FIG. 1 is a schematic diagram that depicts the first embodiment of an exposure apparatus EX according to the present invention.
[0025] In FIG. 1 , the exposure apparatus EX includes a mask stage MST that supports a mask M, a substrate stage PST that supports a substrate P, an illumination optical system IL that illuminates with an exposure light EL the mask M supported by the mask stage MST, a projection optical system PL that projects and exposes a pattern image of the mask M illuminated by the exposure light EL onto the substrate P supported by the substrate stage PST, and a control apparatus CONT that provides overall control of the operation of the entire exposure apparatus EX. The exposure apparatus EX of the present embodiment is a liquid immersion type exposure apparatus that applies the liquid immersion method to substantially shorten the exposure wavelength, improve the resolution, as well as substantially increase the depth of focus, and includes an immersion unit 10 that forms an immersion area AR 2 by filling with a liquid 30 at least one part of a space between the projection optical system PL and the substrate P.
[0026] The immersion unit 10 includes a liquid supply apparatus 1 that supplies the liquid 30 onto the substrate P, and a liquid recovery apparatus 2 that recovers the liquid 30 on the substrate P. At least during the transfer of the pattern image of the mask M onto the substrate P, the exposure apparatus EX forms the immersion area AR 2 of the liquid 30 supplied from the liquid supply apparatus 1 , in one part on the substrate P that includes a projection area AR 1 of the projection optical system PL. Specifically, the exposure apparatus EX fills the space between an optical element PLa of the tip part of the projection optical system PL and the surface of the substrate P with the liquid 30 ; projects the pattern image of the mask M onto the substrate P via the liquid 30 between the optical element PLa of this projection optical system PL and the substrate P, and via the projection optical system PL; and exposes the substrate P. Furthermore, the exposure apparatus EX includes a vaporization suppression unit 20 that constitutes at least one part of a vaporization suppression apparatus that suppresses the vaporization of the liquid 30 , which is discussed in detail later.
[0027] The present embodiment will now be explained as exemplified by a case of the use of the scanning type exposure apparatus (so-called scanning stepper) as the exposure apparatus EX in which the substrate P is exposed with the pattern formed on the mask M while synchronously moving the mask M and the substrate P in mutually different directions (opposite directions) in the scanning directions. In the following explanation, the direction that coincides with an optical axis AX of the projection optical system PL is the Z axial direction, the direction in which the mask M and the substrate P synchronously move in the plane perpendicular to the Z axial direction (the scanning direction) is the X axial direction, and the direction perpendicular to the Z axial direction and the Y axial direction is the Y axial direction (the non-scanning direction). In addition, the directions around the X, Y, and Z-axes are the θX, θY, and θZ directions. Herein, “substrate” includes one in which a semiconductor wafer is coated with a photoresist, which is a photosensitive material, and “mask” includes a reticle formed with a device pattern subject to the reduction projection onto the substrate.
[0028] The illumination optical system IL illuminates with the exposure light EL the mask M supported by the mask stage MST, and includes an exposure light source, an optical integrator that uniformizes the intensity of the luminous flux emitted from the exposure light source, a condenser lens that condenses the exposure light EL from the optical integrator, a relay lens system, and a variable field stop that sets an illumination region on the mask M illuminated by the exposure light EL to be slit-shaped, and the like. The illumination optical system IL illuminates the prescribed illumination region on the mask M with the exposure light EL, having a uniform illumination intensity distribution. Those usable as the exposure light beam EL radiated from the illumination optical system IL include, for example, bright lines (g-ray, h-ray, i-ray) in the ultraviolet region radiated, for example, from a mercury lamp, far ultraviolet light beams (DUV light beams) such as the KrF excimer laser beam (wavelength: 248 nm), and vacuum ultraviolet light beams (VUV light beams) such as the ArF excimer laser beam (wavelength: 193 nm) and the F 2 laser beam (wavelength: 157 nm). ArF excimer laser light is used in the present embodiment.
[0029] The mask stage MST supports the mask M, and is two dimensionally movable in the plane perpendicular to the optical axis AX of the projection optical system PL, i.e., in the XY plane, and is finely-rotatable in the θZ direction. A mask stage drive apparatus MSTD, includes a linear motor and the like, drives the mask stage MST. The control apparatus CONT controls the mask stage drive apparatus MSTD. A movable mirror 50 is provided on the mask stage MST. In addition, a laser interferometer 51 is provided at a position opposing the movable mirror 50 . The laser interferometer 51 measures in real time the position, in the two dimensional direction, and the rotational angle of the mask M on the mask stage MST, and outputs the measurement results to the control apparatus CONT. The control apparatus CONT drives the mask stage drive apparatus MSTD based on the measurement results of the laser interferometer 51 , thereby positioning the mask M, which is supported by the mask stage MST.
[0030] The projection optical system PL projects and exposes the pattern of the mask M onto the substrate P with a predetermined projection magnification β. The projection optical system PL includes a plurality of optical elements, including the optical element (lens) PLa provided at the tip part on the substrate P side. These optical elements are supported by a lens barrel PK. In the present embodiment, the projection optical system PL is a reduction system having a projection magnification β of, for example, ¼ or ⅕. The projection optical system PL may be either a unity magnification system or an enlargement system. In addition, the optical element PLa of the tip part of the projection optical system PL of the present embodiment is attachably and detachably (replaceably) provided to and from the lens barrel PK, and the liquid 30 that forms the immersion area AR 2 contacts the optical element PLa.
[0031] The substrate stage PST supports the substrate P. The substrate stage PST includes a Z stage 52 that holds the substrate P via a substrate holder, and an XY stage 53 that supports the Z stage 52 . Further, a base 54 supports the XY stage 53 of this substrate stage PST. A substrate stage drive apparatus PSTD includes a linear motor and the like, drives the substrate stage PST. The control apparatus CONT controls the substrate stage drive apparatus PSTD. Driving the Z stage 52 controls the position in the Z axial direction (the focus position) and in the θX and θY directions of the substrate P held on the Z stage 52 . In addition, driving the XY stage 53 controls the position of the substrate P in the XY direction (the position in a direction substantially parallel to the image plane of the projection optical system PL). In other words, the Z stage 52 controls the focus position and the inclination angle of the substrate P and aligns the surface of the substrate P with the image plane of the projection optical system PL in an auto-focus manner and an auto-leveling manner. Further, the XY stage 53 positions the substrate P in the X axial direction and Y axial direction. Furthermore, the Z stage and the XY stage may be integrally provided. A movable mirror 55 is provided on the substrate stage PST (the Z stage 52 ). In addition, a laser interferometer 56 is provided at a position opposing the movable mirror 55 . The laser interferometer 56 measures in real time the position in the two dimensional direction and the rotational angle of the substrate P on the substrate stage PST, and outputs the measurement results to the control apparatus CONT. The control apparatus CONT drives the substrate stage drive apparatus PSTD based on the measurement results of the laser interferometer 56 , thereby positioning the substrate P supported on the substrate stage PST.
[0032] The liquid supply apparatus 1 of the immersion unit 10 fills with the liquid 30 at least one part of the space between the projection optical system PL and the substrate P by supplying the prescribed liquid 30 onto the substrate P. The liquid supply apparatus 1 includes a tank that accommodates the liquid 30 , a filter that eliminates foreign matter from the liquid 30 , a pressure pump, and the like. Furthermore, the liquid supply apparatus 1 includes a temperature adjusting-device that adjusts the temperature of the liquid 30 supplied onto the substrate P. The temperature adjusting-device adjusts the temperature of the liquid 30 to be supplied to substantially the same level as, for example, the temperature of the space inside the chamber apparatus housed by the exposure apparatus EX. One end of a supply pipe 3 is connected to the liquid supply apparatus 1 , and a supply nozzle 4 is connected to the other end of the supply pipe 3 . The supply nozzle 4 is disposed close to the substrate P, and the liquid supply apparatus 1 supplies the liquid 30 between the projection optical system PL and the substrate P via the supply pipe 3 and the supply nozzle 4 . In addition, the control apparatus CONT controls the operation of supplying the liquid of the liquid supply apparatus 1 , and can control the liquid supply amount per unit time of the liquid supply apparatus 1 .
[0033] In the present embodiment, pure water is used as the liquid 30 . Pure water is capable of transmitting not only ArF excimer laser light, but also deep ultraviolet light (DUV light), such as the bright lines (g, h, and i lines) in the ultraviolet region emitted from, for example, a mercury lamp, and KrF excimer laser light (248 nm wavelength).
[0034] The liquid recovery apparatus 2 recovers the liquid 30 on the substrate P, and includes a suction apparatus, such as, for example, a vacuum pump, a tank that accommodates the recovered liquid 30 , and the like. One end of a recovery pipe 6 is connected to the liquid recovery apparatus 2 , and a recovery nozzle 5 is connected to the other end of the recovery pipe 6 . The recovery nozzle 5 is disposed close to the substrate P, and the liquid recovery apparatus 2 recovers the liquid 30 via the recovery nozzle 5 and the recovery pipe 6 . In addition, the control apparatus CONT controls the operation of recovering the liquid by the liquid recovery apparatus 2 , and can control the liquid recovery amount per unit time of the liquid recovery apparatus 2 .
[0035] The control apparatus CONT drives the liquid supply apparatus 1 to supply a predetermined amount of liquid 30 per unit of time on the substrate P via the supply pipe 3 and the supply nozzle 4 , and drives the liquid recovery apparatus 2 to recover a predetermined amount of liquid 30 per unit of time from on the substrate P via the recovery nozzle 5 and the recovery pipe 6 . Thereby, the liquid 30 is disposed between the tip part PLa of the projection optical system PL and the substrate P, forming the immersion area AR 2 .
[0036] The vaporization suppression unit 20 suppresses the vaporization of the liquid 30 by setting the space surrounding the liquid 30 higher than a predetermined vapor pressure. This vaporization suppression unit 20 includes a partition member 21 that encloses the space surrounding the liquid 30 between the projection optical system PL and the substrate P, and a humidifier 28 that constitutes at least one part of a supply apparatus that supplies vapor to a closed space 24 , which is formed by the partition member 21 and includes the space surrounding the liquid 30 . The partition member 21 includes a wall member 22 affixed to the vicinity of a circumferential edge part of the substrate stage PST (Z stage 52 ) so that it encloses the substrate P, and having a wall surface of a predetermined height; and a cover 23 affixed to the lens barrel PK of the projection optical system PL, and having a lower surface substantially parallel to the XY plane and of a predetermined size. The cover 23 may be affixed to a support member (not shown) that supports the projection optical system PL (lens barrel PK). The wall member 22 and the cover 23 that constitute the partition member 21 form the closed space 24 that encloses the substrate P and the liquid 30 between the projection optical system PL and the substrate P. A small gap 25 is formed between an upper end part of the wall member 22 and the lower surface of the cover 23 so that the movement of the substrate stage PST in the X, Y, and Z axial directions and the inclination of the substrate stage PST are not interfered. In addition, through holes through which the supply pipe 3 and the recovery pipe 6 can be respectively disposed are provided in one part of the cover 23 . Sealing members (not shown) are provided that each restrict the flow of liquid through the gap between the through holes and the respective supply pipe 3 and collection pipe 6 .
[0037] A through hole 26 is formed in one part of the wall member 22 provided on the substrate stage PST, and one end of an elastically provided piping 27 is connected to this through hole 26 . Meanwhile, the humidifier 28 that supplies vapor to the closed space 24 is connected to the other end of the piping 27 . The humidifier 28 supplies high humidity gas to the closed space 24 via the piping 27 , and supplies a vapor of the same substance as the liquid 30 . In the present embodiment, the liquid 30 is water (pure water), so the humidifier 28 supplies water vapor to the closed space 24 . The control apparatus CONT controls the vapor supply operation of the humidifier 28 . Furthermore, by supplying vapor to the closed space 24 using the humidifier 28 , the vaporization suppression unit 20 raises the vapor pressure (pressure in the vapor phase) in the closed space 24 on the inner side of the partition member 21 higher than the outer side thereof (i.e., the interior of the chamber apparatus).
[0038] FIG. 2 is a front view that depicts the vicinity of the tip part of the projection optical system PL of the exposure apparatus EX. The tip part of the optical element PLa at the lowest end of the projection optical system PL is formed in a long, thin rectangular shape in the Y axial direction (the non-scanning direction), leaving just the portion needed in the scanning direction. During scanning exposure, the pattern image of one part of the mask M is projected onto the rectangular projection area AR 1 directly below the optical element PLa, and, synchronized to the movement of the mask M at a speed V in the −X direction (or the +X direction) with respect to the projection optical system PL, the substrate P moves at a speed β·V (where β is the projection magnification) in the +X direction (or the −X direction) via the XY stage 53 . Further, after the exposure of one shot region is completed, the next shot region moves to the scanning start position by the stepping movement of the substrate P, and the exposure process is subsequently performed sequentially for each shot region by the step-and-scan system. In the present embodiment, the liquid 30 is set so that it flows parallel to and in the same direction as the movement direction of the substrate P.
[0039] FIG. 3 depicts the positional relationship between the projection area AR 1 of the projection optical system PL, the supply nozzles 4 ( 4 A- 4 C) that supply the liquid 30 in the X axial direction, and the recovery nozzles 5 ( 5 A, 5 B) that recover the liquid 30 . In FIG. 3 , the projection area AR 1 of the projection optical system PL is a rectangular shape that is long and thin in the Y axial direction. Further, the three supply nozzles 4 A- 4 C are disposed on the +X direction side and the two recovery nozzles 5 A, 5 B are disposed on the −X direction side so that the projection area AR 1 is interposed therebetween in the X axial direction. The supply nozzles 4 A- 4 C are connected to the liquid supply apparatus 1 via the supply pipe 3 , and the recovery nozzles 5 A, 5 B are connected to the liquid recovery apparatus 2 via the recovery pipe 6 . In addition, supply nozzles 8 A- 8 C and recovery nozzles 9 A, 9 B are disposed in an arrangement substantially 180° rotated from the supply nozzles 4 A- 4 C and the recovery nozzles 5 A, 5 B. The supply nozzles 4 A- 4 C and the recovery nozzles 9 A, 9 B are alternately arrayed in the Y axial direction, the supply nozzles 8 A- 8 C and the recovery nozzles 5 A, 5 B are alternately arrayed in the Y axial direction, the supply nozzles 8 A- 8 C are connected to the liquid supply apparatus 1 via a supply pipe 11 , and the recovery nozzles 9 A, 9 B are connected to the liquid recovery apparatus 2 via a recovery pipe 12 .
[0040] The following explains the procedure for using the exposure apparatus EX discussed above to expose the pattern of the mask M onto the substrate P.
[0041] After the mask M is loaded on the mask stage MST and the substrate P is loaded on the substrate stage PST, the control apparatus CONT drives the liquid supply apparatus 1 and the liquid recovery apparatus 2 of the immersion unit 10 , and forms the immersion area AR 2 between the projection optical system PL and the substrate P. In addition, the control apparatus CONT drives the humidifier 28 of the vaporization suppression unit 20 , thereby supplying vapor to the closed space 24 that includes the surrounding space of liquid 30 that is formed by the immersion area AR 2 , thereby the vapor phase pressure of this closed space 24 becomes higher than a predetermined vapor pressure. Specifically, by supplying the water vapor, which is a high humidity gas, to the closed space 24 , the vaporization suppression unit 20 sets this closed space 24 to the saturated vapor pressure of the liquid (pure water) 30 .
[0042] The vapor pressure of the closed space 24 rises higher than the vapor pressure on the outside of the closed space 24 . Normally, the humidity on the outside of the closed space 24 , i.e., inside the chamber that houses the exposure apparatus EX, is 30%-40%, but the interior of the space 24 is constantly maintained near the saturated vapor pressure (approximately 95% humidity) because the humidifier 28 of the vaporization suppression unit 20 is continuously supplying water vapor. It is possible to maintain the interior of the space 24 near the saturated vapor pressure because the gap 25 provided between the upper end part of the wall member 22 and the cover 23 is extremely small.
[0043] If scanning exposure is performed by moving the substrate P in the scanning direction (the −X direction) depicted by an arrow Xa (refer to FIG. 3 ), then the liquid supply apparatus 1 and the liquid recovery apparatus 2 use the supply pipe 3 , the supply nozzles 4 A- 4 C, the recovery pipe 6 , and the recovery nozzles 5 A, 5 B to supply and recover the liquid 30 . On the other hand, if scanning exposure is performed by moving the substrate P in the scanning direction (the +X direction) depicted by an arrow Xb, then the liquid supply apparatus 1 and the liquid recovery apparatus 2 use the supply pipe 11 , the supply nozzles 8 A- 8 C, the recovery pipe 12 , and the recovery nozzles 9 A, 9 B to supply and recover the liquid 30 . Thus, the immersion unit 10 uses the liquid supply apparatus 1 and the liquid recovery apparatus 2 to flow the liquid 30 along the direction of movement of the substrate P and in a direction the same as the direction of movement of the substrate P. In this case, the liquid 30 can be easily supplied between the projection optical system PL and the substrate P, even if the supplied energy of the liquid supply apparatus 1 is small, because the liquid 30 supplied, for example, from the liquid supply apparatus 1 via the supply nozzles 4 A- 4 C flows so that it is drawn between the projection optical system PL and the substrate P as the substrate P moves in the −X direction. Further, even if the substrate P is scanned in either the +X direction or the −X direction by switching the direction in which the liquid 30 flows in accordance with the scanning direction, the liquid 30 can be filled between the projection optical system PL and the substrate P, and a high resolution and large depth of focus can thereby be obtained. In addition, because the minute gap 25 is provided between the upper end part of the wall member 22 and the cover 23 , the substrate stage PST can also be moved while maintaining the inside of the closed space 24 near the saturated vapor pressure.
[0044] As explained above, the partition member 21 forms the closed space 24 surrounding the substrate P and the liquid 30 that forms the immersion area AR 2 , and water vapor is supplied inside this closed space 24 ; therefore, the vaporization of the liquid 30 and of the liquid 30 adhering to the tip part of the projection optical system PL and the substrate P can be suppressed, and the liquid 30 , the projection optical system PL, and the substrate P can be maintained at the desired temperature. In particular, if an immersion area is formed on one part of the substrate P while recovering the liquid on the substrate P, then, even if the un-recovered residual liquid adheres to the substrate P, the vaporization of that residual liquid can be prevented, and it is possible to suppress temperature changes and deformations (expansion and contraction) of the substrate P. In addition, even if liquid adheres to the side surfaces of the optical element PLa of the projection optical system PL, the vaporization of that adhered liquid can be prevented, thereby enabling the suppression of temperature changes and deformation of the optical element PLa.
[0045] In the present embodiment, the movable mirror 55 affixed to the substrate stage PST is provided on the outside of the closed space 24 , and the measurement of the position of the substrate stage PST by the interferometer 56 using the movable mirror 55 is consequently not affected by the environment inside the closed space 24 . In addition, because water vapor of pure water the same as the liquid (pure water) 30 is supplied to the closed space 24 to humidify the closed space 24 , there is no drop in the purity of the liquid (pure water) 30 between the projection optical system PL and the substrate P, nor any change in the transmittance or other characteristics.
[0046] In the present embodiment, the vapor supplied to the closed space 24 has the same physical properties as the liquid 30 that forms the immersion area AR 2 . However, if deterioration in the purity of the liquid 30 between the projection optical system PL and the substrate P is permissible to some extent, then the physical properties of the liquid 30 supplied from the liquid supply apparatus 1 for forming the immersion area AR 2 need not be the same as those of the vapor supplied inside the closed space 24 .
[0047] In the present embodiment, the interior of the closed space 24 is set to substantially the saturated vapor pressure (approximately 95% humidity), but may be set lower than that, e.g., approximately 60%. In other words, the pressure of the vapor phase of the closed space 24 may be set to a predetermined vapor pressure that is lower than the saturated vapor pressure. Here, the predetermined vapor pressure is a pressure wherein fluctuations in the pattern transfer accuracy due to temperature fluctuations in the tip part of the projection optical system PL, the substrate P, or the liquid 30 caused by vaporization of the liquid 30 can be kept within a permissible range. Accordingly, by setting the space surrounding the liquid 30 for foaming the immersion area AR 2 higher than the predetermined vapor pressure with the aid of the vaporization suppression unit 20 , the pattern transfer accuracy can be kept within the permissible range.
[0048] Although the liquid 30 in the present embodiment is water (pure water), it may be a liquid other than water. For example, if the light source of the exposure light EL is an F 2 laser, then this F 2 laser light will not transmit through water, so it would be acceptable to use as the liquid 30 a fluorine based liquid, such as fluorine based oil, capable of transmitting the F 2 laser light (e.g., Fomblin® and PFPE). In that case, the vapor of the fluorine based liquid is supplied to the space surrounding the substrate P (the closed space 24 ). If a fluorine based liquid is used for the immersion exposure, then a substance the same as that liquid may be vaporized, and that vapor may be supplied inside the closed space 24 . In addition, it is also possible to use, as the liquid 30 , those (e.g., cedar oil) that is transparent to the exposure light EL, has the highest possible refractive index, and is stable with respect to the projection optical system PL and the photoresist coated on the surface of the substrate P.
[0049] In either case, vapor having physical properties the same as that liquid, or a vapor having a chemical composition the same as the vapor produced by vaporizing that liquid may be supplied to the space surrounding the substrate P (the closed space 24 ).
[0050] The above embodiments are not particularly limited to the nozzle configurations discussed above, e.g., the liquid 30 may be supplied and recovered by two pairs of nozzles on the long sides of the projection area AR 1 of the projection optical system PL. In this case, the supply nozzles and the recovery nozzles may be disposed so that they are arrayed vertically in order to enable the supply and recovery of the liquid 30 from either the +X direction or the −X direction.
[0051] In addition, as shown in FIG. 4 , supply nozzles 41 , 42 and recovery nozzles 43 , 44 may also be provided respectively on both sides in the Y axial direction, wherebetween the projection area AR 1 of the projection optical system PL is interposed. These supply nozzles and recovery nozzles can stably supply the liquid 30 between the projection optical system PL and the substrate P, even when the substrate P is moving in the non-scanning direction (the Y axial direction) during the stepping movement. In addition, if the liquid 30 supply nozzles and recovery nozzles are provided so that they surround the projection area AR 1 of the projection optical system PL, then it is possible also to switch the direction in which the liquid 30 flows in response to the movement direction of the substrate P at times such as when the substrate P is being stepped in the Y axial direction.
[0052] The following explains the second embodiment of the exposure apparatus EX according to the present invention, referencing FIG. 5 . In the explanation below, constituent parts that are identical or equivalent to those in the first embodiment discussed above are assigned the identical reference characters, and the explanation thereof is simplified or omitted.
[0053] In FIG. 5 , the vaporization suppression unit 20 includes a partition member 60 affixed onto the base 54 . In other words, the partition member 21 according to the abovementioned first embodiment includes the wall member 22 and the cover 23 , and forms a gap 25 , but there is no gap in the partition member 60 according to the present embodiment, and a closed space 61 formed by this partition member 60 is an approximately sealed closed space. In this case, the substrate stage PST moves inside the closed space 61 on the base 54 . By making the closed space 61 an approximately sealed closed space, it is that much easier to maintain the interior of this closed space 61 near the saturated vapor pressure of the liquid 30 , and the impact on the outside of the closed space 61 can be eliminated. Here, if the measurement light of the interferometer used to measure the position of the substrate stage PST passes through the interior of the closed space 61 , then a tubular member can elastically cover the optical path of the measurement light so that the vapor inside the closed space 61 does not impact the measurement operation.
[0054] The abovementioned first and second embodiments are configured so that the space surrounding the substrate P and the liquid 30 for forming the immersion area AR 2 are made a closed space, and so that vapor is supplied into this closed space. However, it is also acceptable to suppress the vaporization of the liquid 30 for forming the immersion area AR 2 by simply blowing the vapor to the space surrounding the liquid 30 (to the vicinity of the tip part of the projection optical system PL, and to the vicinity of the surface of the substrate P), without forming the closed space. In this case, the same as discussed above, the optical path (luminous flux) of the interferometer may be covered by the tubular member so that the vapor does not affect the interferometer's measurements.
[0055] In addition, in the first and second embodiments discussed above, a humidity sensor may be disposed inside the closed spaces 24 , 61 , and the humidifier 28 may be controlled based on the output of that humidity sensor.
[0056] In addition, after the exposure of the substrate P is completed, the vapor pressure inside the closed spaces 24 , 61 is made substantially the same as the vapor pressure of the space on the outside of the closed spaces 24 , 61 , after which the substrate P may be transported out of the closed spaces 24 , 61 .
[0057] In the abovementioned first and second embodiments, a humidifier 28 is provided that supplies vapor to the interior of the closed spaces 24 , 61 , but it is also acceptable to omit this. In other words, even if only forming the closed spaces 24 , 61 , the vaporization of the liquid can be suppressed because the liquid that contacts (adheres to) the substrate P and the vicinity of the tip of the projection optical system PL can be protected from contact with the dried air inside the chamber that houses the apparatus, or the airflow inside the chamber.
[0058] In addition, the abovementioned first and second embodiments suppress the vaporization of the liquid by forming the closed spaces 24 , 61 , but it is also acceptable to blow a high vapor pressure (high humidity) vapor toward the vicinity of the tip of the projection optical system PL and the surface of the substrate P, without providing the partition members 21 , 60 .
[0059] In addition, the present invention is not limited to the large closed spaces 24 , 61 such as in the first and second embodiments, and a local closed space may be provided so that it encloses the portion that makes contact with (adheres to) the liquid.
[0060] As discussed above, the liquid 30 in the present embodiment includes pure water. Pure water is advantageous because it can be easily obtained in large quantities at a semiconductor fabrication plant, and the like. Further, because pure water has no adverse impact on the optical element (lens), the photoresist on the substrate P, and the like. In addition, because pure water has no adverse impact on the environment and has an extremely low impurity content, it can also be expected to have the effect of cleaning the surface of the substrate P, and the surface of the optical element provided on the tip surface of the projection optical system PL. Further, because the refractive index n of pure water (water) for the exposure light EL having a wavelength of approximately 193 nm is substantially 1.44, the use of ArF excimer laser light (193 nm wavelength) as the light source of the exposure light EL would shorten the wavelength on the substrate P to 1/n, i.e., approximately 134 nm, thereby obtaining a high resolution. Furthermore, because the depth of focus will increase approximately n times, i.e., approximately 1.44 times, that of in air, the numerical aperture of the projection optical system PL can be further increased if it is preferable to ensure a depth of focus approximately the same as that when used in air, and the resolution is also improved from this standpoint.
[0061] In each of the abovementioned embodiments, a lens is affixed as the optical element PLa at the tip of the projection optical system PL, and the optical characteristics of the projection optical system PL, e.g., aberrations (spherical aberration, coma aberration, and the like) can be adjusted by this lens. The optical element PLa may also be an optical plate that adjusts the above optical characteristics. Further, the optical element PLa that contacts the liquid 30 can also be a plane parallel plate lower in cost than the lens. Using a plane parallel plate as the optical element PLa is advantageous because, even if a substance (e.g., a silicon based organic substance, and the like) that lowers the uniformity of the transmittance of the projection optical system PL during the transport, assembly, and adjustment of the exposure apparatus EX, and the illumination intensity and the illumination intensity distribution of the exposure light EL on the substrate P adheres to that plane parallel plate, only the plane parallel plate needs to be replaced immediately before supplying the liquid, and that replacement cost is lower than that compared with using a lens as the optical element that contacts the liquid. In other words, because the surface of the optical element that contacts the liquid becomes contaminated because of the adhesion of scattered particles generated from the resist due to the irradiation of the exposure light EL, and because of impurities in the liquid, and the like, that optical element must be periodically replaced. However, by using a low cost plane parallel plate for this optical element, the cost of the replacement part is lower compared with a lens, less time is needed to effect the replacement, and it is possible to suppress any increase in the maintenance cost (running cost) or decrease in throughput.
[0062] If a high pressure is generated by the flow of the liquid between the substrate P and the optical element PLa at the tip of the projection optical system PL, then instead of making the optical element replaceable, the optical element may be firmly fixed by that pressure so that it does not move.
[0063] Each of the abovementioned embodiments is constituted so that the liquid is filled between the projection optical system PL and the surface of the substrate P, but may be constituted so that the liquid is filled in a state wherein, for example, a cover glass comprising a plane parallel plate is affixed to the surface of the substrate P.
[0064] The substrate P in each of the above-mentioned embodiments is not limited to a semiconductor wafer for fabricating semiconductor devices, and is also applicable to a glass substrate for a display device, a ceramic wafer for a thin film magnetic head, or a mask or the original plate of a reticle (synthetic quartz, silicon wafer) used by an exposure apparatus, and the like.
[0065] In addition to a step-and-scan system scanning type exposure apparatus (scanning stepper) that scans and exposes the pattern of the mask M by synchronously moving the mask M and the substrate P, a step-and-repeat system projection exposure apparatus (stepper) that exposes the full pattern of the mask M with the mask M and the substrate P in a stationary state is also applicable as the exposure apparatus EX. In addition, the present invention is also applicable to a step-and-stitch system exposure apparatus that partially and superimposingly transfers at least two patterns onto the substrate P.
[0066] In the embodiments discussed above, an exposure apparatus is used that locally fills liquid between the projection optical system PL and the substrate P, but the present invention is also applicable to a liquid immersion exposure apparatus that moves a stage, which holds the substrate to be exposed, in a liquid bath, as disclosed in Japanese Unexamined Patent Application, First Publication No. H06-124873, as well as to a liquid immersion exposure apparatus that forms a liquid bath having a predetermined depth on the stage, and holding the substrate therein, as disclosed in Japanese Unexamined Patent Application, First Publication No. H10-303114.
[0067] In addition, the present invention is also applicable to twin-stage type exposure apparatuses as disclosed in Japanese Unexamined Patent Applications, First Publication No. H10-163099 and No. H10-214783, and Published Japanese Translation No. 2000-505958 of the PCT International Publication.
[0068] The type of exposure apparatus EX is not limited to semiconductor device fabrication exposure apparatuses that expose the pattern of a semiconductor device on the substrate P, but is also widely applicable to exposure apparatuses for fabricating liquid crystal devices or displays, exposure apparatuses for fabricating thin film magnetic heads, imaging devices (CCD), or reticles and masks, and the like.
[0069] If a linear motor is used in the substrate stage PST or the mask stage MST (refer to U.S. Pat. No. 5,623,853 and U.S. Pat. No. 5,528,118), then either an air levitation type that uses an air bearing or a magnetic levitation type that uses Lorentz's force or reactance force may be used. In addition, each of the stages PST, MST may be a type that moves along a guide, or may be a guideless type not provided with a guide.
[0070] For the drive mechanism of each of the stages PST, MST, a planar motor may be used that opposes a magnet unit wherein magnets are arranged two dimensionally to an armature unit wherein coils are arranged two dimensionally, and drives each of the stages PST, MST by electromagnetic force. In this case, any one among the magnet unit and the armature unit is connected to the stages PST, MST, and the other one of the magnet unit and the armature unit should be provided on the moving surface side of the stages PST, MST.
[0071] The reaction force generated by the movement of the substrate stage PST may be mechanically discharged to the floor (ground) using a frame member so that it is not transmitted to the projection optical system PL, as recited in Japanese Unexamined Patent Application, First Publication No. H08-166475 (U.S. Pat. No. 5,528,118).
[0072] The reaction force generated by the movement of the mask stage MST may be mechanically discharged to the floor (earth) using a frame member so that it is not transmitted to the projection optical system PL, as recited in Japanese Unexamined Patent Application, First Publication No. H08-330224 (U.S. Pat. No. 5,528,118).
[0073] The exposure apparatus EX of the embodiments in the present application as described above is manufactured by assembling various subsystems, including each constituent element recited in the claims of the present application, so that a predetermined mechanical accuracy, electrical accuracy, and optical accuracy are maintained To ensure these various accuracies, adjustments are performed before and after this assembly, including an adjustment to achieve optical accuracy for the various optical systems, an adjustment to achieve mechanical accuracy for the various mechanical systems, and an adjustment to achieve electrical accuracy for the various electrical systems. The assembly process, from the various subsystems to the exposure apparatus includes the mutual mechanical connection of the various subsystems, the wiring and connection of electrical circuits, the piping and connection of the atmospheric pressure circuit, and the like. Naturally, before the process of assembling from these various subsystems to the exposure apparatus, there are processes for assembling each of the individual subsystems. When the assembly process from various subsystems to the exposure apparatus has completed, a comprehensive adjustment is performed to ensure the various accuracies of the exposure apparatus as a whole. It is preferable to manufacture the exposure apparatus in a clean room wherein the temperature, the cleanliness level, and the like, are controlled.
[0074] As shown in FIG. 6 , a micro-device, such as a semiconductor device is manufactured by: a step 201 that designs the functions and performance of the micro-device; a step 202 that fabricates a mask (reticle) based on this design step; a step 203 that fabricates a substrate, which is the base material of the device; an exposure processing step 204 wherein the exposure apparatus EX of the embodiments discussed above exposes a pattern of the mask onto the substrate; a device assembling step 205 (comprising a dicing process, a bonding process, and a packaging process); a scanning step 206 ; and the like. | An immersion lithography system includes a wafer stage, a lens for projecting an image onto a wafer located on the wafer stage, an immersion fluid supply for supplying immersion fluid between the lens and the wafer, and a purge fluid conveying device for conveying about the supplied immersion fluid a purge fluid saturated with a component of the immersion fluid. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is related to the field of construction and, more particularly, to an apparatus including a hopper with an auger for placing grout, mortar and similar fluent materials in block walls, foundations and the like at construction job sites.
[0003] 2. Description of the Related Art
[0004] In the construction field, machines are typically used to pour grout, mortar or slurry concrete into forms or hollow walls. Such machines generally have a hopper with a tube in which an auger is rotatably mounted. Mortar or concrete slurry is poured into the hopper and then moved through the tube to a discharge hose by rotating the auger.
[0005] Many grouting applications require that the machines be lifted to an elevated location, such as the top of a concrete block wall. Accordingly, the machines are often designed to be mounted on a forklift or similar front end loading equipment and are driven by the power-take-off (PTO) hydraulics of the loading equipment. Hence, the operator of the loading equipment, in positioning the grouting machine, is also responsible for controlling activation of the auger while another person controls placement of the hose to direct the slurry to the desired location. Once properly positioned, the hose operator must signal the loading equipment operator, such as by hand signals, to activate and deactivate the auger. This can be problemmatic, particularly when the hose operator and the loading equipment operator are not in view of one another such as, for example, when the point of material discharge is elevated relative to the loading equipment operator or behind a wall.
[0006] When deactivation of the auger is necessary, this communication problem is exacerbated by the fact that delay in stopping the auger can result in wasted mortar or slurry concrete as the hose continues to discharge material, and extra work necessitated to clean up of the excess material. The hose operator may try to kink the hose or stop the flow in some other manner, but this is not always effective given the weight of the hose when filled with material which make the hose difficult to handle. One solution to this problem is set forth in U.S. Pat. No. 7,152,762 which discloses a control valve having a pair of arms that externally clamp onto the hose to stop or limit the flow of fluent material. U.S. Pat. No. 6,206,249 (“the '249 patent”) seeks to facilitate the stoppage of flow through the use of rigid auger blades that are spaced from the tube wall within which the auger rotates. The gap between the blades and the tube wall reduces the build up of pressure between the interior of the hopper and the interior passage of the hose so that, when the hose is pinched closed, the grout material does not continue to flow due to the pressure differential. The design of the '249 patent has reduced efficiency, however, as the gap allows grout material to accumulate between the auger and the hopper, which wastes grout material and can lead to clogging.
[0007] Finally, slurry concrete, mortar and grout are materials that can be corrosive and are difficult to remove from surfaces once they have dried. As a result, grouting machines must be cleaned promptly and on a regular basis in order to prevent jamming of the moving parts and obstruction of the discharge lines. Such cleaning typically requires disassembly of the machine, a process that is time consuming and which can result in the loss of components such as fastening elements during the time between disassembly, cleaning and reassembly.
[0008] Accordingly, a need exists for a grout placement machine that overcomes the foregoing difficulties and which is reliable and sturdy in operation, can be manufactured at a reasonable cost, and will be easy to use at the construction job site and to clean thereafter.
SUMMARY OF THE INVENTION
[0009] In view of the foregoing, the present invention is directed to a grout placement apparatus for placing grout, mortar and similar fluent materials in block walls, foundations and the like at construction job sites. For ease of reference, the general term “grout material” will be used herein to refer to any fluent material used in construction including mortar, slurry concrete, all types of fluid masonry material that dry to provide structural support. The term “grout material” is also intended to include other fluent materials that may not harden, as the grout placement apparatus described herein could be effectively used with these materials as well.
[0010] The grout placement apparatus according to the present invention has a generally V-shaped hopper with an auger in the trough of the V-shape which can be rotated in both forward and reverse directions by an auger motor. According to one embodiment referred to specifically hereinafter as “the PTO grout apparatus”, the auger motor is powered by the PTO hydraulics of the loading equipment, such as a forklift, for supporting the apparatus. In an alternate embodiment referred to specifically hereinafter as “the gas-powered grout apparatus”, the apparatus includes its own gasoline-powered engine to independently drive the hydraulic system of the apparatus. The indicated terminology will be used herein when one or the other of the embodiments is being addressed individually, as appropriate in those situations when the two embodiments present structural and/or operational distinctions. However, in most instances, the general phrase “grout placement apparatus” will be used and is intended to refer to both embodiments as they share many common features.
[0011] The V-shaped hopper has straight sidewalls that connect with a curved or generally cylindrical trough having a radius approximating the radius of the auger blades. When properly angled, the straight sidewalls promote a smooth, uninterrupted flow of grout material to the auger. The upper edges of the hopper walls preferably have inwardly angled flanges or splash guards to minimize material loss from the top of the hopper.
[0012] The auger has flexible blades and is mounted so that the curved blades contact the trough or bottom of the hopper. This structure promotes self-cleaning and efficient flow, and minimizes the amount of grout material remaining on the bottom of the hopper when work is completed. Forward rotation of the auger moves the grout material along the bottom of the hopper toward and through a discharge sleeve that extends from the front of the hopper. Coupled to the discharge sleeve is a discharge assembly having a flow control valve that is automatically opened and closed by the forward and reverse rotation of the auger, respectively. A flexible discharge conduit or hose coupled to the discharge assembly conveys the grout material from the hopper to the desired placement location when the flow control valve is open.
[0013] The discharge assembly includes a housing that is hingedly mounted to the hopper, allowing a “swing away” movement of the discharge assembly from its operating position, in which the housing is locked against the discharge sleeve of the hopper, to the “swing away” position away from the hopper. With the discharge assembly in the swing away position, easy access is provided to the discharge sleeve of the hopper for both cleaning and examination thereof, as necessary.
[0014] The housing of the discharge assembly is further provided with rinse-out grates on the front and top thereof which allow the housing to be cleaned without disassembly thereof. The grates also enable air to freely flow into and out of the housing which prevents the possibility of a vapor lock condition inside the discharge assembly and/or discharge hose which could result in clogging, thereby promoting the free flow of grout material through the grout delivery apparatus and increasing the overall efficiency of the apparatus.
[0015] To facilitate servicing of the apparatus, the auger is removable from the hopper. In the PTO grout apparatus, the auger can be removed through the top of the hopper while the gas-powered grout apparatus allows the auger to be removed through the hopper discharge sleeve.
[0016] For optimal coverage when placing the grout material, the present invention further includes a hopper support frame which allows the hopper to rotate 360° on roller bearings. A three-position lock controls the position of the hopper on the support frame, allowing it to turn 360° for cleaning and filling, turn 180° for grout placement, and lock in four different positions.
[0017] The grout placement apparatus according to the present invention also has a radio-frequency (wireless) remote control capability by which activation of the auger can be controlled by the hose operator at the point of grout material placement, rather than by the loading equipment operator. This allows for more precise timing and accuracy in starting and stopping the flow of grout material, reducing waste and the possible confusion associated with the use of hand signals to communicate with the loading equipment operator.
[0018] Accordingly, it is an object of the present invention to provide a grout placement apparatus having a discharge assembly that is pivotally mounted to swing away from the hopper so as to provide easy access to the discharge sleeve of the hopper.
[0019] Another object of the present invention to provide a grout placement apparatus in accordance with the preceding object in which the discharge assembly includes a flow control valve that is automatically opened and closed by forward and reverse rotation of the auger, respectively.
[0020] A further object of the present invention to provide a grout placement apparatus in accordance with the preceding objects in which the discharge assembly housing is provided with one or more rinse-out grates that promote the free flow of grout material through the housing and into the discharge conduit, avoids clogging and also facilitates cleaning of the housing by eliminating the need for disassembly thereof.
[0021] Yet a further object of the present invention is to provide a grout placement apparatus with a hopper having an auger that is driven by the PTO hydraulics of a piece of loading equipment and which can be removed from the top of the hopper.
[0022] A still further object of the present invention is to provide a grout placement apparatus with a hopper having an auger that is driven by a dedicated gas-powered engine.
[0023] Another object of the present invention is to provide a grout placement apparatus in accordance with the preceding objects in which the apparatus has a hopper with straight sidewalls that connect with a curved or generally cylindrical bottom or trough having a radius approximating the radius of the auger blades to form a continuous V-shape that promotes smooth uninterrupted flow of grout material to the auger.
[0024] Yet another object of the present invention is to provide a grout placement apparatus in accordance with the preceding objects in which the auger has flexible blades that effectively self-clean the bottom or trough of the hopper through their contact therewith, providing efficient discharge from the hopper and minimizing the cleaning burden as well as grout material waste.
[0025] Still another object of the present invention is to provide a grout placement apparatus in accordance with the preceding objects in which the upper edges of the hopper walls have inwardly directed splash guards to mimimize grout material loss through the top of the hopper.
[0026] A still further object of the present invention is to provide a grout placement apparatus in accordance with the preceding objects in which the hopper can be rotated 360° and locked in various positions.
[0027] Yet a further object of the present invention is to provide a grout placement apparatus carried by a piece of loading equipment and having an auger that can be remotely activated and deactivated by an individual other than the loading equipment operator, such as the person placing the grout material placement and delivery hose used to convey the grout material from the hopper to the desired placement site.
[0028] An additional object of the present invention is to provide a grout placement apparatus in accordance with the preceding objects that will conform to conventional forms of manufacture, be of relatively simple construction and easy to use and clean so as to provide an apparatus that will be economically feasible, long lasting, durable in service, relatively trouble free in operation, and a general improvement in the art.
[0029] These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a perspective view from the discharge or front end of a grout placement apparatus in accordance with a first embodiment of the present invention.
[0031] FIG. 2 is a perspective view from the motor or rear end of the grout placement apparatus shown in FIG. 1 .
[0032] FIG. 3 is a side view of the grout placement apparatus shown in FIG. 1 .
[0033] FIG. 4 is a front view of the grout placement apparatus shown in FIG. 1 .
[0034] FIG. 5 is a detailed side and partial cross-sectional view of the grout placement apparatus shown in FIG. 1 .
[0035] FIG. 6 is a side cross-sectional view of the grout placement apparatus shown in FIG. 1 .
[0036] FIG. 7 is an exploded rear perspective view illustrating various components of the hopper of the grout placement apparatus shown in FIG. 1 .
[0037] FIG. 8 is an exploded front perspective view illustrating the hopper upper support frame of the grout placement apparatus shown in FIG. 1 .
[0038] FIG. 9 is an exploded rear perspective view illustrating the hopper lower support frame of the grout placement apparatus shown in FIG. 1 .
[0039] FIG. 10 is a cutaway side view of the auger as mounted in the hopper of the grout placement apparatus shown in FIG. 1 .
[0040] FIG. 11 is a cutaway side view of the hopper and auger shown in FIG. 10 , illustrating a first step in removal of the auger from the grout placement apparatus.
[0041] FIG. 12 is a cutaway side view of the hopper and auger shown in FIG. 11 , illustrating a second step in removal of the auger from the grout placement apparatus.
[0042] FIG. 13 is an exploded view of the discharge sleeve and discharge assembly of the grout placement apparatus shown in FIG. 1 .
[0043] FIG. 14 is a perspective view of an alternate configuration of the grout placement apparatus of FIG. 1 in which a clamp-style locking mechanism is used to secure the discharge assembly in the locked position, shown with the discharge assembly in the swing-away position.
[0044] FIG. 15 is a schematic drawing illustrating a manual control embodiment of a hydraulic control system for the PTO grout placement apparatus shown in FIG. 1 .
[0045] FIG. 16 is a schematic drawing illustrating a piping layout for the hydraulic control system shown in FIG. 15 .
[0046] FIG. 17 is an exploded view of the remote control components for use with a remote control embodiment of a hydraulic control system for the grout placement apparatus shown in FIG. 1 .
[0047] FIG. 18 is a schematic drawing illustrating the hydraulic circuit for the remote control embodiment of the PTO grout placement apparatus shown in FIG. 1 .
[0048] FIG. 19 is a schematic drawing illustrating an electrical circuit for the radio frequency remote control system shown in FIG. 18 .
[0049] FIG. 20 is a perspective view from the discharge or front end of a grout placement apparatus in accordance with a second embodiment of the present invention.
[0050] FIG. 21 is an exploded view of various components of the discharge assembly of the grout placement apparatus shown in FIG. 20 .
[0051] FIG. 22 is a perspective view of the grout placement apparatus of FIG. 20 , shown with the discharge assembly in the swing-away position.
[0052] FIG. 23 is an exploded perspective view illustrating various components of the hopper of the grout placement apparatus shown in FIG. 20 .
[0053] FIG. 24 is a schematic drawing illustrating a gas-powered hydraulic control system for the grout placement apparatus shown in FIG. 20 .
[0054] FIG. 25 is a schematic drawing illustrating a piping layout for the hydraulic control system shown in FIG. 24 .
[0055] FIG. 26 is a schematic drawing illustrating an electrical circuit for the gas-powered grout placement apparatus shown in FIG. 20 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] In describing a preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
[0057] As shown in FIGS. 1-6 , a first preferred embodiment of a grout placement apparatus according to the present invention is generally designated by reference numeral 10 . The apparatus includes a hopper 20 with a hopper discharge sleeve 22 , a hopper support frame generally designated by reference numeral 24 , an auger 26 mounted within the bottom or trough of the hopper (see FIG. 6 ), a swing-away discharge assembly generally designated by reference numeral 30 , and a discharge conduit generally designated by reference numeral 33 including a hose 120 .
[0058] The hopper 20 , shown in isolation and from the rear in FIG. 7 , has a front wall 40 and a rear wall 90 that are generally parallel with one another, and two opposing sidewalls 36 joining the front and rear walls 40 , 90 to form a grout holding area, generally designated by reference numeral 35 , with a rectangular open top generally designated by reference numeral 34 . The opposed sidewalls 36 converge downwardly in a V-shape into a curved bottom or trough 38 . The hopper discharge sleeve 22 is fitted at the forward end of the curved bottom 38 and extends out past the hopper front wall 40 (see FIG. 5 ).
[0059] The sidewalls 36 of the hopper 20 are angled to minimize grout material build up and to direct the grout material flow toward the auger 26 in the curved bottom 38 . The sidewalls themselves are straight, i.e., they have no angular changes from their upper edges 37 to the bottom 38 . The straight configuration of the sidewalls, and their continuous slope from top to bottom of the sidewalls, and their continuous slope from top to bottom promotes the smooth uninterrupted flow of grout material toward the bottom 38 of the hopper. The angle of each sidewall is preferably no more than 45° from the vertical, to form an included angle between the sidewalls of about 90°. Within this range, a preferred angle of each sidewall 36 is about 35°, to form an included angle of about 70°.
[0060] The upper edges of the sidewalls 36 are preferably provided with inwardly angled flanges or splash guards 42 that help to prevent loss of the grout material from the top of the hopper during transport of the grout placement apparatus. These splash guards 42 are also provided on the upper edges of the front and rear hopper walls 40 , 90 so that the entire hopper opening is configured to prevent inadvertent spillage of the grout material.
[0061] The hopper 20 is removably mounted on the hopper support frame 24 which allows the hopper to be replaced with a similar or different capacity hopper as needed. As shown in FIGS. 8 and 9 , the hopper support frame includes an upper frame, generally designated by reference numeral 44 , and a lower frame, generally designated by reference numeral 46 . The upper frame 44 includes a base platform 48 having two pairs of upwardly depending support arms generally designated by reference numeral 50 that are angled outwardly to correspond with the angles of sidewalls of the hopper 20 , i.e., no more than about 45° from vertical, preferably about 35°, to form an included angle between the sidewalls of no more than about 90°, preferably about 70°. Each pair of arms 50 includes a front arm 51 , 52 and a rear arm 53 , 54 that are joined by generally planar opposed mounting plates 55 , 56 , each having elongated apertures 58 that receive fastening elements 59 . The arms and mounting plates form a cradle generally designated by reference numeral 60 therebetween that receives the hopper 20 . The elongated apertures 58 in the mounting plates 55 , 56 allow for adjustable positioning of the fastening elements 59 used to secure the hopper in the cradle 60 .
[0062] Mounted to the right front arm 52 is a hinge support arm 62 that extends forwardly from the arm 52 as shown in FIG. 8 . The hinge support arm 62 is pivotally connected to an articulating element 64 that couples the upper frame 44 or the hopper 20 to the discharge assembly 30 , as will be described more fully hereinafter.
[0063] The upper frame 44 is rotatably supported on the lower frame 46 by a pivot 66 mounted within an aperture 68 in the center of the base plate 48 . The bottom 70 of the pivot is positioned within an upwardly extending tubular boss 72 mounted on the base element 74 of the lower frame 46 and is suitably held in place by plate 75 (see FIGS. 5 and 6 ). Extending outwardly from the tubular boss 72 are a plurality of horizontally directed arms 76 that are preferably evenly spaced from one another and which include heavy duty roller bearings 78 suitably mounted adjacent the distal ends of arms 76 . The base plate 48 of the upper frame 44 and base element 74 of the lower frame 46 are generally parallel with one another and are held in a spaced relationship from one another by the pivot 66 , tubular boss 72 and roller bearings 78 . The arms 76 include associated pivot stops 80 that are configured to allow the upper frame 44 with the hopper 20 attached thereto to be locked into various rotational positions. According to a preferred embodiment, the hopper 20 can swivel 360° and can lock in four different positions.
[0064] As shown in FIG. 9 , the lower frame 46 is fixedly mounted on a pair of parallel forklift-receiving box beams 82 that are configured to receive the forks of a conventional forklift that can support the entire grout placement apparatus in a manner known in the art.
[0065] The outwardly extending hopper discharge sleeve 22 is configured as a tube that communicates with the discharge or forward end 84 of the auger 26 as shown in FIGS. 6 and 10 . The distance to which the forward end 84 of the auger extends into the discharge sleeve 22 is sufficient so that the auger is self-supported in the sleeve, eliminating the need for a support bushing or the like for the auger forward end 84 . The rear end 86 of the auger 26 is connected to a coupling 88 extending through the rear wall 90 of the hopper and is connected to and supported by the auger motor 92 (see FIG. 6 ). The auger motor 92 is preferably covered by a protective cowling 94 as shown in FIG. 10 .
[0066] In the PTO grout placement apparatus, the discharge sleeve 22 is relatively short in length, extending only about 9.75 inches. The forward end 84 of the auger 26 does not extend through the discharge sleeve 22 nor into the discharge assembly 30 . Rather, the discharge sleeve 22 has a diameter that is only slightly smaller than the diameter of auger 26 . The closeness of these two diameters allows the auger forward end 84 to be supported in the sleeve 22 without a bushing and to be removed easily through the top of the hopper.
[0067] The sequence by which the auger is removed is illustrated in FIGS. 11 and 12 after the discharge assembly 30 has been moved to its swing-out position (and is not shown in FIGS. 11 and 12 ). As shown, the auger 26 is moved forwardly into the discharge sleeve 22 until the rear end 86 of the auger is freed from the coupling 88 , as shown in FIG. 11 . This movement is made possible by the size of the sleeve 22 and the flexibility of the auger blades 27 . The rear end 86 of the auger 26 may then be drawn upwardly to remove the auger from the hopper, as shown in FIG. 12 .
[0068] The auger 26 is mounted so as to be in contact with the bottom 38 of the hopper 20 . While this is not immediately apparent from the drawings as set forth in FIGS. 6 , 10 and 11 , the spacing shown is the result of the curved nature of the bottom of the hopper. The auger has flexible blades or flighting 27 and is to Thiessen. Such an auger is commercially available from Talet Equipment International of Strathmore, Alberta, Canada. The flexibility of the blades 27 prevents binding of the auger 26 and provides superior flow control and efficiency since the blades effectively sweep and self-clean the bottom 38 of the hopper to discharge material from the hopper while leaving minimal residual grout material therein.
[0069] The positive displacement generated by the blades 27 from the forward rotation of the auger 26 pushes the grout material through the hopper discharge sleeve 22 and into the discharge assembly 30 shown in FIG. 13 . The discharge assembly 30 includes a housing 100 having a hinge support arm 102 mounted thereto (see FIGS. 1 and 8 ). The housing hinge support arm 102 is coupled by pivot pin 103 to the opposite end of the same articulating element 64 shown in FIG. 8 that is pivotally connected by pivot pin 63 to the hinge support arm 62 on the upper frame support 44 . As mounted on the hinge support arms 62 , 102 and articulating element 64 , the discharge assembly 30 is able to swing outwardly from a locked position adjacent to the front wall 40 of the hopper 20 and against the outlet end of the discharge sleeve 22 , to a swing-away position away from the hopper such as that shown in FIG. 14 .
[0070] When pivoted to the locked position (see FIG. 1 ), the discharge assembly 30 is secured to the front wall 40 or to the discharge sleeve 22 using any known locking mechanism as would be understood by persons of ordinary skill in the art. In the first embodiment shown in FIGS. 1-4 and 13 , a T-handle generally designated by reference numeral 108 is provided for this purpose. FIG. 14 , on the other hand, illustrates an alternate configuration of the first embodiment in which a clamp-style locking mechanism 206 mounted on the side of the discharge sleeve 22 is used. (The clamp 206 is shown in greater detail in FIG. 21 which pertains to the second, gas-powered, embodiment of the grout placement apparatus, as will be discussed hereinafter.) In the alternate configuration of FIG. 14 , the hinge support 62 is coupled to the hopper 20 rather than to the upper frame 44 .
[0071] In both the first embodiment of FIGS. 1-4 and 13 , and the alternate configuration thereof shown in FIG. 14 , the discharge assembly 30 includes a face plate 85 with a circular cutout 91 which mates with the circular distal end 93 of the discharge sleeve 22 and forms a sealed flow communication with the discharge sleeve opening 95 (see FIG. 14 ), when the discharge assembly 30 is in the locked position. Positioned in the lower portion of face plate 85 opposite cutout 91 is an inlet tube 87 which extends into the housing 100 and cooperates with a flapper-type control valve, generally designated by reference numeral 110 , within the discharge assembly 30 .
[0072] The top and front of the housing 100 are provided with rinse-out grates 104 , 106 , best seen in FIGS. 1 and 13 . The rinse-out grates have openings 105 that provide air flow into and out of the housing to prevent a vacuum-lock condition in the discharge assembly or the upper part of the hose 120 as might otherwise occur if the housing formed a fully sealed enclosure. With the equalization of pressure, the grout material flows freely through the housing and into the hose 120 without clogging, thereby increasing the efficiency of the apparatus.
[0073] When the discharge assembly 30 is in the swing-out position, the discharge sleeve 22 is readily accessible and can be cleaned and/or inspected. The face plate 85 and inlet tube 87 can also be easily cleaned. The rinse-out grates 104 , 106 also allow for more effective cleaning of the inside of the housing 100 , allowing water to be directed therein through the openings 105 without having to disassemble the housing.
[0074] For use of the apparatus, the discharge assembly 30 is pivoted to the locked position adjacent the front wall 40 and against the discharge sleeve 22 of the hopper where it is secured to the front wall 40 or to the discharge sleeve 22 using the T-handle 108 , clamp 206 or any other fastening mechanism suitable for this purpose as has already been noted. When the discharge assembly 30 is in the locked position, it is automatically aligned with the auger 26 and sleeve 22 as described above.
[0075] The PTO grout placement apparatus can be operated in one of two modes, a manual mode and an optional radio frequency (wireless) remote control mode. When operating in the manual mode, the hydraulic control system of the apparatus is connected to the hydraulic quick coupling connectors on the forklift or other loading equipment supporting the apparatus. The forklift operator then initiates the starting and stopping of the auger in response to hand signals received from the hose operator. A schematic drawing of the hydraulic connections when operating in the manual control mode is provided in FIG. 15 , and a piping layout thereof is set forth in FIG. 16 . A manifold 250 , which is connected to the PTO 252 of the loading equipment (the PTO not being a part of the present invention) is directly coupled to the drive motor 92 which drives the auger 26 . The motor 92 is also coupled through hydraulic hoses 256 , 257 to a valve hydraulic cylinder 116 , which operates the flapper-type control valve 110 .
[0076] The control valve 110 is fitted within the discharge assembly 30 and both seals the hopper 20 and stops the flow of grout material by closing off the exit opening 115 of inlet tube 87 (see FIG. 13 ). The valve 110 includes the closing flap 112 supported on a lever arm 113 pivotally mounted on an axle 114 (see FIGS. 5 , 6 and 13 ). The flap 112 and lever arm 113 are operated by valve hydraulic cylinder 116 tied into the hydraulic circuit of the grout placement apparatus 10 as above described. In the manual mode shown in FIG. 15 , a hydraulic manifold 250 controls the pressure and flow of the hydraulic fluid to the valve hydraulic cylinder 116 . When the auger 26 is rotated in a forward direction by hydraulic auger motor 92 to move grout material out of the hopper, through sleeve 22 and inlet tube 87 and into housing 100 , the valve hydraulic cylinder 116 is retracted to automatically rotate the lever arm 113 upwardly about the axle 114 and open the flapper valve 112 away from the outlet 115 of the inlet tube 87 . To discontinue flow of grout material, the forward rotation of the auger is discontinued and then temporarily reversed by the hydraulic controls of the auger drive motor 92 . In response, the valve hydraulic cylinder 116 is extended to automatically rotate lever arm 113 downwardly and cause the flapper valve 112 to close over the outlet 115 of inlet tube 87 and preclude any material from exiting the hopper.
[0077] As shown in FIG. 1 , the hose 120 of the discharge conduit 32 delivers the grout material to the desired location by the positive rotation of the flexible bladed auger 26 . The hose 120 is preferably flexible but could, in some cases, be a rigid tube or pipe-like conduit. The hose 120 preferably has a handle 124 to assist in directing the grout material to the desired location.
[0078] To facilitate more precise control of the auger rotation, the PTO grout placement apparatus 10 is configured to alternatively operate in a remote control mode. According to a preferred embodiment, a remote radio frequency system, such as that shown in FIG. 17 and generally designated by reference numeral 130 , allows the hose operator to control the flow of material at the point of delivery by providing inputs to a hand-held remote controller 132 . The remote controller 132 is preferably provided with separate buttons or comparable input elements for forward and reverse rotation of the auger 26 . Radio frequency signals transmitted from the remote controller 132 are received by a receiver unit 134 suitably mounted on the grout placement apparatus and powered by a battery 136 held within a battery box 137 and cover 138 ; according to one embodiment, the remote control receiver unit 134 is mounted at storage location 57 on the support frame 24 (see FIG. 1 ).
[0079] Remote-controlled operation improves the accuracy of grout material placement, reduces waste caused by overflow, and eliminates the potential for confusion in hand signals otherwise used to signal the loading equipment operator to start and stop the auger. The RF controller can also be bypassed to transfer control of the auger 26 back to the operator of the loading equipment.
[0080] According to a preferred embodiment, the remote controller 132 is configured to provide momentary control, i.e., when the forward or reverse button is depressed, the auger is turned on but, as soon as the button is released, the auger stops. A schematic drawing illustrating the hydraulic control system for the remote control embodiment is set forth in FIG. 18 . An electrical circuit for this embodiment is provided in FIG. 19 . As shown, the receiver 134 is coupled to a battery 136 through a switch battery isolator 262 . The switch battery isolator 262 allows the receiver 134 to be turned on and off, conserving power when the receiver 134 and remote controller 132 are not being used.
[0081] A second embodiment of the present invention, namely the gas-powered grout placement apparatus noted earlier, is illustrated in FIGS. 20-23 and generally designated by the reference numeral 300 . Components that are common with the PTO grout placement apparatus will not be discussed again to avoid unnecessary repetition. Components serving the same purpose but having different dimensions are identified by the same numbers but preceded by the digit “3”.
[0082] The gas-powered grout placement apparatus 300 has, as the name implies, its own gasoline powered engine 200 which is supported on a bracket 202 above the discharge sleeve 322 and preferably covered with a cowling 204 as shown in FIG. 20 . To provide sufficient length to support the engine, the discharge sleeve 322 is longer than in the PTO embodiment, extending outwardly from the hopper front wall 340 about 22.28 inches. Due to this longer length, the auger cannot be removed from the top of the hopper 320 but instead is removed, if necessary, through the hopper discharge sleeve 322 , after the discharge assembly 330 has been moved to its swing-away position.
[0083] As in the alternate configuration of the first embodiment, the discharge assembly 330 is secured to the hopper 320 using a clamp 206 as shown in FIGS. 21 and 22 . In the swing-out position shown in FIG. 23 , the discharge sleeve 322 is exposed for cleaning and inspection as in the first embodiment including the alternate configuration thereof.
[0084] As best shown in FIG. 23 , the gas-powered grout placement apparatus 300 can be configured to include a lifting bail 210 mounted within the hopper 320 . The bail 210 has a handle or lifteye 212 to allow the apparatus to be picked up by a crane or other lifting apparatus. When using the bail 210 , the delivery hose is preferably positioned to the desired delivery location using the hook pivot of the crane and not the pivoting capability of the hopper.
[0085] Since the gas-powered grout placement apparatus 300 does not operate off of the PTO of the loading equipment, the hydraulic connections are different from those of the PTO grout placement apparatus 10 . A representative schematic is set forth in FIG. 24 and includes the engine 200 , hydraulic gear pump 270 and hydraulic tank 272 ; a piping layout of the hydraulics is shown in FIG. 25 .
[0086] Given the placement of the auger motor on the back side of the hopper, the gas-powered grout placement apparatus 300 shown in FIGS. 20 and 22 is operable only remotely. An electrical schematic for remote operation of the gas-powered grout placement apparatus is shown in FIG. 26 . To protect against loss or separation from the apparatus, the remote controller 3132 is preferably secured to the apparatus 300 by a tether 221 while, as in the PTO embodiment, the receiver 3134 is secured at a storage location 357 on the support frame 324 . The second embodiment also includes a lanyard configuration (not shown) in which the remote controller is secured with the receiver 3134 at the storage location 357 . Alternatively, suitable connections and wiring could be established to allow the gas-powered placement apparatus 300 to be controlled with a wired remote controller, preferably by the operator positioning the grout delivery hose.
[0087] The foregoing descriptions and drawings should be considered as illustrative only of the principles of the invention. The invention may be configured in a variety of shapes and sizes and is not limited by the dimensions of the preferred embodiment. Numerous applications of the present invention will readily occur to those skilled in the art. For example, the device as described herein may be used in contexts other than construction, being equally applicable to other services in which the placement of a material that can be conveyed with an auger and delivered through a conduit is required. Therefore, it is not desired to limit the invention to the specific examples disclosed or the exact construction and operation shown and described. Rather, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | The grout placement apparatus has a V-shaped hopper with a flexible-bladed auger mounted therein that can be rotated in both forward and reverse directions by an auger motor. The auger has flexible blades to drive the grout material along the bottom of the hopper to a discharge sleeve that extends from the hopper. Coupled to the discharge sleeve is a discharge assembly having a flow control valve that is automatically opened and closed by the forward and reverse rotation of the auger, respectively. The discharge assembly is hingedly movable with respect to the hopper, allowing the discharge assembly to “swing away” from its operating position against the discharge sleeve to a position that uncovers the discharge sleeve for easy cleaning. A flexible discharge conduit or hose coupled to the discharge assembly conveys the grout material to the desired placement location. The rotation of the auger can be remotely controlled by a wireless remote controller, and the auger motor can be powered by the hydraulics of separate lifting equipment or by a dedicated combustion engine mounted on the placement apparatus. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field
[0002] The present invention relates generally to the field of peptides reactive with antibodies directed against HPV. Some have termed this type of peptide as antigenic or immunoreactive. More particularly, the invention relates to peptides derived from the early coding region of the E2, E6, and E7 oncoproteins of human papillomavirus [HPV] and a method for their use for the diagnosis of HPV associated epithelial cell abnormalities via an immunoassay.
[0003] 2. State of the Art
[0004] The human papillomaviruses (HPV), named because certain types induce warts or papillomas, cause virtually all cervical cancers (Nobbenhuis et al., “Relation of human papillomavirus status to cervical lesions and consequences for cervical-cancer screening: a prospective study”, The Lancet, 354:20-25, 1999; Cuzick et al., “A systematic review of the role of human papilloma virus (HPV) testing within a cervical screening programme: summary and conclusions”, British Journal of Cancer, 83:561-565, 2000). These encompass not only squamous cell carcinomas (Nobbenhuis et al., 1999) but also adenocarcinomas (Pirog et al., “Prevalence of human papillomavirus DNA in different histological subtypes of cervical adenocarcinoma,” American Journal of Pathology, 157:1055-1062, 2000). These viruses are also strongly associated with vulvar and vaginal carcinomas (Frisch et al., “Human papillomavirus-associated carcinomas in Hawaii and the mainland US”, Cancer 88:1464-1469, 2000; Sugase et al., “Distinct manisfestations of human papillomaviruses in the vagina”, International Journal of Cancer, 72:412-415, 1997), as well as cancers of the anus (Frisch et al., 2000) and penis (Gregoire et al., “Preferential association of human papillomavirus with high-grade histologic variants of penile-invasive squamous cell carcinoma”, Journal of the National Cancer Institute, 87:1705-1709,1995). Moreover, HPV may be responsible for certain carcinomas in the head and neck region (Mellin et al., “Human papillomavirus (HPV) DNA in tonsillar cancer: clinical correlates, risk of relapse, and survival”, International Journal of Cancer, 89:300-304,2000; Zumbach et al., “Antibodies against oncoproteins E6 and E7 of human papillomavirus types 16 and 18 in patients with head-and-neck squamous-cell carcinoma”, International Journal of Cancer, 85:815-818, 2000), seem associated with the more deadly melanomas (Dreau et al., “Human papilloma virus in melanoma biopsy specimens and its relations to melanoma progression”, Annals of Surgery, 231:664-671,2000), and could play a role in lung carcinomas (Soini et al., “Presence of human papillomavirus DNA and abnormal p53 protein accumulation in lung carcinoma”, Thorax 51:887-893, 1996) and perhaps other cancers. HPV exist as different genetic types, designated by numbers, concerning which only a subset is oncogenic or cancer causing. Over 100 HPV genotypes have been identified. Cancers stem overwhelmingly from HPV 16 and 18 but also from types 31, 33, 35, 45, 51, 52, 56 and 58. The virus infects cervical and other cells that can support virus propagation, where it causes abnormal cellular changes that can lead to life threatening malignancies. Cervical cancer is the second most common cancer among women worldwide. Each year, about 450,000 women worldwide are diagnosed with cervical cancer, and nearly 300,000 women die of this disease. Since the advent of organized cervical cancer screening via cytology 50 years ago, the mortality rate of cervical cancer has dramatically decreased in developed countries. In fact, cervical cancer can be considered preventable. The key to prevention is the timely identification and management of precancerous lesions through accessible and affordable screening programs. At present, 11.8% of global cancer incidence in females is due to HPV infections of the cervix. There is consensus that oncogenic HPV detection would be an effective way to identify cancer victims or those at high risk for the disease. Notably, HPV detection would facilitate early detection, when cancer would exist at a more readily curable stage.
[0005] HPV infection requires cells able to replicate their DNA, specifically those in the basal epidermal layer. Entry occurs through microlesions that expose basal proliferating cells to the surface. The virus attaches to a cell surface receptor and gains entry into the cytosol. The infecting virus particle contains a closed-circular double-stranded DNA genome of 7000 to 8000 base pairs composed of eight early transcribed open reading frames, E1 to E8, which are unequally represented among HPV genotypes, two late open reading frames, and a noncoding long control region.
[0006] Much has been discovered about how HPV DNA integrates into host chromosomes and how the E1 and E2 oncoproteins are involved with this process. Its relevance to immunological diagnostics is that antibodies against E1 and E2 gene products comprise evidence that HPV infection has occurred.
[0007] The manner by which infection by HPV leads to cancer centers about the E6 and E7 gene products. In host cells, these form complexes with the cellular p53 and retinoblastoma tumor suppressing proteins regulating cell division. By functionally neutralizing or inactivating these proteins, cells enter into the S phase of the cell cycle. The E7 oncoprotein further destabilizes cell control through its interaction with the cyclin-dependent kinase inhibitor protein, p21. These interactions set the stage for controlling host cell proliferation and differentiation (i.e., transformation), a first step in the conversion of normal cells to preneoplastic ones and ultimately to the full expression of malignancy.
[0008] The E6 and E7 oncoproteins are constitutively expressed in tumor cells, and silencing these genes yields reversion of the malignant phenotype. Thus, the E6 and E7 gene products seem tumor-specific antigens, and possible targets or probes for antibodies in immunological cancer tests as well as antigens in vaccines for controlling HPV induced tumors.
[0009] Indeed, the E6 and E7 oncoproteins appear natural targets for antibody production due to their consistent expression in cervical cancer cells. The response against the E7 one in earlier studies had only been moderately disease specific, but E7 lgG and IgA have now been verified as strongly disease associated. Antibodies against the E6 and E7 oncoproteins are at high levels in sera from cervical cancer patients compared against non-cancer controls. Moreover, such antibodies seem detectable by immunological means even when present in lesser amounts. Sensitivity for identifying HPV infections and possible cancers increases with a combination of serological tests of multiple virus proteins. Hence, using both oncoproteins yields positive immunological results with samples from cervical cancer patients.
[0010] The main method for public health screening for cervical cancer has been the Papanicolaou smear. For a variety of reasons, the Papanicolaou smear is less than an ideal screening test. Drawbacks include difficulty of obtaining samples, high rate of false negatives (up to 20%), and requirements for specialized labs staffed by highly trained personnel. Nucleic acid methods have been developed, but are not ideal primarily due to their high cost and like requirement for highly trained personnel. Another assay is the so-called “DNA Hybrid Capture”. This method suffers from high cost and sampling difficulties. What is needed is a low cost, simple, sensitive and specific assay that can be performed on readily obtainable bodily samples.
[0011] An object of the invention is to develop antibody active peptides derived from the HPV E2 protein and the HPV 16 and 18 E6 and E7 oncoproteins. It is a further object to provide these peptides in a chemically pure form. It is a still further object to provide a simple, rapid, less expensive and more sensitive test for diagnosing not only HPV infections, but also most, if not all, HPV associated neoplasms. A further object is to provide antigens for use in HPV inoculums that will induce antibody production and killer T cell activity.
SUMMARY OF THE INVENTION
[0012] The above stated objects and other objects of the invention are accomplished by novel peptides, the sequences of which were derived by the inventor from careful analysis of the early coding regions of the E2, E6, and E7 oncoproteins of HPV 16 and 18. The peptides lend themselves to a highly sensitive and specific diagnostic immunoassay. Antibodies to the E2 oncoprotein are found in those infected with HPV. Antibodies to the E6 and E7 oncoproteins are found in those with HPV associated neoplasms. The peptides of the invention, ranging in size from about 19 amino acid residues to about 30 amino acids can readily be synthesized by chemical means and obtained at purities that can exceed 99%. Although the peptides could be obtained by other means, in their pure form there may be a much reduced likelihood for undesirable cross reactivity with random antibodies. Hence, the pure peptides of the invention lend themselves to diagnostic immunoassays of high specificity. The diagnostic immunoassay method comprises taking a sample of body fluid or tissue likely to contain antibodies, if present, reacting it with one or more of the peptides of the invention, then assaying for the presence of an antibody-peptide reaction.
[0013] Immunoassays employing peptides derived from the E2 region serve as reliable indicators that HPV infection has or has not occurred. Immunoassays employing the peptides derived for the E6 and E7 oneoproteins serve as reliable indicators that HPV associated malignancy or premalignant cell transformation has taken place. One of the most useful aspects of the invention is in diagnosing cervical carcinoma, both squamous cell and adenocarcinoma as well as any epithelial cell abnormality associated with oncogenic HPV infection including koilocytosis; hyperkerotosis; precancerous conditions encompasssing intraepithelial neoplasias or intraepithelial lesion; high-grade dysplasias; and invasive or malignant cancers. Besides cervical cancer, detection of antibodies to peptides derived from the HPV E6 and E7 oncoproteins is useful for detecting head and neck cancers, small cell lung cancers, penal and anal squamous cell carcinomas, and melanoma.
DESCRIPTION OF THE DRAWINGS
[0014] The invention will be described in more detail below, reference being made to the accompanying drawings in which:
[0015] [0015]FIG. 1 is a table showing the single letter code used for the corresponding amino acid used in the FIGS. 2 - 4 ;
[0016] [0016]FIG. 2 is a coded depiction of the early coding region of the E2 oncoprotein wherein SEQ NO and SEQ NO 2 of the invention are underlined;
[0017] [0017]FIG. 3 is a coded depiction of the early coding region of the E6 oncoprotein wherein SEQ NO 3 of the invention is underlined;
[0018] [0018]FIG. 4 is a coded depiction of the early coding region of the E7 oncoprotein of HPV 18 wherein SEQ NO 5 of the invention is underlined;
[0019] [0019]FIGS. 5 and 6 are a table showing the results of a diagnostic immunoassay on controls and patients with HPV infection and HPV associated neoplasms.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] The peptides of the invention are derived from the early coding regions of the E2, E6, and E7 oncoproteins of HPV 16 and 18. The derivation of the peptides of the invention were based on their predicted ability to react with antibodies formed in a host infected with oncogenic HPV. Among the specific factors used in the selection process is solubility in aqueous solution or hydrophilic nature. It was assumed that hydrophilic regions of the oncogene product protein were more likely oriented toward the surface of the complete protein under natural conditions, and that such are consequently antigenic regions against which antibody reactivity would most likely occur.
[0021] Another factor included having a single lysine or cysteine near the N-terminus. By near, it is meant at the terminus or no more than two residues from the terminus. By single, it is understood that additional lysine or cysteine residues are at least eight residues from the N-terminus. It is preferable that lysine or cysteine be added to the N-terminus of a reactive peptide, if such a residue were not already at or near the N-terminus. It is also preferable that an overall relative paucity of cysteine residues in the amino acid sequence be maintained. Also preferred was an overall paucity of tryptophan and methionine residues and a relative abundance of glycine or asparagine residues. By paucity, it is meant that there are as few occurrences as possible and by abundance, it is meant that there is no limit on the number of occurrences in the sequence. A still more preferred embodiment of the peptide compositions includes up to six additional amino acid residues attached to the carboxy terminus where those residues are any combination of glycine and asparagine. Additional glycines and asparagines orient the peptide in the aqueous reaction medium in a fashion that increases antibody binding.
[0022] FIGS. 2 - 4 disclose five specific peptide sequences ranging from 16 to 30 residues. The key to the coded sequences in FIGS. 2 through 4 is given in FIG. 1. As depicted in FIG. 2, SEQ NO. 1 and NO. 2 were derived from the E2 Region of HPV 16. Decoded and using the standard three letter abbreviations sequence, numbers 1 and 2 are as follows:
Asp Ile Cys Asn Thr Met His Tyr Thr Asn Trp Thr His Ile Tyr Ile (SEQ. NO. 1) 1 5 10 15 Cys Glu Glu His Lys Ser Ala Ile Val Thr Leu Thr Tyr Asp Ser Glu Trp Gln Arg (SEQ. NO. 2) 1 5 10 15
[0023] Sequences number 3 and 4 are derived from the E7 early coding region of HPV 16 as depicted in FIG. 3. Decoded using the standard three letter abbreviations sequence number 3 is as follows:
Pro Thr Leu His Glu Tyr Met Leu Asp Leu Gln Pro Glu Thr Thr Asp (SEQ. NO. 3) 1 5 10 15 Leu Tyr Cys Tyr Glu Gln Leu Asn Asp Ser Ser Glu Glu Glu 20 25 30 Cys Asp Ser Thr Leu Arg Leu Cys Val Gln Ser Thr His Val Asp Ile (SEQ. NO. 4) 1 5 10 15 Arg Thr Leu Glu 20
[0024] Sequence number 5 is derived from the E2 early coding region of HPV 18 as depicted in FIG. 3. Decoded using the standard three letter abbreviations sequence number 5 is as follows:
Glu Lys Thr Gly Ile Leu Thr Val Thr Tyr His Ser Glu Thr Gln Arg Thr (SEQ. NO.5) 1 5 10 15 Lys Phe
[0025] The use of the peptides in a diagnostic method is based on the fact that antibodies to the native epitopes of the E2, E6, and E7 oncoproteins of HPV 16 and 18 are found in those suffering from a variety of HPV associated epithelial cell abnormalities ranging from mere infection to malignancy. More particularly, such HPV associated cellular abnormalities may include, but are not limited to, koilocytosis; hyperkerotosis; precancerous conditions encompassing intraepithelial neoplasias or intraepithelial lesions; high-grade dysplasias; and invasive or malignant cancers. The malignant neoplasms associated with HPV are discussed above. The method comprises taking a sample of body fluid or tissue likely to contain antibodies. This sample is preferably easy to obtain and may be serum or plasma derived from a venous blood sample. However, cervical secretions, cervical tissue, tissue from other body parts, or other bodily fluids are known to contain antibodies and may be used as a source of the patient sample. Once the peptide antigen and sample antibody are permitted to react in a suitable medium, an assay is then performed to determine to presence of an antibody-peptide reaction.
Synthesis of the Peptide Sequences
[0026] While the peptides of the invention could be obtained by a variety of prior art methods, among them recombinant sources, chemical synthesis is the preferred method as it facilitates accumulation of a sizable amount of peptide in a substantially pure form, around 99% by weight in the present case. The synthesis of peptides was done on a 0.25 scale using (9-fluorenyl) methoxycarbonyl (FMOC)-protected L-amino acids, with super acid-labile 2-chlorotrityl resin (Novabiochem, Nottingham, UK) as a solid support. Resin preloaded into a reaction vessel was washed with dimethyl formamide and then drained completely. To this resin was added 10 ml of 20% piperidine in dimethyl formamide. The mixture was then shaken for 5 minutes and drained. Another 10 ml of 20% piperidine in dimethyl formamide was added, and the mixture shaken for 30 minutes. After draining, the resin was washed with dimethyl formamide four times, and then once with dichloromethane. The resin beads were considered appropriately prepared if these turned blue using the standard ninhydrin test.
[0027] For each amino acid, coupling solution was prepared: 1 mmol Fmoc Amino Acid of choice; 2.1 ml 0.45 M 2-(1H-benzotriazole-1-yl)-1,1,3,3-tetramethyluronium-hexafluoro-phosphate/hydrobenzotriazole [1 mmol]; 348 μl of N,N-diisopropylethylamine [2 mmol]. The mixture was shaken for a minimum of 30 minutes. The reaction vessel was drained, the resin washed four times with dimethylformamide, and a final time with dichloromethane. A standard ninhydrin test was performed to ascertain coupling of the amino acid. For each amino acid, coupling solution was added to the resin in the appropriate order, with the coupling reaction repeated until all amino acids were in place along the peptide.
[0028] The completed peptide was cleaved from the resin by reaction for two hours with a solution of 5% H 2 O, 5% phenol, 3% thioanisole, 3% ethanedithiol, 3% triisopropylsilane, 81% trifluoroacetic acid. After cleavage, the resin mixture was filtered into cold methyl-tbutyl-ether. The precipitated peptide was then washed twice with cold methyl-tbutyl-ether and dried under gaseous nitrogen. The molecular weight of the peptide was checked by Matrix-Assisted laser Desorption Time-of Flight Mass Spectrometry, and the purity by High Performance Liquid Chromatography using a C 18300A 5 μ column. The synthesized peptide sequences were at a 99% level of purity, but it is emphasized that lesser levels were still considered possibly appropriate for assay purposes.
Storage of the Amino Acid Sequences
[0029] The manufactured amino acid sequences were suspended in PBS at pH 7.0 to a concentration of 1 mg/ml. The sequence solutions were split to 500 μg peptide per tube and storage was done at −20° C.
Maleic Anhydride Binding of the Amino Acid Sequences to Titer Plates
[0030] REACTI-BIND™ Maleic Anhydride Activated Polystyrene Plates (Pierce, Rockford, Ill.) were employed. Each amino acid sequence was diluted to 12.5 μg/ml with coating buffer (100 mM sodium bicarbonate buffer, pH 9.4). To each titer well, 100 μl (1.25 μg) of the diluted sequence solution was added. The plate was then incubated for one hour at room temperature with shaking. The plate was emptied and residual liquid tapped onto a clean paper towel. Each well was washed with 100 μl wash buffer (0.1% bovine serum albumin and 0.05% Tween-20 in phosphate buffered saline, pH 7.0). This was repeated for a total of three times. Each time, the plate was emptied and residual liquid tapped onto a clean paper towel. To each well, 200 μl of blocking solution (3% bovine serum albumin and 0.05% Tween-20 in phosphate buffered saline, pH 7.0) was then added. Blocking solution was left in each well for one minute. The titer plate was then emptied by inversion. Filling with blocking solution and emptying was done three times. Finished titer plates were dried at room temperature and stored at 4° C. for up to four months.
Sample Collection
[0031] All samples were taken from female patients during their scheduled visits for gynecological examinations. Cotton swabs were used to obtain endocervical cells. Cells for the ThinPrep Pap smear (Cytyc Corporation, Stamford, Conn.) were dispersed in ThinPrep preservative solution. Cells for the HPV DNA Hybrid Capture assay (Digene Corporation, Silver Spring, Md.) were suspended in the same medium. Both the ThinPrep Pap smear and the HPV DNA Hybrid Capture assay are further elucidated below.
[0032] Venous blood was obtained by usual phlebotomy methods, with a 21- or 22-gauge double-pointed needle into a agar barrier tube. A total of 7-9 ml blood was taken from each subject. After allowing 15 minutes at room temperature for clot formation, the blood was centrifuged for 15 minutes. Serum was aspirated away from the cells, using a disposable pipette, dispensed into Eppendorf tubes as 0.25-ml aliquots, and stored at −80° C.
Immunoassay
[0033] As a negative control, serum had been obtained from virgin females, ages 14 and 15. Subject and control sera were diluted 1:25 with wash buffer (0.1% bovine serum albumin and 0.5% Tween-20 in phosphate buffered saline, pH 7.0). To each well, 100 μl of diluted serum was added, and the assay plate incubated for one hour at room temperature with shaking. Each well was then rinsed three times, each with 200 μl wash buffer. Each rinse was for five minutes. The plate was emptied each time by tapping residual liquid onto a clean paper towel.
[0034] To each well was added 100 μl horseradish peroxidase conjugated-mouse-anti-human IgG diluted 1:8000 with wash buffer. The assay plate was then incubated for 1 hour at room temperature. Using multiple pipettes, each well was rinsed with 200 μl wash buffer four times. Each rinse was for five minutes. Before each rinse, the plate was emptied and residual liquid tapped on a paper towel.
[0035] To each well was added 100 μl 3,3′,5,5′ tetramethylbenzidine, a substrate for horseradish peroxidase. This was incubated at room temperature until a visually obvious green-blue color developed, 5-30 minutes, and the reaction stopped by placing 150 μl 1.5 M H 2 SO4 into each well.
Comparisonal Tests—ThinPrep Pap Test and HPV DNA Hybrid Capture
[0036] ThinPrep Pap Test—Cleared as a replacement for the conventional Pap smear, the ThinPrep Pap Test overcomes the limitations of the conventional method. By improving the way the sample slide is prepared, the ThinPrep Pap Test actually improves the quality of the test. In clinical trials, the ThinPrep Pap Test improved the detection of low-grade and more severe lesions by 65% in screening populations and by 6% in high-risk populations. Its use also reduced the number of less-than-adequate specimens by more than 50%. Hence, the ThinPrep Pap test was used here to optimize the results from cervical cytology.
[0037] Rather than smearing the cervical sample onto a slide as is done with the conventional Pap smear, the cervical swab was rinsed in a vial of preserving solution. The specimen was sent to a certified clinical laboratory, where an instrument, the ThinPrep 2000 processor, was used to disperse and filter the contents to reduce blood, mucus, and inflammation. A thin, even layer of the cervical cells was then mechanically deposited onto a slide, the result being a uniform preparation of well-preserved cells ready for precise microscopic examination. Slides were microscopically examined and interpreted by a board certified gynecological cytologist.
[0038] Hybrid Capture II HPV DNA Testing—The Hybrid Capture II HPV DNA test (HC II, Digene Corporation, Silver Springs, Md.) was employed as a comparison to the ELISA test with peptides of the invention. It is approved by the U.S. Food and Drug Administration to test for oncogenic HPV DNA, as reflexive follow-up of an ASCUS (Atypical Squamous Cells of Undetermined Significance) or other abnormal Pap results. The hybrid capture involves a molecular hybridization that uses non radioactive probes with amplification of the detection of the hybrid ones for chemoluminescence. The material for analysis is denatured and reacts with specific genic probe forming hybrid RNA/DNA that are captured by antibodies that cover the walls of the tube. To follow the hybrids immobilized, these are reacted with specific antibodies against RNA/DNA conjugated with alkaline phosphatase. Forming a stable substratum, the hybrids are detected by chemoluminescence via spectometry.
[0039] The test was run according to the manufacturer's protocol using the microtiter plate based format and probes for “high carcinogenic risk” HPV types. This was done at the same certified clinical laboratory at which the ThinPrep Pap smear was processed. Human papillomavirus determinations were quantitative, with samples producing readings of 1 or more times the positive control (1 μg/mL HPV DNA or 5000 HPV genome copies per test) considered to contain virus DNA.
Visualization/Interpretation of Completed ELISA Tests
[0040] The bottom of the titer plate was cleaned with 70% ethanol, and the titer plate loaded into the Plate Reader.
[0041] Absorbance was read at 450 nm, with 100 ml of TMB solution plus 100 ml of 2N HCl used as a blank control. The wells marked A1& A2 were used to assess background (A1, A2).
Results
[0042] The results comparing Pap smear, Digene HPV DNA assay, and immunoassay according to the invention are given in Table 1 shown in FIGS. 5 and 6. Thirty one subjects were tested. Samples 19 through 31 were from women with a low pre-test probability by virtue of sexual history and/or prior Pap smears and results were negative in all samples for all tests actually performed. This indicates a low rate of false positives and a high negative predictive value.
[0043] Samples 1 through 18 were from women with a high pre-test probability by virtue of proven clinical/pathological history or a sexual history of multiple partners. In all of these samples at least one immunoassay performed according to the invention was positive. This indicates a high positive predictive value. Since in some cases only one of the three immunoassays was positive, the value of employing the combination of peptides is demonstrated. The low false positives and high true positives indicates a test of high sensitivity and high specificity.
[0044] Also worth noting is that patient 1 had pathology proven adenocarcinoma of the cervix. Patient number 2 had squamous cell carcinoma of the cervix.
[0045] Whereas this invention is here illustrated and described with reference to embodiments thereof presently contemplated as the best mode of carrying out such invention in actual practice, it is to be understood that various changes may be made in adapting the invention to different embodiments without departing from the broader inventive concepts disclosed herein and comprehended by the claims that follow.
[0046] More particularly, the various changes that may be made were summarized in U.S. Pat. No. 5,629,146 to Dillner, et al., who said:
[0047] “By showing that a peptide is immunoreactive, the inventors have defined that it contains an epitope reactive with human sera. The epitope contained within this peptide sequence is not absolutely dependent on the exact sequence of the peptide, but can also be contained in a variety of minor modifications of the original peptide. Such modifications include extensions, truncations, cyclizations and amino acid substitutions. Sometimes the question arises if such a modified peptide should be considered a new peptide containing a new epitope. By competitive immunoassays with the original peptide and the modification thereof, it is straightforward to determine if the modified peptide is substantially immunoreactive with antibodies to the original peptide and thus contains the same epitope. It should be emphasized that a peptide can be produced in many different ways. Herein peptide synthesis by organic chemistry methods has been used, but the same peptides can also be produced by many other means for example by recombinant DNA expression systems.
[0048] It is understood that the herein contained description of the methods is intended to exemplify, but not limit, the present invention. An immunoassay can for example be performed in a variety of different ways. Detection of the antibodies that have bound to the specific antigen can for example be achieved with various antibodies to antibodies (anti-antibodies) or other compounds with affinity for antibodies, such as protein A or protein G. These reagents can be labelled in many different ways, for example radioactively (radioimmunoassay), with fluorescein (fluoro immunoassay) or enzymatically (enzyme-linked immunoassay, ELISA or EIA). A special case of enzymatic immunoassay is when the antigen-antibody complexes are detected on tissue sections. Such a procedure is instead referred to as immunostaining or immunohistocytochemistry, although the underlying principle is the similar as for ELISA.
[0049] An ELISA procedure can also be carried out in a variety of formats. Methods for enhancement of ELISA sensitivity using several layers of anti-antibodies, avidin-biotin complexes and enzyme-anti-enzyme antibody complexes are well known in the art. The solid support for fixation of antigen is usually plastic, as described here, but a variety of other solid supports such as latex or agarose have been described. It is also not necessary for the antigen to be directly fixed onto the solid support. There is for example a commonly used ELISA format that fixes the specific antigen to the solid support via a solid-phase-fixed antibody to the antigen, so-called catching antibody ELISA or sandwich ELISA. A special case of immunoassay which involves a blotting (transfer) of antigen to a solid support in sheet format is termed immunoblotting. Typically, the solid support is nitro-cellulose or nylon sheets, but other supports have been described. It is also a typical feature of this method that, prior to blotting, the antigens are separated according to size by gel electrophoresis or similar methods. Detection of antibodies bound to the specific antigen on the sheet can be carried out in similar ways as for other immunoassays. The here described detection using an anti-antibody, a biotin-avidin complex enhancement step and an enzymatic labelling is just one example of such a detection.
[0050] For diagnostic methods in general it is well known that a combination of several diagnostic methods produces a diagnostic method with better sensitivity and/or specificity than the individual tests contained in the combination. It is self-evident that any of the here described antibody tests could be combined with each other, or with other tests, to produce a combined diagnostic test with optimal sensitivity and specificity.”
1
8
1
19
PRT
Artificial Sequence
Derived from theE2 early region of HPV-16
1
Asp Ile Cys Asn Thr Met His Tyr Thr Asn Trp Thr His Ile Tyr Ile
1 5 10 15
Cys Glu Glu
2
16
PRT
Artificial Sequence
Derived from the E2 early region of HPV-16
2
His Lys Ser Ala Ile Val Thr Leu Thr Tyr Asp Ser Glu Trp Gln Arg
1 5 10 15
3
30
PRT
Artificial Sequence
Derived from the E7 early region of HPV-16
3
Pro Thr Leu His Glu Tyr Met Leu Asp Leu Gln Pro Glu Thr Thr Asp
1 5 10 15
Leu Tyr Cys Tyr Glu Gln Leu Asn Asp Ser Ser Glu Glu Glu
20 25 30
4
20
PRT
Artificial Sequence
Derived from the E7 early region of HPV-16
4
Cys Asp Ser Thr Leu Arg Leu Cys Val Gln Ser Thr His Val Asp Ile
1 5 10 15
Arg Thr Leu Glu
20
5
19
PRT
Artificial Sequence
Derived from the E2 early region of HPV-18
5
Glu Lys Thr Gly Ile Leu Thr Val Thr Tyr His Ser Glu Thr Gln Arg
1 5 10 15
Thr Lys Phe
6
19
PRT
Artificial Sequence
Derived from the E2 early region of HPV-16
6
Asp Ile Xaa Asn Thr Met His Tyr Thr Asn Trp Thr His Ile Tyr Ile
1 5 10 15
Xaa Glu Glu
7
30
PRT
Artificial Sequence
Derived from the E7 early region of HPV-16
7
Pro Thr Leu His Glu Tyr Met Leu Asp Leu Gln Pro Glu Thr Thr Asp
1 5 10 15
Leu Tyr Xaa Tyr Glu Gln Leu Asn Asp Ser Ser Glu Glu Glu
20 25 30
8
20
PRT
Artificial Sequence
Derived from the E7 early region E7 of HPV-16
8
Xaa Asp Ser Thr Leu Arg Leu Xaa Val Gln Ser Thr His Val Asp Ile
1 5 10 15
Arg Thr Leu Glu
20 | The invention provides peptides designed to be highly reactive with antibodies from patients infected with oncogenic HPV. Also disclosed is a method for their use in an immunoassay to detect HPV infection and HPV associated epithelial cell abnormalities, most notably those associated with premalignant and malignant epithelial cell lesions. The peptides and the disclosed method are particularly useful for diagnosing carcinomas of the uterine cervix, or pre-stages thereof, or those at risk of development of carcinoma. The detection can be effected on blood samples, or other bodily fluid or tissue, by ascertaining the presence of IgA or IgG antibodies against HPV 16 and/or 18. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Publications
[0002] Brown, Paul D. & Morra, Matthew J.(1 997)“Control of Soil-Borne Plant Pest Using Glucosinolate-Containing Plants”, Advances in Agronomy, Vol 61, pp167-231.
[0003] Harvey, S. G., Hannahan, H. N. & Sams, C. E.(2001)“Indian Mustard and Allyl Isothiocyanate Inhibit Sclerotium rolfsii”, J. Amer. Soc.Hort.Sci. 127(1) pp27-31.
[0004] Borek, V., Morra, M. J., Brown, P. D., & McCaffrey, J. P.(1 995)“Transformation of the glucosinolate-derived alleochemicals allyl isothiocyanate and allyl nitrile in soil” J. Agric. Food Chem. 43, 1935-1940.
[0005] Kjaer, A. (1976)“Glucosinolates in the Cruciferae”, The Biology and Chemistry of the Cruciferae, Academic Press, pp207-219.
BACKGROUND OF INVENTION
[0006] As environmental and human health concerns mount with the use of conventional synthetically produced pesticides, many are being banned, phased out or restricted from use. Pesticides such as organophosphates and methyl bromide, although in use now, are slowly being phased out and banned from use in the future. With the reduction in these chemicals, many end users are searching for safe environmentally friendly alternatives to these harmful products.
[0007] Biopesticides, which are pesticides that are derived from natural materials such as plants, animals, bacteria and certain minerals, has proved to be a safer alternative to conventional pesticides. The Environmental Protection Agency in 1994 set up a branch to evaluate and facilitate the registration these products under the Biopesticides & Pollution Division (BPPD) to help speed up the registration process. Since biopesticides tend to pose fewer risk than conventional pesticides, their use is encouraged.
[0008] One type of biopesticide is derived from plant materials. Certain plants have naturally occurring chemical defense mechanisms to protect itself from parasites, fungi and predators. One family of plants, the Cruciferae family, has such a defense mechanism. This family of plants contains glucosinolates and myrosinase enzymes, which upon destruction form Allyl Isothiocyanates (AITC's) and other compounds which are harmful to parasites, such as nematodes, pathogenic fungi and produces a pungent bitter taste for chewing predators.
[0009] Of the Cruciferae family, one species, brassica juncea , commonly known as Oriental or Indian Mustard, has an abundance of these compounds which would make it a prime candidate as a biopesticide in the control of root invading nematodes and pathogenic fungi.
SUMMARY OF INVENTION
[0010] The present invention is to be utilized as a biopesticide, nematicide and fungicide in the control of damaging nematodes and pathogenic fungi in the soil. And as a replacement or alternative to synthetically produced pesticides which are harmful to the environment, humans, animals and aquatic life.
[0011] The inventor has found that naturally occurring compounds in the seed pod of the species brassica juncea , commonly known as Oriental or Indian Mustard, once ground to a power and injected into the soil as a slurry or incorporated into the soil dry, create and release compounds which are toxic to both damaging nematodes and pathogenic fungi.
[0012] The embodiment of the invention is the utilization of the whole ground harvested seedpods from the species brassica juncea . Once the seed pods are harvested the entirety of the seed pod, which include the seed with seed oils intact, the husk or hull of the seed and stem material of the seed intact, ground to a powder of varying consistencies. This powder is then incorporated into the soil either as a slurry injected via a soil injection system, or applied dry to the soil and incorporated into the soil via mechanical means.
DETAILED DESCRIPTION
[0013] The present invention of Whole Ground Oriental Mustard Biopesticide once entering the soil by means of a soil injection system in a liquid slurry or incorporated dry into the soil by mechanical means, begins a natural degradation process in the presence of water and organic material. The glucosinolates sinigrin and gluconasturtiin contained in the Whole Ground Oriental Mustard are converted during this degradation process by the family of enzymes myrosinase to create allyl isothiocyanates (AITC's) and other biologically active products such as oxazolidinethiones (OZT's) which are released into the soil. The release of these biologically active products along with the mustard oils present in the invention, control the pathogenic fungi and suppress the damaging nematode population.
[0014] The invention may be applied in varying quantities and soil depths to produce sufficient control.
[0015] The Whole Ground Oriental Mustard Biopesticide is from the species brassica juncea and may be obtained from any variety or cultivar of that species which are commonly grown throughout the world. Once the seedpods are harvested, they remain intact until ground. The grinding process mechanically grinds the whole seed pod including the seed with oils intact, husk or hull and remaining stem material to a powder of varying consistencies to be utilized as the invention.
[0016] The Whole Ground Oriental Mustard Biopesticide as a natural organic pesticide can be handled safely and without harm to the environment or human health, as the biologically active products are formed and released once the material has entered the soil structure. Since the material is made of organic material there is associated benefits in the utilization of this invention. The invention has capabilities to retain moisture within the soil structure thereby relieving certain stresses to plants and turf caused by water infiltration problems. As an organic material, the invention contains carbohydrates and proteins which can be converted within the soil by natural degradation to food sources for plants and microbial life. The invention also adds organic matter directly to the soil structure to aid in the plants development.
[0017] Whole Ground Oriental Mustard Biopesticide may be applied with a liquid polymer, such as a commercially available product named JETWET from Poulenger USA, Inc., containing linear polymers and sulfates, to enhance the effects of the invention.
[0018] In addition a Biostimulant with high carbohydrate content, such as a commercially available product named RUTOPIA by Poulenger USA, Inc., will enhance and aid in the effects of the invention.
[0019] The following are examples of test results of the use of the invention and are for purposes of illustration and are not intended to limit the scope of the invention.
EXAMPLE 1
[0020] The invention, Whole Ground Oriental Mustard Biopesticide, was incorporated as a slurry into the soil via the use of a soil injection system to a depth of 3 inches and at an applied rate of 150 lbs. per acre. Test plot was of a golf course green with Bermuda grass planted. The results are as follows:
[0021] Nematode assay performed and number of plant parasitic nematodes were recovered from 100 cc of soil samples.
Sampling of soil prior to treatment. (Test date 03/08/02) Sting (Belonolaimus) 50 per 100 cc of soil Lance (Hoplolaimus) 14 per 100 cc of soil Spiral (Helicotylenchus) 55 per 100 cc of soil Root Knot (Meloidogyne) 55 per 100 cc of soil Ring (Criconemella) 792 per 100 cc of soil Sheathoid (Hemicriconemodies) 19 per 100 cc of soil
[0022] [0022] Sampling of soil after application. Test date 03/15/02 Sting (Belonolaimus) 0 per 100 cc of soil Lance (Hoplolaimus) 0 per 100 cc of soil Spiral (Helicotylenchus) 0 per 100 cc of soil Root Knot (Meloidogyne) 0 per 100 cc of soil Ring (Criconemella) 192 per 100 cc of soil Sheathoid (Hemicriconemodies) 0 per 100 cc of soil
EXAMPLE 2
[0023] The invention, Whole Ground Oriental Mustard Biopesticide, was incorporated dry into the soil of 1 gallon test pots infected with strains of pathogenic fungi. The incorporation rate was equal to 150 lbs. per acre, and then water was introduced at a rate of 16 ounces per day for 7 days. The results of the test are as follows:
Treatment performed on 2/11/02, and tested for fungi on 2/18/02 Pot 1: Fusarium 100% Growth inhibition Pot 2: S. rolfsii 100% Growth inhibition Pot 3: Basidiomycetes 53% Growth inhibition Pot 4: Pythium 60% Growth inhibition Pot 5: Rhizoctonia 100% Growth inhibition
[0024] Although the invention has been describe with detail, other versions and variations are possible. Therefore the preferred embodiments of the present invention have been described, the present invention is not limited to these preferred embodiments, but includes variations and modifications within the scope and spirit of the claims. | The invention provides a novel biopesticide comprised of Whole Ground Oriental Mustard for controlling soil born pathogens such as fungi and damaging nematodes. The present invention can replace many synthetically produced pesticides such as organophosphates and methyl bromide, which are damaging to the environment and to human health. | 0 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation of international patent application PCT/EP2009/008265 filed on Nov. 20, 2009 designating the U.S., which international patent application has been published in German language and claims priority from German patent application DE 10 2008 060 005.9 filed on Nov. 25, 2008. The entire contents of these priority applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a safety controller and a method for controlling an automated installation, and more particularly to a safety controller and a method providing enhanced diagnosis capabilities.
A safety controller within the meaning of the present invention is an apparatus or an arrangement which receives input signals delivered by sensors and produces output signals therefrom by means of logic combinations and sometimes further signal or data processing steps. The output signals can then be supplied to actuators, which then effect desired actions or reactions in the installation on the basis of the input signals.
A preferred area of application for safety controllers of this kind is in the field of machine safety for monitoring emergency-off pushbuttons, two-hand controllers, guard doors or light grids. Such sensors are used in order to safeguard a machine, for example, which presents a hazard to humans or material goods during operation. When the guard door is opened or when the emergency-off pushbutton is operated, a respective signal is produced which is supplied to the safety controller as an input signal. In response thereto, the safety controller then uses an actuator, for example, to shut down that part of the machine which is presenting the hazard.
In contrast to a “normal” controller, a characteristic of a safety controller is that the safety controller always ensures a safe state of the installation or machine presenting the hazard, even if a malfunction occurs in the safety controller or in a device connected to it. Extremely high demands are therefore put on safety controllers in terms of their own failsafety, which results in considerable complexity for development and manufacture.
Usually, safety controllers require particular approval from competent supervisory authorities, such as by the professional associations or the TÜV in Germany, before they are used. In this case, the safety controller must observe prescribed safety standards as set down, by way of example, in the European Standard EN 954-1 or a comparable standard, such as standard IEC 61508 or standard EN ISO 13849-1. In the following, a safety controller is therefore understood to mean an arrangement or an apparatus which complies at least with safety category 3 of the cited European standard EN 954-1.
A programmable safety controller provides the user with the opportunity to individually define the logic combinations and possibly further signal or data processing steps according to his needs using a piece of software that is typically called the user program. This results in a great deal of flexibility in comparison with earlier solutions, in which the logic combinations were established by defined hardware wiring between various safety components. By way of example, a user program can be written using a commercially available personal computer (PC) and using appropriately set-up software programs.
The user program executed in the safety controller defines the process which runs on the installation controlled by the safety controller. This process is monitored by means of process diagnosis. The installation diagnosis involves a check to determine which of a plurality of installation states for the system to be controlled is present at a defined time. Hence, both admissible and inadmissible installation states are detected. One aim is to detect inadmissible installation states, what are known as faults, and to display them on a display unit, so that the operating personnel on the system to be controlled can rectify the fault. Usually, such a display unit is a display unit integrated in the control console of the system to be controlled.
Overall, the installation diagnosis and the associated display of the detected or determined installation states present a process map on the display unit which comprises both the admissible and the inadmissible installation states.
The installation states detected by means of the installation diagnosis are established by virtue of logic requests, inter alia, which is why determined inadmissible installation states may be referred to as logical errors in the following. These logic requests involve threshold value or area comparisons, by way of example, being performed for variables detected by means of sensors, i.e. the respective measured value of the detected variable is compared with one or more threshold values.
One example is monitoring the filling level of a container. To this end, the container has associated a filling level sensor. The filling level sensor produces a filling level signal which represents the detected filling level of the container. Usually, the filling level signal is a voltage, the value of the voltage being proportional to the filling level which is present in the container. Depending on whether the further processing takes place in analog or digital fashion, this voltage value itself or a variable derived therefrom is compared with a threshold value. If this comparison determines that the threshold value has been exceeded, this may be interpreted as “container full” and no diagnosis report is created. If, by contrast, the comparison determines that the threshold value has not been reached, this may be interpreted as “container empty”. This is assumed to be an inadmissible installation state, i.e. an error state is present. The display unit is used to display a diagnosis report which represents this inadmissible installation state. Hence, the display unit is used to present a logical error.
There are now two possible situations. In the first situation, the container is actually empty. In this case, the determined installation state, i.e. the determined logical error, is based on reality. The diagnosis report presented on the display unit correctly reproduces reality. The container needs to be filled by the operating personnel, such as maintenance personnel.
However, a second situation is also conceivable, in which the container is actually not empty. In this case, the determined installation state, i.e. the determined logical error, is not based on reality and the diagnosis report presented on the display unit does not correctly reproduce reality. This may be the case, by way of example, when the filling level sensor is faulty or there is an error in the wiring connecting the filling level sensor to the safety controller, or an error in the safety controller itself. In all cases, a diagnosis report is displayed which indicates that the container is empty even though the container is full. The display of this diagnosis report is not only misleading, the operating personnel is either not provided with any advice of the actual cause that led to the installation diagnosis determining the installation state on which the displayed diagnosis report is based.
The above thoughts show that the diagnosis measures used in the known safety controllers and methods are still not optimal.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a safety controller and a method offering better information to operating personnel about faults which might occur during operation of the system, and to give them better support for rectifying these faults.
According to an aspect of the invention, there is provided a safety controller for controlling an automated installation in accordance with a user program that defines a plurality of installation states of the installation, said installation having a plurality of installation hardware components each comprising a number of sensors and a number of actuators connected to the safety controller so as to form a controller system, the safety controller comprising a control unit to which a plurality of control input signals from the plurality of sensors are supplied, wherein the control unit is designed to produce a plurality of control output signals on the basis of the control input signals in accordance with the user program, wherein the plurality of control output signals are used to actuate the plurality of actuators in order to adopt one of the plurality of installation states; a display unit for displaying diagnosis reports; an installation diagnosis evaluation unit to which a number of installation diagnosis input signals are supplied, wherein the installation diagnosis evaluation unit produces a number of installation state signals on the basis of the installation diagnosis input signals, the installation state signals representing which one of the plurality of installation states is existent at a defined moment of time; a system diagnosis evaluation unit to which a number of system diagnosis input signals are supplied, wherein the system diagnosis evaluation unit produces a number of system state signals on the basis of the number of system diagnosis input signals, with each system state signal representing one from a plurality of operational system states of the controller system at the defined moment of time; and a diagnosis report unit to which the installation state signals and the system state signals are supplied; wherein the diagnosis report unit produces a number of diagnosis signals depending on the installation state signals, depending on the system state signals, and depending on predefined associations between said installation states and said operational system states; wherein said diagnosis signals represent a number of diagnosis reports, which are a result of a combination of both the installation states and associated operational system states; and wherein the diagnosis signals are supplied to the display unit for the purpose of displaying the diagnosis reports.
According to another aspect, there is provided a method for controlling an automated installation in accordance with a user program that defines a plurality of installation states of the installation, said installation having a plurality of installation hardware components each comprising a number of sensors and a number of actuators connected to a safety controller so as to form a controller system, the method comprising the steps of receiving a plurality of control input signals from the plurality of sensors at the safety controller; producing a plurality of control output signals in response to the control input signals in accordance with the user program executed on the safety controller, and providing the control output signals to the plurality of actuators in order to adopt one of the plurality of installation states; producing a number of installation state signals representing which one of the plurality of installation states is existent at a defined moment of time; producing a number of system state signals representing a plurality of operational system states of the controller system at the defined moment of time; producing a number of diagnosis signals depending on the installation state signals, depending on the system state signals, and depending on predefined associations between said installation states and said operational system states, said diagnosis signals representing a number of diagnosis reports which are a result of a combination of both the installation states and associated operational system states; and supplying said diagnosis signals to a display unit for the purpose of displaying the diagnosis reports.
There is also provided a storage medium comprising a computer program having program code designed to be executed on a safety controller for controlling an automated installation having a plurality of installation states, said installation having a plurality of installation hardware components each comprising a number of sensors and a number of actuators connected to a safety controller so as to form a controller system, and the computer program being designed to carry out a method comprising the steps of receiving a plurality of control input signals from the plurality of sensors at the safety controller; producing a plurality of control output signals in response to the control input signals; and providing the control output signals to the plurality of actuators in order to adopt one of the plurality of installation states; producing a number of installation state signals representing which one of the plurality of installation states is existent at a defined moment of time; producing a number of system state signals representing a plurality of operational system states of the controller system at the defined moment of time; producing a number of diagnosis signals depending on the installation state signals, depending on the system state signals, and depending on predefined associations between said installation states and said operational system states, said diagnosis signals representing a number of diagnosis reports which are a result of a combination of both the installation states and associated operational system states; and supplying said diagnosis signals to a display unit for the purpose of displaying the diagnosis reports.
The new safety controller and the method are based on the idea of combining installation diagnosis with system diagnosis. To this end, an installation diagnosis evaluation unit is provided which is designed to receive a number of installation diagnosis input signals supplied to said installation diagnosis evaluation unit as a basis for determining which of a plurality of installation states for the installation to be controlled is present at a first defined time. Overall, there may be a number of installation states determined at the first defined time. In addition, a system diagnosis evaluation unit is provided which is designed to receive a number of system diagnosis input signals which are supplied to said system diagnosis evaluation unit as a basis for determining which of a plurality of system states for the safety controller is present at a second defined time. Overall, there may be a number of system states determined at the second defined time.
A system state of the safety controller is any state which the safety controller as such, i.e. the physical unit where logic components such as processors and memories required for implementing control tasks are accommodated, and which components of the installation electrically connected to said physical unit, such as sensors, actuators or what are known as signaling devices, such as example mode selection switches, can adopt. This definition also includes all wiring. With a view to diagnosis, primarily those system states in which an error occurs on one of the components listed above are of interest. These errors are referred to as physical errors.
The installation diagnosis and system diagnosis are combined by providing a diagnosis report for a determined installation state on the basis of this installation state itself and on the basis of a number of system states associated with said installation state.
The effect achieved by the approach is that the provision of a diagnosis report simultaneously takes account of the installation state itself and of system states associated with this installation state. This means that the provision of the diagnosis report covers not only the determined installation state itself, but also any system states which cause said installation state. In other words: the provision of the diagnosis report takes account not only of the logical error, but also of any physical errors causing the latter.
Simultaneous consideration of an installation state and of the related system states forms the basis for comprehensive instruction of the operating personnel about faults which occur during the operation of an installation. The operating personnel can be notified of the physical error on which a logical error is based. This allows the operating personnel to immediately take measures to rectify the physical error and hence the fault.
At the same time, the approach increases the reliability for any diagnosis report which represents a determined installation state. If a display unit is used to display a diagnosis report which merely comprises information relating to a determined installation state, i.e. relating to a logical error, and comprises no advice of an underlying system state and hence of a physical error causing the logical error, this means—as a result of the approach—that the determined installation state is correctly reproducing reality and there is no physical cause of error for the diagnosis report. This is because the safety controller needs to be implemented such that every conceivable physical error is detected in order to achieve failsafe control.
The approach therefore achieves better instruction of the operating personnel about faults which occur during operation of an installation and better assistance in rectifying these faults.
Where the term operating personnel is used in connection with the safety controller and the method according to the invention, this should be understood to mean not only conventional operators on an installation, but also maintenance personnel, set-up personnel, the programmer of a user program or the manufacturer of the safety controller.
According to the above description, the installation diagnosis evaluation unit is designed to determine which of a plurality of installation states of the installation to be controlled is present at a first defined time, whereas the system diagnosis evaluation unit is designed to determine which of a plurality of system states for the safety controller is present at a second defined time. The distinction into a first and a second defined time takes account of the following circumstance: a programmable safety controller is a microprocessor-based discrete-time system operating at a defined clock rate. For this reason, signals with a continuous presence over time, i.e. analog signals, as are provided by sensors, for example, need to be converted into digital signals so that they can actually be processed in the safety controller. The conversion takes place at times which are prescribed by the clock rate. It may therefore arise that the requests which can be used to determine the presence of the respective state are made at slightly different times for an installation state and an associated system state. By way of example, this is the case when a variable which can be evaluated for the installation state is provided in the safety controller quicker than a variable which can be evaluated for the system state. Consequently, the installation state and the system state are determined in the safety controller at different times. Usually, these two times lie within a small defined time interval, the length of which corresponds to a multiple of the period prescribed by the clock rate. In this case, the first defined time and the second defined time are very close together, and the system state and the installation state are determined more or less simultaneously. The consideration of a first defined time and of a second defined time is also intended to cover the circumstance in which there are several seconds or even minutes between the determination of an installation state and the determination of a system state.
The functional split, described above, into an installation diagnosis evaluation unit, a system diagnosis evaluation unit and a diagnosis report unit is not intended to have any guideline for the structural embodiment specifically implemented within a safety controller. It is thus possible to implement these three units separately in terms of structure, or to implement the installation diagnosis evaluation unit and the system diagnosis evaluation unit as a joint structural unit or even all three units may be implemented as one joint structural unit.
In a preferred refinement, the diagnosis report unit is designed to determine a number of association variables, wherein the association variables indicate which of the number of determined system states is respectively associated with which of the number of determined installation states, wherein the diagnosis report unit is designed to establish the number of associated system states on the basis of the number of association variables.
This measure is a simple procedure for associating a system state with an installation state. Hence, the number of determined system states which cause a determined installation state is associated with this installation state.
In a preferred refinement, the diagnosis report unit has an association memory unit which stores a plurality of association variables at least for a plurality of the installation states and at least for a plurality of the system states, wherein the stored association variables indicate which of the plurality of system states is respectively associated with which of the plurality of installation states on the basis of a predefined association, wherein the diagnosis report unit is designed to select a number of stored association variables for a number of pairings between the number of determined system states and the number of determined installation states, wherein each of these selected association variables represents at least one of the pairings, wherein the diagnosis report unit is designed to establish the number of associated system states on the basis of the number of association variables.
This measure provides a simple and also very reliable way of establishing the number of associated system states. As a result of the association memory unit permanently storing the predefined associations which respectively exist between the plurality of system states and the plurality of installation states, it is possible to explicitly determine which of the determined system states is respectively associated with which of the determined installation states. This ensures that the operating personnel on a system has complete and reliable instruction.
Preferably, these association variables are in the form of logic variables which indicate for which of the combinations conceivable between the plurality of system states and the plurality of installation states a respective association exists. A plurality of embodiments are conceivable for the association variables. Thus, by way of example, a matrix may be involved in which a logic one has been entered into a matrix array when a predefined association exists between the installation state associated with the matrix array for the logic one and the system state associated with this matrix array, and in which a logic zero has been entered into a matrix array when no predefined association exists between the installation state associated with this matrix array and the system state associated with this matrix array. Alternatively, the association variables may be a plurality of vectors. In this case, each of these vectors represents one of the plurality of installation states and indicates those system states which are associated with this installation state by means of predefined associations. In a further alternative, the process variables may be a plurality of tuples. Each of these tuples represents a combination of one of the plurality of system states and one of the plurality of installation states between which there is a predefined association.
In a preferred refinement, the diagnosis report unit is designed so that, when a determined installation state and a number of associated system states are present, it provides a number of system diagnosis reports as a diagnosis report for this installation state, wherein the number of the system diagnosis reports represent the number of associated system states.
As already stated, an installation state, i.e. a logical error, has a system state, i.e. a physical error, as its cause. The effect achieved by this measure is that, for a determined installation state, it is not the installation diagnosis report representing it but rather immediately the system diagnosis reports representing the number of associated system states that are displayed on the display unit. Hence, the operating personnel on an installation is immediately provided with a display of what physical errors are present. The operating personnel can therefore immediately start rectifying the fault. This measure therefore allows faults to be rectified in optimum times.
In a preferred refinement, the diagnosis report unit is designed so that, when a determined installation state and a number of associated system states are present, it provides a combination diagnosis report as a diagnosis report for this installation state, wherein the combination diagnosis report comprises both an installation diagnosis report and a number of system diagnosis reports, wherein the installation diagnosis report represents the determined installation state and the number of system diagnosis report represents the number of associated system states.
This measure has the advantage that the operating personnel on an installation is instructed comprehensively both about a determined installation state and about those determined system states which are associated with this installation state. Hence, the operating personnel are instructed about a logical error which is present and about the physical errors causing this logical error. Not only is comprehensive instruction of the operating personnel ensured, immediate rectification of a fault state is also possible on the basis of the comprehensive instruction.
In a further refinements of the aforementioned measure, the display unit may be designed to first display the installation diagnosis report and, when a system diagnosis request is present, to replace the installation diagnosis report with at least one of the number of system diagnosis reports or, as a supplement to the installation diagnosis report, to display at least one of the number of system diagnosis reports; or to display the installation diagnosis report and at least one of the number of system diagnosis reports simultaneously; or to display only at least one of the number of system diagnosis reports.
If the diagnosis report provided is a combination diagnosis report, various procedures concerning the display of the information comprised in the combination diagnosis report are conceivable, in principle.
Both the first alternative, in which first of all the installation diagnosis report and, when a system diagnosis request is present, at least one of the system diagnosis reports is displayed as an alternative or in addition, and the second alternative, in which the installation diagnosis report and at least one of the system diagnosis reports are displayed simultaneously from the outset, have the advantage of comprehensively instructing the operating personnel. In comparison with the second alternative, the first alternative has the advantage that the presentation on the display unit is initially clearer and, if needed, for example when the display unit is being read by a person who has appropriate access authorization allowing action in the system to rectify a fault, one or more of the physical errors and hence of the faults which are present in the system can be displayed. The third alternative, on the basis of which merely at least one of the system diagnosis reports is displayed from the outset, allows the operating personnel on the installation to immediately start rectification of the fault. In addition, it has the advantage of clear presentation.
In a preferred refinement, the diagnosis report unit is designed so that, when a determined installation state and a number of associated system states are present, it first of all provides an installation diagnosis report as a first diagnosis report and, when a system diagnosis request is present, it additionally provides a number of system diagnosis reports as a second diagnosis report, wherein the installation diagnosis report represents the determined installation state and the number of system diagnosis reports represent the number of associated system states.
This measure involves the provision of the diagnosis reports in two steps. In a first step, only the installation diagnosis report is provided. When a system diagnosis request is present, a number of system diagnosis reports are provided in a second step. This ensures that computer capacity is not unnecessarily occupied by the provision of diagnosis reports. On the basis of this approach, computer capacity needs to be mustered for the provision of the system diagnosis reports only when there is a system diagnosis request present.
In a further refinement of the aforementioned measure, the display unit is designed to replace the installation diagnosis report with at least one of the number of system diagnosis reports or to display at least one of the number of system diagnosis reports as a supplement to the installation diagnosis report.
This measure allows comprehensive and also clear instruction of the operating personnel on an installation.
In a further refinement of the aforementioned measure, the display unit has an associated system diagnosis request unit, wherein the system diagnosis request unit is designed to detect a system diagnosis request.
This measure allows a person reading the display unit to easily send out a system diagnosis request so as to have system diagnosis reports displayed when needed. Advantageously, the display unit and the system diagnosis request unit form a physical unit.
In a preferred refinement, the installation diagnosis evaluation unit is designed to repeatedly determine which of a plurality of installation states is respectively present at a defined time, and/or the system diagnosis evaluation unit is designed to repeatedly determine which of a plurality of system states is respectively present at a defined time.
This measure ensures that diagnosis reports are created not only within a short interval of time but over a relatively long period of time, for example throughout the operation of the installation. This ensures that the operating personnel on the installation is comprehensively instructed—also in respect of time—about faults which occur. The defined times at which it is determined which of a plurality of installation states is present in each case are determined by the first defined time and, by way of example, the clock rate at which the safety controller operates. A similar situation applies to the system states, but based on the second defined time.
In a further refinement of the aforementioned measure, the diagnosis report unit has a state memory unit which is designed to repeatedly store determined installation states and determined system states, wherein the diagnosis report unit is designed to use determined system states already stored and/or determined installation states already stored when establishing whether the system state to be stored is an associated system state and/or when establishing whether associated system states are present for an installation state that is to be stored.
This measure allows to combine installation states and system states which have been determined at different instances of time considerably spaced apart from one another, i.e. allows those system states which are associated with an installation state to be established and appropriate diagnosis reports to be provided. The reason is that the following situation is conceivable: a system state and hence a physical error are actually determined at an earlier time, for example because a sensor is faulty. At this time, however, no installation state, i.e. no logical error, has been determined to date because at this time a routine which is comprised in the user program, for example, and in which the signal provided by the sensor is processed has not yet even been called. In this case, the installation state and the system state can be combined. Overall, this measure allows comprehensive instruction of the operating personnel on an installation.
Advantageously, determined system states already stored and/or determined installation states already stored are used in the process of determining an association variable for a system state to be stored and/or for an installation state to be stored. On the one hand, those association variables are selected which represent those predefined associations which indicate with which installation states the system state to be stored is associated, and, on the other hand, those association variables are selected which represent those predefined associations which indicate which system states are associated with the installation state to be stored. This advantageously takes into account which of the association variables have already been selected at an earlier time. This avoids diagnosis reports being displayed again.
Advantageously, in addition to the determined installation states, those installation diagnosis reports which represent these installation states are also stored. Similarly, those system diagnosis reports which represent these system states are also stored for the determined system states.
The continual storage of the determined installation states and of the determined system states in the state memory unit has further advantages. It is thus possible to provide a report about the current status of the system to be controlled and/or the safety controller. In this case, not only the currently determined installation states and the currently determined system states, but also already determined installation states and already determined system states which are stored in the state memory unit can be considered. In addition, it is possible to provide a report which represents a change in the status. Furthermore, evaluation and hence diagnosis can be performed regarding what diagnosis reports are currently pending. Moreover, an event report can be created which comprises details regarding the time at which a diagnosis report appeared, i.e. was provided, and the time at which a diagnosis report disappeared again, i.e. that fault which is represented by the diagnosis report was rectified.
In a preferred refinement, the control unit has an input/output unit having a plurality of inputs and having a plurality of outputs, wherein the input/output unit is designed to use a number of the plurality of inputs to respectively receive at least one of the plurality of control input signals and to use a number of the plurality of outputs to respectively output at least one of the plurality of control output signals, wherein the user program comprises a plurality of program variables, wherein the plurality of program variables comprise a plurality of input variables and a plurality of output variables, wherein, pursuant to an association rule defined during the creation of the user program, firstly the input variables are respectively associated with one of the inputs and with a control input signal received via this input and secondly the output variables are respectively associated with one of the outputs and with a control output signal output via this output, wherein the stored association variables have been created on the basis of the association rule.
This measure makes it possible to determine the stored association variables, to be more precise the predefined associations, easily and without great complexity. In any case, a substep in the creation of a user program is association of the input variables with the control input signals and hence with the input terminals of the safety controller and association of the output variables with the control output signals and hence with the output terminals of the safety controller, because the installation cannot be controlled by the user program without these associations. This association is usually referred to as I/O mapping. This association reveals the combination between firstly the process which is represented by the input variables and the output variables and secondly the system which is represented by the control input signals and the control output signals or the input terminals and the output terminals of the safety controller. This association can therefore be used as a basis for combining the installation states and the system states, to be more precise the association of system states with installation states. The order, i.e. whether a variable is associated with the signal and hence with a terminal or whether a variable is associated with a terminal and hence with a signal, is irrelevant in this case. It is merely important that these three details are brought together.
The example below is intended to illustrate the mode of action. By way of example, if there is an error on an input terminal, termed here as a physical error, a corresponding system state is determined then. On the basis of the error on the input terminal, the associated input variable is also erroneous. If this input variable is now used for looking at threshold values, which is the basis for determining an installation state, then the erroneous input variable is taken as a basis for recognizing a logical error and hence determining an installation state. On the basis of the association information used for the I/O mapping, it is now certain that the determined system state is associated with the determined installation state.
In a preferred refinement, the user program is created by providing a plurality of software components, wherein the plurality of the software components correspond to the plurality of installation hardware components, wherein at least a number of the software components respectively have an associated number of the plurality of installation states and an associated number of installation diagnosis reports, wherein the number of installation diagnosis reports represent the number of the plurality of installation states.
This measure makes it a simple matter to write a user program. The association of installation states and of installation diagnosis reports representing the installation states with individual software components has a plurality of advantages. The use of software components having associated installation states and installation diagnosis reports representing said installation states ensures unity within a user program in the form that software components which are identical to one another in terms of installation diagnosis are provided for identical installation hardware components comprised in the installation to be controlled, given appropriate selection. This ultimately also contributes to an increase in failsafety.
In a preferred refinement, the user program has a hierarchically structured design with a plurality of hierarchical levels, wherein during the creation of the user program an installation structure variable is established which represents the hierarchically structured design of the user program, wherein the diagnosis report unit is designed to provide the number of diagnosis reports on the basis of the installation structure size.
Individual hierarchical levels each contain an associated number of software components, wherein each of these software components corresponds to an installation hardware component. If the installation hardware component is a simple component, the relevant software component in this case is in the form of an elementary component, which itself does not contain any further software components. If, by contrast, the installation hardware component is a complex component then the relevant software component is in the form of a group component, and itself in turn comprises software components. The group components result in the hierarchically structured design of the user program, which in turn is based on the design of the installation to be controlled.
The provision of the number of diagnosis reports on the basis of the installation structure variable has the following advantage: a determined installation state is explicitly associated with a software component. Consequently, a diagnosis report can be provided for the determined installation state and is stored in the software component with which it is associated. On the basis of the installation structure size, in turn, it is known which software component on the next highest hierarchical level or an even higher hierarchical level has the associated software component on a structure-related basis, with which the determined installation state is more easily associated. This structure-related association can now be used to provide a diagnosis report—instead of the diagnosis report which is stored in the software component with which the determined installation state is associated—which is stored in a software component which is situated on the next highest or an even higher hierarchical level and which has the associated software component on a structure-related basis with which the determined installation state is associated. By way of example, this approach allows to provide what is termed here as a collective diagnosis report. The provision of a collective diagnosis report is advantageous in the following situation: a plurality of installation states are determined. These installation states are associated not only with one software component but rather with a plurality of software components. These software components, in the hierarchical structure of the user program, open into a software component which is included on a higher hierarchy level. Instead of now providing a diagnosis report for each determined installation state, it is possible to provide a diagnosis report which is comprised in the software component into which the other software components open. Overall, this increases the clarity when displaying diagnosis reports.
The applicant reserves the right to pursue the approach on which the measure described above is based in a separate application too.
In a further refinement, the installation diagnosis evaluation unit has an installation diagnosis memory unit, wherein the installation diagnosis memory unit stores the plurality of installation states and also a number of installation diagnosis reports, wherein the installation diagnosis reports each represent one of the plurality of installation states, wherein the plurality of installation states and/or the installation diagnosis reports are created when the user program is created. In addition, the installation diagnosis memory unit stores the installation structure size.
On the basis of this measure, all details required for comprehensive installation diagnosis are stored coherently at a central location. This allows rapid determination of installation states. In addition, possible sources of error can be ruled out, which may arise when the aforementioned details are stored at multiple locations.
In a preferred refinement, the system diagnosis evaluation unit has a system diagnosis memory unit, wherein the system diagnosis memory unit stores the plurality of system states and also a number of system diagnosis reports, wherein the system diagnosis reports each represent one of the plurality of system states.
This measure has the advantage that all details that are required for comprehensive system diagnosis are stored centrally. Rapid determination of system states is therefore also possible in this case. Possible sources of error are also ruled out, which may arise when the aforementioned details are stored at multiple memory locations.
Advantageously, the plurality of system states and the number of system diagnosis reports are defined by the manufacturer of the safety controller. This measure helps to increase failsafety. Furthermore, it is advantageous if both the plurality of system states and the number of system diagnosis reports are stored unalterably in the system diagnosis memory unit, and can therefore be changed neither by the operator of the installation nor by the writer of the user program running in the safety controller. This measure also helps to increase failsafety.
In a preferred refinement, the safety controller comprises a plurality of control hardware components, wherein at least a number of the control hardware components are respectively associated with a number of the plurality of system states and number of system diagnosis reports, wherein the number of system diagnosis reports represent the number of the plurality of system states.
This measure ensures that a control hardware component is associated with relevant system states and system diagnosis reports corresponding to said system states. Taking into account the defined association rule, explicit association of a system state with an installation state is therefore possible.
In a preferred refinement, the safety controller has a hierarchically structured design, wherein the system diagnosis memory unit stores a control structure variable which represents the hierarchically structured design of the safety controller, wherein the diagnosis report unit is designed to provide the number of diagnosis reports on the basis of the control structure variable.
This measure also allows the provision of collective diagnosis reports—already described further above in connection with the installation diagnosis—for the system diagnosis. Therefore, the advantages demonstrated in connection with the installation diagnosis apply accordingly in this case.
The applicant reserves the right to pursue the approach on which the measure described above is based in a separate application too.
In a further refinement, the user program has at least one safety control module, in which safety-related control input signals are processed in failsafe fashion, and at least one standard control module, in which predominantly process-related control input signals are processed.
In this refinement, the plurality of sensors advantageously comprise a number of first sensors which are designed to detect safety-related variables, wherein these safety-related variables are supplied to the safety control module by means of safety-related control input signals, and a number of second sensors which are designed to detect process-related variables, wherein these process-related variables are supplied to the standard control module by means of process-related control input signals. Furthermore, this refinement advantageously has provision for the plurality of control output signals to comprise a number of first control output signals, which are determined in the safety control module and which are intended for actuating a number of first actuators which are designed to perform safety-related actions, and to comprise a number of second control output signals, which are determined in the standard control module and which are intended for actuating a number of second actuators which are designed to perform process-related actions. This design of the user program, according to which the user program comprises at least one safety control module and at least one standard control module, allows one and the same user program to be able to be used to handle both control tasks which are associated with the safety control aspect and control tasks which are associated with the standard control aspect. Hence, a safety controller designed in accordance with this aspect can be used to implement both control tasks which are associated with the safety control aspect and control tasks which are associated with the standard control aspect. This has the advantage that, for comprehensive control of an installation, i.e. for control which covers both the safety control aspect and the standard control aspect, only one controller is required rather than two controllers, one of which handles the control tasks which are associated with the safety control aspect and one of which handles the control tasks which are associated with the standard control aspect. This also reduces the complexity required for wiring. Overall, this measure is an cost-effective way of implementing comprehensive control for an installation. At this occasion, it should be pointed out that the wording that predominantly process-related control input signals are processed in the standard control module means that it is also possible for safety-related control input signals to be processed in the standard control module.
Advantageously, the display unit is a display unit integrated in the control console of the installation to be controlled. Alternatively, it may be a further display unit which is provided in the installation to be controlled in addition to the display unit integrated in the control console. By way of example, the display unit may be in the form of an LCD screen, in the form of a cathode-ray-based screen or in the form of an alphanumeric text area.
For the sake of completeness, the following should be noted at this occasion: if an installation state has been determined and if no system states associated with this installation state have been determined then the diagnosis report provided is that installation diagnosis report which represents the determined installation state.
It goes without saying that the features mentioned above and the features which are yet to be explained below can be used not only in the respectively indicated combination but also in other combinations or on their own without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments are illustrated in the drawing and are explained in more detail in the description below, in which:
FIG. 1 shows a schematic illustration of an installation to be controlled,
FIG. 2 shows a schematic illustration of a component part of the installation to be controlled,
FIG. 3 shows a schematic illustration of a subcomponent that is comprised in the component part, and the individual components thereof,
FIG. 4 shows a simplified illustration of a graphical interface for writing a user program,
FIG. 5 shows a schematic illustration of the software components and aspect blocks provided for the installation to be controlled on a topmost hierarchy level for the user program,
FIG. 6 shows a schematic illustration of the software components and aspect blocks provided for the component part,
FIG. 7 shows a schematic illustration of the software components and aspect blocks provided for the subcomponent,
FIG. 8 shows a schematic illustration of the aspect blocks provided for an individual component comprised in the subcomponent,
FIG. 9 shows an overview illustration of the hierarchic structure of a written user program,
FIG. 10 shows an overview illustration of the hierarchic structure of a safety controller,
FIG. 11 shows a schematic illustration of a safety controller.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 , an installation to be controlled is denoted as a whole by the reference numeral 10 . The installation 10 comprises three components, namely a handling station 12 , a process station 14 and a test station 16 , and two contactors 18 , 20 . The handling station 12 is used to fill the process station 14 with workpieces. These workpieces are machined in the process station 14 . Next, the machined workpieces are forwarded by the handling station 12 to the test station 16 , in which a check is performed to determine whether the machined workpiece satisfies appropriate examination criteria. If these examinations are passed, the process station 14 can again be filled with a new workpiece for machining. The two contactors 18 , 20 connect the loads 22 in the system 10 to a power supply—not shown. The system has an associated first emergency-off pushbutton 24 which can be used to disconnect the system 10 and in so doing transfer it to a safe state in the event of a hazard. To this end, the two contactors 18 , 20 are actuated so that the loads 22 are isolated from the power supply. The system 10 is controlled by a safety controller 26 , the safety controller 26 comprising a plurality of control hardware components 28 , 30 , 32 . The individual control hardware components may be associated with individual component parts, but this does not necessarily have to be the case. In the present exemplary embodiment, the control hardware component 28 is meant to be associated with the component part 12 , the control hardware component 30 is meant to be associated with the component part 14 and the control hardware component 32 is meant to be associated with the component part 16 . Since this is a schematic illustration, no wiring has been considered.
In FIG. 2 , the process station component part is denoted as a whole by the reference numeral 14 . The fact that subsequently only the process station and the hardware components comprised therein are considered is not intended to have any limiting effect. The comments below also apply in corresponding fashion to the handling station 12 and the test station 16 .
The process station 14 comprises a rotary table 40 , an examination module 42 , a drilling module 44 and an ejection module 46 . The rotary table 40 can be used to transport all workpieces in the process station 14 between the individual modules 42 , 44 , 436 . The examination module 42 is used to check workpieces that are to be machined for the presence of prescribed properties. The drilling module 44 is used to machine the workpieces located in the process station 14 . The ejection module 46 is used to remove the machined workpieces and to forward them to the test station 16 . The process station 14 has an associated second emergency-off pushbutton switch 48 which can be used to disconnect the process station 14 and in so doing to transfer it to a safe state in the event of a hazard.
In FIG. 3 , the drilling module is denoted as a whole by the reference numeral 44 .
As individual components with a mechanical or electrical or electromechanical function, the drilling module 44 has a motor 60 , a transfer cylinder 62 and a drilling cylinder 64 . The two cylinders 62 , 64 can be used to move the motor 60 along a guidance unit relative to the workpiece that is to be machined, specifically with the drilling cylinder 64 in a vertical direction and with the transfer cylinder 62 in a horizontal direction. The drilling module 44 has an associated third emergency-off pushbutton switch 66 which can be used to disconnect the drilling module 44 and in so doing to transfer it to a safe state in the event of a hazard. The reference numeral 68 denotes those control hardware components which are comprised in the control hardware component 30 and which are associated with the drilling module 44 .
As can be seen from the illustrations in FIGS. 1 to 3 , the system 10 to be controlled comprises a plurality of installation hardware components, namely at least the component parts 12 , 14 , 16 shown in FIG. 1 , the components rotary table 40 , examination module 42 , drilling module 44 and ejection module 46 shown in FIG. 2 , and the components motor 60 , transfer cylinder 62 and drilling cylinder 64 shown in FIG. 3 . To these are added further components, namely those which are comprised in the handling station 12 and in the test station 16 , which have not been discussed explicitly above, however.
Similarly, the illustrations in FIGS. 1 to 3 reveal that the safety controller comprises a plurality of control hardware components and overall has a hierarchically structured design.
In FIG. 4 , a graphical interface is denoted as a whole by reference numeral 80 . This graphical interface allows a programmer to write a user program.
The graphical user interface 80 comprises a software component area 82 which comprises a set 84 of predefined software components in the form of graphical symbols. The predefined software components have been created by the provider of the computer program which is used to carry out the method for writing a user program and are stored in a database included in said computer program. In addition, the software component area 82 comprises a set 86 of freshly written software components in the form of graphical symbols. The freshly written software components are such software components as the programmer writes when writing the user program for installation hardware components comprised in the system 10 to be controlled which have no corresponding predefined software component comprised in the aforementioned database. The database comprised in the computer program is extended by these software components.
Those software components which themselves do not contain any further software components are illustrated by means of a small block. These software components are referred to as elementary components. By contrast, those software components which themselves contain further software components are illustrated by means of a large block. These software components are referred to as group components.
The user program is written by providing a plurality of software components. For this purpose, the graphical user interface 80 comprises a component area 88 . The software components to be provided are selected and are transferred to the component area 88 , as indicated by means of two arrows 90 , 92 . The selection and transfer can be effected using what is known as a drag & drop function, for example.
The component area 88 accordingly comprises a plurality 94 of software components which have been provided. These are the software components on the topmost hierarchy level of the user program. The logic combination of the plurality 94 of software components is used to write a component program part. To this end, at least some of the logic inputs and at least some of the logic outputs of the software components are connected to one another, which is illustrated by a plurality 96 of connections. On the basis of the internal logic combinations which are respectively comprised in the software components, said comprised software components are automatically also combined if these software components contain elementary components and/or group components. As a result, it is sufficient for the writing of the component program part to involve the software components comprised on the topmost hierarchy level being logically combined with one another.
The user program is hierarchically structured. The provided plurality 94 of software components defines a topmost hierarchy level. If this plurality 94 of software components comprises a software component which is in the form of a group component, the number of software components which is comprised in said software component defines a further hierarchy level situated below the topmost hierarchy level.
Before the further areas comprised in the graphical interface 80 are discussed, the basic design of a software component will be presented first of all. This will be done by leaping ahead to FIG. 8 , which is yet to be described.
FIG. 8 shows the basic design of a software component in the form of an elementary component. An elementary component has a plurality of aspect blocks. Each of these aspect blocks is associated with one of a plurality of control aspects which are different from one another, each of said control aspects representing a separate control aspect of the safety controller. In this case, the software component comprises all those aspect blocks which are of significance to that installation hardware component related to the software component. Hence, the installation hardware component is described fully with a view to the control aspects of the safety controller by the software component which represents it. In comparison with an elementary component, a group component comprises not only the aspect blocks but additionally software components which may be in the form of an elementary component or in the form of a group component.
Advantageously, the control aspects which are different from one another may be the following control aspects: standard control aspect which represents the standard control aspect part; safety control aspect which represents the safety control aspect part; diagnosis aspect which represents the diagnosis aspect part; visualization aspect which represents the visualization aspect part; drive regulation aspect which represents the drive regulation aspect part; cooling aspect which represents the cooling aspect part; access authorization aspect which represents the access authorization aspect part; servicing aspect which represents the servicing aspect part; locking aspect which represents the locking aspect part; manual operation aspect which represents the manual operation aspect part; data management aspect which represents the data management aspect part.
For each aspect block comprised in a software component, at least those logic variables and/or those parameters and/or those sensor signals which are required for processing and can be supplied to the aspect block via associated inputs and those logic variables and/or those parameters and/or those output signals which are respectively determined in the number of aspect blocks and which are output from the aspect block via associated outputs are first of all defined on their merits. The specific sensors and/or actuators which can be connected to the respective aspect block are ultimately defined only when the user program is written.
In addition, at least some of the aspect blocks comprised in a software component each store a functional program which defines aspect properties of the hardware component for that control aspect with which the respective aspect block is associated.
The graphical interface 80 also comprises an aspect area 98 . This aspect area 98 comprises a plurality 100 of aspect blocks. Each of these aspect blocks is associated with the same control aspect. In the exemplary embodiment, this is intended to be the standard control aspect, which represents the standard control aspect part. The plurality 100 of aspect blocks comprise the aspect blocks which are comprised on all hierarchy levels of the user program and which are associated with the standard control aspect, specifically regardless of whether they are comprised on one of the hierarchy levels separately or as part of a software component. The aspect area also comprises the aspect blocks which are comprised on the topmost hierarchy level of the user program.
The graphical interface 80 also comprises a sensor area 102 . This sensor area 102 comprises a plurality 104 of graphical sensor symbols. For each sensor which is comprised in the system 10 that is to be controlled, the sensor area 102 comprises an associated graphical sensor symbol. The plurality 104 of graphical sensor symbols represent both the sensors comprised for the safety control aspect and the sensors comprised for the standard control aspect in the system 10 that is to be controlled. As a further area, the graphical interface 80 comprises an actuator area 106 . This actuator area 106 comprises a plurality 108 of graphical actuator symbols. For each actuator which the system 10 that is to be controlled contains, the actuator area 106 comprises an associated graphical actuator symbol. The plurality 108 of graphical actuator symbols comprise both the actuators comprised for the safety control aspect and the actuators comprised for the standard control aspect in the installation to be controlled.
For the plurality 100 of aspect blocks which is comprised in the aspect area 98 , an aspect program part is written. To this end, at least for some of the aspect blocks comprised in the aspect area 98 , both the inputs thereof and the outputs thereof have what is known as I/O mapping performed for them. That is to say that at least some of the signal inputs are assigned those sensor means whose sensor signals are processed in the respective aspect block. This is shown by way of example by an arrow 110 . Furthermore, at least some of the signal outputs are assigned actuators which are actuated using the output signals determined in the respective aspect block. This is shown by way of example by an arrow 112 . Alternatively, the I/O mapping can also be performed by means of text inputs in an input area 114 .
The method described above for writing a user program involves all program variables being comprised in the aspect blocks. Consequently, the signal inputs of the aspect blocks have associated input variables comprised in the user program, and the signal outputs of the aspect blocks have associated output variables comprised in the user program. The association between the sensors and the signal inputs therefore defines the association between sensors and input variables, to be more precise between control input signals and input variables. Since it is known which sensor is connected to which input of an input/output unit comprised in the safety controller, the association between inputs, control input signals and input variables is therefore defined overall. The association between the actuators and the signal outputs also defines the association between actuators and output variables, to be more precise between control output variables and output variables. Since it is known which actuator is connected to which output of the input/output unit, the association between outputs, control output variables and output variables is therefore defined.
Once the aspect program parts have been written for all the control aspects, the association rule is defined completely and the association variables to be stored can be created.
Overall, one aspect program part is written for each control aspect. Once all the aspect program parts have been written, the component program part and the aspect program parts are combined to form the user program.
FIG. 5 shows those software components and aspect blocks for the system 10 to be controlled which are comprised on the topmost hierarchy level.
Specifically, these are the following software components: a first software component 120 , which corresponds to the first emergency-off pushbutton switch 24 and is in the form of an individual component, a second software component 122 , which corresponds to the handling station 12 , a third software component 124 , which corresponds to the process station 14 , a fourth software component 126 , which corresponds to the test station 16 , wherein the software components 122 , 124 , 126 are each in the form of a group component. Each of the software components 122 , 124 , 126 represents a real mechatronic installation hardware component which is present in the system 10 that is to be controlled. The software components are connected to one another by means of a first plurality 128 of logical connections in order to implement flow control.
In addition, the following aspect blocks are involved: a first aspect block 130 which is associated with a standard control aspect, a second aspect block 132 which is associated with a safety control aspect, a third aspect block 134 which is associated with a diagnosis aspect, a fourth aspect block 136 which is associated with a visualization aspect, a fifth aspect block 138 which is associated with a drive regulation aspect, and a sixth aspect block 140 which is associated with a locking aspect.
Each of these aspect blocks stores a functional program which is designed to handle those control tasks which are part of the control aspect with which the respective aspect block is associated. The third aspect block 134 stores those examination conditions and installation diagnosis reports which are required for performing installation diagnosis for the system 10 that is to be controlled as such. The system 10 that is to be controlled as such is defined by the cluster comprising the handling station 12 , the process station 14 and the test station 16 and therefore by the cluster of the software components 122 , 124 , 126 on the topmost hierarchy level of the user program. Logical connections between individual aspect blocks themselves and to a software component have not been shown for reasons of clarity.
FIG. 6 shows the software components and aspect blocks comprised in the third software component 124 .
The reference numeral 150 denotes a fifth software component which corresponds to the second emergency-off pushbutton switch 48 and which is in the form of an elementary component. The reference numeral 152 denotes a sixth software component which corresponds to the rotary table 40 . The reference numeral 154 denotes a seventh software component which corresponds to the examination module 42 . The reference numeral 156 denotes a eighth software component which corresponds to the drilling module 44 . The reference numeral 158 denotes a ninth software component which corresponds to the ejection module 46 . The software components 152 , 154 , 156 , 158 are in the form of group components. The software components are connected to one another by means of a second plurality 160 of logical connections in order to implement a flow control. The software components 152 , 154 , 156 , 158 also each represent a real mechatronic installation hardware component which is present in the system 10 that is to be controlled.
In addition, the third software component 124 has a plurality of aspect blocks: a seventh aspect block 162 which is associated with the standard control aspect, an eighth aspect block 164 which is associated with the safety control aspect, a new aspect block 166 which is associated with the diagnosis aspect, a tenth aspect block 168 which is associated with the visualization aspect, an eleventh aspect block 170 which is associated with the drive regulation aspect, and a twelfth aspect block 172 which is associated with the locking aspect. These aspect blocks also each store a functional program. The ninth aspect block 166 stores those examination conditions and installation diagnosis reports which are necessary for performing installation diagnosis for the process station 14 as such. Logical connections between individual aspect blocks themselves and to a software component have not been shown for reasons of clarity.
FIG. 7 shows the software components and aspect blocks which are comprised in the eighth software component 156 . These are a tenth software component 180 which corresponds to the third emergency-off pushbutton switch 66 , an eleventh software component 182 which corresponds to the drilling cylinder 64 , a twelfth software component 184 which corresponds to the transfer cylinder 62 , and a thirteenth software component 186 which corresponds to the motor 60 . These software components are in the form of elementary components.
In addition, the eighth software component 156 comprises a thirteenth aspect block 188 which is associated with the standard control aspect, a fourteenth aspect block 190 which is associated with the safety control aspect, a fifteenth aspect block 192 which is associated with the diagnosis aspect, a sixteenth aspect block 194 which is associated with the visualization aspect, a seventeenth aspect block 196 which is associated with the drive regulation aspect, and a eighteenth aspect block 198 which is associated with the locking aspect. The fifteenth aspect block 192 stores those examination conditions and installation diagnosis reports which are necessary for performing installation diagnosis for the drilling module 44 as such.
The software components and some of the aspect blocks are connected to one another by means of a plurality of logical connections for the purpose of implementing flow control. The logical connections have not been shown completely for reasons of clarity.
FIG. 8 shows those aspect blocks which are comprised in a software component which corresponds to a cylinder which the system 10 that is to be controlled contains. In the present exemplary embodiment, this is the eleventh software component 182 , for example. This is not intended to have any limiting effect, however, and the comments below likewise apply to the twelfth software component 184 .
The eleventh software component 182 comprises a nineteenth aspect block 210 , which is associated with the standard control aspect, and a twentieth aspect block 212 , which is associated with the diagnosis aspect. Since the mode of operation of an aspect block associated with the diagnosis aspect is meant to be explained with reference to the standard control aspect, no further aspect blocks are shown in FIG. 8 .
The fourth logical connections 214 are used to supply the nineteenth aspect block 210 with signals which are produced by two end position sensors, and which each indicate that the drilling cylinder 64 is occupying one of the two possible end positions. These two signals are likewise supplied to the twentieth aspect block 2121 via the fourth logical connections 214 . In the nineteenth aspect block 210 , control output signals are produced in accordance with the functional program stored in said aspect block, said control output signals being used to actuate the drilling cylinder 64 . These control output signals are supplied to the twentieth aspect block 212 via fifth logical connections 216 . The twentieth aspect block 212 performs installation diagnosis on the basis of the signals supplied to it. This installation diagnosis can be used to determine the following installation states: “The cylinder is not retracted”; “The cylinder is not extended”; “Both limit switches have been operated”. The installation diagnosis report which represents the determined installation state is output via a sixth logical connection 218 .
In FIG. 9 , a first hierarchic structure is denoted as a whole by the reference numeral 220 .
This first hierarchic structure represents both that hierarchic structure on which the system 10 that is to be controlled is based and that hierarchic structure on which the user program for the safety controller is based. In the illustration chosen for FIG. 9 , each block has two meanings. The reference numeral which precedes the oblique stroke indicates which installation hardware component of the system 10 that is to be controlled is represented by the respective block. The reference numeral which follows the oblique stroke indicates which software component is represented by the respective block in the user program.
The reference numeral 222 denotes a block which represents the system 10 that is to be controlled as a whole or the user program as a whole. The reference numeral 224 denotes a topmost system hierarchy level, the installation hardware components of which are referred to as component parts. The reference numeral 226 denotes a first system hierarchy level which is situated directly below the topmost system hierarchy level and the installation hardware components of which are referred to as subcomponents. The reference numeral 228 denotes a second system hierarchy level which is situated directly below the first system hierarchy level and the installation hardware components of which are referred to as individual components. In FIG. 9 , the first system hierarchy level is not shown for each component part shown and the second system hierarchy level is not shown for each subcomponent shown. This is not intended to have any limiting effect.
The individual blocks which the structure comprises have associated installation states and installation diagnosis reports which represent the installation states. Thus, by way of example, the block 60 / 180 has the associated installation state “motor overload” and the associated installation diagnosis report “motor overloaded”. The blocks 62 / 184 and 64 / 182 have a plurality of associated installation states. A first installation state “cylinder position” with the two installation diagnosis reports “cylinder is not retracted” and “cylinder is not extended”. A second installation state “end position switch” with the installation diagnosis report “Both end position switches operated”. A third installation state “signal state” with the installation diagnosis report “Invalid input/output signal”. A fourth installation state “Time condition” with the two installation diagnosis reports “Retraction time exceeded” and “Extension time exceeded”. The blocks 24 / 120 , 48 / 150 and 66 / 180 have two associated installation states. A first installation state “State” with the installation diagnosis report “Actuated” and a second installation state “Confirmation” with the installation diagnosis report “No confirmation”.
On the basis of the hierarchic structure, installation states which occur in a block on the second system hierarchy level, for example, can be forwarded to the associated block on the first system hierarchy level or even on the topmost system hierarchy level.
In FIG. 10 , a second hierarchic structure is denoted as a whole by the reference numeral 240 . This second hierarchic structure reproduces the design of the control hardware components 68 which the safety controller contains, allowing for the third emergency-off pushbutton switch 66 . That is to say those control hardware components which are associated with the drilling module 44 . The restriction to the drilling module 44 is not intended to have any limiting effect. It goes without saying that an appropriate hierarchic structure can be specified for the entire safety controller which is used to control the system 10 .
The reference numeral 242 denotes a logic unit which executes that portion of the user program which is used to control the drilling module 44 . The logic unit 242 defines a topmost control hierarchy level. The reference numeral 244 denotes a first control hierarchy level which is situated directly below the topmost hierarchy level. The reference numeral 246 denotes a second control hierarchy level which is situated directly below the first control hierarchy level. The reference numeral 248 denotes a third control hierarchy level which is situated directly below the second control hierarchy level.
The first control hierarchy level 244 comprises a standard bus unit 250 , which is associated with the standard control aspect, and a safety bus unit 252 , which is associated with the safety control aspect. These two bus units are used to perform the data transmission, separated according to safety-related and process-related data.
The second control hierarchy level 246 comprises a first plurality 254 of input/output modules which are connected to the standard bus unit 250 . These input/output modules provide a plurality 256 of standard outputs which can be used to output control output signals for the purpose of actuating actuators. In addition, these input/output modules provide a plurality 258 of standard inputs which can be used to receive control input signals.
The second control hierarchy level 246 also comprises a second plurality 260 of input/output modules which are connected to the safety bus unit 252 . These input/output modules provide a plurality 262 of safety inputs and a plurality of safety outputs—not shown.
By way of example, the third control hierarchy level 248 may have the following associated system diagnosis reports: “Hardware fault”, “Short circuit to 0 V”, “Short circuit to 24 V”. The second control hierarchy level 246 may have the following associated system diagnosis reports, for example: “Module missing”, “Internal error”, “Supply voltage error”. Both the first control hierarchy level 244 and the topmost control hierarchy level may have the following associated system diagnosis reports, for example: “Internal error”, “Supply voltage error”. It goes without saying that the individual system diagnosis reports may be associated with the individual modules or units.
FIG. 11 shows a safety circuit which is denoted as a whole by the reference numeral 270 and which has a safety controller 26 which is designed to control an system denoted as a whole by the reference numeral 10 . The system 10 comprises a plurality 272 of actuators and a plurality 274 of sensors. The loads which the system 10 comprises are denoted by the reference numeral 22 .
The safety controller 26 comprises a control unit 276 . The control unit 276 is of two-channel redundant design in order to achieve the requisite failsafety for controlling safety-critical processes. As a representation of the two-channel design, FIG. 11 shows two isolated processors 278 , 280 which are connected to one another by means of a bidirectional communication interface 282 in order to be able to monitor one another and to interchange data. Preferably, the two channels of the control unit 276 and the two processors 278 , 280 are diversitary, i.e. of different design from one another, in order to largely rule out systematic errors.
The reference numeral 284 denotes an input/output unit which is connected to each of the two processors 278 , 280 . The input/output unit 284 receives a plurality 286 of control input signals from the plurality 274 of sensors and forwards said signals in an adjusted data format to each of the two processors 278 , 280 . In addition, the input/output unit 284 takes the processors 278 , 280 as a basis for producing a plurality 288 of control output signals which are used to actuate the plurality 272 of actuators.
The reference numeral 290 denotes a chip card which is used to store a user program 292 . The user program 292 is written using a programming tool. By way of example, the programming tool is a computer program 294 which can be executed on a conventional PC 296 . In this case, the use as a chip card 290 as a storage medium allows simple interchange of the user program 292 even without direct connection to the PC 296 on which the programming tool is executed. Alternatively, the user program 292 may also be stored in a memory, for example an EEPROM, which is permanently installed in the control unit 276 . The loading of the user program 292 onto the chip card 290 is indicated by a line 297 .
The user program 292 defines the control tasks to be performed by the safety controller 26 . To this end, the user program 292 comprises a safety control module 298 in which those control tasks which are associated with the safety control aspect are performed. In the safety control module 298 , safety-related control input signals 300 produced by safety sensors 302 associated with the safety control aspect are processed in failsafe fashion. By way of example, the safety sensors 302 are emergency-off pushbutton switches, two-hand controllers, guard doors, rotation speed monitoring appliances or other sensors for picking up safety-related parameters. In accordance with the associated control tasks in the safety control aspect, the safety-related control input signals 300 are taken as a basis for producing safety-related control output signals 304 , which are used to actuate contactors 18 , 20 , what are known as safety actuators, i.e. actuators which are associated with the safety control aspect. The operating contacts of the contactors 18 , 20 are arranged in the connection between a power supply 306 and the loads 22 . The contactors 18 , 20 can be used to disconnect the power supply for the loads 22 , which means that it is possible to transfer the loads 22 to a safe state when a relevant malfunction occurs.
Furthermore, the user program 292 has a standard control module 308 which is used to perform those control tasks which are associated with the standard control aspect. To this end, the standard control module 308 is used to process process-related control input signals 310 which are produced by standard sensors 312 . The standard sensors 312 are such sensors as detect input variables which are required for drive regulation, for example. By way of example, these may be rotation speeds, angles or speeds. On the basis of the process-related control input signals 310 , process-related control output signals 314 are produced in accordance with the control tasks associated with the standard control aspect and are supplied to standard actuators 316 . By way of example, the standard actuators 316 may be motors or control cylinders.
The design chosen in the exemplary embodiment for the user program 292 , according to which said user program comprises a safety control module 298 and a standard control module 308 , which is why the control unit 276 performs both control tasks which are associated with the safety control aspect and control tasks which are associated with the standard control aspect, is not intended to have any limiting effect. It goes without saying that it is also conceivable for the control unit 276 to perform merely control tasks which are associated with the safety control aspect. In this case, the user program 292 does not contain a standard control module 308 .
The input/output unit 284 is also used for linking further components which the safety controller 26 comprises to the two processors 278 , 280 . Thus, a number 320 of installation diagnosis input signals are supplied to an installation diagnosis evaluation unit 318 from the input/output unit 284 . The installation diagnosis evaluation unit 318 is designed to take the number 320 of installation diagnosis input signals as a basis for determining which of a plurality of installation states for the system 10 which is to be controlled is present at a first defined time. The installation diagnosis evaluation unit 318 produces a number 322 of installation state signals, wherein the number 322 of installation state signals represents a number of determined installation states, wherein the number of determined installation states are present at the first defined time. The number 322 of installation state signals are supplied to the input/output unit 284 . Hence, the control unit 276 can take suitable measures in accordance with the determined installation states.
In addition, a number 326 of system diagnosis input signals are supplied to a system diagnosis evaluation unit 324 from the input/output unit 284 . The system diagnosis evaluation unit 324 is designed to take the number 326 of system diagnosis input signals as a basis for determining which of a plurality of system states for the safety controller 26 is present at a second defined time, wherein the system diagnosis evaluation unit 324 is designed to produce a number 328 of system state signals, wherein the number 328 of system state signals represents a number of determined system states, wherein the number of determined system states are present at the second defined time. The number 328 of system state signals are supplied to the input/output unit 284 . Hence, the control unit 276 can take suitable measures in accordance with the determined installation states.
In this case, a system state is intended to detect not only the units and components which the safety controller 26 comprises but also all units which are electrically connected to the safety controller 26 . These are the safety sensors 302 , the contactors 18 , 20 , in more general terms the safety actuators, the standard sensors 312 , the standard actuators 316 and also a display unit that is yet to be described and a system diagnosis request unit that is yet to be described. In addition, the system state is intended to cover all wiring which is present between the safety controller 26 and the units listed above.
The safety controller 26 comprises an interface 330 for a display unit 332 . The display unit 332 is designed to display diagnosis reports. In addition, the safety controller 26 comprises an interface 334 for a system diagnosis request unit 336 , which is designed to detect a system diagnosis request 337 . The display unit 332 and the system diagnosis request unit 336 can form a physical unit 338 .
Furthermore, the safety controller 26 has a diagnosis reporting unit 340 . The diagnosis reporting unit 340 is supplied with the number 322 of installation state signals and with the number 328 of system state signals. In addition, the diagnosis reporting unit 340 is supplied firstly with a number 342 of installation diagnosis reports, wherein the installation diagnosis reports represent the determined installation states. Secondly, the diagnosis reporting unit 340 is supplied with a number 344 of system diagnosis reports, wherein the system diagnosis reports represent the determined system states.
The diagnosis reporting unit provides a number of diagnosis reports for the number of determined installation states and for the number of determined system states, wherein at least for one of the determined installation states a diagnosis report is provided on the basis of said installation state and a number of associated system states which are comprised in the number of determined system states and which are associated with said installation state. The diagnosis reporting unit 340 produces a number 346 of diagnosis signals, wherein the number of diagnosis signals represent the number of diagnosis reports. The number 346 of diagnosis signals are supplied to the display unit 332 via the input/output unit 284 for the purpose of displaying the number of diagnosis reports.
The installation diagnosis evaluation unit 318 , the system diagnosis evaluation unit 324 and the diagnosis reporting unit 340 are combined in a diagnosis unit 348 .
The diagnosis reporting unit 340 has an association memory unit 350 which stores a plurality of association variables at least for a plurality of the plurality of installation states and at least for a plurality of the plurality of system states. The stored association variables indicate which of the plurality of system states is respectively associated with which of the plurality of installation states on the basis of a predefined association. A number of pairings for the number of determined system states and for the number of determined installation states have a number of stored association variables selected for them. Each of these selected association variables represents at least one of the pairings. The number of associated system states is determined on the basis of the number of association variables.
The diagnosis reporting unit 340 has a state memory unit 352 which is designed to repeatedly store determined installation states and determined system states. The diagnosis reporting unit 340 is designed to consider already stored determined system states and/or already stored determined installation states when establishing whether the system state to be stored is an associated system state and/or when establishing whether there are associated system states present for an installation state that is to be stored.
The installation diagnosis evaluation unit 318 has an installation diagnosis memory unit 354 which stores the plurality of installation states, the installation diagnosis reports representing the latter and an installation structure size. All of these are provided and transferred to the installation diagnosis memory unit 354 when the user program 392 is written, as indicated by a line 356 . Alternatively, this information can also be transferred to the chip card 290 via the line 297 and forwarded by said chip card to the installation diagnosis memory unit 354 . The system size is made available to the diagnosis reporting unit 340 , as indicated by a line 358 .
The association variables stored in the association memory unit 350 are likewise created and supplied to the association memory unit 350 when the user program 292 is written, as indicated by a line 360 .
The system diagnosis evaluation unit 324 has a system diagnosis memory unit 362 which stores the plurality of system states and also a number of system diagnosis reports, wherein the system diagnosis reports each represent one of the plurality of system states. This information is stored permanently and originates from the manufacturer of the safety controller 26 . In addition, the system diagnosis memory unit 362 stores a control structure variable which is made available to the diagnosis reporting unit 340 , as indicated by a line 364 .
The input/output unit 284 is used to interchange test signals 364 between the safety controller 26 and the safety sensors 302 , the contactors 18 , 20 , the display unit 332 , the system diagnosis request unit 336 . The test signals 364 can be used in the safety controller 26 to determine whether the units and components connected to the latter are operating correctly, which is necessary, since it must be ensured that the system 10 to be controlled is in a safe state as soon as a malfunction occurs on an appliance connected to the safety controller 26 . | A safety controller for controlling an automated installation in accordance with a user program has a control unit receiving a plurality of control input signals from a plurality of sensors. The control unit produces a plurality of control output signals on the basis of the control input signals in accordance with a user program. The control output signals drive actuators in order to adopt one of a plurality of installation states of the automated installation. An installation diagnosis evaluation unit produces a number of installation state signals representing which one of the plurality of installation states is existent at a defined moment of time. In addition, a system diagnosis evaluation unit produces a number of system state signals, with each system state signal representing one from a plurality of operational system states of the controller system, which is formed by the control unit and its connected sensors and actuators, at the defined moment of time. A diagnosis report unit produces a number of diagnosis signals depending on the installation state signals, depending on the system state signals, and depending on predefined associations between said installation states and said operational system states. The diagnosis signals represent a number of diagnosis reports which are a result of a combination of both the installation states and associated operational system states. A display unit displays the diagnosis reports in response to the diagnosis signals. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] All priority benefits under 35 USC 119(e) of Provisional Patent Application Ser. No. 61/005,021 filed Dec. 3, 2007 are hereby claimed and the contents thereof in their entirety incorporated herein by reference. The present invention is the subject matter of a Disclosure Document filed in the United States Patent and Trademark Office on Aug. 4, 2006 and registered as No. 604318. All benefits of said registered Disclosure Document are claimed under 35 U.S.C. Section 122, 37 C.F.R. Section 1.14, and MPEP section 1706. The present application also is related to applicant's application Ser. No. 10/241,855 filed Sep. 13, 2002, which was published Mar. 18, 2004 as 2004 0050507, subsequently issued as U.S. Pat. No. 6,848,492 on Feb. 1, 2005, and the contents thereof in their entirety are hereby incorporated herein by reference.
FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates in general to the technological field of portable photovoltaic (PV) systems, and more particularly to the applications of such systems in buildings or houses to produce electricity for powering devices and appliance in the absence of (or as supplement to) more conventional power resources.
[0006] One of the principal drawbacks of known portable electric power producing systems such as electric generators and the like, is that their. operation generally relies on non-renewal energy sources such as batteries, gasoline, diesel fuel or similar petroleum based products. In the event of remote and/or portable operation of these devices where conventional electricity utility service is unavailable or for some reason not operational, the equipment user will need access to batteries or power systems driven by petroleum based products for equipment operation. An additional drawback is that burning of petroleum based products adds carbon emissions to the earth's atmosphere.
[0007] With the noted drawbacks mentioned above and considering the frequently escalated cost of fossil fuels, increasing attention is being paid to renewable energy sources such as solar and wind power. Solar power characteristically utilizes modules comprised of photovoltaic (PV) cells to produce electric current. These PV modules typically are installed in arrays of collection panels permanently mounted to building, for example on a rooftop. In most building applications, photovoltaic (PV) solar units are permanently roof-top mounted devices.
[0008] What is needed is a fully portable renewable energy system that can be conveniently placed and repositioned by hand as necessary to capture energy from the sun so as to power devices such as computers, small appliances, alarms, emergency lighting and communication systems such as radios and television sets. More particularly, a system is needed that would fit snuggly within a window or door frame so as to be directly impacted by outside solar energy, and readily movable to another window or doorway as necessary to follow solar position changes for operational efficiency.
[0009] 2. Description of the Prior Art
[0010] Thomas' U.S. Pat. No. 6,848,492 discloses an inexpensive lightweight, reusable and detachable insulating cover device for residential and commercial dwellings and similar heated structures. The inner-portion of the insulating pad fit inside of a typical entrance or window unit framing. The outer-portion of the insulating pad overlaps the window unit or entrance framing.
[0011] The outer portion of Thomas' insulating pad may be secured to the building wall structure surrounding the window or entrance framing by using hook and loop type fasteners available under the Velcro® brand name. During cold weather months, the Thomas insulating cover device will restricts warm air from escaping between small crevices in inept window systems by fitting firmly into window framing using an insulating material, thus creating a thermal barrier and improving the efficiency of the furnace and lessening electricity or fuel consumption.
[0012] Fronek's U.S. Pat. No. 6,646,196 discloses a multi-panel window structure with a photovoltaic panel permanently affixed in the window unit. While Fronek provides an alternative to roof-mounted PV panel arrays, it is still a permanently mounted feature and not easily removed, changed and/or upgraded. A major drawback of current solar applications is that they are expensive and permanently mounted roof-top structures, and with no emphasis placed on portability.
[0013] Using the earth's wind currents to produce energy is another well known renewal energy source. While this form of renewal energy has promise, it requires open spaces of land and tall wind vane columns, clearly not feasible for portable and emergency energy production purposes. Compactness, stability and ease of assembly in remote and emergency locations are highly desirable aspects of any portable renewal energy devices.
[0014] Azzam, in U.S. Pat. No. 6,974,904 presents a portable solar powered unit which features a wheeled frame. This technology does offer a compact and portable means to provide electrical power in remote locales and emergency situations. It is suited for use in remote, isolated and underdeveloped regions of the world such as deserts and small villages that lack energy infrastructure. However, this particular solar powered unit is an item of relativity high cost and typical consumers would not be willing to make so high a capital investment for an item of such limited use. Azzam's units are believed to be better suited for commercial applications rather than used by the everyday consumer/homeowner.
[0015] Typically when building integrated photovoltaic (BIPV) units are incorporated into fixed roof mounted structures, the weight of these units must be considered in roof load designs by architects and home designers. Also, current BIPV units are not suited for portable, compact, lightweight micro-solar energy applications. Accordingly, there is a need for a portable, flexible, compact and lightweight BIPV unit that is configured to face a window unit when installed permitting it to be exposed to direct sunlight, thus producing solar electric energy. In event of a power outage this portable BIPV device can serve as a back-up source of electric energy.
[0016] Also included in the prior art is a portable solar technology for automotive use. Sundar's U.S. Pat. No. 4,955,203 features an air conditioning unit for a parked automotive vehicle. Electricity to power the vehicle air conditioning system is produced by a portable solar panel located interiorly near the front window of the vehicle.
[0017] While Sundar's disclosure presents a portable solar design, it does not allow for the portable solar panel to be conveniently withdrawn and repositioned in other automobile windows by detaching and relocating the solar panel. Thus, the scope and use of Sundar's system is severely limited in this respect. In addition, there is no suggestion that the Sundar device could be applied to various window openings in a building to supply electricity to any of a number of devices. While interchangeability of the solar panel is, in hindsight, conceivable in his design, Sundar makes no reference of this ability in his patent document and the venue or context of use described in no way suggests interchangeability. To the contrary, interchangeability and multiple applications are a major objective of the present invention which now will be described in more detail.
BRIEF SUMMARY OF THE INVENTION
[0018] There has been a longstanding need for a portable building-integrated photovoltaic system that is both simple and cost effective to install at first application, and particularly one that does not damage or alter existing window, window framing or adjacent wall structures. The present invention provides a technique for generating solar power in existing buildings by using portable and removable fabric window coverings, an elastic cord lanyard array, hook fastener and/or suction cup attachment method/system to arrange solar panels in a position to best capture and convert solar energy from direct sunlight incidental to the location of the window itself.
[0019] Since the effectiveness of a solar collection panel is generally dependent upon its relative position to the sun, it is found that easy portability enables the user to selectively place the panel adjacent windows with more advantageous solar incidence. The present invention employs a lightweight and flexible fabric material which incorporates hook and loop fasteners (e.g., of the type available under the trade name Velcro®) and an elastic cord fastened around the perimeter of the fabric material. The hook and loop fasteners and elastic chord feature are used to secure the fabric material over the interior-side generally (or the exterior) of window units. A generally central portion of the fabric material incorporates sets of hook and loop fasteners employed in mounting at least one light weight solar panel.
[0020] While fabric material is described as a suitable support mount for the solar panel, this feature can be omitted completely and the solar panel could be secured in place directly at the window unit with a lanyard support array or suction cup attachment feature. Either of these applications will make the present invention a more universal device which could be used in more diverse building environments.
[0021] An important object of the present invention is to offer a person with little knowledge of solar energy equipment a quick and simple method to convert sunlight into solar energy without making significant alterations to the building or window unit being used as a light-source.
[0022] Another important object of the present invention is that in event of power outages, this device could serve as a back-up source to deliver electric power where needed. In communities ruined by natural or man-made disasters, this device allows victims an easy and low-cost means to operate household electrical devices until regular power service is restored.
[0023] Still another object of the present invention is that this reusable device could be among the equipment supplied in an emergency response kit. The early response teams could install these unique devices in disaster command centers and use them to produce electrical power for their mobile communication equipment and medical apparatus. This device will also work well as a supplemental electrical power source for recreational vehicles (RVs) and used as a back-up recharging source in electrical automobiles.
[0024] The present invention could be modified to incorporate thermal insulating material inside the layers of fabric window covering thus making the device a reusable dual energy conservation and alternative energy producing device.
[0025] The present invention will be better understood and appreciated from the following detailed description of one embodiment thereof, selected for purposes of illustration and shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE VARIOUS VIEWS OF THE DRAWINGS
[0026] FIG. 1 is a perspective view of an exterior house structure with the present invention installed;
[0027] FIG. 2 is an elevation view of the front window facing side of the present invention with the solar panel unit installed;
[0028] FIG. 2A is a exploded side elevation view showing a schematic of various parts used to assemble the present invention as illustrated in FIG. 2 and FIG. 5 .
[0029] FIG. 2B is a modified side elevation exploded similar to the FIG. 2A showing a schematic the various parts used to assemble the present invention, while omitting optional features;
[0030] FIG. 3 is an elevation view of the front window facing side of the present invention similar to FIG. 2 but without the solar panel unit installed;
[0031] FIG. 4 is a partial elevation of an exterior house structure showing the installation of the present invention;
[0032] FIG. 5 is an elevation view of the rear, room facing, side of the present invention;
[0033] FIG. 6 is a partial elevation of an interior house structure showing the installation of the present invention;
[0034] FIG. 6A is a partial elevation of an interior house structure showing the installation of the wall-affixed hook and loop fastener elements;
[0035] FIG. 6B is a partial elevation of an interior house structure showing the installation of the wall-affixed fastening mounts.
[0036] FIG. 6C are detailed orthographic views of the wall fastening mounts shown in FIG. 6B ;
[0037] FIG. 7 is a partial elevation of an interior house structure showing the installation of the present invention, omitting the fabric window covering and using the lanyard support array;
[0038] FIG. 7A is a front and side elevation view of the solar panel with the optional solar panel mounts as illustrated in FIG. 7 .
[0039] FIG. 7B is a front elevation view of the solar panel with the optional full perimeter solar panel mount;
[0040] FIG. 7C is a side and front elevation of the mounting lanyard used in FIG. 7 ;
[0041] FIG. 7D is a modified elevation view of FIG. 7 wherein sill and window frame mounts are employed to install the inventive device;
[0042] FIG. 7E is a modified elevation view resembling view FIG. 7 , this view shows a suction cup installation design of the patent invention;
[0043] FIG. 7F show the three optional fastening devices discussed in other drawings, displaying different mounting features;
[0044] FIG. 7G is a front and side elevation view of the solar panel with the optional solar panel mounts as illustrated in FIG. 7 and the optional suction cup attachment feature.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Illustrated in FIG. 1 is a perspective view of an exterior house or building structure 21 with the present invention installed. In this ( FIG. 1 ) illustration the present invention is installed on the interior side of window unit 20 depicted as positioned within an opening defined in a house or building wall 22 . This installation is fully illustrated in FIG. 6 . The solar panel 04 is attached to the fabric window covering 01 and positioned in a manner to convert solar energy from direct sunlight incidental to the location of the window unit 20 itself.
[0046] An elevation view depicted in FIG. 2 shows the front or outward window-facing side of the present invention with the solar panel unit 04 installed. Shown in this view is a fabric window covering 01 used as a mounting support for an installed solar panel unit 04 . The solar panel unit 04 is centered on said fabric window covering 01 in a manner that when installed the solar panel unit is located facing (outwardly toward) direct sunlight incidental to the building window or defined opening. The covering 01 may be configured to fully cover a window (or doorway) recess typical of such framed openings. This offers the added features of insulating the opening and positioning the solar panel unit 04 outwardly (into the recess) to its maximum extent to take advantage of solar incidence.
[0047] The solar panel unit 04 may be secured to, and supported by, the fabric window covering 01 using uniformly spaced hook and loop fasteners 03 (or their equivalents); these fasteners are affixed along the perimeter of the non-photovoltaic cell side (or rearward facing side) of solar panel unit 04 in direct alignment with corresponding hook/loop fastener elements 03 affixed to fabric window covering 01 . Along the perimeter of the front window-facing side of the fabric window covering 01 are also uniformly spaced hook and loop fasteners 03 (or their equivalents).
[0048] These fastener elements are deployed to attach the photovoltaic device and its support to the area bordering around the window unit. Besides hook and loop fasteners, these elements may also include any other conventional fastening means, for example snaps or hooks, threaded or non-threaded fasteners and so forth. The present invention includes an optional mounting method using elastic cord material 02 .
[0049] The fabric window covering 01 can, if desired, be fabricated to comprise two (or more) layers of material. The layers of covering 01 may be sewn together or joined using threading material 05 such as nylon or other high strength threading. Of course, a stapling technique or other equivalent fastening process may be employed such as adhesives, heat seal, and the like. Once attached, the elastic cord material 02 may be looped around the perimeter of the fabric window covering 01 as illustrated in FIG. 2 . The elastic cord material 02 is uniformly spaced and firmly attached to covering 01 . Where fabric layers are utilized, the cord material 02 may be tucked in segments and firmly anchored between the joined layers of fabric window covering 01 . Attached to the solar panel 04 is electrical wiring in the form of a power cord 06 . The cord 06 penetrates the fabric window covering 01 using cover penetration opening 07 .
[0050] An exploded view presented as FIG. 2A is a simple illustration of the various components of the present invention. FIGS. 2 and 5 show the alignment and placement of the components as fully assembled. FIG. 2A illustrates an optional insulation material 14 (between layers of fabric covering 01 ) and further shows uniformly spaced hook and loop fasteners 03 . Again, any suitable equivalent fastener means may be employed. A modified exploded view of FIG. 2A is illustrated by FIG. 2B which eliminates optional features such as insulation material 14 , elastic cord material 02 and one layer of the fabric window covering 01 . While a storage pouch 08 is shown, it also is optional and could be omitted, if desired.
[0051] The front window-facing (or outwardly facing) surface of the present invention is illustrated in elevation FIG. 3 , but without the solar panel unit installed. This view incorporates all the features and attributes of FIG.2 except the solar panel unit 04 and (electrical wiring) power cord 06 have been omitted to show the corresponding hook and loop fasteners 03 affixed to fabric window covering 01 .
[0052] A partial elevation view, FIG. 4 , depicts exterior house structure 21 revealing the installation of the present invention. The present invention is installed on the room-side (i.e., interior) of the window unit 20 (or other wall opening) thus positioning the solar panel unit 04 in a manner that the component will be exposed to direct sunlight incidental to the location of the window unit 20 . The room-side (inside) installation of the present invention is illustrated with greater detail in FIG. 6 .
[0053] FIG. 5 is an elevation view of the room-facing (rearward or inwardly facing) side of the present invention. This view incorporates all the features and attributes of FIG. 2 except the solar panel unit 04 , power cord 06 and hook and loop fasteners 03 which are omitted. Sewn to the fabric window covering 01 is a storage pouch 08 . This storage pouch 08 provides a convenient method to store the electrical power inverter 10 and power cord 06 or other items as may be desired. The fabric window covering 01 and the optional storage pouch 08 are sewn and assembled together using nylon threading material 05 in a manner as illustrated in the exploded view FIG. 2A .
[0054] FIG. 6 is a partial elevation of an interior house structure 22 further describing the installation of the present invention. This partial elevation view shows an interior house structure 22 with the portable photovoltaic window unit installed over a window unit 20 (not visible in this view). An outer perimeter of the photovoltaic panel supporting fabric window covering 01 overlaps onto a wall area surrounding the window unit 20 (again, not visible in this view).
[0055] The electrical wiring or power cord 06 is shown passing through the cover penetration opening 07 (see FIG. 5 ), then to the electrical power inverter 10 and onward toward a point of application. The inverter 10 serves to convert solar direct electrical current (DC) to alternating electrical current (AC). In this illustration one power cord 06 branches off to support an AC electrical device 12 and the other branches off to a DC storage battery 11 or similar charging system; while not shown, this same power cord 06 can by-pass the inverter 10 and connect directly to the DC storage battery 11 . Also note the optional elastic cord 02 element employed as a mounting support to secure the present invention in place by attachment to wall fastening mounts 09 .
[0056] FIG. 6A is a partial elevation of an interior house structure showing the installation of wall-affixed hook and loop fasteners 03 . These uniformly spaced hook and loop fasteners 03 are installed around the window unit 20 in a manner that they will be in direct alignment with corresponding hook and loop fasteners 03 installed on the present invention as illustrated in FIG. 2 . As is well known in the art, either hook units or loop units may be placed on the wall and/or the device as long as they engage attachable opposites.
[0057] Shown in FIG. 6B is a partial elevation of an interior house structure showing the installation of the wall-affixed fastening mounts. These wall fastening anchors in the form of mounts 09 will be used as an optional device mounting system to secure the present invention over the window unit 20 (or other defined wall opening) using elastic cord material 02 . This elastic cord material 02 is installed on the present invention as illustrated in FIG. 2 . These fastening mounts 09 are uniformly spaced around the window unit 20 and are used to secure the present invention in place as illustrated in FIG. 6 .
[0058] FIG. 6C presents detailed orthogonal views of the present invention's wall fastening mount 09 . This drawing shows the top, front, right-side and bottom orthographic sides of wall fastening anchor or mount 09 . Note the bottom (wall facing) side of this mount 09 component has an adhesive 19 applied to it. This adhesive 19 will be used to secure the fastening mount 09 directly to the surrounding wall surface. The form of the fastening mounts 09 is not to be considered limiting, as any equivalent, conventional fastening method or system will suffice, for example (but not limited to) hooks, straps, cords, lacing, braces, clamps and the like.
[0059] A partial elevation is presented by FIG. 7 showing an interior house structure 22 including the installation of the present invention. This partial elevation view shows an interior house structure 22 with the portable photovoltaic panel installed over a window unit 20 . The fabric material covering 01 has been entirely omitted and functionally supplanted by a lanyard support array for the solar panel 04 . With the lanyard support array the solar panel is set and maintained in position using a series of uniformly spaced mounting lanyards 15 . These mounting lanyards 15 are braced around wall fastening mounts 09 and firmly connected to the solar panel mounts 13 .
[0060] Solar panel mounts 13 are securely attached to the solar panel 04 using an adhesive, by sewing, or affixed by mechanical means. The power cord 06 is then routed to the electrical power inverter 10 which (as explained hereabove) changes the solar direct current (DC) to alternating current (AC). In this illustration one power cord 06 branches off to support an AC electrical device 12 and the other branches off to a DC storage battery 11 or similar charging system; while not shown, this same power cord 06 can by-pass the inverter 10 and connect directly to the DC storage battery 11 .
[0061] FIG. 7A is a front and side elevation view of the solar panel with optional solar panel support mounts 13 . Support mounts 13 are affixed to solar panel 04 in any of a variety of ways including, but not limited to, adhesives, sewing, or mechanical elements. Note the eyelet 16 features allowing the mounting lanyard 15 to be firmly attached to solar panel mount 13 as illustrated in FIG. 7 . The term eyelet 16 , by the way, is intended to connote any of a variety of well known mechanical fixtures which can serve as discrete anchors to which loops, cords and the like can be applied for securement.
[0062] FIG. 7B is a front elevation view of the solar panel 04 showing it optionally supported about its full perimeter by a modified panel mount 13 . This view shows the solar panel mount 13 attached on all sides of solar panel 04 . This feature will of course provide multidirectional support for solar panel 04 .
[0063] A side and front elevation of the mounting lanyard 15 used in FIG. 7 is illustrated in FIG. 7C as having first and second ends. Mounting lanyard 15 has three primarily components including loop or hook 17 , elastic cord material 02 and clamp 18 . The clamp 18 will firmly secure a looped segment of the elastic cord material in a manner that will allow section mounting lanyard 15 to have a fastening end. The loop or hook 17 is firmly attached to the opposite end of the elastic cord material 02 . In use, the loop or hook 17 will firmly attach about eyelet 16 of the solar panel mount 13 as illustrated in FIG. 7 . “Eyelet” in the present context refers to a fixed anchor element which may or may not include an opening.
[0064] FIG. 7D is a modified elevation view of FIG. 7 . This partial elevation view shows an interior house structure 22 with the portable photovoltaic window panel 04 installed over window unit 20 . Note in this modification that the wall fastening mounts 09 have been completely removed, thus saving time and steps in the installation process. This variation of the lanyard support array uses the optional dual-hook mounting lanyard 15 to install the present invention in the following manner.
[0065] Along the top protruding edges of window unit frame 20 a first end of mounting lanyard 15 is secured firmly by its hook 17 and the lanyard 15 second end has its hoop 17 secured on a corresponding eyelet 16 of the solar panel mount 13 . At least one lanyard 15 is thus attached at opposite edges of solar panel mount 13 so as to secure it in place relative to window unit 20 . As illustrated, for example, three lanyards 15 are employed by hooks 17 at the top frame 20 edge and bottom sill 25 . The opposing ends of the lanyards 15 are looped to corresponding eyelets 16 on the solar panel mounts 13 . The eyelet 16 feature is clearly depicted in FIG. 7A .
[0066] These solar panel mounts 13 are securely attached to the solar panel 04 using an adhesive, sewn or other mechanical elements. As described hereabove, the power cord 06 is then routed to the electrical power inverter 10 which in turn alters the collected solar direct electrical current (DC) to alternating electrical current (AC). In this illustration one power cord 06 branches off to support an AC electrical device 12 and the other branches off to a DC storage battery 11 or similar charging system; while not shown, this same power cord 06 can by-pass the inverter 10 and connect directly to the DC storage battery 11 .
[0067] FIG. 7E is a modified view as compared to that depicted in FIG. 7 . The FIG. 7E view shows a window unit 20 reconfigured to depict one large fixed single glass pane window. Illustrated here, for example is an array of three solar panel units 04 mounted directly to the window glass pane 26 using optional suction cup fasteners 24 . More than, or fewer than, three solar panels may clearly be applied. As described above, solar panel mounts 13 are securely attached to firmly support the solar panels 04 using an adhesive, by sewing or employing other mechanical means.
[0068] Each suction cup fastener 24 is inserted through an eyelet 16 (or other suitable openings extending through solar panel mounts 13 ), forming a releasable interconnection between the solar panel mounts 13 and the window glass pane 26 . Using manually applied compressive force, the faces of suction cup fasteners 24 collectively attach to the window glass pane 26 , thus installing the solar panels 04 . The power cords 06 for all three solar panels 04 are then routed to the electrical power inverter 10 . Again, this inverter serves to convert collected solar direct electrical current (DC) to alternating electrical current (AC). In this illustration, as before, one power cord 06 branches off power inverter 10 to support an AC electrical device 12 and the other branches off to a DC storage battery 11 or similar charging system; while not shown, this same power cord 06 can by-pass the inverter 10 and connect directly to the DC storage battery 11 . The application of the suction cup fastener 24 is covered in greater detail in FIG. 7G .
[0069] FIG. 7F is a detailed view of three optional fastening devices discussed in other drawings. The first fastening device described is the modified mounting lanyard 15 with two opposed mounting hooks 17 as illustrated in FIG. 7D . These opposed hooks 17 are firmly connected to the centered elastic cord material 15 . The second device is the suction cup fastener 24 . The use of this latter device is illustrated in FIG. 7E and FIG. 7G . The third device is a modified mounting lanyard 15 which omits the elastic cord 17 feature of the other designs. This rigid connector 27 design can replace other mounting lanyards 15 where the additional elastic cord is not needed.
[0070] FIG. 7G is a modified front and side elevation view of the solar panel with the optional solar suction cup fastener 24 installed onto the solar panel mounts. The suction cup fastener 24 is affixed firmly in the eyelet 16 feature of the solar panel mount 13 ; this eyelet 16 feature is fully illustrated in FIG. 7A . The application of the suction cup attachment feature is fully illustrated in FIG. 7E .
[0071] It is important to note that the fabric window covering 01 may be made of any suitable material such as flame retardant material, cotton, plastic, polyester, paper or plastic with aluminum foil backing, nylon, and the like. In addition this fabric window covering 01 can be made from a durable transparent or translucent polymer or other conventional material having these properties.
[0072] The optional insulation material 14 may be any conventional type of insulation such as polyester batting, fiberglass, bubble-foil insulation, plastic, cotton, rubber and any conventional insulation material including flame retardant material which is designed to resist the transfer of heat through its surface. The eyelets 16 on the solar panel mounts 13 are not to be considered as limiting since any form of clamps, brackets, bolting or equivalent conventional fastening means can be used.
[0073] In addition to hook and loop fasteners 03 , other fasteners could be used such as snaps, hooks or any other types of conventional fastening means. While nylon threading material 05 has been mentioned, it will obvious that in addition to nylon threading material 05 , snap fasteners, staples, hot seals, epoxy or other glue-like material can be used. In addition the elastic cord material 02 may substituted with other suitable products.
[0074] An additional advantage of the present invention is that its portable and lightweight design. While the present invention is presented as a home or house appliance, it could well find application outside the home. For example, it would make an excellent auxiliary electrical power device for recreation vehicles (RVs) and spacecraft. This device could supplement the solar power generation abroad aircraft and spacecraft, or on boats, as well as serve as a emergency backup power source in virtually any location.
[0075] Although the foregoing description makes reference to a number of specific features and embodiments, these should not be construed as limiting the scope of the present invention. Instead, the described invention should be viewed as susceptible of modification, combinations and alterations. Accordingly, the following claims are intended to cover all such modifications which are within the spirit and scope of the invention. In other words, the scope of the invention should be determined by the appended claims and their equivalents, rather than limited in any manner by the examples given. | A portable, lightweight and detachable photovoltaic window system affording a resource for converting solar power in existing buildings and similar structures. At least one photovoltaic panel is interconnected to a building window or entrance casing or directly to a window pane through use of lanyards, hook and loop fasteners, or suction cups. Solar energy is captured from direct sunlight incidental to the location of the window. A panel may be removably supported by a fabric material interconnected to an interior wall via hook and loop fasteners. An inverter converts energy from DC to AC for powering electrically driven devices. A pocket is provided on the panel support for temporarily storing the auxiliary devices. This system enables a person with little knowledge of solar energy equipment a convenient and inexpensive method to convert sunlight into useful energy without major alterations to the building or window unit being used as a light-source. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to electrically conducting polymers, and is particularly directed to such polymers obtained from mono- or difunctional phenylacetylene-substitued Schiff's base monomers.
For many years synthetic organic polymers have attracted attention in a variety of electrical and electronic applications because of their outstanding insulator properties. However, since the discovery of the conducting properties of polyacetylene in the mid-seventies, replacement of metallic conductors with conductive polymers has been an important goal in chemically oriented research. During the past decade research efforts have intensified in obtaining improved, electroconductive, themosetting polymers useful, for example, in applications such as low-cost photovoltaic cells, moldable electrodes for use in light-weight batteries, composites, electromagnetic shielding devices, and the like.
The term "conductive polymer" is typicaly used to describe three distinct categories of polymeric materials. In the first category there are metal or graphite-filled polymers where conductivity is due solely to the filler. While most often these polymers exhibit high conductivity, a major drawback lies in the relatively large amount of filler which is needed, often changing the base polymer properties.
The second category includes "doped" polymer systems. These systems will typically consist of unsaturated polymers which contain no conductive filler but are treated to contain amounts of selected oxidizing or reducing agents. Although highly conductive polymers can be prepared by this means, most of the polymers will suffer from a loss of conductivity on simple exposure to normal atmospheric conditions or mild heat. Many of these polymers are difficult to prepare and isolate, and cannot be processed by ordinary polymer techniques.
The third category of conductive polymers includes polymers which are conductive in the pristine state. In this category, conductivity is due to the molecular configuration of the thermally post-cured polymer. Conductive polymers within this category are known in the prior art. See, for example, U.S. Pat. No. 4,178,430 to Bilow, and U.S. Pat. Nos. 4,283,557 and 4,336,362 to Walton. The monomeric precursors of these conductive polymers are ordinarily solids at room temperature. On heating, the monomers pass through a measurable temperature range in which they are in a viscous liquid or thermoplastic state. Within this range, prior to the onset of curing and the development of conductivity, these materials can be readily processed, in bulk, from the melt. The "processing window" of a conductive monomer herein is the temperature range between the endothermic minimum (where melting is just completed) and the temperature where polymerization just begins and is measured using a Differential Scanning Calorimeter (DSC) technique. This processing window where the monomer is in a liquid or thermoplastic state is a characterizing property of individual monomers and varies greatly with the monomer structure. In general, monomers having an unsymmetrical structure are likely to have a desirable wide processing window as compared to processing windows exhibited by symmetrical monomers.
Largely because of the noted deficiencies of the filled and doped polymers, interest in new intrinsically conductive or semi-conductive polymers remains high.
SUMMARY OF THE INVENTION
The present invention provides a new class of mono- or difunctional phenylacetylene-substituted Schiff's base monomers which melt on heating, go through a thermoplastic, viscous liquid state, and thereafter on continued heating at high temperatures become thermoset, electrically conducting polymers. The invention further provides monomeric precursors of conducting polymers where most members of the class will slowly cure to set when held at temperatures above the melting point and cure more rapidly at temperatures greater than 200° C. or more. It further provides an opportunity to produce cured polymeric molded articles possessing a bulk electroconductivity (σ) of a least 10 -2 S/cm.
The molecular formula of the novel monomers of the invention are: ##STR1## where B is ##STR2## and R is CH 2 , C(CH 3 ) 2 , CHOH, ##STR3## C(CF 3 ) 2 , SO 2 , S, CH 2 CH 2 , HC═CH, O, ##STR4## n=0 or 1; and ##STR5## where G is C.tbd.CH, H, ##STR6## and ##STR7## where A is ##STR8## where G' is C.tbd.CH, H, and ##STR9##
The mono- or difunctional phenylacetylene-substituted Schiff's base monomers of Structure I above are prepared by first catalytically reacting phenylacetylene with a suitable bromobenzaldehyde to yield a corresponding phenylethynylbenzaldehyde intermediate. Another intermediate, phenylethynylaniline is prepared by catalytically reacting an aminophenylacetylene with bromobenzene. Other means for preparing these intermediates are known and may be used. For example, phenylethynylaniline may be prepared starting with a nitrobromobenzene which is reacted with phenylacetylene. The resulting nitro compound is later reduced to the amine. Either of the two intermediates is thereafter further reacted with compounds such as, for example, phenylene diamine, methylene dianiline, oxydianiline, aminophenyl sulfone, terephthalaldehyde, and isophthalaldehyde, where the aldehyde and amine groups are reacted to provide the acetylene-substituted Schiff's base monomers of the invention.
Monomers of structures (II) above require different intermediates, e.g. intermediates prepared from a palladium catalyzed coupling reaction of the appropriate bromobenzaldehyde with ethynylbenzaldehyde or the reaction of ethynylaniline with an appropriate bromoaniline. Subsequent reaction of the dialdehyde intermediate with aniline, ethynylaniline or phenylethynylaniline or reaction of the diamine intermediate with benzaldehyde, ethynylbenzaldehyde or phenylethynylbenzaldehyde yields the desired difunctional phenylacetylene substituted Schiff's base monomers.
Additionally, the reaction of these phenylethynylbenzaldehyde intermediates with aniline or ethynylanilines or the reaction of phenylethynylaniline with benzaldehyde or ethynylbenaldehyde will result in the formation of the monofunctional phenylacetylene substituted structures represented in (III) above. Reaction of the two intermediates, i.e., phenylethynylbenzaldehyde and phenylethynylaniline, with one another yields a corresponding phenylethynyl monomer containing the Schiff's base functionality.
DESCRIPTION OF PREFERRED EMBODIMENTS
With respect to the coupling reaction of the bromobenzaldehyde and the phenylacetylene as well as the reaction of bromobenzene and aminophenylacetylene, the reaction is run preferably in triethylamine which serves as a solvent and scavenger for the hydrogen bromide generated during the ethynylation reaction. Other useful amines which can be used in place of triethylamine are, for example, diethylamine, butylamines (mono, di and trisubstituted), pyridine, and the like. A co-solvent such as toluene, xylene, dimethylformamide, and dimethylacetamide can also be used to improve the solubility of the starting materials. The reaction requires the presence of a catalytic amount of a palladium catalytic species which, for example, may be palladium acetate, palladium chloride, etc. Optionally, to hasten the coupling reaction a co-catalyst may also be used. Suitable co-catalysts include cuprous salts, for example, cuprous chloride, cuprous bromide, and cuprous iodide which is preferred. Use of palladium catalysts to promote coupling reactions of aromatic halides with acetylene compounds is described in the literature, for example, Richard F. Heck, Palladium Reagents in Organic Syntheses, Academic Press, New York 1985, Chapter 6, Section 6.8.1. Additionally, to improve the utility of the palladium catalyst, a solubilizing phosphine ligand is often used. Examples of such phosphine ligands include triorthotoluylphosphine and triphenylphosphine which is preferred because of its availability and cost.
The reaction is run in an inert atmosphere at atmospheric pressure at a temperature of 75°-85° C. for about 6-18 hours. The reaction is monitored by gas-liquid chromatography tracking the disappearance of starting material and/or appearance of product.
The reaction conditions for providing Schiff's bases are well known and no special precautions are needed herein.
The monomeric compounds of the invention are solid, non-conductors. Heating melts the monomers to yield a thermoplastic, tacky, viscous liquid mass. Most of the monomers of the invention will start to melt at temperatures between 140°-160° C. It is in this state that the monomers are molded or conveniently processed to produce the desired end-products. To provide the thermoset electrically conducting polymer, thermal post-curing in the range of 300°-800° C. for about 10 to 100 hours is required. The monomers herein also may be solution polymerized and the polymer thereafter subjected to thermal post-curing to develop electroconductivity.
In addition to providing homopolymers by heating of the monomeric precursors, it is also within the scope of the invention to provide electrically conducting copolymers where mixtures of two or more monomers of the invention are well mixed in their viscous liquid state. Copolymers may also be prepared from mixtures using monomers of the invention and monomer(s) selected from the classes of maleimide and bis-maleimide monomers as well as other compatible monofunctional acetylenic monomers which produce heat stable polymers. The monomers of the invention may constitute a minor or major portion of the "mixed" copolymer.
The Schiff's base monomers herein as well as described mixtures can also find use in bonding articles by placing the monomer in contact between the articles to be bonded and exposing the composite to heat or heat and pressure, sufficient to polymerize the monomer. Likewise, one or more layers of woven fabric can be impregnated with a monomer (or monomer blend) of the invention to provide a high temperature stable composite thereof. The woven fabric can be made from, for example, glass, graphite or high temperature stable polyamide fibers.
The invention is further illustrated in connection with the following examples.
EXAMPLE I
Preparation of 4-Phenylethynylbenzaldehyde
A multinecked, round bottom flask fitted with a mechanical stirrer, reflux condenser and thermometer was flushed and maintained under a positive pressure of nitrogen. The flask was charged with 25 g (0.135 mol) of 4-bromobenzaldehyde, 250 ml of dried, degassed triethylamine, 15.2 g (0.148 mol) of phenylacetylene, 0.108 g (0.152 mmol) of bis(triphenylphosphine)palladium II chloride, 0.50 g (1.90 mmol) of triphenylphosphine and 0.5 g (0.262 mmol) of cuprous iodide. The mixture was brought to reflux temperature and maintained at that temperature overnight.
The following morning gas chromatography indicated no presence of 4-bromobenzaldehyde. The reaction mixture was cooled to room temperature. To separate the product from the triethylamine hydrobromide by-product, 500 ml of ether was added to the flask and the mixture was stirred for 1 hour. The triethylamine hydrobromide was separated by filtration and the filtrate was concentrated on a rotary evaporator yielding a crystalline solid in the mother liquor. The mixture was chilled overnight in the refrigerator and subsequent filtration yielded 23.3 g (0.113 mol, 84% yield) of product as off-white platelets.
Analysis: IR (KBr pellet), 2225 cm -1 (C.tbd.C, weak) 1710 cm -1 (C═O).
1 HMR (CDCl 3 ), δ10.0 (s, 1H, CHO), 6.8-8.3 (m, 9H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 95.5° C., minimum 98.8° C. (endothermic transition, 146 J/g).
EXAMPLE 2
Preparation of 3-Phenylethynylbenzaldehyde
A multinecked flask as described in Example I was charged with 100 g (0.54 mol) of 3-bromobenzaldehyde, 400 ml of dried, degassed triethylamine, 55.2 g (0.54 mol) of phenylacetylene, 0.43 g (0.61 mol) of bis(triphenylphosphine)palladium II chloride, 1.99 g (7.58 mmol) of triphenylphosphine and 0.10 g (0.52 mmol) of cuprous iodide. The mixture was brought to mild reflux and maintained at that temperature overnight.
The following morning gas chromatography indicated only a trace presence of 3-bromobenzaldehyde. The reaction mixture was cooled to room temperature and 250 ml of ether was added. The mixture was allowed to stir for 1 hour and then filtered to remove the triethylamine hydrobromide by-product. The filtrate was concentrated on the rotary evaporator to a yellow solid to which 100 ml of petroleum ether was added. On filtration, 101.2 g (0.49 mol, 91% yield) of the product was obtained as a yellow crystalline solid.
Analysis: IR (KBr pellet), 2225 cm -1 (C.tbd.C, weak) 1700 cm -1 (CαO).
1 HMR (CDCl 3 ) δ9.2 (s, 1H, CHO), 6.4-7.3 (m, 9H, Ar-H)ppm. DSC (10° C./min, N 2 ) onset 44.6° C., minimum 48.0° C. (endothermic transition 95 J/g.
EXAMPLE 3
Preparation of 3(3-Formylphenyl)ethynylbenzaldehyde
A multinecked flask as described in Example I was charged with 35 g (0.27 mol) of 3-ethynylbenzaldehyde, 300 ml of dried, degassed triethylamine, 49.7 g (0.27 mol) of 3-bromobenzaldehyde, 0.21 g (0.30 mmol) of bis(triphenylphosphine)palladium II chloride, 1.0 g (3.8 mmol) of triphenylphosphine, and 0.05 g (0.262 mmol) of cuprous iodide. The system is brought to mild reflux and maintained at that temperature overnight.
The following morning gas chromatography indicated only a trace of each reactant. The mixture was cooled to room temperature and filtered. The funnel cake, a physical mixture of triethylamine hydrobromide and product, was washed with water to dissolve the hydrobromide salt. The insoluble product was filtered and dried overnight on the funnel, 55.5 g of the product was obtained (0.23 mol, 85% yield).
Analysis: IR (KBr pellet), 1700 cm -1 (C═O).
1 HMR (CDCl 3 ) δ9.8 (s, 2H, CHO), 7.0-8.2 (m, 8H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 101° C., minimum 106.4° C. (endothermic transition 95 J/g).
EXAMPLE 4
Preparation of 3-Phenylethynylaniline
A multinecked flask as described in Example I was charged with 50 g (0.427 mol) of 3-aminophenylacetylene, 300 ml of dried, degassed triethylamine, 67 g (0.427 mol) of bromobenzene, 0.34 g (0.48 mmol) of bis(triphenylphosphine)palladium II chloride, and 0.05 g (0.262 mmol) of cuprous iodide. The system is brought to mild reflux and maintained at that temperature overnight.
The following morning gas chromatography indicated only a trace presence of 3-aminophenylacetylene. The system was cooled to room temperature and 200 ml of a 1:1 mixture of tetrahydrofuran and ether was added to the reaction mixture and allowed to stir for 1 hour. The triethylamine hydrobromide by-product was removed by filtration.
Concentration of the filtrate yielded the product as a dark oil which solidified on standing. Yield of product was 65%, based on amount of triethylamine hydrobromide isolated.
Analysis: IR (neat), 3460 and 3380 cm -1 (NH 2 ), 2210 cm -1 (C.tbd.C).
1 HMR (CDCl 3 ) δ6.2-8.0 (m, 9H, Ar-H), 3.5 (s broad, 2H, NH 2 ) ppm.
EXAMPLE 5
Preparation of Schiff's Base from 3-phenylethynylbenzaldehyde and 1, 4-Phenylenediamine
A multinecked round bottom flask fitted with a mechanical stirrer, reflux condenser, thermometer and a positive pressure of argon was charged with 19 g (0.092 mol) of 3 phenylethynlbenzaldehyde and 200 ml of ethanol. The mixture was heated to 40° C. and 4.6 g (0.042 mol) of 1, 4-phenylenediamine was added portion-wise. After the addition was completed, the mixture was allowed to cool to room temperature and was stirred overnight. The product, a dark yellow solid, was recovered by filtration: 20 g (0.033 mol, 97% yield). Recrystallization of the compound from heptane/benzene (3:1) yielded gold-colored crystals.
Analysis: IR (KBr pellet) 1620 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.5 (s, 2H, CH=N), 7.8-8.2 (m, 22H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 182.2° C., minimum 185.7° C. (endothermic transition, 125 J/g), onset 289.8° C., maximum 314.7° C. (exothermic transition, 446 J/g), Processing Window 89° C.
EXAMPLE 6
Preparation of Schiff's Base from 4-Phenylethynylbenzaldehyde and 1, 4-Phenylenediamine
This compound was prepared using a procedure similar to that described in Example 5. The reaction was carried out using 6.5 g (0.315 mol) of 4-phenylethynylbenzaldehyde, 100 ml of ethanol, and 1.6 g (0.015 mol) of 1, 4-phenylenediamine. The crystalline product was isolated in a 87% yield (6.5 g, 0.013 mol).
Analysis: IR (KBr pellet) 1620 cm -1 (CH═N).
DSC (10° C./mm, N 2 ) onset 271.7° C., minimum 277.3° C. (endothermic transition 89 J/g), onset 312.8° C., maximum 326.3° C. (exothermic transition 446 J/g), Processing Window 7° C.
EXAMPLE 7
Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 1,3-Phenylenediamine
Using a procedure similar to that described in Example 5, the reaction was carried out using 5.2 g (0.025 mol) of 3-phenylethynylbenzaldehyde, 50 ml of ethanol and 1.3 g (0.12 mol) of 1,3-phenylenediamine. The crystalline product was isolated in a 91% yield (5.3 g, 0.011 mol).
Analysis: IR (KBr pellet) 1620 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.45 (s, 2H, CH═N), 6.9-8.2 (m, 22H, Ar-H) ppm.
DSC (10° C./min, N 2 ) onset 112.6° C., minimum 125.6° C. (endothermic transition 72 J/g), onset 285.5° C., maximum 308.8° C. (exothermic transition 515 J/g), Processing Window 139° C.
EXAMPLE 8
Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 4, 4'-Methylenedianiline.
A multi-necked flask as described in Example 5 was charged with 6.5 g (0.0315 mol) of 3-phenylethynylbenzaldehyde and 125 ml of ethanol. To this mixture was added, portionwise, 3.0 g (0.150 mol) of 4,4'-methylenedianiline. The resultant mixture was then heated to 60° C. for 15 minutes, cooled to room temperature and allowed to stir overnight. The product, an off-white solid, 8.5 g (0.0147 mol, 98% yield) was isolated by filtration. The compound can be recrystallized by boiling in heptane and adding just enough toluene to effect solution.
Analysis: IR (KBr pellet) 1630 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.35 (s, 2H, CH═N), 6.6-8.0 (m, 26H, Ar-H), 3.9 (s, 2H, CH 2 ) ppm.
DSC (10° C./min, N 2 ), onset 172.8° C., minimum 176.7° C. (endothermic transition 99 J/g), onset 281.9° C., maximum 315.2° C. (exothermic transition 471 J/g), Processing Window 78° C.
EXAMPLE 9
Preparation of Schiff's Base from 3-Phenylethynylaniline and Terephthalaldehyde
A multinecked flask as described in Example 5 was charged with 3.0 g (0.022 mol) of terephthalaldehyde and 50 ml of ethanol. To this mixture is added 8.9 g (0.046 mol) of 3-phenylethynylaniline in 50 ml of ethanol. The resultant mixture is stirred overnight at room temperature. The product, a yellow solid, was isolated by filtration; 10.0 g (0.021 mol, 95% yield). The product is recrystallized from isobutyl alcohol.
Analysis: (KBr pellet) 1625 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.5 (s, 2H, CH═N), 7.1-8.1 (m, 22H, Ar-H) ppm.
DSC (10° C./min, N 2 ) onset 161.9° C., minimum 168.8° C. (endothermic transition 94 J/g), onset 272.8° C., maximum 298.1° C. (exothermic transition 456 J/g), Processing Window 81° C.
EXAMPLE 10
Preparation of Schiff's Base from 3-Phenylethynylaniline and Isophthalaldehyde
This compound was prepared using a procedure similar to that of Example 9. The reaction was carried out using 3 g (0.022 mol) of isophthalaldehyde, a total of 100 ml of ethanol, and 8.9 g (0.046 mol) of 3-phenylethynylaniline. The product, a yellow solid, was isolated by filtration; 9.8 g (0.02 mol, 91% yield).
Analysis: IR (KBr pellet) 1625 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.5 (s, 2H, CH═N), 6.8-8.2 (m, 22H, Ar-H) ppm.
DSC (10° C./min, N 2 ) onset 105.2° C., minimum 120.1° C. (endothermic transition 39 J/g), onset 269.5° C., maximum 302.6° C. (exothermic transition 330 J/g), Processing Window 124° C.
EXAMPLE 11
Preparation of Schiff's Base from 3-phenylethynylaniline and 3(3-Formylphenyl)ethynylbenzaldehyde
A multinecked flask as described in Example 5 was charged with 10.1 g (0.525 mol) of 3-phenylethynylaniline and 50 ml of ethanol. The system was heated to 50° C. at which point 5.8 g (0.0248 mol) of 3(3-formylphenyl)ethynylbenzaldehyde in 50 ml of ethanol was added to the reaction mixture. The temperature of the mixture was maintained at 50° C. for 30 minutes. The mixture was then cooled to room temperature and stirred overnight. The product, a tan solid, was isolated by filtration: 13.0 g (0.022 mol, 89% yield).
Analysis: IR (KBr pellet) 1625 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.5 (s, 2H, CH═N), 6.8-8.2 (m, 26H, Ar-H) ppm.
DSC (10° C./min, N 2 ) onset 159.1° C., minimum 168.4° C. (endothermic transition 80 J/g), onset 266.3° C., maximum 307.1° C. (exothermic transition 527 J/g), Processing Window 66° C.
EXAMPLE 12
Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 3-Phenylethynylaniline
This compound was prepared using a procedure similar to that used in the preparation of the monomer of Example 9. The reaction was carried out using 4.7 g (0.022 mol) of 3-phenylethynylbenzaldehyde, 100 ml of ethanol and 4.4 g (0.023 mol) of 3-phenylethynylaniline. The product was isolated by filtration: 7.5 g (0.021 mol, 95% yield). The product was recrystallized from isopropyl alcohol/water (7:3).
Analysis: (KBr pellet) 1635 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.45 (s, 1H, CH═N), 7.0-8.2 (m, 18H, Ar-H) ppm.
DSC (10° C./min, N 2 ) onset 111.8° C., minimum 123.6° C. (endothermic transition 78 J/g), onset 286° C., maximum 310.9° C. (exothermic transition 567 J/g), Processing Window 141° C.
EXAMPLE 13
Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and Aniline
A multinecked flask as described in Example 5 was charged with 5.4 g of 3-phenylethynylbenzaldehyde, 50 ml of ethanol and 2.3 g (0.025 mol) of aniline. The solution was heated to 55° C. and held at that temperature for 5 minutes. The solution was cooled to room temperature, stirred overnight, and then concentrated on a rotary evaporator to a yellow oil which solidified on standing to give 6.9 g of product (0.024 mol, 96% yield), as a tan solid. The compound was recrystallized from petroleum ether.
Analysis: IR (KBr pellet) 1630 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.45 (s, 1H, CH═N), 6.9-8.1 (m, 14H, Ar-H) ppm.
DSC (10° C./min. N 2 ) onset 55.1° C., minimum 59.1° C. (endothermic transition 79 J/g), onset 296.8° C., maximum 324.2° C. (ethothermic transition 577 J/g), Processing Window 223° C.
EXAMPLE 14
Preparation of Schiff's Base from 3-phenylethynylbenzaldehyde and 3-Aminophenylacetylene
This compound was prepared using a procedure similar to that used in the preparation of the monomer of Example 13. The reaction was carried out using 5.0 g (0.024 mol) of 3-phenylethynylbenzaldehyde, 50 ml of ethanol, and 3.0 g (0.025 mol) of 3-aminophenylacetylene. The product was isolated as a red oil which solidified on standing: 6.8 g (0.022 mol, 92% yield).
Analysis: IR (KBr pellet) 3295 cm -1 (C.tbd.CH), 1630 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.3 (s, 1H, CH═N), 6.6-8.1 (m, 13H, Ar-H), 3.1 (s, 1H, C.tbd.CH) ppm.
DSC (10° C./min, N 2 ) onset 215.9° C., maximum 245.2° C. (exothermic transition 753 J/g), Processing Window 160° C.
EXAMPLE 15
Preparation of Schiff's Base from 3-Aminophenylacetylene and 3(3-Formylphenyl)ethynylbenzaldehyde.
Using a procedure similar to that described in Example 5, 10.8 g (0.044 mol) of 3(3-formylphenyl)ethynylbenzaldehyde was reacted with 11.2 g (0.096 mol) of 3-aminophenylacetylene in 150 ml of ethanol. The product precipitated as an off-white solid, 15.8 g (0.036 mol, 82% yield). This monomer was used without further purification.
Analysis: IR (KBr pellet), 3280 cm -1 (C.tbd.CH), 1635 cm -1 (CH═N).
1 HMR (CDCl 3 ) δ8.35 (s, 2H, CH═N), 6.9-8.1 (m, 16H, Ar-H), and 3.10 (s, 2H, C.tbd.CH) ppm.
DSC (10° C./min. N 2 ) onset 100.7° C., minimum 110.6° C. (endothermic transition, 83.9 J/g), onset 206.5° C., maximum 229.9° C. hermic transition, 526 J/g), Processing Window 54° C.
EXAMPLE 16
Preparation of Schiff's Base from 4-Phenylethynylbenzaldehyde and 3-Phenylethynylaniline
This monomer was prepared using a procedure similar to that described in Example 5. The reaction was carried out using 4.8 g (0.025 mol) of 3-phenylethynylaniline, 75 ml of ethanol and 5.2 g (0.025 mol) of 4-phenylethynylbenzaldehyde. The product which initially oils out solidified on standing to yield 8.1 g (0.022 mol; 89% yield). This monomer was purified by dissolving the crude product in hot isopropyl alcohol, filtering, and concentrating the filtrate.
Analysis: IR (KBr pellet), 1630 cm -1 (CH═N)
1 HMR (CDCl 3 ) δ8.44 (s, 1H, CH═N), 7.20-8.00 (m, 18H, Ar-H) ppm.
DSC (10° C./min. N 2 ) onset 133.8° C., minimum 140.4° C. (endothermic transition, 74.5 J/g), onset 268.3° C., maximum 302.0° C. (exothermic transition, 519 J/g), Processing Window 95° C.
EXAMPLE 17
Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 4,4'-Oxydianiline
Using a procedure similar to that described in Example 5, 3.2 g (0.016 mol) of 4,4'-oxydianiline was reacted with 6.6 g (0.032 mol) of 3-phenylethynylbenzaldehyde in 75 ml of ethanol. The product precipitated as an off-white solid and was filtered and dried (8.6 g, 0.015 mol, 94% yield). This monomer was purified by recrystallization from isopropyl alcohol/toluene.
Analysis: IR (KBr pellet), 1630 cm -1 (CH═N), 1250 cm -1 (Ar-O-Ar).
1 HMR (CDC 3 ) δ8.45 (s, 2H, CH═N), 6.90-8.20 (m, 26H, Ar-H) ppm.
DSC (10° C./min. N 2 ) onset 143.4° C., minimum 146.5° C. (endothermic transition, 97.1 J/g), onset 298.1° C., maximum 327.6° C. (exothermic transition, 467 J/g), Processing Window 134° C.
EXAMPLE 18
Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 4-Aminophenylsulfide
Using a procedure similar to that described in Example 5, 3.4 g (0.016 mol) of 4-aminophenylsulfide was reacted with 6.6 g (0.032 mol) of 3-phenylethynylbenzaldehyde in 75 ml of ethanol. The product precipitates as a yellow solid which was recrystallized from heptane/toluene (8.9 g, 0.015 mol, 94% yield).
Analysis: IR (KBr Pellet), 1630 cm -1 (CH═N).
1 HMR (THF-d 8 ) δ8.60 (s, 2H, CH═N), 7.10-8.30 (m, 26H, Ar-'uns/H/ ).
DSC (10° C./min. N 2 ) onset 170.3° C., minimum 175.6° C. (endothermic transition, 107 J/g), onset 291.2° C., maximum 313.7° C. (exothermic transition, 445 J/g), Processing Window 104°C.
EXAMPLE 19
Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 3-Aminophenylsulfone
Using a procedure similar to that described in Example 5, 3.7 g (0.015 mol) of 3-aminophenylsulfone was reacted with 6.2 g (0.03 mol) of 3-phenylethynylbenzaldehyde in 75 ml of ethanol. The product, which initially oiled out of solution, was dissolved in hot ethanol which on cooling yielded off-white crystals, 8.0 g (0.013 mol, 85% yield).
Analysis: IR (KBr pellet), 1635 cm -1 (CH═N), 1305 and 1150 cm -1 (SO 2 ).
DSC (10° C./min. N.sub. 2) onset 129.5° C., minimum 139.0C. (endothermic transition, 79 J/g), onset 272.2° C., maximum 305.8° C. (exothermic transition, 419 J/g), Processing Window 116° C.
EXAMPLE 20
Blend of Schiff's Base Monomer from Example 5 with the Schiff's Base Monomer from Example 8 (1:1)
To 0.6445 g of molten Schiff's base monomer from Example 5 was dissolved 0.6445 g of Schiff's base monomer from Example 8. Upon complete dissolution the material was allowed to cool to a hard glass-like solid. The sample remained completely homogeneous.
EXAMPLE 21
Blend of Schiff's Base Monomer from Example 9 with the Schiff's Base Monomer from Example 8 (3:1)
To 0.9668 g of molten Schiff's base monomer from Example 9 was dissolved 0.3223 g of Schiff's base monomer from Example 8. Upon complete dissolution the material was allowed to cool to a hard glass-like solid. The sample remained completely homogeneous.
EXAMPLE 22
Representative Schiff's base monomers of the invention were evaluated for thermal and oxidative stability employing a thermogravimetric analysis technique (TGA). All of the monomers undergo polymerization to a highly crosslinked polymer during the TGA procedure. Thermal-oxidative stability is an important property of these polymeric compounds particularly because high temperature post-cure for extended periods is needed to obtain conductivity in the thermoset polymers. Dynamic TGA's were run on the Schiff's base monomers at 10° C./min under compressed air using a DuPont 1090 Thermal Analyzer System with a DuPont 951 module. Thermal stability in the absence of oxygen was also determined in a similar manner.
Results showing the temperature at which decomposition begins and the percent residue of the sample after exposure to 800° C. in a nitrogen atmosphere are summarized in Table I below.
TABLE I______________________________________Monomer Decomposition % ResidueExample No. Onset (°C.) at 800° C.______________________________________5 527.5 73.86 521.8 79.97 509.6 75.28 522.8 72.99 522.6 76.310 515.9 76.711 522.1 65.512 299.4 65.213 270.1 27.114 510.5 --*15 543.4 --*16 345 (500) 52.517 510 55.518 500 57.219 470 --*______________________________________ *not determined
EXAMPLE 23
In this example the electroconductivity of typical post-cured Schiff's base monomers of the invention was evaluated.
Thermal polymerization of the disubstituted acetylene monomers was carried out in bulk from the melt by placing 1.0 to 1.5 g of monomer in a aluminum circular mold (1.0" diam.) and heating in an air circulating oven (Blue M) at 233° C. for 6 days. At this temperature, each monomer polymerized to a glossy surfaced, hard black solid within 5 hours. Weight loss data for representative samples after 6 days was recorded and is given in Table II below:
TABLE II______________________________________Monomer ofExample No. Weight loss (%)______________________________________5 3.677 3.008 1.079 2.8710 0.9211 1.0112 8.9313 65.15 0.13 (gain)______________________________________
The initially cured samples were then subjected to thermal post-cure under a nitrogen atmosphere in order to develop electroconductivity. Two post-cure methods were used (described below as Method A and Method B). Both methods yield substantially equivalent conductivity measurements.
Method A--In this method, portions of the solid pellet of polymer which results from the initial cure weighing between 50-90 mg are broken off and placed in the furnace of the thermogravmetric analyser for post-cure treatment. The sample is heated under nitrogen at a rate of 10° C./min from room temperature to a temperature of 800° C., and then rapidly cooled to room temperature.
Method B--In this method, the entire solid pellet of polymer which results from the initial cure is post-cured by heating under nitrogen in a programmable oven for 50 hours at 300° C., then heated at a rate of 0.5° C./min to a temperature of 600° C., and held at 600° C. for 50 hours. The oven temperature setting is then returned to room temperature.
Electrical conductivity evaluations were carried out on the post-cured samples at room temperature using an in-line four point probe. Bulk resistivity and bulk conductivity were calculated according to the following formula: ##EQU1## where S=probe spacings in cm
V=voltage drop in volts
A=applied current in amps
and
σ=1/ρ
Table 3 shows the bulk electrical conductivity for representative samples post-cured by Method A. Table 4 shows conductivity measurements for representative samples post-cured by Method B. Both tables also show the % weight loss of the samples during these post-cure conditions.
TABLE 3______________________________________(Method A)Monomer ConductivityExample No. (S/cm) Wt. loss (%)______________________________________5 1.23 × 10.sup.-1 21.27 4.75 × 10.sup.-2 22.08 5.91 × 10.sup.-2 25.99 5.33 × 10.sup.-2 20.910 6.37 × 10.sup.-2 21.312 5.22 × 10.sup.-2 19.416 8.03 × 10.sup.-2 17.617 7.83 × 10.sup.-2 25.518 7.46 × 10.sup.-2 24.619 9.91 × 10.sup.-2 21.420 1.40 × 10.sup.-2 27.721 7.46 × 10.sup.-2 24.6______________________________________
TABLE 4______________________________________(Method B)Monomer ConductivityExample No. (S/cm) Wt. loss (%)______________________________________5 4.23 × 10.sup.-2 12.27 3.13 × 10.sup.-2 15.69 3.40 × 10.sup.-2 14.810 4.35 × 10.sup.-2 14.411 3.64 × 10.sup.-2 12.115 4.75 × 10.sup.-2 9.1______________________________________
Now that the preferred embodiments of the present invention have been described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is to be limited only by the appended claims, and not by the foregoing disclosure. | Novel mono- or difunctional phenylacetylene-substituted Schiff's base monomers useful in the preparation of electrically conducting polymers is disclosed. On heating, these monomers melt to a viscous liquid state, and on continued heating above about 300° C. polymerize to form an electrically insulating thermoset polymer. On further post-cure heat treatment, the polymer becomes electroconductive showing a bulk conductivity of at least 10 -2 S/cm. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a method and apparatus for detecting a fault and also the direction of a fault in electric lines.
FIELD OF THE INVENTION
During each switching process in an electric power supply system and particularly during the occurrence of a fault, for example of a short circuit on a line, a transient wave, which has its origin at the switching or at the fault location, propagates through the power supply system. At any test location in the power supply system, the switching process or the fault is indicated by the occurrence, with a time delay which is a function of the transit time of the transient wave from the switching or fault location to the test location, in each case of a transient component in the line voltage and the line current. Voltage and current signals corresponding to these can be derived, for example by means of instrument transformers, from the line voltage and the line current. If in each case the transient component is separated out from the voltage and the current signal, for example by subtracting the steady-state operating frequency component, a voltage and a current step signal is obtained. The instantaneous values of these step signals define as the co-ordinates in a Cartesian co-ordinate system formed by hemselves, a point which, with time, runs through a line of motion starting from the origin of this co-ordinate system. The switching process or the fault can be detected by monitoring the point for transgressions of triggering boundaries within this co-ordinate system, for example by comparing the instantaneous values of one of the step signals with a boundary value which depends on the instantaneous values of the respective other step signal. The direction from test location to switching or fault location can in this arrangement be derived from the type of quadrant in which the transgression of a triggering boundary occurs (quadrant criterion). A uniform fault direction is determined by respectively diagonally opposite quadrants. Since the line of motion generally reaches a greater distance from the origin with a fault than with a normal switching process or, in the case of a multi-phase system, with faults on adjacent phases, the switching processes and the faults on other phases can be distinguished from the direct faults by means of triggering boundaries which have a suitable distance from the origin. The total time required for detecting a fault is only a fraction of one system period. This is why the method described finds preferred use in extra high voltage systems in which the prevention of damage to the generally very expensive system components depends on faults being detected as rapidly as possible.
A method of the type described has been disclosed (German Auslegeschrift 2,841,009) in which higher harmonics contained in the step signals are suppressed by filtering during the process of deriving the step signals. The consequence of the presence of higher harmonics in the step signals is that the point defined by the instantaneous values of the step signals in the Cartesian co-ordinate system formed by the step signals fluctuates widely. As a result of this fluctuation, the point can exceed one of the triggering boundaries even though its mean line of motion does not exceed this triggering boundary. These fluctuations are critical in the case of faults occurring shortly after a line voltage maximum. With these faults, the mean line of motion of the point runs through two adjacent quadrants of the coordinate system at a distance from the triggering boundaries which is in some cases very small, and exceeds one of these triggering boundaries only in a third quadrant. In this case, a transgression as a function of fluctuations and occurring in the second and center quadrant passed through would lead to a false fault direction decision. In the known solution for this problem, which is to dampen the fluctuations by suppressing the higher harmonics in the step signals, however, the time for fault detection is extended.
SUMMARY OF THE INVENTION
Accordingly, a primary object of this invention is to provide a novel method and apparatus for detecting a fault and fault direction in electric lines wherein fault direction decisions are always reliably guaranteed on the basis of the quadrant criterion.
This and other objects are achieved according to the invention by providing a novel method and apparatus for detecting a fault and also the direction of a fault in electric lines, wherein a triggering signal is generated if in a Cartesian coordinate system, one-co-ordinate of which corresponds to voltage step signals and the other coordinate of which corresponds to current steps signals, a point defined by these step signals describes a line of motion which trangresses triggering boundaries, wherein boundary zones are located ahead of the triggering boundaries and for the purpose of preventing erroneous signals at least the triggering boundary of the next adjacent quadrant passed through in the direction of the line of motion is displaced.
It is accordingly essential for the solution according to the invention to record the entry of the point into a boundary zone which, seen from the origin, is located ahead of a triggering boundary in a first quadrant of the co-ordinate system. At a predeterminable time after such recording triggering boundary is adjusted, at least in sections for a greater distance to the origin of the co-ordinate system, in the second quadrant which adjoins the first quadrant. This adjustment is made at least in the sense of the direction of movement of the mean line of motion of the point. As a result, the mean line of motion of faults occurring in each case shortly after a maximum in the line voltage passes through three adjoining quadrants, as explained, in the middle one of these quadrants a greater safety margin between the triggering boundary and the line of motion of the point is produced and thus the reliability of the fault direction decision is decisively increased in the case of the faults mentioned. However, the greater safety margin between the triggering boundary and the mean line of motion of the point in the middle one of the three quadrants also results in that a greater margin of play is available for the fluctuations of the point. This largely eliminates the need for damping the fluctuations by suppressing the higher harmonics in the step signals which advantageously allows the time for fault detection to be shortened.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation 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. 1a, b each are illustrations of a co-ordinate system formed by one voltage and one current step signal, the coordinate system showing a line of motion and the predetermined triggering boundaries, with the boundary zones, according to the invention, placed ahead of the line of motion;
FIG. 2 is a block diagram of a circuit for executing the method according to the invention;
FIG. 3 is a block diagram example of the first function generator contained in the circuit of FIG. 2;
FIG. 4 is a block chart of a process computer system;
FIG. 5 shows a flow diagram of a computer program for executing the method according to the invention, and
FIG. 6 is an illustration of a co-ordinate system as in FIG. 1 for explaining the computer program.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the figures, identical parts are designated by identical symbols.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIGS. 1a and 1b thereof, in each case a Cartesian co-ordinate system is shown which is formed by a voltage step signal Su as the abscissa and a current step signal Si as the ordinate. In this co-ordinate system in each case a motion line B of the point defined in this co-ordinate system by the instantaneous values of the step signals Su, Si is plotted for a fault which has occurred shortly after a maximum in the line voltage. As a result of the influence of the higher harmonics in the step signals Su, Si, this line of motion B fluctuates around a mean line of motion B' which is represented in FIG. 1a and FIG. 1b in each case by a broken line. In addition, FIG. 1a and FIG. 1b show in each quadrant QI, QII, QIII, QIV of the co-ordinate system in each case a triggering boundary AI, AII, AIII, AIV. If the point or its line of motion B transgresses one of these triggering boundaries AI, AII, AIII, AIV, a fault is detected. If this transgression takes place in quadrant QII, or QIV, for example, a forward fault is detected and if the transgression takes place in quadrant QI or QIII, a reverse fault is correspondingly detected. Forward and reverse fault locations are situated on both sides of the test location. In the case of a fault which, as in the example of FIGS. 1a and 1b, has occurred shortly after a maximum in the line voltage and the mean line of motion B', as drawn, passes initially through two quadrants QII, QI without transgressing triggering boundaries AII, AI and transgresses such a boundary (AIV) only in a third quadrant QIV, it can nevertheless happen as a result of the effect of the fluctuations that a transgression of one of the triggering boundaries occurs in the first quadrant QII or in the second quadrant QI of the three quadrants QII, QI, QIV passed through. In the latter case, shown in FIG. 1a, instead of a forward fault corresponding to a transgression of the triggering boundary AIV in quadrant QIV, a reverse fault would be erroneously detected. A trangression occurring as a result of the fluctuations in the first QII of the three quadrants QII, QI, QIV passed through, as shown in FIG. 1b, is on the other hand harmless since this quadrant corresponds to the same fault direction as the opposite third quadrant QIV passed through, as explained. Thus the danger of a false fault direction determination as a result of the fluctuations exists only in the middle quadrant QI of the three quadrants QII, QI, QIV passed through. In order to prevent a transgression of the triggering boundary AI in this middle quadrant QI as a result of the fluctuations, according to the invention, the triggering boundary AI is adjusted in this middle quadrant QI to a greater distance from the origin O. As a criterion for this adjustment, the entry of the point into a boundary zone GII is analyzed, which boundary zone is located in the first quadrant QII passed through ahead of the triggering boundary AII seen from the origin O. The middle quadrant QI, in which the adjustment takes place, is located in each case, together with the quadrant QII passed through first, on the same side of the co-ordinate axis formed by the voltage step signal Su. The adjustment can be carried out at a predeterminable time after the point has entered into the boundary zone GII and preferably when the point is leaving the boundary zone GII again. Naturally, no adjustment needs to be made if the point leaves the boundary zone GII via the associated triggering boundary AII. The triggering boundary AI also does not need to be adjusted over its whole length to a greater distance from the origin O in the middle one, QI, of the quadrants passed through. An adjustment in sections of the triggering boundary AI to a greater distance or an adjustment in sections to different distances to the origin O is sufficient. According to a preferred embodiment of the invention, the triggering boundaries AI, AIII and AII, AIV of in each case opposite quadrants QI, QIII, and QII, QIV are jointly adjusted to a greater distance to the origin O which further increases reliability of detection. The depth of the boundary zone GII located ahead of a triggering boundary AII and the factor by which a triggering boundary AI is in each case adjusted to a greater distance to the origin O of the co-ordinate system is preferably a function of the strength of the permitted fluctuations. If the depth of a boundary zone GII located ahead of a triggering boundary AII is measured from any point on the triggering boundary AII in the direction to the origin O of the co-ordinate system, for example a fixed value of between 5% and 50% of the distance of the respective point from the original O can be selected for the depth of the boundary zone GII determined in this manner. On the other hand, the depth of the boundary zone GII along the respective triggering boundary AII measured at rightangles to this triggering boundary AII can be selected to be uniform. The above-mentioned factor can be, for example, a value of between 1.05 and 2.
Advantageously, boundary zones and a possibility for adjusting triggering boundaries to a greater distance from the origin should be provided uniformly in all four quadrants of the co-ordinate system so that all types of faults can be dealt with in the same manner. For reasons of clarity, FIG. 1 shows only one boundary zone in the second quadrant and a switched triggering boundary in the first quadrant.
FIG. 2 shows a circuit used as a means of executing the method according to the invention. This circuit includes four identical monitoring circuits UI, UII, UIII, UIV, each of which monitors in respective quadrant QI, QII, QIII, QIV of the co-ordinate system the point or its line of motion B for transgression of the respective triggering boundary AI, AII, AIII, AIV and in this event generates a triggering signal PI, PII, PIII or PIV. In addition, each of the monitoring circuits UI, UII, UIII, UIV monitors the point or its line of motion B for entry into the boundary zone GII, etc., located ahead of the respective triggering boundaries, AII, etc., or for re-emergence from these boundary zones and in this event generates an adjusting signal, SI, SII, SIII or SIV which is used for adjusting the triggering boundary AI or the triggering boundaries AI, AIII in the respective adjoining quadrant or quadrants QI, QIII.
To the monitoring circuits UI, UII, UIII, UIV the voltage Su and the current step signal Si are applied. In each of the monitoring circuits UI, UII, UIII, UIV, the voltage step signal Su is connected via a first function generator F1 to one inputs of a first comparator K1. Current step signal Si is connected to a second input of K1. The first function generator F1 generates from the voltage step signal Su an output signal which is related to this voltage step signal in accordance with a predetermined function corresponding to the mathemathical function of the respective triggering boundary AI, AII, AIII, AIV. At the binary output of the first comparator K1 in each case a logical "1" fault signal is produced if the current step signal Si becomes absolutely greater than the output signal of the first function generator F1, that is to say the point transgresses the predetermined triggering boundary AI, AII, AIII, AIV. In exactly the same manner, a second comparator K2 and a second function generator F2 are used to monitor the entry of the point into the boundary zone GII located in each case ahead of the triggering boundary AII and to generate in this event a binary entry signal E which is a logical "1". The function predetermined in the second function generator F2 in each case corresponds to the mathematical form of the boundary which, next to the triggering boundary AII, limits the boundary zone GII. The entry signal E is connected via a first time delay section Z1 having a predetermined decay delay t2 to the D input of a D flip flop FF and to a first input of an AND gate U. A second and a third input of this AND gate U are in each case connected to the outputs or the inverted outputs, respectively, of a third comparator Ki and fourth comparator Ku jointly preceding the four monitoring circuits UI, UII, UIII, UIV. The third comparator Ki then generates at its output a logical "1" when the current step signal Si is positive and a logical "0" when it is negative. At the inverted output of the third comparator Ki the logical states appear in the exactly opposite sense. The equivalent applies to the fourth comparator to which the voltage step signal Su is applied. The monitoring circuits UI, UII, UIII, UIV are connected to the outputs or inverted outputs of the third comparator Ki and fourth comparator Ku in such a manner that a logical "1" always appears on both of the lines applied to a particular monitoring circuit only when the point happens to be located in the quadrant QI, QII, QIII or, QIV associated with the respective monitoring circuit UI, UII, UIII, UIV. If the point is located, for example, in quadrant UI a logical "1" is in each case present at the second and third input of the AND gate U in the monitoring circuit UI. In the remaining monitoring circuits UII, UIII, UIV, on the other hand, a logical "0" is present at at least one of the two second and third inputs of the respective AND gate U. Thus the third and fourth comparator Ki, Ku together form a sign logic.
From the output of the AND gate U in all monitoring circuits UI, UII, UIII, UIV either directly or via a second time delay section Z2 the clock input of the D flip flop FF is supplied which generates at its output Q in each case the adjusting signal SI, SII, SIII, SIV. Correspondingly, the output Q of the D flip flop FF in the monitoring circuit UI is connected to one digital adjusting input DE each of the first function generator F1 in the monitoring circuit UIV and UII. The output of the D flip flop FF in the monitoring circuit UII is in each case connected to a digital adjusting inpput DE of the first function generator F1 in the monitoring circuit UIII and UI; the output of the D flip flop FF in the monitoring circuit UIII is in each case connected to a digital adjusting input DE of the first function generator F1 in the monitoring circuit UIV and UII and the output of the D flip flop FF in the monitoring circuit UIV is in each case connected to a digital adjusting input DE of the first function generator F1 in the monitoring circuit UIII and UI.
The adjusting signal SI, SII, SIII, SIV present at the digital adjusting input DE of the first function generator F1 in each case causes the function predetermined in the first function generator F1 to be adjusted to a different function corresponding to the mathematical form of the triggering boundary A'I, A'II, A'III, A'IV with a distance from origin O which is greater at least in sections.
The time at which the adjustment of the first function generator F1 takes place in each case is determined by the characteristics of the clock input C at the D flip flop FF. If this input is a dynamic input at which only a change of the logic state at the output of the AND gate U from "0" to the "1" is effective, the adjusting signal SI, SII, SIII, SIV appears, provided there is no second time delay section Z2, simultaneously with the signal which is the last one to go from "0" to "1" at the input of the AND gate U. According to the preceding explanation, this means that the adjusting signal SI, SII, SIII, SIV appears when the point enters the boundary zone GII located ahead of the triggering boundary AII in the respective quadrant QII.
If the second time delay section Z2 is present and if a rise-time delay t1 has been predetermined, the adjusting signal SI, SII, SIII, SIV appears delayed by the predetermined delay time after entry of the point into the boundary zone GII located ahead of the triggering boundary AII in the respective quadrant QII.
If the clock input C at the D flip flop FF, on the other hand, is a dynamic input with negation in which only a change of the logic state at the output of the AND gate U from "1" to "0" is effective, the adjusting signal SI, SII, SIII, SIV appears simultaneously with the signal which is the first one to go from "1" to "0" at the input of the AND gate U before which all these signals must have been at "1". According to the preceding explanation this means that the adjusting signal SI, SII, SIII, SIV appears when the point is re-emerging from the boundary zone GII located ahead of the triggering boundary AII in the respective quadrant QII.
FIG. 3 shows an example of the configuration of the first function generator F1 contained in the circuit arrangement of FIG. 2. The voltage step signal Su is applied in each case to the analog input AE of the function generator F1. This voltage step signal is amplified by an amplifier V by a positive or negative factor m and then added in a summing section S to a constant signal level, which has been tapped off for example at a voltage source, and is then supplied to the analog output AA of the function generator. The constant signal level can be adjusted to at least two different values by a changing section W. The changing section W is actuated via a digital input DE which corresponds to the adjusting input of the function generator F1. Function generators F1 configured in this way supply linear triggering boundaries such as are shown, for example, in FIG. 1.
FIG. 4 shows a block diagram of a process computer system which has a first input unit EI to which the voltage step signals Su are applied and a second input unit EII to which the current step signals Si are applied. Each of these input units EI, EII consists, for example, of an analog/digital converter ADC which samples, digitizes and temporarily stores the instantaneous analog values of the step signals Su, Si. From the input units EI, EII the input data, the digitized instanstaneous values of the step signals Su, Si, are transferred via a data link DV into a main memory AS. This main memory AS can be accessed by the central processing unit CPU of the process computer system, for example again via the data link DV. The central processing unit CPU also checks and controls via control units and control lines, which are a part of the data link DV, the whole data flow in the process computer system. In addition, at least one output unit AG is connected to the data link DV.
Process computer systems of the type described and all their components and all programs necessary for operating them are state of the art (see for example CAMAC, "A modular instrumentation system for data handling", Euratom Report No. EUR 4100e) and are available on the market. The only requirement to be made of the process computer system is that it is able to process a data rate of some kilohertz which makes it possible to meet the requirements of the sampling theorem for the step signals. For example, the process computer system should be able to process a data rate of at least 1 KHz. A data rate of 10 KHz may be reached with fast process computer systems commercially available. In order to be able to execute the method according to the invention by means of a process computer system, however, a new computer program must be generated. This computer program must read the instantaneous digital values, stored in the main memory AS, for example in a file, of the step signals Su, Si, execute with these values the individual steps of the method according to the invention, form output values which correspond to the triggering signals PI, PII, PIII, PIV of the circuit arrangement already described and write these values back into the main memory AS, again into a file. From the main memory AS, the output values can then be supplied via the data link DV and the output unit AG to external units such as a triggering circuit.
An example of such a computer program is given below in the programming language PASCAL. A description of PASCAL can be found, among others, in "Pascal-Systematische Darstellung von Pascal und Concurrent Pascal fur Anwender" (Pascal-Systematic description of Pascal and Concurrent Pascal for users) by Rudolf Herschel & Friedrich Pieper, R. Oldenburg Verlag, Munich, Vienna, (1981).
______________________________________"program fault --detection (data, data);typesignal = integer;section = recordquadrant : integer;level : integerend;mode = (normal, a --switched, b --switched);direction = none, forward, reverse);data = recordvoltage : integer;current : integerend:filein = file of data;fileout = file of direction;vardelta --u, delta --i : signal;operation : mode;old section, new --section : section;fault : direction;datain : filein;dataout : fileout;procedure determine --section (delta --u, delta --i : signal;var new --section : section);constr = <integer value>;c = array [10..3] of (0,<integer --value>,<integer --value>,<integer --value>);vark, a, b : integer;begin (*determine --section*)with new --section dobeginif delta --i> = 0 thenif delta --u> = 0 then quadrant := 1 else quadrant := 2else if delta --u> = 0 then quadrant := 4 else quadrant := 3;a := abs (r*delta -- i + delta --u);b := abs (r*delta --i - delta --u);for k := 0 to 2 doif (a> = c[k]) and (a<c [k+1]) and ((quadrant = 1) or(quadrant = 3)) or (b> = [k]) and (b<c[k+1]) and((quadrant = 2) or (quadrant = 4))then level := k;if (a = c[3]) or (b >= c[3]) then level := 3endend (*determine --section*);procedure check --boundaries (old --section, new --section :section;var operation : mode;var fault : direction);varq --old, q --new : integer;begin (*check boundaries*)q --old := old --section.quadrant;q --new := new --section.quadrant;if (old --section.level = 1) and (new --section.level = 1) thenbeginif ((q --old = 2) or (q --old = 4) and ((q --new = 1) or (q --new= 3))then operation := a --switched;if ((q --old = 1) or (q --old = 3) and ((q --new = 2) or (q --new= 4))then operation := b --switchedend;if (old section.level = 1) and (new --section.level = 0) thenbeginif q --old = q -- new thenbeginif q --old = 1) or (q -- old = 3) then operation := b --switchedelse operation := a --switchedendend;if (old --section.level = 1) and (new --section.level = 2) thenbeginif (q --old = q --new) and (operation = normal) thenbeginif (q --old = 1) or (q --old = 3) then fault := reverseelse fault := forwardend;if (old --section.level = 2) and (new --section.level = 3) thenbeginif (q --old = q new) and (operation normal) thenbeginif ((q --old = 1) or (q --old = 3)) and (operation = a --switched)then fault := reverse;if ((q --old = 2) or (q --old = 4)) and (operation = b --switched)then fault := forwardendend;if (old --section.level = 2) and (new --section.level = 2) thenbeginif ((q --old = 1) or (q --old = 3)) and ((q --new = 2) or q --new= 4))and (operation = a --switched) then fault := forward;if ((q --old = 2) or q --old = 4)) and ((q --new = 1) or (q -- new= 3))and (operation = b --switched) then fault := reverseendend (*check --bondaries*);begin (*fault --detection*)with old --section dobegin quadrant:= 1; level := 0 end;operation := normal;fault := none;reset (datain);while fault = none dobeginget (datain);delta --u := datain↑.voltage;delta --i := datain↑.current;determine --section (delta --u, delta --i, new section);check --boundaries (old --section, new --section, operation,fault);old --section := new --sectionend;reset (dataout);write (dataout, fault);end (*fault detection*)."______________________________________
This program will be further explained with the aid of the flow chart of FIG. 5:
The instruction part of the program begins with an assignment of initial values to the variables "old-section", "operation" and "fault". The variable "old-section" describes in which quadrant and in which zone of FIGS. 1a, b or FIG. 6 respectively, the point defined by the current values of the step signals happens to be located. The variable "operation" describes whether a triggering boundary must be shifted or has been shifted, and in which way, and the variable "fault" describes if a fault is present and the direction of the fault. The initial value is assigned in such a way that a normal fault-free condition is used as the starting point for running the further program, the point being located in quadrant 1 in zone 0.
For this reason, the subsequent enquiry whether a fault is present or not mandatorily leads into the instruction block located in the right-hand branch of the flow diagram of FIG. 5. This leads in each case back to the fault enquiry in the form of a loop. In the instruction block, initially the current values of the step signals Su, Si represented in the program by the variables "delta-u", "delta-i" are read by a "data-in" file stored in the main memory AS. It must be assumed here that the current values of the step signals Su, Si have first been stored there by the process computer system as described.
The current values of the step signals Su, Si are then used to call up a subroutine called "determine section" which calculates in which quadrant and in which zone in the co-ordinate system the point defined by the current values of the step signals Su, Si is located. The result is assigned to a variable "new section". By comparing "old-section" with "new-section", another subroutine called "check boundaries" then determines if the point has changed quadrants or zones. From this the subroutine further calculates if a fault if present or if a triggering boundary has to be shifted. After that the program returns to fault enquiry and, in principle, can from here run via the instruction block as many times through the loop described as required. Before the values of the step signals Su, Si are again read in, however, it is necessary for these values to have been replaced by new and more current values in the meantime. This updating of the values of the step signals Su, Si can take place, for example, during a brief interruption of the program run before read-in and is controlled by the known higher-ranking operating system of the process computer system.
If during the fault enquiry run it is found, after the loop has been run through, that a fault is present, the program leaves the loop and follows an alternative path on which the value of the variable "fault" which describes the fault and the fault direction is written into the "dataout" file. This terminates the program.
Obviously, numerous 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, the invention may be practiced otherwise than as specifically described herein. | A method and apparatus for detecting a fault and also the direction of a fault in electric lines, wherein voltage (Su) and current step signals (Si) corresponding to the transient components in the line voltage and line current are derived; the instantaneous values of these step signals (Su, Si) define, in a co-ordinate system formed by the step signals (Su, Si) themselves, a point which passes through a line of motion (B) after the occurrence of a fault; and if the point transgresses a triggering boundary (AI, AII, AIII, AIV) in the co-ordinate system the fault is detected. In this event the direction of the fault is found from the quadrant (QI, QII, QIII, QIV) in which the transgression takes place. At a predetermined time after entry of the point into a boundary zone provided in one quadrant, located in the line of motion ahead of a triggering boundary in next adjacent quadrant, a triggering boundary in at least the next adjacent quadrant is adjusted to a greater distance from the origin of the co-ordinate system which is located in the same semicircular space bounded by the axis of the voltage step signal (Su). This measure considerably increases the reliability of detection with respect to fault direction and, in addition, reduces the time required for fault detection. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to an improved fluid valve structure, more particularly one which combines anti-siphon and anti-backflow features in a single element.
The valve structure of the present invention is in the category or class of valves which are adapted to insertion in a fluid feed line between a nozzle or discharge orifice and the fluid supply from which fluid is drawn. Such a valve can be used in a multiplicity of lines and is especially adaptable to self-contained fluid systems or in systems having limited space.
The invention is herein described in the context of the utilization of water systems which are found in mobile homes or recreational vehicles, and is applicable to any system which incorporates a flexible hose connection, whether it be found in a shower, wash basin, bath tub, or the like. The valve of this structure is especially useful in such an environment due to the fact that such fluid systems incorporate a closed or self-contained water supply source from which all utilization of water derives. Another characteristic of such systems is that they operate under low fluid pressure conditions.
Because of the character of such a self-contained water supply system and the danger of contaminating the water, such systems are subject to rather stringent sanitary codes which require the insertion in the supply line of valves which prevent back flow or re-entry into the system of previously used or contaminated water.
Valves designed to achieve this result have been in use for several years, and are associated with or contain means to permit the entry of air into the water line under conditions that would otherwise create a siphon condition. In such valves, many complex designs have been used in order to open and close such air vents and to prevent the fluid from leaking through said air vents.
Most existing valves incorporate dual co-operating air valves and check valves, some of which are cumbersome and large, but all of which are relatively expensive. Even those incorporating a single valve chamber, such as in U.S. Pat. No. 3,951,164, utilize very complex structure within that chamber.
It is accordingly an object of this invention to provide a novel valve structure which is simple in its design, efficient in its operation and which is inexpensive to produce.
SUMMARY OF THE INVENTION
The improved valve consists of a single chamber, having insertable therein a simple structure which separates said chamber into two chambers and which at the same time fixes in place a one piece flexible flapper type diaphragm member which overlies a water inlet portion and an air vent portion of said chamber.
The valve itself is designed so to be inserted in a fluid line as a normal ordinary plumbing installation. At the inlet end of the chamber there is a conventional opening to permit the flow of fluid and at the outlet end there is a conventional opening to permit the flow of fluid through and from the chamber. Also at the inlet end of the chamber there is an air port to permit entry of air into the line under conditions which would otherwise permit siphoning of fluid.
At the inlet end of the chamber there is positioned the single-piece diaphragm member which covers the fluid inlet and the air port. A disc is positioned at the outlet end of the chamber. The disc has an outer diameter which is the same as the inside diameter of the chamber and has a plurality of holes therein to permit the flow of fluid therethrough.
Fixed to the disc, or molded integrally therewith, is a solid plate portion which extends beyond the periphery of the disc and is of a length equal to the distance as the depth of the slots described previously and of a length equal to the distance between the disc and the diaphragm member. In effect, the solid plate portion, when the assembly is inserted, separates the chamber into two distinct chambers without any access between them and with the diaphragm member being anchored over the liquid inlet and air port.
When the valve is inserted into the fluid line and the liquid is flowing, by virtue of the user turning a conventional valve which is not shown, the flexible diaphragm member is displaced from its position over the inlet opening. During the time that the liquid is flowing, the flexible diaphragm member presses against the air port thereby preventing the leakage of water. When the liquid flow is terminated, the diaphragm, through a combination of its elasticity and the mild vacuum created behind the valve, closes the opening and prevent fluid beyond the valve from returning to the liquid source.
When the pressure downstream the valve is less then that about the valve, such when there is no pressurized flow through the valve, that portion of the diaphragm member which covers the air port is flexed away from contact with the air port, permitting air to enter the stream of fluid. This equalizes the pressure, bleeds the downstream liquid, and prevents reverse flow or siphoning of the liquid.
The diaphragm member is shaped to fit a recess in the inlet end of the chamber and is held in place by the plate portion of the disc previously described. The diaphragm member is of a commonly used flexible material which is durable and long-lasting. Due to its simplicity, the valve components can be manufactured at a very reasonable cost.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the valve;
FIG. 2 is a perspective view of the valve, with portions removed to display the interior structure;
FIG. 3 is an exploded view of the valve, with portions removed to display the interior configuration;
FIG. 4 is a longitudinal sectional view of the valve, showing the air port portion in the open position and the liquid inlet portion in the closed position, in a mode to prevent siphoning;
FIG. 5 is a longitudinal sectional view of the valve, showing the valve during normal flow conditions with the air port closed and the liquid port open;
FIG. 6 is a cross sectional view of the valve along the line 6--6 in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, a backflow preventing and anti-siphoning valve 10 includes a valve body 12 defined in part by a tubular wall 14. This wall surrounds and defines a main valve chamber 16 within valve 10. Wall 14 contains threads 18 on its exterior in order that the valve may be mated into a plumbing system (not shown).
Extending downwardly from and formed integrally with valve body 12 is valve inlet nipple 20, also of tubular configuration and of a smaller diameter than valve body 12. Inlet nipple 20 is externally threaded as at 22 for mating into the plumbing system. Inlet nipple 20 has an internal passageway 24 through which fluids flow into valve chamber 16.
Valve body 12 has a bottom wall 30 which surrounds inlet nipple 20. Bottom wall 30 includes, spaced from inlet nipple 20, at least one air port 32 connecting valve chamber 16 to ambient air. Bottom wall 30 also includes an internal recess 34 surrounding liquid port or passageway 24 and air port 32. In the area surrounding liquid passageway 24, recess 34 preferably has a radius at least twice the radius of passageway 24. In the area surrounding air port 32, recess 34 has a radius preferably of approximately twice the radius of air port 32. These two radii are tangently connected to form tear drop shaped recess 34 as may be seen in FIGS. 3 and 6. Although the size of recess 34 has been expressed in its preferential size, it will be understood that the size is not critical. It is only important that it extends beyond the edges of air port 32 and fluid passageway 24 to permit diaphragm member 36 to cover both. A slightly different shape is permissable without departing from the scope of the invention, provided that the recess serves the purpose for which it is intended.
The purpose of recess 34 is to serve as a seat for flexible flapper-type diaphragm member 36. The depth of recess 34 approximates the thickness of diaphragm member 36 and the peripheral shapes of the recess and the diaphragm member are generally the same. Recess 34 serves to prevent the diaphragm member 36 from rotating or sliding from its position over liquid passageway 24 and air port 32.
Forming a part of valve 10 is insert 40 which is positioned within valve chamber 16 and which retains diaphragm member 36 in position. Insert 40 divides valve chamber 16 into two distinct and separate chamber parts 46 and 47, and provides each chamber part with one or more outlets at the outlet end of valve chamber 16. Chamber part 46 is the chamber into which ambient air is permitted to enter and chamber part 47 is that through which the liquid of the system normally flows.
Insert 40 includes two basic elements, a disc 42 and a plate 44. The elements may be formed separately and connected by conventional bonding means, but are preferably formed as an integrally molded unit. When inserted into valve chamber 16, disc 42 forms the upper wall of valve body 12, and plate 44 separates valve chamber 16 into its heretofore described two distinct, separate and non-communicating chamber parts 46 and 47.
The diameter of disc 42 is substantially the same as the inside diameter of valve chamber 16, so that a press fit is effected when insert 40 is mated with valve body 12. Plate 44 extends from disc 42 a distance equal to the depth of valve chamber 16, so that, when mated, plate 44 abuts valve body bottom wall 30 and disc 42 is flush with the outlet end of valve body 12. Plate 44 is located between air port 32 and passageway 24 where it abuts bottom wall 30 and serves to hold and anchor diaphragm member 36 within recess 34.
Disc 42 includes a plurality of openings 48, spaced about its perimeter, through which liquid flows or ambient air is permitted entry into the system. In the preferred embodiment, there are six such equally spaced openings, four of which provide passage of liquid through chamber part 47 and two of which provide passage of air through chamber part 46.
Plate 44 extends transversely beyond the edge of disc 42 to provide tab sides 45. On the inside of tubular wall 14 of valve body 12, extending the length of valve chamber 16, are two opposed slots 50, 51, which accommodate plate tab sides 45 of insert 40 to prevent plate 44 from "fluttering", insert 40 from rotating and to fix plate 44 in its proper holding position with regard to diaphragm member 36. If a permanently assembled valve is desired, insert 40 can be bonded to valve body 12. Having described the various structural components of the valve and their inter-relationship, its operation will again be briefly reviewed.
During the time that liquid is flowing through the valve, as shown in FIG. 5, that portion of flexible diaphragm member 36 which extends into chamber part 47 flaps upwardly, permitting the uninhibited flow of liquid from passageway 24 through the system and out openings 48 of the chamber. During this same time, that portion of diaphragm member 36 which extends into chamber part 46 is normally held against air port 32.
When a low-pressure condition arises downstream of valve 10 which might cause undesirable siphoning, such as when the fluid flow through the valve is terminated and liquid drains downstream from valve 10, that portion of diaphragm member 36 in chamber part 46 flexes to permit the entry of air through air port 32, as shown in FIG. 4, into chamber 46 and therefrom into the system, thereby permitting draining of the plumbing system downstream of valve 10. At this same time, it will be seen that diaphragm member 36 within chamber part 47 remains fast against liquid passageway 24, generally by the negative pressure within the connected upstream plumbing system, thereby preventing the backflow of any liquid through the valve and back into the self-contained fluid plumbing system.
It will thus be seen that the air flow portion and the liquid flow portion of the diaphragm member, being of the flapper-type, work completely independently of one another, even though they are opposite ends of a singular member. Each is able to respond rapidly to varying conditions of pressure and flow.
The foregoing has been achieved with a device having no moving parts, with the exception of the flapper member, and an extremely simple and economic insert. This makes the valve easy to insert into the plumbing system and, when the flapper member eventually wears out, the flapper may be quite easily replaced.
It is to be understood that this invention is not to be limited to the details above described but it may be modified in accordance with the following claims. | A fluid valve structure which combines anti-siphon and anti-backflow features in a single element. The valve utilizes an insert which separates the valve body into two distinct and non-communicating chambers, permits the flow of air through one of the chambers and fluid through the other and fixes a flexible flapper-type diaphragm over the entry passages into the chambers. Due to the flexibility of the diaphragm and the independence of the chambers, that portion of the diaphragm in each chamber operates independently of the other in response to varying conditions of pressure and flow. | 8 |
FIELD OF THE INVENTION
The invention relates to a device, for use in a press, for feeding fasteners, especially nuts, and attaching the fasteners in workpieces by pressing with a punching head. Joining and pressing of the fasteners in the workpieces takes place, with an infeed and loading means on a tool or press part, and on a rigid feed, which together with a punching head can be attached to one of two antagonistic tool or press parts. A first conveyor section for the fasteners is located between the punching head and the loading means, and forms the fasteners. Each of the fasteners is supplied individually to a loading position of the loading means and each is moved by an infeed element from the loading position into a subsequent first conveyor section, forming a row which extends into the punching head, in which the fasteners tightly abut one another.
BACKGROUND OF THE INVENTION
Production of workpieces from sheet metal unwound from a coil (for example, steel sheet) or from individual sheets or plates using a press or tool located in this press (for example, also follow-on tools) by punching, by permanent deformation, etc. is known. Here, providing tools with fasteners at the same time in production in the press is also known, by joining or insertion of the pertinent fastener into a prepared (punched) hole and by subsequent pressing of the fastener in the workpiece.
Fasteners are, among others, nuts or threaded nut pieces which for example have a circular cylindrical peripheral surface and which are provided with a collar on one front face, with which the respective nut fits into the prepared hole of the workpiece and is attached there by pressing.
To feed and attach especially nuts in workpieces a device for use in a press, for feeding fasteners, especially nuts, and attaching the fasteners in workpieces by pressing with a punching head has been suggested (P 43 40 642.4-14). This device consists essentially of a punching head which is provided on one or two antagonistic tool or press parts, and with the interposition of an insertion plunger causes joining of the respective fastener into the prepared hole of the workpiece and also with the cooperation of the other of the antagonistic tool and press parts causes subsequent attachment or fixing of the fastener in the workpiece by pressing, i.e., by permanent deformation of the material of the workpiece in the area of the hole. Furthermore, the known device has a rigid feed on which a loading and infeed means is provided and which, between this loading means and the punching head, forms a first rigid conveyor section which ends in the punching head or in a plunger channel formed there and which in the transportation and conveyance direction of the fastener adjoins a second, likewise rigid conveyor section, in the area of which the infeed means is provided at the transition between the two conveyor sections.
In this device the infeed means has an infeed element made as an infeed rocker which is normally in an active position, in which it elastically adjoins by one surface the last fastener in the first conveyor section and in this way prestress this fastener for movement in the direction of the punching head.
From this active position which is the normal position of the infeed rocker, the latter is moved by the motion of the antagonistic tool or press parts into an inactive position in which the infeed rocker is outside of the rigid feed, during each downstroke of the press shortly before reaching bottom dead center of the press stroke. At bottom dead center of the press stroke the fastener which is ready in the punching head is joined to the workpiece. During the subsequent upstroke of the press a new fastener from the second conveyor section is reloaded into the first conveyor section by the infeed rocker which returns to the normal position, i.e., to the active position.
Among others, the disadvantage here is that for reloading from the loading position into the "first" conveyor section only a relatively short time is available, specifically the time of a partial stroke of the press directly after bottom dead center.
SUMMARY OF THE INVENTION
The object of this invention is to develop this device such that the time available for reloading is greatly prolonged, so that even with extremely high press performance (number of strokes per unit of time) operating reliability is improved.
To achieve this object a device having an infeed element, for infeed out of an initial position outside of a conveyor section, which can be moved with an infeed surface into the conveyor section and can be moved with an infeed stroke along the conveyor section is designed. The infeed element is moved back each time immediately following completed infeed into the initial position. At the loading position there is at least one stop for fasteners, which pass only with infeed by the infeed element.
For the purpose of the invention "press" is defined here as a machine with at least two tool or press parts which are antagonistic or which can move relative to one another. Preferably a press is a tool press of the initially mentioned type for producing workpieces from sheet metal by punching, permanent deformation, etc.
Antagonistic tool and press parts in this connection are those parts of the press or the tool provided in the press which are moved relative to one another in one axial direction, preferably in a vertical axis, and which act directly or indirectly on the workpiece to be manufactured or on the sheet metal used for this purpose.
These tool or press parts are for example the hold-down which travels accordingly up and down in the press stroke on the one hand and the opposite tool which interacts with it on the other, but also for example the press component which carries this opposite tool, for example, a clamping plate on the press table or an intermediate plate which is attached there for the opposite tool, etc.
One particular of the device according to the invention is among others that the infeed element is normally in the inactive position, i.e., this inactive position is the normal position of the infeed element, and is moved only for the infeed or reloading of a fastener into the first conveyor section out of this inactive position for infeed motion or an infeed stroke and subsequent backward motion or a backward stroke so that minus this short loading time which is necessary for the infeed and the return stroke the entire time or almost the entire time of a complete press stroke is available for routing a fastener to the loading position. Furthermore, reloading can also take place by the infeed element as much as possible independently of the press stroke, of course however only such that this reloading is completed each time before bottom dead center of the press movement is reached.
In the device according to the invention there is a stop for the fastener supplied at the time, at the loading station; the stop is passed by the fastener only during reloading, i.e., as it continues to move through the infeed element.
In the device according to the invention the fasteners are preferably nuts which are oriented with their axes parallel to one another and perpendicular to the infeed direction, not only in the rigid feed which together with the punching head and the loading means forms a complete structural unit, but also in an external feed via which the nuts reach the device from a supply or feed means.
The fasteners are supplied to the loading position by their being "injected" individually and in time succession using compressed air via the external feed and the second conveyor section to the loading position. Control of the external feed means and the loading means takes place via control electronics depending on the sensors provided on the rigid feed or their control signals, for example, such that whenever a stipulated number of fasteners is not present at the loading position, fasteners are conveyed by injection to the loading position until the required number of fasteners is present there and/or that when there is no fastener in the punching head or in the plunger channel there, by moving the infeed element and by injection of fasteners to the loading position the first conveyor section is reloaded until the first fastener present in this conveyor section is in the plunger channel.
A first sensor arrangement is located in the punching head or the plunger channel there. A second sensor arrangement is located in the area of the infeed means, the first sensor means recording the absence of a fastener on the punching head and causing injection of a fastener to the loading positions and reloading by the infeed device, while the second sensor means records essentially the presence of a fastener at the loading position and/or the injection of a fastener to this loading position.
Developments of the invention are the subject of the subclaims.
DETAILED DESCRIPTION OF THE DRAWINGS
The invention is detailed below using the figures on one embodiment.
FIGS. 1 and 2 show a fastener in the form of a nut and a sheet or a workpiece before inserting this nut into a hole prepared in a workpiece or after inserting and attaching the nut in the workpiece by pressing;
FIG. 3 shows in a simplified representation and in a side view one embodiment of the device according to the invention together with a press and with a tool provided in the press, for example, a follow-up tool;
FIG. 4 shows in an enlarged partial representation and in cross section the device according to the invention;
FIG. 5 shows in a simplified representation a horizontal section through the device of FIG. 4;
FIG. 6 shows a section through a hose for feed of the fasteners to the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the FIGS., 1 is a workpiece which is produced from a sheet by punching and which is reproduced as a flat workpiece for the sake of easier representation, but which can also have any other necessary shape.
A fastener is labelled 2 which in the embodiment shown is made as a nut which can be attached with collar 2' in hole 3 made in the workpiece by punching, by inserting and by subsequently pressing using plunger 4 of a punching head 5 and wraparound ring 6 of an opposite tool 7, in workpiece 1.
Workpiece 1 is produced in press 8 in a tool which is provided in this press and which is for example a follow-on tool and among others also has opposite tool 7 with wraparound ring 6. As is detailed below, in this embodiment insertion of the respective fastener into pertinent opening 3 takes place from underneath.
Press 8 consists essentially of press frame 9 which forms lower part 10 of the press and on which press plunger 11 is guided to move up and down in the vertical direction.
On lower part 10 there is clamping plate 12 on which lower tool part 13 is attached directly or via an intermediate plate. On the bottom of press plunger 11 is clamping plate 14 to which upper tool part 15 is attached in the form of a force plate.
Furthermore, press 8 has spring-mounted hold-down 16 which is located between upper tool part 15 and lower tool part 13 and which is supported against workpiece 1 with press 8 closed via the force of hold-down springs 17 which act between hold-down 16 and tool part 15. In hold-down 16 for example there is also opposite tool 7 which is made as a slide or plunger.
For controlled feed of nuts 2 to "insertion area" 18 of the tool, on which (insertion area) these nuts are inserted each into pertinent opening 3 of workpiece 1, the device is used which is labeled 19 throughout in the FIGS. and which is mounted on lower tool part 13 such that punching head 5 is located in insertion area 18.
Device 19 forms rigid conveyor section 20 which is joined with its one end via flexible tube 21 to sorting and feed means 22. Via this sorting and feed means 22 which is set up beside press 8, nuts 2 are each supplied in a stipulated position or orientation (in position) individually to device 19 or conveyor section 20, by injection via hose 21, for which the sorting and feed means but also device 19 are controlled in the manner detailed below. For positioned feed of nuts 2 tube 21 has channel 21' with a rectangular cross section such that nuts 2 then fit in this cross section when they are oriented with their axis in the vertical direction and are arranged horizontally to the top with their collar 2'.
The general conveyance direction of conveyor section 20 is shown by arrow B in the Figures. The conveyor section consists for example essentially of guide groove or conveyor channel 23 which is made in carrier 24 and which is closed on its top by plate 25.
On the end of conveyor section 20 facing away from tube 21, loading and infeed means 26 is formed with a design which is detailed below. Conveyor section 20 passes there into conveyor section 27 which, like conveyor section 20 which is shorter than conveyor section 27, is made rigid and straight through guide groove 23 in carrier 24 and on its end away from means 26 has punching head 5.
To form conveyor section 27 guide groove 23 is closed by two plates 28 on the top of carrier 24 except for a narrow slot which extends in the longitudinal direction in the center of conveyor section 27.
During operation, conveyor section 27 is occupied by a stipulated number of nuts 2, such that these nuts tightly abut one another in the longitudinal direction or conveyance direction B of conveyor section 27 and in each downstroke of the press a precisely stipulated number of nuts is located in the conveyor section, with the first nut 2 on the end of conveyor section 27 which is away from means 26, in the area of punching head 5 or in the area of plunger channel 29 which is formed there and which intersects conveyor section 27.
On conveyor section 27 there are several spring-mounted retaining elements or return catches 30 and 31, i.e., two return catches 30 on punching head 5 or plunger channel 29 there and the return catch on the end of conveyor section 27 adjacent to device 26. Return catches 30 and 31 are each levers which can swivel against the action of a thrust spring or another spring element around a vertical axis and which extend with one hook end into conveyor section 27 such that they deflect nuts 2 which move in the conveyance direction (arrow B), but prevent nuts 2 from moving past against conveyor direction B. Thus respective nut 2 is held or positioned reliably in punching head 5 or plunger channel 29 by two return catches 30. Return catch 31 ensures that these nuts 2 which have been reloaded or inserted in the manner detailed below into conveyor section 27 cannot return from the conveyor section to device 26 or to loading positions 32 which is formed in conveyor section B directly in front of return catch 31.
On the end of conveyor section 27 which is away from device 26, i.e., in plunger channel 29 of punching head 5 there is furthermore ratchet 33 which can be swivelled against spring force and which interacts with an electrical sensor, for example, with a proximity sensor, and is swivelled against the action of a reset spring into an activated position when nut 2 is located in plunger channel 29. In this state the sensor delivers a positive signal which confirms the presence of a nut to control means 36 which controls device 19, especially also its loading means and feed means 22.
On means 26 in conveyor direction B in front of loading position 32 is swivelling ratchet 37 which is under the action of a spring and which interacts with sensor 38, for example, a proximity switch, and when nut 2 moves past to loading position 32 it is swivelled briefly out of inactivated position laterally into the activated position. Sensor 38 in doing so delivers to control means 36 a second control signal which confirms that nut 2 has passed.
As the infeed element means 26 has infeed rocker 39 which with its lower end under the level of conveyor sections 20 and 27 can be swivelled by means of hinge pin 40 around a horizontal axis which is perpendicular to conveyor direction A, i.e., around an axis which is perpendicular to the conveyor direction and at the same time also perpendicular to the axis of nuts 2 in conveyor sections 20 and 27.
In the embodiment shown, infeed rocker 39 is made of flat material essentially similar to a flat lever and with its larger surface sides is perpendicular to the axis of hinge pin 40.
The length of infeed rocker 38 and the swivelling angle for this rocker are selected such that the upper end which is away from hinge pin 40 or one end or a sword-like flat section 39' of the rocker which forms this end and infeed surface 39" which is formed by this section in the inactive position shown in FIG. 4 or the normal or initial position of rocker 39 are swivelled away from punching head 5 toward conveyor section 20 and are located under the plane of conveyor sections 20 and 27 so that nuts 2 can move above on infeed rocker 39 which is swivelled into the inactive position past the rocker to loading position 32. In the active position in which the rocker with its section 39' or with its infeed surface 39" is swivelled in the direction of punching head 5 and with its longitudinal extension is located essentially in the vertical direction, section 39' projects through slot 41 from underneath into the part of conveyor section 20 which runs in the area of means 26.
Swivelling of infeed rocker 39 takes place by double-acting pneumatic cylinder 42, in turn controlled by control means 36.
The basic mode of operation of device 19 which with punching head 5, rigid conveyor sections 20 and 27 and means 26 form a complete structural unit and as such can be mounted and dismounted in press 8 or a tool there can be described as follows:
When press 8 moves to its bottom dead center, if hold-down 16 rests against workpiece 1, a nut ready in the punching head is inserted from underneath into opening 3 of workpiece 1 using insertion plunger 4 which is moved by a ram which is provided in tool part 13 and which is moved upward by the motion of the tool, for example, by the motion of hold-down 16. During the subsequent downstroke of press 8 nut 2 is attached in workpiece 1 by pressing in the above described manner.
Infeed rocker 39 is in its initial or normal position. Last nut 2 which is in conveyor section 27 is safeguarded or kept in the correct position by return catch 31 and first nut 2 which is in punching head 5 or in plunger channel 29 is safeguarded or is held in the correct position by return catches 32 at least until this nut has been acquired by injection plunger 4 and has been moved into upper part of plunger channel 29.
If nut 2 which in plunger channel 29 is disposed of, i.e., this nut is attached to workpiece 1, after leaving bottom dead center of press movement via control means 36 feed means 22 is activated so that then another nut 2 is injected by this feed means via hose 21 with compressed air into conveyor section 20 and then reaches loading position 32. The spring force of return catch 31 there is set such that it stops the injected nut at loading position 32. The injected nut has passed ratchet 37 beforehand so that sensor 38 has delivered the second sensor signal to control means 36, this control means has therefore confirmed the presence of new nut 2 at loading position 32. Subsequently, cylinder 42 is activated for swivelling or an infeed stroke and subsequent return stroke of infeed rocker 39 from the initial position into its active position (infeed position) and back into the initial position, by which nut 2 which is ready at loading position 32 is pushed or reloaded on return catch 31 past into conveyor section 27, and in doing so the entire row of nuts 2 continues to move by the size of one nut so that in turn the first nut in conveyor section 27 reaches plunger channel 29. If a nut is ascertained to be present in plunger channel 29 by ratchet 33 and pertinent sensor 34, i.e., the first control signal is present, infeed rocker 39 remains in its inactive position. Feed means 22 is not activated again for injection of nut 2. The latter state is reached before press 8 again approaches its bottom dead center or reaches it.
Respective nut 2 is safeguarded in loading position 32 by ratchet 37. If nuts 2 are made of a ferromagnetic material, in loading position 32 respective nut 2 is secured again by permanent magnet 44 which is provided at loading position 32 above the conveyor section such that this magnet 44 exerts a force acting in conveyor section B on respective nut 2 at loading position 32; this, for example, is done by the magnetic focus or the focus of the magnetic field lines of permanent magnet 44 being shifted towards to return catch 31. There is another magnet 43 at the start of conveyor section 27.
One particular of device 19 also consists in that by the action of return catches 30 and 31 feed rocker 39 is swivelled only for a short infeed movement from the initial position into the infeed position and is otherwise in the initial position, so that even when press 8 is operating at high speed there is enough time for injection of nut 2 to loading position 32.
If conveyor section 27 is completely empty, as is the case for example in initial start-up of device 19, by control means 36 repeated injection of one individual nut 2 at a time in succession to loading position 32 takes place with subsequent swivelling of infeed rocker 39 out of the initial position into the infeed position for pushing nut 2 injected at the time into conveyor section 27 until the first sensor signal delivered by sensor 34 confirms the presence of nut 2 on plunger channel 29 and in this way injection of nuts 2 by feed means 22 is ended. It goes without saying that with this complete loading of conveyor section 27 cylinder 42 is activated for the infeed stroke each time only when the presence of nut 2 at loading position 32 has been confirmed beforehand by the second control signal of sensor 34.
Device 19 ensures flawless feed of nuts 2 to punching head 5. By means of individual injection of nuts 2 via hose 21 and empty conveyor section 20 to loading position 32 using compressed air, flawless feed of nuts 2 to this loading position 32 is ensured, even when hose 21 is long and greatly curved. Mutual sticking of nuts 2 in hose 21 is not possible.
By means of a sensor which is not shown it is furthermore ensured that control of functions takes place synchronously wit h the press stroke.
In the following means 26 and punching head 5 are detailed.
Loading and Infeed Means 26
As was already mentioned, important elements of this means are infeed rocker 39 and cylinder 42 which actuates this infeed rocker. To hold these elements, on the bottom of carrier 24 housing 45 is attached with which cylinder 42 is provided and also infeed rocker 39 is swivel-mounted. Piston rod 46 of cylinder 42 fits via pin 47 into longitudinal hole 48 which is provided roughly in the center of lever-like infeed rocker 39. An adjustable stop for infeed rocker 39 with which the infeed position of this infeed rocker can be exactly adjusted is labelled 49.
Permanent magnet 43 which follows loading position 32 in transport direction B supports continued movement of nut 2 from loading position 32 into conveyor section 27 and also prevents reloaded nut 2 from moving back. A plunger plate via which injection plunger 4 is activated is labelled 52. Another sensor which is labelled 53 is provided following return catch 31 at the start of conveyor section 27 and checks whether there is in fact nut 2 at the start of conveyor section 27 immediately after loading position 32.
Punching Head 5
On the end of conveyor section 27 away from means 26 punching head 5 forms plunger channel 29 which extends with its axis in the direction of the press stroke and which is open on top 5' of punching head 5 for applying respective nut 2. In this plunger channel or in housing 50 of punching head 5, the housing which is attached to carrier 24, injection plunger 4 can be moved against the action of compression spring 51 from a lower inactive position in which injection plunger 4 lies with its upper front surface in the conveyor plane of conveyor section 27 into a raised position in which then nut 2 which lies on the front face of injection plunger 4 is raised to the extent that it projects at least with its collar 2" for insertion into workpiece 1 and for pressing there over top 5'.
The invention was described above using one embodiment. It goes without saying that changes and modifications are possible without departing form the inventive idea underlying the invention.
Basically it is also possible to make loading position 32 such that there is room for at least two nuts 2 there following one another in transport direction B, then during each infeed motion of infeed rocker 39 in normal operation one nut 2 is moved into conveyor section 27, while second nut 2 remains in reserve in loading position 32 for the case in which another nut has not be re-injected at the proper time to loading position 32. It goes without saying that in this case feed rocker 39 can execute strokes of different size. Feed means 22 is controlled via control means 36 depending on the second control signal delivered by sensor 38 such that nuts 2 are re-injected in any case whenever there are not two nuts 2 at loading position 32. | A device, for use in a press, for feeding fasteners, especially nuts, and attaching the fasteners in workpieces by pressing with a punching head. Joining and pressing of the fasteners in the workpieces takes place, with an infeed and loading means on a tool or press part, and on a rigid feed, which together with a punching head can be attached to one of two antagonistic tool or press parts. A first conveyor section for the fasteners is located between the punching head and the loading means, and forms the fasteners. Each of the fasteners is supplied individually to a loading position of the loading means and each is moved by an infeed element from the loading position into a subsequent first conveyor section, forming a row which extends into the punching head, in which the fasteners tightly abut one another. An infeed element, for infeed out of an initial position outside of a conveyor section, is moved with an infeed surface into the conveyor section and is moved with an infeed stroke along the conveyor section is designed. The infeed element is moved back each time immediately following completed infeed into the initial position. At the loading position there is at least one stop for fasteners, which pass only with infeed by the infeed element. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Background of the Invention
This invention relates in general to vehicle steering or suspension systems and in particular to an improved ball joint for use in such a motor vehicle steering or suspension system.
Ball joints provide an articulated connection between two relatively movable parts. Ball joints are commonly used in motor vehicle steering systems and in motor vehicle suspension systems.
In a vehicle steering system, ball joints are commonly adapted to be connected to a steering arm of each of a wheel knuckle. Typically, a ball joint for a motor vehicle steering system includes a ball stud with a spherical ball end and a housing or socket member with a spherical socket. A bearing member in the socket receives the ball end and supports the ball end for rotational and pivotal movement. Such a steering system having a ball joint is disclosed in U.S. Pat. No. 7,261,487 B2 to Urbach, the disclosure of this patent incorporated by reference herein in entirety.
SUMMARY OF THE INVENTION
This invention relates to an improved ball joint for use in such a motor vehicle steering or suspension system.
According to one embodiment, the ball joint comprises: a housing; a bearing disposed in the housing; and a ball stud supported within the housing by the bearing; wherein the bearing includes at least a first bearing member formed from a first material and a second bearing member formed from a second dampening material attached to at least a portion of an outer surface of the first bearing member, the first bearing member having a bidirectional slot formed therein which is configured to allow the ball stud to articulate in a first direction and restrict and dampen articulation in a second direction which is generally transverse to the first direction.
According to this embodiment of the ball joint, the bidirectional slot includes a first slot portion having a first shape and a second slot portion having a second shape different from the first shape.
According to this embodiment of the ball joint, the first shape of the first slot portion is generally oval-shaped and the second shape of the second slot portion is generally concave shaped.
According to this embodiment of the ball joint, the first slot portion is generally in the center of the bearing and the second slot portion is formed by a pair of generally concave shaped slots disposed on opposed sides of the first slot portion.
According to this embodiment of the ball joint, the bearing includes an opened first end having a first opening formed therein and an opposite opened second end having a second opening formed therein which is different from the first opening.
According to this embodiment of the ball joint, the ball stud includes a ball portion and a pin portion, wherein the pin portion is disposed in the first slot portion and the ball portion is disposed in the second slot portion.
According to this embodiment of the ball joint, the second bearing member is secured to substantially the entire outer surface of the first bearing member.
According to this embodiment of the ball joint, the first bearing member is formed from one of metal or plastic and the second bearing member is formed from one of rubber or plastic.
According to this embodiment of the ball joint, the second direction defines a minor axis of the ball joint such that when the ball joint is impacted with loads in the direction of the minor axis the first bearing member partially unseats from a portion of a housing internal counterbore whereby the second member is operative to dampen the loads into the ball joint.
According to another embodiment, a ball joint comprises: a housing having a chamber; a bearing disposed in the chamber of the housing; and a ball stud supported within the chamber of the housing by the bearing; wherein the bearing includes a first bearing member formed from a first material and a second bearing member formed from a second dampening material and attached to at least a portion of an outer surface of the first bearing member, the first bearing having a first slot portion and a second slot portion formed therein, wherein the first slot portion is configured to allow the ball stud to articulate in a first direction and the second slot portion is configured to restrict and dampen articulation in a second direction which is generally transverse to the first direction.
According to this embodiment of the ball joint, the first slot portion has a first shape and a second slot portion has a second shape different from the first shape.
According to this embodiment of the ball joint, the first shape of the first slot portion is generally oval-shaped and the second shape of the second slot portion is generally concave shaped.
According to this embodiment of the ball joint, the first slot portion is generally in the center of the bearing and the second slot portion is formed by a pair of generally concave shaped slots disposed on opposed sides of the first slot portion.
According to this embodiment of the ball joint, the bearing includes an opened first end having a first opening formed therein and an opposite opened second end having a second opening formed therein which is different from the first opening.
According to this embodiment of the ball joint, the ball stud includes a ball portion and a pin portion, wherein the pin portion is disposed in the first slot portion and the ball portion is disposed in the second slot portion.
According to this embodiment of the ball joint, the second bearing member is secured to substantially the entire outer surface of the first bearing member.
According to this embodiment of the ball joint, the first bearing member is formed from one of metal or plastic and the second bearing member is formed from one of rubber or plastic.
According to this embodiment of the ball joint, the second direction defines a minor axis of the ball joint such that when the ball joint is impacted with loads in the direction of the minor axis the first bearing member partially unseats from a portion of a housing internal counterbore whereby the second member is operative to dampen the loads into the ball joint.
According to another embodiment, a bearing for a ball joint comprises: a first bearing member formed from a first material and a second bearing member formed from a second dampening material attached to at least a portion of an outer surface of the first bearing member, the first bearing member having and first opened end portion, a main body portion, and a second end portion, wherein the first bearing member includes an inner bearing seat defined by a first slot portion and a second slot portion, wherein the first slot portion is configured to allow the ball stud to articulate in a first direction and the second slot portion is configured to restrict and dampen articulation in a second direction which is generally transverse to the first direction.
According to this embodiment of the bearing, the first slot portion has a first shape and a second slot portion has a second shape different from the first shape.
According to this embodiment of the bearing, the first shape of the first slot portion is generally oval-shaped and the second shape of the second slot portion is generally concave shaped.
According to this embodiment of the bearing, the first slot portion is generally in the center of the bearing and the second slot portion is formed by a pair of generally concave shaped slots disposed on opposed sides of the first slot portion.
According to this embodiment of the bearing, the second direction defines a minor axis of the ball joint such that when the ball joint is impacted with loads in the direction of the minor axis the first bearing member partially unseats from a portion of a housing internal counterbore whereby the second member is operative to dampen the loads into the ball joint.
Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view, with portions cut away, of an embodiment of a ball joint in accordance with the present invention.
FIG. 2 is a sectional view, with portions cut away, of the ball joint.
FIG. 3 is another sectional view of the ball joint.
FIG. 4 is another sectional view of the ball joint.
FIG. 5 is a view taken through a portion of the ball joint showing the possible allowable articulation of the ball joint.
FIG. 6 is an exploded view of the bearing (without the damper) and ball stud of the ball joint.
FIG. 7 is a view of the bearing with the damper of the ball joint.
FIGS. 9-10 are view of the bearing without the damper of the ball joint.
FIG. 11 is an enlarged view of a portion of the ball joint showing an operating condition of the ball joint.
FIG. 12 is an enlarged view of a portion of the ball joint showing another operating condition of the ball joint.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-4 , there is illustrated an embodiment of a ball joint, indicated generally at 10 , in accordance with the present invention. The general structure and operation of the ball joint 10 is conventional in the art. Thus, only those portions of the ball joint which are necessary for a full understanding of this invention will be explained and illustrated in detail. As is well known in the art, the ball joint 10 is configured to interconnect relatively movable vehicular parts, such as for example, a steering knuckle or steering yoke, with a control arm, steering yoke or steering knuckle, or other associated parts of the vehicle steering or suspension system. Also, although this invention will be described and illustrated in connection with the particular ball joint 10 disclosed herein, it will be appreciated that this invention may be used in connection with other kinds, types or designs of ball joints if so desired. For example, the ball joint 10 can be used in connection with a vehicle suspension system and/or a ball joint as shown in U.S. Pat. No. 6,042,294 to Urbach, the disclosure of this patent incorporated by reference herein in entirety.
As shown in FIGS. 1-5 , the ball joint 10 includes a socket shell or housing 12 which defines an axis A, a first or upper “throat” bearing 14 , a ball stud 16 , a second or “lower” bearing 18 and a socket plug 20 . In the illustrated embodiment, the housing 12 is formed from a suitable material, such as for example steel or plastic. The housing 12 includes an interior chamber 12 A, an opened first or upper end 12 B, and an opened second or lower end 12 C. The housing preferably further includes an annular groove or recess 12 D provided in an inner side wall thereof. Alternatively, the construction, configuration, or shape of the housing 12 can be other than illustrated and described if so desired.
In the illustrated embodiment, the first bearing 14 is formed from a suitable material, such as for example plastic or steel. The first bearing 14 is generally annular in shape and is configured to be disposed in the annular groove 12 D provided in the inner side wall of the housing 12 . Alternatively, the construction, configuration, or shape of the first bearing 14 can be other than illustrated and described if so desired.
In the illustrated embodiment, the ball stud 16 is formed from a suitable material, such as for example steel. The ball stud 16 is configured to be operatively centered on the axis A of the ball joint 10 . The ball stud 16 includes a first or shank portion 16 A, a second or ball portion 16 B and a third or pin portion 16 C. The shank portion 16 A of the ball stud 16 is configured to be operatively connected or coupled to a suitable vehicle steering or suspension component, such as for example, a steering knuckle (not shown), in a known manner. For example, the shank portion 16 A can be provided with external threads (not shown) used for connecting the shank portion 16 A, and therefore the ball joint 10 , to the associated vehicle component. Alternatively, the construction, configuration, or shape of the ball stud 16 and/or the method of connecting it to the associated vehicle component can be other than illustrated and described if so desired.
In the illustrated embodiment, the second bearing 18 preferably includes at least a first or “inner” member 22 and a second or “outer” member 24 . The first member 22 is generally annular in shape and is formed from a suitable material, such as for example steel, plastic, brass, bronze, or phenolic. In the illustrated embodiment, the first member 22 is preferably formed from high strength low alloy steel, such as for example 50F or 70F stamped steel.
In the illustrated embodiment as best shown in FIGS. 8-10 , the first bearing member 22 includes a first or “upper” flanged opened end portion 22 A, a second or main body portion 22 B, and a second or “lower” end portion 22 C which preferably is also opened. The first member 22 further includes an “inner” bearing seat or surface, indicated generally at 26 , extending generally from the upper end portion 22 A to the lower end portion 22 C. The upper end portion 22 A includes a generally circular shaped opening 30 and the lower end portion 22 C includes a generally oval shaped or elongated slot shaped opening 32 . As best shown in FIG. 2 , the flanged opened end portion 22 A of the first member 22 is normally disposed adjacent and in engagement with a shoulder 12 E of an internal counterbore 12 F of the housing 12 .
In the illustrated embodiment, the bearing seat 26 of the first member 22 includes a uniquely shaped “bidirectional stud travel” slot which is configured to operatively receive the ball portion 16 B and the pin portion 16 C of the ball stud 16 therewithin. As can be seen best in FIGS. 7 and 8 , in the illustrated embodiment the bidirectional slot includes a first slot portion 26 A having a first shape and a second slot portion 26 B having a second shape. The first slot portion 26 A is formed generally in the center of the main body portion 22 B of the first member 22 and is generally an oval-shaped slot.
In the illustrated embodiment, at least the opposed end portions the first slot 26 A preferably extend generally the entire depth of the first member 22 , i.e., extend generally from the flanged upper end portion 22 A to the lower end portion 22 C. As shown in the illustrated embodiment, the first slot portion 26 A includes generally curved end walls and generally planar or flat side walls. In the illustrated embodiment, the first slot portion 26 A is generally configured to receive and support the pin portion 16 C of the ball stud 16 and controls the orientation of the ball stud 16 and allows the articulation of the ball stud 16 in a first direction, generally indicated by double headed arrow D 1 in FIG. 8 .
In the illustrated embodiment, the second slot portion 26 B includes a pair of slots 34 A and 34 B which are formed in the main body portion 22 B of the first member 22 on opposed sides of the first slot portion 26 A. In the illustrated embodiment, the slots 34 A and 34 B are generally concave shaped, such as for example spherical. In the illustrated embodiment, the slots 34 A and 34 B preferably extend only partially the depth of the first member 22 of the second bearing 18 , i.e., extend generally from the flanged upper end portion 22 A toward the lower end portion 22 C, as the slots 34 A and 34 B generally converge or merge with the first slot portion 26 A as indicated by lines 36 A and 36 B, respectively, in FIG. 7 .
In the illustrated embodiment, the second slot portion 26 B is generally configured to receive and support the ball portion 16 B of the ball stud 16 and allows the articulation of the ball stud 16 in the first direction D 1 , but via the pin portion 16 C in the first slot portion 26 A the articulation of the ball stud 16 is restricted in a second direction, generally indicated by double headed arrow D 2 . As can be seen in FIG. 8 , the second direction D 2 is generally opposite or transverse (i.e., 90 degrees), relative to the first direction D 1 . Thus, the bi-directional slot of the second bearing 18 is operative to allow directional ball stud 16 articulation in the first direction D 1 , while restricting the articulation in the second direction D 2 .
In the illustrated embodiment, the second member 24 of the second bearing 18 defines a bushing or damper and is preferably formed from a suitable material, such as for example preferably rubber but can be made from plastic. In the illustrated embodiment, the second member 24 is preferably provided and is bonded, glued, or otherwise permanently attached to an outer surface of the main body portion 22 B of the first member 22 . Preferably, the second member 24 covers the entire outer surface of the main body portion 22 B of the first member 22 . Alternatively, the construction, structure or configuration of the first member 22 and/or the second member 24 of the second bearing 18 and/or the method for attaching the second member 24 to the first member 22 can be other than illustrated and described if so desired.
One potential advantage of the illustrated embodiment of the invention is that ball joint second bearing 18 —which preferably includes the stamped “thin wall” steel first member 22 having a dampening second member 24 attached thereto—allows directional stud articulation in one direction while generally restricting articulation in a generally opposite (i.e., ninety degrees). Also, during operation of the vehicle, as the ball joint 10 is impacted with loads in the “restricted stud” direction of a minor axis thereof (i.e., the direction of the minor axis (vehicle fore/aft) being shown in FIG. 6 generally by arrow M 1 ), the rubber, plastic or similar “dampening” material of the second member 24 of the second bearing 18 allows the second bearing 18 to partially unseat from the shoulder 12 E of the internal counterbore 12 F of the housing 12 (as shown in FIG. 11 ), whereby the second member 24 is operative to absorb/dampen the loads into the ball joint 10 . The second bearing 18 also allows the ball joint 10 to hang the associated steering linkage at an angle perpendicular or opposed to its center of gravity. The major axis (i.e., the major axis being shown in FIG. 6 generally by arrow M 2 ), of the ball joint 10 allows for full ball stud 16 articulation in the major axis M 2 in suspension jounce or rebound without any dampening (as shown in FIG. 12 ). As can be seen from FIGS. 6 and 8 , the minor axis M 1 of the ball joint 10 generally coincides or is in line with the second direction D 2 of articulation of the ball stud 16 in the second bearing 18 and the major axis M 2 of the ball joint 10 generally coincides or is in line with the first direction D 1 of articulation of the ball stud 16 in the second bearing 18 .
The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope. | An improved ball joint for use in a motor vehicle steering or suspension system includes a housing, a bearing disposed in the housing, and a ball stud supported within the housing by the bearing. The bearing includes at least a first bearing member formed from a first material and a second bearing member formed from a second dampening material attached to at least a portion of an outer surface of the first bearing member. The first bearing member has a bidirectional slot formed therein which is configured to allow the ball stud to articulate in a first direction and restrict and dampen articulation in a second direction which is generally transverse to the first direction. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to copper interconnects. More particularly, the present invention relates to a via-first dual damascene process capable of avoiding bridging defects.
2. Description of the Prior Art
Damascene processes incorporated with copper interconnect technique are known in the art, which are also referred to as “copper damascene processes” in the semiconductor industry. The continuous miniaturization of copper chip wiring and consequently shrinkage of line width and via size/space poses significant challenges.
In a via-first approach, the vias are defined first in the inter-layer dielectric, followed by patterning the trenches. The sequence of forming the damascene recesses in the via-first approach begins by exposing the via patterns with the first mask. After etching the vias completely through the entire dielectric stack (except not through the barrier layer at the bottom of the dielectric stack) and stripping the resist, a second mask is used to pattern the trenches. The trenches are then created by etching the dielectric down to the embedded etch-stop layer.
Typically, the barrier layer at the bottom of the vias is protected from further etching during the trench-etch by a resist layer that floods the vias. After the resist is stripped and the etch-stop layer at the bottom of the via is removed by dry-etching, the metal that fills both the vias and the trenches can be deposited. After deposition, it is polished back to create the dual-damascene structure.
FIGS. 1–5 are schematic, cross-sectional diagrams showing several typical intermediate phases of a semiconductor wafer during the via-first dual damascene process according to the prior art method. As shown in FIG. 1 , conductive structures 111 and 112 such as damascened copper wirings are provided in a device layer 101 of a semiconductor substrate 100 . A capping layer 115 such as silicon nitride is deposited to cover the exposed conductive structures 111 and 112 , and the device layer 101 . A dielectric stack 120 is then deposited on the capping layer 115 . The dielectric stack 120 is composed of a first dielectric layer 121 , a second dielectric layer 123 , and an etch stop layer 122 interposed between the first dielectric layer 121 and the second dielectric layer 123 . A silicon oxy-nitride layer 130 is then deposited on the first dielectric layer 121 .
A first photoresist layer 140 having via openings 141 and 142 is formed on the silicon oxy-nitride layer 130 , assuming that the via opening 141 is an isolated via pattern, i.e. there is no other via opening located in the proximity of the via opening 141 , and the via opening 142 is a dense via pattern. Using the first photoresist layer 140 as a etching mask, an etching process is performed to etch away, in the order of, the silicon oxy-nitride layer 130 , the dielectric stack 120 , to the capping layer 115 , through the via openings 141 and 142 , thereby forming via holes 151 and 152 a/b.
As shown in FIG. 2 , after stripping the first photoresist layer 140 off the silicon oxy-nitride layer 130 , a gap-filling polymer (GFP) layer 200 is coated on the semiconductor substrate 100 and fills the via holes 151 and 152 a/b . The GFP layer 200 is typically composed of resist materials known in the art. Coating of the GFP layer 200 is known in the art and an additional post-baking step may be carried out if desired.
As shown in FIG. 3 , the GFP layer 200 is then etched back to a predetermined depth so as to form plug 201 in the isolated via hole 151 and plugs 202 a / 202 b in the dense via holes 152 . The top surface of the plugs 201 and 202 a/b is lower than the top surface of the silicon oxy-nitride layer 130 , forming recesses 301 , 302 a and 302 b . As shown in FIG. 4 , a second photoresist layer 400 is coated on the semiconductor substrate 100 and fills the recesses 301 and recesses 302 a/b using methods known in the art such as spin coating.
As shown in FIG. 5 , following the coating of the second photoresist layer 400 , a lithographic process is carried out. The exposed second photoresist layer 400 is developed using a proper developer. Trench 411 is formed above the recess 301 , trench 412 a is formed directly above the recess 302 a , and trench 412 b is formed directly above the recess 302 b.
Please refer to FIG. 6 and briefly back to FIG. 5 , wherein FIG. 6 is a plan view of the via holes and trench patterns of the second photoresist layer 400 of FIG. 5 , and FIG. 5 is a cross-sectional view taken along line I—I of FIG. 6 . As shown in FIGS. 5 and 6 , the line width L of the trench 412 a is equal to the diameter of the underlying via hole 152 a . Likewise, the line width of the trench 412 b is equal to the diameter of the underlying via hole 152 b . The line width of the trench pattern 411 is larger than the diameter of the underlying via hole 151 .
One drawback of the above-described prior art method is that when etching trench lines into the dielectric stack 120 in the following trench forming step, the exposed first dielectric layer 121 of the dielectric stack 120 in the recesses 301 , 302 a and 302 b are also laterally etched. Since the via 152 a and via 152 b are very close to each other, such lateral etch of the exposed first dielectric layer 121 between the dense via 152 a and 152 b usually causes bridging defect after copper CMP.
SUMMARY OF THE INVENTION
It is the primary object of the present invention is to provide an improved via-first dual damascene process to alleviate or eliminate the via-to-via bridging problem.
To achieve the above object, a via-first dual damascene process is provided. The via-first dual damascene process includes the following steps:
providing a semiconductor substrate having a dielectric layer deposited over the semiconductor substrate, wherein the dielectric layer has a via opening;
filling the via openings with a gap-filling polymer to form a gap-filling polymer (GFP) layer on the dielectric layer;
etching the GFP layer back to a predetermined depth to form a GFP plug in the via opening, wherein an exposed surface of the GFP plug is lower than a top surface of the dielectric layer, thereby forming a recess above the via opening;
coating a photoresist layer over the dielectric layer, the photoresist layer filling the recess;
performing a lithographic process to form a trench line pattern in the photoresist layer above the via opening, wherein the trench line pattern has a first section that has a substantially constant line width L and does not overlap with the via opening, and a second section that is directly above the via opening and has a tapered line width smaller than L, wherein the line width L is substantially equal to diameter of the via opening; and
etching the dielectric layer and the GFP layer through the trench line pattern using the photoresist layer as an etching mask.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 to FIG. 5 are cross-sectional schematic diagrams showing several typical intermediate phases of a semiconductor wafer during the via-first dual damascene process according to the prior art method;
FIG. 6 is a top view of FIG. 5 ;
FIG. 7 to FIG. 12 are cross-sectional schematic diagrams illustrating the via-first dual damascene process according to one preferred embodiment of this invention;
FIG. 13 is a plan view of the via holes previously formed in the dielectric stack and trench patterns of the second photoresist layer of FIG. 11 ;
FIG. 14 depicts the layout of a photo mask for printing a pattern of photoresist corresponding to the interconnection area depicted in FIG. 13 ; and
FIG. 15 is a plan view of the dual-damascene structures of FIG. 12 .
DETAILED DESCRIPTION
Please refer to FIG. 7 to FIG. 12 . FIG. 7 to FIG. 12 are schematic, cross-sectional diagrams illustrating the via-first dual damascene process according to the preferred embodiment of this invention. As shown in FIG. 7 , a semiconductor substrate 700 is provided. Conductive structures 711 and 712 such as damascened copper wirings are provided in a device layer 701 of the semiconductor substrate 700 . The device layer 701 may be a low-k dielectric, but not limited thereto. Subsequently, a capping layer 715 such as silicon nitride is deposited to cover the exposed conductive structures 711 and 712 , and the device layer 701 over the semiconductor substrate 700 .
Likewise, a dielectric stack 720 is formed on the capping layer 715 . The dielectric stack 720 is composed of a first dielectric layer 721 , a second dielectric layer 723 , and an etch stop layer 722 interposed between the first dielectric layer 721 and the second dielectric layer 723 . Preferably, both of the first dielectric layer 721 and the second dielectric layer 723 have a dielectric constant of less than 3.0. For example, suitable low-k material for the first dielectric layer 721 and the second dielectric layer 723 may be selected from the group including, but not limited to, FLARE™, SiLK™, poly(arylene ether) polymer, parylene, polyimide, fluorinated polyimide, HSQ, BCB, FSG, silicon dioxide, and nanoporous silica.
Still referring to FIG. 7 , a silicon oxy-nitride layer 730 is then deposited on the first dielectric layer 721 . A first photoresist layer (Via Photo) 740 having via openings 741 and 742 is formed on the silicon oxy-nitride layer 730 , assuming that the via opening 741 is an isolated via pattern, i.e. there is no other via opening located in the proximity of the via opening 741 , and the via openings 742 are dense via pattern. Using the first photoresist layer 740 as an etching mask, an etching process is performed to etch away, in the order of, the silicon oxy-nitride layer 730 , the stacked layer 720 , to the capping layer 715 , through the via openings 741 and 742 , thereby forming deep via holes 751 , 752 a and 752 b . The average diameter of via holes 751 , 752 a and 752 b is about 0.08–0.2 micrometers.
As shown in FIG. 8 , the first photoresist layer 740 is stripped off from the silicon oxy-nitride layer 730 by methods known in the art such as oxygen plasma ashing. A gap-filling polymer (GFP) layer 800 is then coated on the semiconductor substrate 700 and fills the via holes 751 , 752 a and 752 b . The GFP layer 800 may be composed of an i-line resist such as novolak, poly hydroxystyrene (PHS) or acrylate-based resins. Spin coating of the GFP layer 800 is known in the art and optional post-baking step may be carried out if desired.
As shown in FIG. 9 , the GFP layer 800 is then etched back to a predetermined depth so as to form GFP plugs 801 , 802 a and 802 b within the via holes 901 , 902 a and 902 b , respectively. The top surface of the GFP plugs 801 , 802 a and 802 b is lower than the surface of the silicon oxy-nitride layer 730 , thereby forming recesses 901 , 902 a and 902 b . The recesses 901 , 902 a and 902 b are defined by the respective sidewalls 911 , 912 a and 912 b and the corresponding exposed top surfaces of the GFP plugs 801 , 802 a and 802 b . As shown in FIG. 10 , a second photoresist layer (Trench Photo) 1000 is coated on the semiconductor substrate 700 and fills the treated recesses 901 , 902 a and 902 b using methods known in the art such as spin coating.
As shown in FIG. 11 , following the coating of the second photoresist layer 1000 , a photolithographic process is carried out. In the photolithographic process (or trench photo-lithographic process), a photo mask having a predetermined trench pattern thereon (shown in FIG. 14 ) is provided, which is positioned over the semiconductor substrate 700 in an exposure tool. Light such as deep UV is projected on the photo-mask and passes through clear areas of the photo-mask to irradiate the underlying second photoresist layer 1000 , thereby forming latent trench images, which is soluble in a developer, over the respective recesses 901 , 902 a and 902 b in the second photoresist layer 1000 . Thereafter, the exposed second photoresist layer 1000 is developed using a proper developer. The latent trench images are removed to form trench patterns 1011 , 1012 a and 1012 b directly above the recesses 901 , 902 a and 902 b , respectively.
It is the main feature of the present invention that after development the sidewalls 912 a and 912 b of the neighboring recesses 902 a and 902 b are partially masked and protected by the second photoresist layer 1000 , and are thus not exposed to etchant used in the subsequent trench etch step.
Please now refer to FIG. 13 and briefly back to FIG. 11 , wherein FIG. 13 is a plan view of the via holes previously formed in the dielectric stack 720 and trench patterns of the second photoresist layer 1000 of FIG. 11 , and FIG. 11 is a cross-sectional view taken along line II—II of FIG. 13 . As shown in FIGS. 11 and 13 , the line width of the trench pattern 1011 is larger than the diameter of the underlying via hole 751 . According to the preferred embodiment, each of the trench patterns 1012 a and 1012 b includes a first section 1200 that does not overlap with the underlying via hole and has a substantially constant line width of L, and a tapered second section 1300 that is situated directly above the via hole thereof and has a tapered line width that is less than L.
The layout of the photo mask for printing a pattern of photoresist corresponding to the interconnection area depicted in FIG. 13 is illustrated in FIG. 14 . The photo mask 500 includes a dark region 525 , and bright line region 511 for printing trench 1011 in the second photoresist layer 1000 , a bright line region 512 a for printing trench 1012 a , and a bright line region 512 b for printing trench 1012 b . The line width of the bright line region 512 a is equal to the diameter of the underlying via hole 752 a and line width of the bright line region 512 b is equal to the diameter of the underlying via hole 752 b . The via hole 752 a and via hole 752 b are close to each other (i.e., small pitched, dense via holes). The bright line region 512 a is biased with a pair of dark regions 532 a at the area that is directly above the via hole 752 a . The bright line region 512 b is biased with a pair of dark regions 532 b at the area that is directly above the via hole 752 b.
According to the preferred embodiment, the biasing dark regions 532 a and 532 b are equal in size, and each of which is defined by a width w and length l. Preferably, the length l of the biasing dark regions 532 a and 532 b is equal to or greater than the diameter of the via hole, and the width w is about 5%–30% of the length l. For example, for a via hole with a diameter of about 0.2 micrometers, the dimension of each biasing dark region will be 200 nanometers (minimum length)×10–60 nanometers (width).
As shown in FIGS. 12–13 , using the patterned second photoresist layer 1000 as an etching hard mask, a dry etching process is carried out to etch trenches into the first dielectric layer 721 through the trench patterns 1011 , 1012 a and 1012 b directly above the recesses 901 , 902 a and 902 b , respectively. After the resist is stripped and the etch-stop layer at the bottom of the via is removed by dry-etching, the metal that fills both the vias and the trenches can be deposited. After deposition, it is polished back to create the dual-damascene structures 1410 , 1412 a and 1412 b . The dual-damascene structure 1410 comprises via plug 1401 . The dual-damascene structure 1412 a comprises via plug 1402 a . The dual-damascene structure 1412 b comprises via plug 1402 b.
FIG. 15 is a plan view of the dual-damascene structures 1410 , 1412 a and 1412 b of FIG. 12 . As shown in FIG. 15 , each of the dual-damascene structures 1412 a and 1412 b includes a first section 1600 that does not overlap with the underlying via plug and has a substantially constant line width of L, and a notched second section 1700 that is situated directly above the via hole thereof.
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | A via-first dual damascene process is disclosed. When forming trench lines directly above two small pitched, dense via openings having diameter that is substantially equal to the line width of the trench lines, the trench photoresist is biased on the via openings to partially mask the sidewalls of the two dense via openings. By doing this, via-to-via bridging defects can be avoided. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to a method and apparatus for estimating interactions between the wheels of a railway vehicle and the rail tracks, in particular but not only to estimation of the contact forces caused by irregularities in the surfaces of the rails.
BACKGROUND TO THE INVENTION
[0002] Information relating to wheel-rail interactions of rail vehicles such as wagons can be used in various ways, such as to provide an indication of possible derailment of the vehicles, and analysis of wheel or track damage. However, it is generally not possible to make a direct measurement of the interaction forces between the wheels of a railway vehicle and rails on which the wheels are moving, because the contact locations are inaccessible.
[0003] A range of commercial products for indirectly determining these interactions are available, such as the software packages known as VAMPIRE®, ADAMS/Rail®, and NUCARS®. The products involve a forward dynamic model of the vehicle-rail system in which irregularities in the track are measured first and the contact forces are then predicted using the running speed and known properties of the vehicle. However, there are a number of disadvantages in the overall technique, including the cost of the measurement systems which provide the track data and their difficulty of maintenance for normal rolling stock.
[0004] A range of simulation packages which use (Artificial Neural Network) ANN modelling for rail vehicles and interaction forces are also available. These also require track geometry and running speed as input in order to calculate interactions between the wheels and the rails. An ANN model requires sufficient field test data to develop a simulation model for each vehicle type. The process is therefore costly and retains a limitation in that it depends on the most recent track data for daily evaluations of vehicle performance.
[0005] There has not yet been a successful product which is able to calculate wheel-rail forces in real-time, based on parameters of the vehicle and measurements of the motion of the vehicle. This is a non-linear inverse problem involving friction and damping in the wheelsets.
SUMMARY OF THE INVENTION
[0006] It is an object of the invention to provide improved systems for estimation of contact forces between the wheels of a rail vehicle and the rails, or at least to provide an alternative to existing systems.
[0007] In one aspect the invention may therefore broadly be said to reside in a method of estimating contact forces between the wheels of a railway wagon and a rail track along which the wagon is moving, including: determining accelerations of the body of the wagon, calculating forces on the side frames of the wagon based on the accelerations of the body and predetermined parameters of the body, calculating forces on the wheels of the wagon based on the accelerations of the body and predetermined parameters of the body, and calculating contact forces between the wheels and the rails based on the forces calculated for the side frames and the wheels.
[0008] Preferably the accelerations of the wagon body are determined by placing motion sensors at locations on the body of the wagon that are spaced from the centre of mass of the wagon, and receiving data from the sensors at a processor which is also located on the wagon. The data received from the motion sensors is transformed into accelerations which represent lateral, vertical, pitch, roll and yaw movements of the body about the centre of mass of the wagon. The calculations are based on a model which includes approximations for the body, the side frames and wheelsets of the wagon with Hertzian spring and viscous damping parameters.
[0009] In another aspect the invention also resides in apparatus for estimating contact forces between the wheels of a railway wagon and a rail track, including: a set of motion sensors for placement at locations relative to the centre of mass of the wagon, and a processor which receives data from the sensors and contains computer program code which: calculates forces on the side frames of the wagon based on the accelerations of the body and predetermined parameters of the body, calculates forces on the wheels of the wagon based on the forces between the wheels and the rails based on the forces calculated for the side frames and the wheels. A transmitter for sending data relating to the contact forces from the processor to a collection site may also be included.
[0010] The invention also resides in any alternative combination of features which are indicated in this specification. All equivalents of these features are considered to be included whether or not they are mentioned explicitly.
LIST OF FIGURES
[0011] Preferred embodiments of the invention will be described with respect to the accompanying drawings, of which:
[0012] FIG. 1 schematically shows a railway wagon,
[0013] FIG. 2 indicates wheel-rail forces which may arise on a rail,
[0014] FIG. 3 is a simplified model of a wheelset on the wagon or other vehicle,
[0015] FIG. 4 indicates equipment which may be used to monitor motion of the wagon,
[0016] FIG. 5 indicates the characteristics of motion sensors in the equipment,
[0017] FIG. 6 indicates an inverse vehicle dynamic model of a wagon,
[0018] FIG. 7 indicates a determination of inertia forces on a wagon body,
[0019] FIG. 8 outlines operation of program code in the equipment,
[0020] FIG. 9 shows a typical variation of lateral wheel-rail contact force,
[0021] FIG. 10 shows a typical variations of vertical wheel-rail contact force,
[0022] FIG. 11 shows the ratio of lateral to vertical forces in FIGS. 9 and 10 ,
[0023] FIG. 12 shows measured wagon body accelerations,
[0024] FIG. 13 shows estimated vertical wheel force for the measured acceleration,
[0025] FIG. 14 shows estimated lateral wheel force for the measured acceleration, and
[0026] FIG. 15 shows the ratio of lateral to vertical forces for the measured accelerations.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] Referring to these drawings it will be appreciated that the invention can be implemented in various forms for a variety of vehicular systems. These embodiments involve railway wagons and are given by way of example only.
[0028] FIG. 1 shows a rail wagon having a body 10 and two bogies 11 . In this example each bogie has a pair of parallel side frames 12 , each mounted on a vertical suspension unit and carrying a pair of wheels 13 . Wheels on a common suspension unit are considered to be a load sharing group. The side frames are joined by bolsters 14 . Wheelsets are formed by pairs of wheels on opposite ends of an axle. Each bogie therefore has a pair of wheelsets. It will be appreciated that a wide variety of wagon structures are used in practice.
[0029] FIG. 2 indicates lateral and vertical force vectors L, V at the head of a rail. These represent contact forces at the interface between the rail and a wheel and are used to quantify two important criteria of wagon stability. The dynamic vertical force is often expressed as a percentage of its static value thus indicating wheel unloading. The lateral force is often expressed as a ratio in comparison to vertical force in the form of (Lateral Force)/(Vertical Force). This ratio is known as “Nadal's Criteria” or “the derailment index” or “the L/V ratio” and is use to indicate the tendency of the vehicle to derail in wheel climb modes. The force action point varies with the changes of wheel-rail kinematical contact parameters.
[0030] FIG. 3 shows how a mathematical-physical model enables the vertical force to be described by a sum of corresponding spring and damping forces. The following analysis involves a simplified 2 Degrees of Freedom (DOF) system consisting of a wheel and the suspended mass and will provide a basic conception for prediction of the vertical wheel rail contact force. A realistic physical model is more complex and has many more DOFs and the wagon body motion is expressed by three translational accelerations and three rotational accelerations.
[0031] In this system the acceleration of mass m o is used to estimate wheel-rail interface force via the following equations.
[0000] m o a o +C o ( ż o −ż w )+ K o ( z o −z w )+ F Df =0 (1)
[0000] m w {umlaut over (z)} w +C w ( ż w −{dot over (v)} r )+ K w ( z w −v r )=− m o a o (2)
[0000] where a o denotes the acceleration of the mass m o ;{umlaut over (z)} w denotes the acceleration of the mass m w ; linear dampers are defined by C o ;C w ; linear spring stiffnesses are defined by K o ;K w ; vertical displacements and velocities of the masses m o and m w are ż o ;z o and ż w ;z w respectively, v r denotes the vertical track irregularity which is a function of time or distance, and F Df is the non-linear damper (usually friction) that is positioned between masses m o and m w .
[0032] Let
[0000] z wr =z w −v r (3)
[0000] then equation (2) becomes
[0000] m w {umlaut over (z)} wr +C w ż wr +K w z wr =−m o a o (4)
[0033] Define
[0000] F wr =C w ż wr +K w z wr (5)
[0000] as wheel rail vertical contact force and needs to be predicted.
[0034] The inertial force, m o a o and running speed are inputs on the system described in Equation (2). Then the system can be solved numerically to obtain the displacement and velocity, z wr ,ż wr . To the end with Equation (5) the vertical wheel-rail interface force can be determined. There are several methods to be applied to the estimation of load but they have various limitations for prediction of the wheel rail contact forces.
[0035] FIG. 4 shows items of equipment which may be used to monitor the motion of a railway vehicle and perform calculations which lead to estimation of the contact forces. The equipment includes a set of motion sensors 40 such as accelerometers or velocity sensors. These are placed and secured at suitable locations on the wagon body shown in FIG. 1 , spaced from the overall centre of mass, typically at the corners of the wagon body. In general there must be three or more sensors located on the body. A monitoring device 41 is also located on the wagon or possibly elsewhere on the train which includes the wagon, and receives data from the sensors, through wired or wireless connections. The device includes processor 42 , transmitter/antenna 43 and battery 44 . Power supply 45 delivers power from the battery to the processor, transmitter and sensors. The battery is preferably charged by a source on the train such as solar cells 46 . All components are constructed to withstand mechanical damage and are sealed against the ingress of dust and water.
[0036] FIG. 5 indicates the placement and operation of the motion sensors in more detail. The minimum functionality required in these sensors is two axes measured at each of the three locations. One sensor at each end of the wagon measures lateral and vertical motions to allow vertical, lateral, yaw and pitch modes to be calculated. A third 2 axis motion sensor one end measures vertical and longitudinal motions to allow longitudinal and roll motions to be calculated. More accurate results can be achieved with tri-axle accelerometers in each location. The use of tri-axle accelerometers in each location allows correct calculation of large angle movements and includes implicit averaging for wagon body flexure.
[0037] The motion sensors in a prototype are Analog Devices ADXL202/10 dual axis acceleration sensors. The ADXL202/10 measures acceleration in two perpendicular axes and is capable of sensing frequencies from DC to several kilohertz. To secure the full six degrees of freedom for the wagon body motions up to three axis accelerometers are placed at three corners of the wagon body. By the application of a co-ordinate transformation, these signals can be converted into longitudinal, lateral and vertical accelerations as well as pitch roll and yaw. In this preferred embodiment three sensor devices are placed upon the wagon body at locations such that the wagon body motion in six degrees of freedom may be observed. The placement of the motion sensing devices is not unique and a multiplicity of placements may be used to observe the wagon body motion in six degrees of freedom. Changes in placement of the motion sensing devices will cause a change in the mathematical transformation required to determine the accelerations at the wagon body mass centre.
[0038] The motion sensing devices may be implemented with devices other than accelerometers. Gyroscopes or angular position sensors or angular rotation sensors may be used and acceleration signals can readily be determined from their outputs by differentiation. The number of motion sensing devices applied to observe the motion of the wagon body in six degrees of freedom may be other than three. The motion sensor outputs are processed by the processing device. In this preferred embodiment the wheel rail interaction force prediction device is implemented using a Rabbit 3000 processor operating at 40 MHz with has 256 KB of RAM. The wheel rail force indications are transmitted from the device by radio transmitter.
[0039] FIG. 6 shows a physical model used to develop a system of equations that are solved by the prototype device to estimate wheel rail interaction forces. The model preferably has these characteristics:
The bolsters are assumed to be fixed to the wagon body; The pitch of a side frame is neglected so the predicted motion of the two wheelsets on the same bogie is considered to be the same; The side frame is assumed to contact the wheelset without suspension so the mass of side frame is considered a point mass on the adapter; Hertzian stiffness is used to simulate wheel rail normal contact.
[0044] Assuming a wagon with three-piece bogies, (as is widely used in Australian freight and heavy haulage), the model shown in FIG. 6 is a simplified wagon with masses and connections lumped together as follows.
The wagon body mass includes wagon body and bolster masses; The wheelset mass includes the unsprung mass of a three piece bogie: i.e. two wheelsets and two sideframes. The primary suspension is equivalent to the three piece bogie secondary suspension.
[0048] The model in FIG. 6 has 13 Degrees of Freedom as listed in Table 1 and it should be noted that the model can readily be adapted and adjusted to many other bogie designs.
[0000]
TABLE 1
Physical Model Degrees of Freedom
DOF
No. of
No. of
Component
x
y
z
φ
χ
ψ
Items
DOF
Wagon Body
x
x
x
x
x
1
5
Wheel Set
x
x
x
x
2
8
Total DOF
13
x - longit.
y - lateral
z - vertical
φ - roll
χ - pitch
ψ - yaw
[0049] In application, the translation and angular accelerations of the wagon body can be measured at one point different from mass centre at point P (see FIG. 5 ), in this case, the mass centre accelerations of the wagon body in lateral and vertical can be obtained by relative motion relationships below.
[0000]
[
a
x
0
a
y
0
a
z
0
]
=
[
a
x
a
y
a
z
]
-
[
0
-
α
z
α
y
α
z
0
-
α
x
-
α
y
α
x
0
]
[
A
B
H
]
(
6
)
[0000] where a xo ;a yo ;a zo denotes the acceleration of the mass centre at point O in the x, y and z directions, a x ;a y ;a z denotes the accelerations measured at point P, A, B, H denote the distance between the mass centre to the measured point P in longitudinal, lateral and vertical directions. The factors, a x ;a y ;a z are the angular accelerations about the x, y and z axis. The angular accelerations remain unchanged.
[0050] Alternatively, only translation accelerations of wagon body in longitudinal, lateral and vertical directions are measured at three corners of a wagon body (see FIGS. 1 and 5 ) then the mass centre angular accelerations of the wagon body can be described as
[0000]
α
x
=
a
z
3
-
a
z
2
2
B
α
y
=
a
z
3
-
a
z
1
2
A
α
z
=
a
y
1
-
a
y
2
2
A
(
7
)
[0000] and the translation accelerations are
[0000]
a
x
0
=
a
x
2
+
a
x
3
2
-
H
a
z
3
-
a
z
1
2
A
a
y
0
=
a
y
1
+
a
y
3
2
+
H
a
z
3
-
a
z
2
2
B
a
z
0
=
a
z
1
+
a
z
2
2
.
(
8
)
[0051] The use of equations (6), (7) and (8) allow for considerable flexibility in the where motion sensors can be located on the wagon body. Once mounted the position of the motion sensors is used to configure the inverse model to give correct results for that particular wagon.
[0052] The wheel/rail vertical contact forces are determined by the Hertzian spring between wheel and rail. Normal wheel/rail contact force is determined by the vertical force and creepages and the creep forces are used to determine the lateral and longitudinal creep force component. If the lateral oscillations of the wheel set exceed the flange clearance, δ, there is also contact between the wheel flange and the rail. This results in a sudden restoring force, F T , which is called the flange force. A phenomenological description of this force is provided by a stiff linear spring with a dead band,
[0000]
F
T
(
y
)
=
{
k
0
(
y
-
δ
)
,
δ
<
y
,
0
,
-
δ
≤
y
≤
δ
,
k
0
(
y
+
δ
)
,
y
<
-
δ
(
9
)
[0000] where y denotes the lateral displacement of the wheelset, k o denotes impact stiffness between flange and rail; δ denotes the lateral distance between the rail gauge face and the flange when the wheelset is centred. Since the accelerations of wagon body in lateral, vertical, roll, pitch and way directions are known the independent variables of the system reduce to 8. The inverse vehicle model can be described mathematically as:
[0000] [ M]{umlaut over (X)} wr +[K]X wr +[C]{umlaut over (X)} wr =F w +F a +F n +F 1 (10)
[0000] where [M] denotes the mass matrix, [K] is the spring stiffness matrix. [C] is the system damping matrix, F w denotes the weight force vector. F a is the force vector related both to the inertias and measured accelerations of wagon body, F n ,F t denote vertical and lateral wheel-rail contact forces respectively. The vertical force, F n , is determined by:
[0000] F n =[K wr ]X wr +[C wr ]{dot over (X)} wr (11)
[0000] where [K wr ] is the wheel-rail stiffness matrix. [C wr ] is the wheel-rail damping matrix, X wr are independent variable vectors, consisting of translational and angular displacements and defined by:
[0000] X wr =[y w1 ,z w1 ,φ w1 ,ψ w1 ,y w3 ,z w3 ,φ w3 ,ψ w3 ] T . (12)
[0000] where y w1 ;z w1 ;φ w1 ;ψ w1 denote, respectively, lateral displacement, vertical displacement, roll (angular displacement about the y-axis) and yaw (angular displacement about the z-axis) for the first bogie. Similarly y w3 ;z w3 ;φ w3 ;ψ w3 refers to the second bogie.
[0053] For the translation motion the inertia force is calculated by acceleration multiplying wagon body mass, but to the rotation motion, for example, if the roll acceleration of wagon body is known the support forces both in lateral and vertical directions can be determined by the method below (see FIG. 7 ).
[0000]
F
y
=
-
σ
I
x
ϕ
¨
2
b
(
1
+
σ
2
)
,
F
z
=
-
I
x
ϕ
¨
2
b
(
1
+
σ
2
)
,
where
(
13
)
σ
=
h
b
=
F
y
F
z
.
(
14
)
[0000] b, h stand for the lateral and vertical distances from the force acting point to the mass centre respectively, {umlaut over (φ)}; is the roll angular acceleration, in this case about the x axis, (e.g. roll).
[0054] FIG. 8 shows the functional flow of an algorithm for evaluating a wagon model using a monitoring device such as described above. Acceleration data is firstly acquired at a suitable sample rate. The sample rate must be high enough to prevent aliasing as rolling stock vibrations typically include high frequency small amplitude vibrations resulting from track surface and wheel bearing inputs. High frequency acceleration components that are of no significance to wagon dynamics must firstly be filtered from the acceleration data. On freight wagons, signals above 20 Hz have little effect on wagon dynamics. Accelerations of the wagon body are then determined using the acceleration data from the motion sensors and known measurements of the motion sensor positions relative to the wagon body centre of mass. The forces applied to the bogies are then calculated using the measured accelerations and the known mass and inertia of the wagon body. An inverse model is then used to calculated vertical and lateral forces applied at the bogie. These results are used to infer wheel unloading and L/V ratio. As bogie pitch and bogie yaw cannot be derived from motion sensor data of the car body alone, the values calculated represent average wheel unloading and L/V taken across the two wheel-rail contacts on each side of the bogie (i.e. across a sideframe.).
[0055] FIGS. 9 to 15 show results from calculations made using the inverse model described above. FIGS. 9 , 10 , 11 are comparisons of the model data with standard simulations from the VAMPIRE package. VAMPIRE utilises a traditional forward model and all track geometry data must be supplied. The wagon response data obtained from the VAMPIRE model (simulating the data that would be obtained from the motion sensors in this embodiment) was recorded and then used as input to the inverse model. The inverse model was then used to produced lateral force data ( FIG. 9 ) vertical force data ( FIG. 10 ) and L/V data ( FIG. 11 ). In all three cases there is sufficient agreement between the inverse model output and the VAMPIRE output to justify the use of the inverse model as a field device for indicating characteristics such as poor track-wagon interaction, poor track surface and derailment.
[0056] FIG. 12 shows the filtered accelerometer inputs measured by the monitoring device on track tests. FIGS. 13 , 14 , 15 show calculations of vertical, lateral and L/V over 160 m of track using measured accelerometer data from the motion sensors.
[0057] Many variations of the invention are possible within the scope of the following claims. | A method of estimating contact forces between the wheels of a railway wagon and a rail track, for use in determining information such as the likelihood of derailment. Accelerations of the body of the wagon are measured using motion sensors located at suitable points on the body. Forces on the side frames of the wagon are calculated based on the accelerations of the body and predetermined parameters of the body. Forces on the wheels of the wagon are calculated based on the accelerations of the body and predetermined parameters of the body. The contact forces between the wheels and the rails are then calculated based on the forces calculated for the side frames and the wheels. The calculations are carried out using an inverse model of the wagon system. Equipment which implements the method is also described. | 1 |
BACKGROUND OF THE INVENTION
While a number of polygonally-shaped boxes are well-known in the prior art, as exemplified by U.S. Pat. Nos. 1,892,715; 2,156,999; 2,174,687; 2,314,631; 2,319,974 and 2,819,833, each of them either sacrifices ease of assembly for integrity of construction or, while providing a construction of substantial reliability, requires an interlocking assembly of components that is difficult and time-consuming to interconnect during erection and closure of the box.
Therefore, while as noted, multi-sided box constructions have been well-known in the prior art for many decades, none satisfies the criteria of sturdiness, inexpensiveness of manufacture and ease of erection.
SUMMARY OF THE INVENTION
The present invention provides a multi-sided box construction which can be inexpensively manufactured as a one-piece blank, provided with a manufacturer's joint, shipped in a knocked-down configuration to a packager, and quickly and easily erected, filled and closed to provide a sturdy one-piece, multi-sided box assembly.
Thus, the box of the present invention is preferably stamped from a sheet of corrugated cardboard or the like, which is particularly suited for packaging relatively fragile, but often heavy objects, such as glassware, to provide a package which insures against inadvertent separation of the box components and consequent damage or destruction of its contents.
In one preferred embodiment of the invention the box comprises eight-sided top and bottom walls, rectangularly-shaped wall panels joined to the top and bottom walls along opposite edges thereto, trapezoidally-shaped wings intermediate the points of attachment of the side walls to the top and bottom walls, locking tabs and complementary locking slots and a glue flap on a top wall which can be secured to an inner surface of one of the box wall panels.
With this configuration the manufacturer's joint is formed between the glue flap and a wall panel, the resulting, partially assembled box shipped in a flattened condition to a packager, and then erected by displacing the top and bottom walls from their flattened condition to a position in which the top and bottom walls are substantially aligned with each other, the wings and side walls at one end of the box folded inwardly, and the locking tab at that end inserted into its complementary locking slot, the partially assembled box turned on end, the goods to be packaged inserted therein, and the remaining end then folded inwardly in exactly the same fashion as the first end of the box.
In a second preferred embodiment of the invention the construction is substantially the same as that described above and its assembly, erection, filling and closing is substantially the same as those operations are described above, but additional locking ears are provided which interlock and provide additional insurance against inadvertent loss of the box contents.
These and other advantages and features of the present invention will become more readily apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the present invention in the knocked-down configuration;
FIG. 2 is a view similar to FIG. 1, but showing the box erected in a first stage;
FIG. 3 illustrates the closure of one end of the erected box;
FIG. 4 depicts the final step of closing the first end of the box and the insertion into the partially completed box of a product to be packaged therein;
FIGS. 5, 6, 7 and 8 depict sequentially the final closure of the box after insertion of the product to be packaged therein;
FIG. 9 is a plan view showing the box of FIG. 1 in the knocked-down configuration;
FIG. 10 shows the blank from which the box of FIGS. 1 through 8 is constructed;
FIG. 11 shows a box blank from which a second preferred embodiment of the invention is constructed; and
FIGS. 12 and 13 illustrate the erection and closure of the box of the second preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference initially to FIG. 10 of the drawings, it will be seen that the box 10 of the present invention can be formed integrally from a sheet of corrugated cardboard, with the box blank comprising substantially identical, polyganal top and bottom walls 12 and 14, which in the embodiment shown include eight sides, including a first opposing pair of sides 16, a second pair of opposing sides 18 and a third and fourth opposing pairs of sides 20 and 22, respectively.
The box shown consists of eight sides, and it is important in the context of the present invention that in order to obtain the constructional advantages of the present design the box contain eight or more sides with the total number of sides when divided by two equaling an even number, e.g. eight, twelve, sixteen, etc.
A first pair of substantially rectangular wall panels 24 are joined along their inner edges to the first opposing sides 16 of the bottom wall 14, and a second pair of wall panels 26 of substantially the same size and shape as the wall panels 24 are joined along their inner edges to the second opposing sides 18 of the bottom wall 14.
Third pairs of substantially rectangular wall panels 28 are joined along lateral edges 30 thereof to corresponding lateral edges of the second wall panels 26, and fourth pairs of wall panels 32 are joined along inner edges 34 thereof to corresponding outer edges of said third pairs of wall panels 28. Each of the wall panels 24, 26, 28 and 32 are of substantially the same size and shape.
Substantially trapezoidally-shaped wings 36 are joined along their major bases to the sides 20 and 22 of the top and bottom walls 12 and 14, and substantially trapezoidally-shaped extensions 38 are joined along their major bases to the first opposing pair of sides 16 of the top wall 12. The first pair of wall panels 24 are provided with locking tabs 40 and slots 42 are formed along the first opposing pair of sides 16 of the top wall 12 complementary to the locking tabs 40. Lastly, a glue flap 44 of substantially trapezoidal-shape is joined to the top wall 12 along the outer one of its second opposing sides 18.
With this construction the box is initially folded along the line joining the top wall 12 to a side wall panel 26 and a second line joining the bottom wall 14 to an opposing side wall panel 26 to the configuration shown in FIGS. 1 and 9 of the drawings and the glue flap 44 is adhesively secured to an inner surface of the overlying side wall panel 26 to form a so-called "manufacturer's joint".
In this knocked-down configuration the box is shipped to a packager, who then moves the top wall 12 to a position overlying the bottom wall 14, as shown in FIG. 2 of the drawings, and thereafter folds the wings 36 at one end of the box inwardly to the position shown in FIG. 3 of the drawings.
Next, the wall panels 28 and 32 at that end of the box, the right-hand end as seen in FIG. 3 of the drawings, are folded inwardly, the extension 38 at that end is folded downwardly and the wall panel 24 at that end is folded upwardly as shown in FIG. 4 of the drawings and its locking tab 40 inserted into the opposing slot 42, thus completing one end of the box.
Next, the product to be packaged, shown in FIG. 4 of the drawings as an eight-sided glass dish 46, is inserted into the left-hand, open end of the partially completed box and, as seen in FIGS. 5, 6, 7 and 8 of the drawings, the procedure performed on the right-hand end of the box is performed on the left-hand end to close the package with the product 46 enclosed therein.
With this construction it will be seen that the box can be shipped from the manufacturer to the packager in a flattened, knocked-down condition, quickly erected by the packager, the product inserted and the box closed to provide a package which is virtually impossible to inadvertently open and discharge its contents.
As noted above, with the construction shown in FIGS. 1 through 10 of the drawings, it is virtually impossible for the interlocked components to disengage and permit the box contents to be damage.. However, if the product packaged is particularly heavy and subjected to rough handling, in some instances the wall panels 28 and 32 may tend to slip outwardly. To prevent this occurrence the embodiment of FIGS. 11 and 12 of the drawings may be utilized.
The box 50 shown in FIG. 11 includes top and bottom walls 52 and 54 having first and second opposing pairs of sides 56 and 58 and third and fourth pairs of opposing sides 60 and 62. Additionally, rectangularly-shaped wall panels 64 are joined to the bottom wall 54 and a second pair of substantially rectangular wall panels 66 are joined to the bottom wall 54 along its sides 58. Additional wall panels 68, also of substantially rectangular shape, are joined along their inner edges 70 to the wall panels 66.
Also, similarly to the embodiment of FIGS. 1 through 10, the box 50 is provided with substantially trapezoidally-shaped wings 72, trapezoidally-shaped extensions 74 on the top wall 52, locking tabs 76, complementary slots 78 formed along the first pair of sides 56 of the top wall 52, and a glue flap 80.
However, unlike the previous embodiment, the fourth wall panels 68 have joined thereto along their outer edges 82 locking flaps 84, each having pairs of ears 86.
With this construction, and as shown in FIGS. 12 and 13 of the drawings, after the manufacturer's joint has been formed between the glue flap 80 and an inner surface of a wall panel 66 and the top wall 52 moved over into position above the bottom wall 54, the wings 72 on one end of the box are folded inwardly and the ears 86 are locked over edges 88 of the wing 72, so that when the wall panels 64 are bent upwardly and their locking tabs 76 inserted in the complementary slots 78, the wall panels 68 cannot be moved from their closed position without tearing the box material.
With the construction of FIGS. 11 and 12, therefore, added protection is provided against inadvertent disengagement of the box components to provide a package of maximum security and product protection.
While the articles herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise articles and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims. | An eight-sided box having uninterrupted top and bottom walls, which can be inexpensively manufactured as a single sheet of corrugaed cardboard and shipped in a flattened, knock-down configuration with the manufacturer's joint formed, and which can be quickly erected, filled and closed by a packager to provide a secure package. In a second embodiment locking ears are provided which virtually insure that the box cannot be inadvertently opened. | 1 |
BACKGROUND OF THE INVENTION
This invention generally relates to a performance enhancing and force absorbing composite mouthguard for use by athletes, and more particularly to such an adjustable customizable mouthguard appliance that spaces apart the teeth to absorb shock and clenching stress to protect the anterior and posterior teeth of the upper jaw, to lessen condyle pressure force and impact upon the cartilage and temporomandibular joints, the arteries and the nerves and to further increase body muscular strength and endurance.
A number of mouthguards currently exist in the art for protecting the teeth and for reducing the chance of shock, concussions and other injuries as a result of high impact collisions and blows during athletic competition. Mouthguards generally are characterized as being non-personalized, universal and stock model type, or are formed to have direct upper jaw tooth-formed contact. These are customizable mouthguards.
Additionally, the mouthguards may be tethered or untethered. Mouthguards may be tethered to a fastening point, such as a helmet or face guard, to prevent the chance of the mouthguard from being lost as well as to prevent swallowing of the mouthguard or choking on the mouthguard by the user.
The lack of a mouthguard or the use of an improperly fitted mouthguard, when impacts, collisions or blows occur to the jaw structure of an athlete, have recently been found to be responsible for illnesses or injuries. Such injured athletes are susceptible to headaches, presence of earaches, ringing in the ears, clogged ears, vertigo, concussions and dizziness. The cause of these types of health problems and injuries are generally not visible by inspection of the mouth or the jaw but more particularly relate to the temporomandibular joint (TMJ) and surrounded tissues where the lower jaw is connected to the skull in the proximity where the auriculo-temporalis nerves and supra-temporo arteries pass from the neck into the skull to the brain.
In addition to protection of the teeth and the TMJ, athletes clench their teeth during exertion which results in hundreds of pounds of compressed force exerted from the lower jaw onto the upper jaw. Such clenching can result in headaches, muscle spasms, damage to teeth, injury to the TMJ and pain in the jaw. Furthermore, clenching of the teeth makes breathing more difficult during physical exercise and endurance when breathing is most important.
Most importantly, many problems exist with prior mouthguards. Mouthguards with a rigid labial or buccal walls do accept wide teeth, were bulky and had sharp edges. When the custom appliances were placed in hot water to soften for fitting, the mouthguards tended to collapse and permit portions to touch and stick together upon removal from the hot water thus making fitting of such mouthguards always a problem. Delamination and chewing destruction caused short life of the mouthguards.
There is a need for a mouthguard that solves all of the problems disclosed and will further achieve improved performance and long life as well as being easy to fit for the wearer.
SUMMARY OF THE INVENTION
A performance enhancing and force absorbing mouthguard adapted to fit the upper teeth of the mouth of an athlete wherein the mouthguard is quadruple or quintuple composite material of distinct materials. The first internal layer is a non-softenable flexible framework which will permit the mouthguard to hold its shape during fitting as well as to absorb and dissipate significant impact conveyed to the upper teeth. A hard, durable reverse bite plate wedge is thicker rearwardly and lowers the condyle from the temporomandibular joint in a fulcrum action to place the lower jaw in an optimum condition preventing impingement upon the nerves and arteries as well as spacing the upper and lower teeth apart. Elastomeric traction pads are on the bottom of the mouthguard and are grippingly engaged by the posterior teeth of the lower jaw. While the framework, wedge and traction pads are mechanically interlocked, a softenable material is placed over the mouthguard excepting the contact portions of the traction pads to encapsulate the mouthguard and to permit custom fitting.
The principle object and advantage of the present invention is that the mouthguard is that it protects the teeth, jaw, gums, connective tissues, back, head and muscles from concussive impact or blows to the jaw or teeth typically occurring during athletic activity.
Another object and advantage of the present invention is that the materials are substantially mechanically interlocked as well as encapsulated thereby preventing the possibility of delamination or separation of the materials which otherwise may occur during chewing of the mouthguard by the wearer.
Another object and advantage of the present invention is that the mouthguard places the lower jaw in the power position moving the condyle downwardly and forwardly away from the nerves and arteries within the fossia or socket to raise body muscular strength, greater endurance, improved performance by the mouthguard user as well as offer protection against concussive impacts.
Another object and advantage of the present invention is that the mouthguard is customizable to fit the width and configurations of the upper posterior teeth and palate structure of any user. That is, the mouthguard permits customizable fitting, including twisting, contraction and expansion, to permit the various tooth widths, spacing from one side of the mouth to the other side of the mouth, and palate height which also vary substantially from person to person.
Another object and advantage of the present invention is that it has a tough, rubbery elastomeric, unpenetrable bottom layer or traction pad which engages and grips the posterior teeth of the lower jaw and which further prevents the appliance from being chewed through to thereby assure long life to the appliance.
Another object and advantage of the present invention is that the framework of a non-softenable flexible material supports the appliance after heating to maintain shape and to guide the upper teeth during the fitting process.
Another object and advantage of the present invention is that the hard durable reverse bite plate wedge is of a hard very durable material that acts as a bite plate reverse wedge or fulcrum that cannot the penetrated by teeth thereby giving the appliance a longer life cycle.
Another object and advantage of the present invention is that the softenable fourth material extends over the framework wedge and non-exposed portion of the traction pads providing for the formation of a smooth mouthguard with greatly increased comfort and the avoidance of sharp edges.
Another object and advantage of the present invention is that the labial and lingual walls are not rigid allowing the user to manipulate the softenable material and to custom fabricate the mouthguard to accommodate proper fitting and to achieve more comfortable and less intrusive presence in the wearers mouth.
Another object and advantage of the present invention is that an anti-microbial ingredient keeps the appliance free of germs, fungus, virus, yeast and bacteria and also may treat gum disease.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a maxillary mandibular buccal or partial side elevational view of the jaws and temporomandibular joint of the user of the mouthguard of the present invention.
FIG. 1A is an enlarged view of the temporomandibular joint portion of FIG. 1 .
FIG. 2 is similar to FIG. 1 but shows the mouthguard of the present invention in place.
FIG. 3 is a bottom perspective view of the mouthguard in place on the teeth of the upper jaw.
FIG. 4 is a bottom plan view of the mouthguard in place on the teeth of the upper jaw.
FIG. 5 is an exploded perspective view of the mouthguard of the present invention.
FIG. 6, is a side elevational view of the mouthguard in place on the teeth of the upper jaw partially broken away.
FIG. 7 is a bottom plan view of the mouthguard partially broken away.
FIG. 8 is an exploded partially broken away view of the mouthguard aligned for fitting on the teeth of the upper jaw.
FIG. 9 is a cross-sectional view taken along lines 9 - 9 of FIG. 7 .
FIG. 10 is a cross-sectional view taken along lines 10 - 10 of FIG. 7 .
FIG. 11 is a cross-sectional view taken along lines 10 - 10 FIG. 7 .
FIG. 11A is an enlarged view broken away of the mechanical interlock shown in FIG. 11 .
FIG. 12 is an enlarged broken away view similar to FIG. 11 with the mouthguard fitted to the teeth of the wearer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
To understand the structural features and benefits of the dental appliance or mouthguard 70 of the present invention, some anatomy will first be described. Referring to FIGS. 1 and 1A, the user or athlete has a mouth 10 generally comprised of a rigid upper jaw 12 and a movable lower jaw 42 which are movably connected at the temporomandibular joint (TMJ) 32 and 50 .
More specifically, the rigid upperjaw 12 has gum tissue 14 within mouth 10 . Gum tissue 14 , as well as the bone thereunder, supports anterior teeth (incisors and canines) 18 which have incisal or biting surfaces 19 . The gum tissues 14 and the bone thereunder also support posterior teeth (molars and bicuspids) 22 which have cusps or biting surfaces 26 .
Referring to one side of the human head, the temporal bone 28 is located upwardly and rearwardly of the upper jaw 12 and is in the range of {fraction (1/16)} th to {fraction (1/32)} nd inch thick. The articular eminence 30 forms the beginning of the fossae 32 or the socket of the temporomandibular joint 32 and 50 .
Rearwardly and posteriorly to the articular eminence 30 is located cartilage 34 . Through the temporomandibular joint 32 and 50 pass the ariculo-temporalis nerve 36 and supra-temporo artery 38 . Posteriorly to this structure is located the inner ear 40 . Within the mouth is located tongue 39 and the roof or hard palate 41 , which terminates rearwardly into the soft palate and forwardly into the anterior palate or ruggae 43 . The ruggae 43 has a rib surface which is identifiable by the fingers or tongue 39 . The tongue touches the ruggae 43 during speech.
The movable jaw or mandible 42 supports a bone covered by gum tissue 44 which further supports anterior teeth (incisors and canines) 46 with incisal or biting surfaces 47 and posterior teeth (molars and bicuspids) 48 with occlusal biting surfaces 49 . The condyle 50 of the lower jaw 42 forms the ball of the temporomandibular joint 32 and 50 . The anatomical structure is the same for both sides of the head.
Repeated impacts, collisions, blows, stress or forces exerted on the movable lower jaw 42 results in excessive wearing forced upon the condyle 50 and the cartilage, meniscus, or disc 34 —typically resulting in bone deterioration on the head of the condyle or slippage and compressive damage of the cartilage 34 . Thereafter, the lower jaw 42 may be subject to irregular movement, pain, loss of comfortable range of movement, and clicking of the joint 32 and 50 .
The ariculo-temporalis nerve 36 relates to both sensory and motor activity of the body. Any impingement or pinching of this nerve 36 can result in health problems as previously mentioned. This supra-temporal artery 38 is important in that provides blood circulation to portions of the head. Impingement, pinching, rupture or blockage of this artery 38 will result in possible loss of consciousness and reduced physical ability and endurance due to the restriction of blood flow to portions of the brain. Thus, it I extremely important to assure that the condyle 50 does not impinge upon the ariculo-temporalis nerve 36 or the supra-temporal artery 38 . It is also important to note that the temporal bone 28 is not too thick in the area of the glenoid fossae. Medical science has shown that a sharp shock, stress or concussive force applied to the lower jaw 42 possibly could result in the condyle 50 protruding through the glenoid fossae of the temporal bone 28 thereby causing death. This is a suture line (growth and development seam) in the glenoid fossae, resulting in a possible weakness in the fossae in many humans. This incident rarely, but sometimes, occurs with respect to boxing athletes.
The mouthguard of the present invention is shown in the Figures as reference number 70 .
Mouthguard 70 is generally unshaped and is comprised of labial wall 72 , lingual wall 74 which are upstanding from base 76 and channel 78 is formed by this arrangement.
Specifically referring to FIGS. 2 through 8, the moutbguard comprises at least four layers of distinct material 86 , 106 , 114 and 170 . The framework 86 is a non-soflenable flexible material to assist in maintaining the shape of the heated niouthguard 70 and to permit the sizing of the mouthguards by way of twisting, expansion and contraction for variously configured mouths. The reverse bite plate wedge or fulcrum 106 is of a hard durable material permitting displacement of the condyle and proper positioning of the lower jaw 42 . The traction pads 114 are elastomeric and therefore rubbery and grippable. The encapsulating material 170 is softenable and forms wails 72 and 74 , channel 78 and arch 180 where applicable. The portion of the mouthguard 70 softens when heated and permits custom fitting of the mouthguard 70 in a particular mouth configuration. Optionally, an ethylene vinyl acetate skin 270 may be laid over the entire mouthguard to encapsulate it only exposing the traction pad portions 114 which will engage the molars 48 of the lower jaw 42 .
The first shot of the mouthguard 70 is comprised of the non-softenable, flexible framework 86 which is suitably made of polypropylene which exhibits a rigid character in that it holds its shape and can handle hot water because its melting point is 380° F. The material also has excellent bonding qualities with other copolymers. The polypropylene part number appropriate for the framework 86 is AP6112-HS from Huntsman Corporation, Chesapeake, Va. 23320.
The framework 86 suitably may have connecting belvedere bridge 88 which spans across in an arch like manner across the roof or hard palate 41 of the mouth 10 . The bridge 88 then connects to cross-cantilever connectors 90 which connect to occlusal pad plates 92 in various places to assure the relative stability of the framework 86 . The occlusal pad plates 92 have index openings 94 therethrough. Extending forwardly from the plates 92 are disconnected adjustable anterior impact braces 96 with a gap 98 therethrough. The anterior impact braces dissipate concussive blows or impacts to the front of the mouth 10 supporting the anterior teeth 18 from behind. The gap 98 assures appropriate fitting of the impact braces 96 when the anterior teeth 18 and their biting surfaces 19 are irregular. Thus, the impact braces 96 may readily shift upwardly, downwardly, inwardly together or opposingly apart.
The next injection molding shot is that of bite plate or reverse wedge 106 which is very hard and durable suitably made of high-density polyethylene (HDPE). A suitable high-density polyethylene is HD-6706 ESCORENE® injection molding resin from ExxonMobil Chemical Company, P.O. Box 3272 , Houston, Tex. 77253-3272. This material is also very durable and has excellent bonding qualities and will not melt during the molding process as its melting point is 280° F. Thus, this material is hard enough so that it cannot be penetrated by the teeth under maximum biting pressure and thereby forms the bite plate or reverse wedge 106 . The bite plate 106 on its lower surfaces has bosses or raised portions 108 with apertures 110 therethrough. The bosses 108 permit the bite plate 106 to be indexed into the index openings 94 of framework 86 . The apertures 110 permit mechanical interlocking as will be appreciated with the next shot.
The traction pads 114 are the third shot and are created from elastomeric material. The traction pads 114 contact and grip the occlusal biting surfaces 49 of the posterior teeth 48 of the lower jaw and must be composed of a durable, resilient material which deforms somewhat when the jaws are closed and cushion the teeth 48 of the lower jaw 42 .
The durable, resilient material of this layer or third shot comprises a mixture of styrene block copolymer and high-density polyethylene. More specifically, the styrene block copolymer may be DYNAFLEX® part number G2780-0001 from GLS Corporation, 833 Ridgeview Drive, McHenry, Ill. 60050 while the HDPE has been already described to be from ExxonMobil.
The durable resilient material of the traction pads 114 may include in another embodiment the styrene block copolymer and ethylene vinyl acetate (EVA). EVA is available from a number of sources, such as the ELVAX® resins from Dupont Packaging and Industrial Polymers, 1007 Market Street, Wilmington, Del. 19898. It is desirable that the durable resilient material have a Shore “A” hardness of approximately 82, which is very durable, yet rubbery.
In another embodiment of the traction pads 114 , the styrene block copolymer may be mixed with polyolefin elastomer, which is a copolymer of ethylene and octene-1. A suitable copolymer is available as ENGAGE® from Dupont Canada, Inc., P.O. Box 2200, Streetsville, Mississauga, Ontario L5M 2H3.
Another embodiment of the traction pads 114 may be a mixture of thermoplastic rubber and a polyolefin elastomer as described above. Suitably thermoplastic rubbers are SANTOPRENE® from Advanced Elastomer Systems, L.P., 388 South Main Street, Akron, Ohio 44311 and KRATON® Thermoplastic Rubber from the Shell Oil Company, Houston, Tex. Kraton® is composed of a styreneethylene/butylenes-styrene block copolymer and other ingredients. The exact composition of SANTOPRENE® is a trade secret.
Elastomeric traction pads 114 have upwardly projecting interlocking knob projections 116 which will pass through aperture 110 and lock the bite plate 110 and framework 86 together as may be appreciated in FIGS. 5, 10 , 11 , 11 A and 12 . The interlocking knob projections 116 suitably have a radius portion 118 to assure the mechanical interlock and to prevent the shearing away of the knobs 116 from the bite plate 106 .
Also bucket lip or retaining lid 120 wraps around from the bottom exposed portion of pads 114 to the top of the bite plate 106 to again assure a sufficient mechanical interlock. The traction pads 114 also may have disconnected elastomeric adjustable anterior impact braces 122 with gap 124 therebetween braces 122 are in front of the anterior teeth 18 and have all of the adjustable customizable advantages of the impact braces 96 of framework 86 . However, the impact braces 122 are softer than the framework braces 96 to assist in the dissipation of external forces.
The fourth shot of the rnoutbguard 70 comprises a encapsulation material 170 which is suitably softenable and forms the walls 72 and 74 and channel 78 as well as base 76 of the mouthguard 70 . Thus, the softenable material comprises labial wall 172 , lingual wall 174 , and base 176 . The material 170 has fraction pad cutouts 177 to permit exposure of the traction pads 114 as it is undesirable to have the pads 114 encapsulated. The material 170 also forms channel 178 and palate arch 180 with its ruggae opening 182 which is suitable to permit the tongue 39 to contact the ruggac 43 to permit clear speech.
The softenable material 170 suitably comprises a mixture of EVA and polycaprolactone. A suitable polycaprolactone is TONE® Part No. Polymer P-767 from Union Carbide Corporation, 39 Old Ridgebury Road, Danbury, Conn. 06817-0001. However, the softenable material may consist of the polycaprolactone alone as the possibility of ethylene vinyl acetate alone may also be utilized.
Another embodiment of the material 170 may be a mixture of polycaprolactone and the polyolefin elastomer. Preferably, the polyolefin elastomer is copolymer of ethylene and octene-1. A suitable copolymer is available as ENGAGE® from Dupont Canada, Inc., P.O. Box 2200 Streetsville, Mississauga, Ontario L5M 2H3.
An optional fifth shot of soft skin material 270 may be used. Material 270 may be ethylene vinyl acetate (EVA) as previously discussed to give a soft touch to the mouthguard 70 and to remove any hard or sharp edge feelings which may otherwise annoy the tongue, gums or mouth. The fifth layer of the soft EVA skin 270 includes labial wall 272 , lingual wall 274 , base 276 with traction pad cutouts 277 as was previously discussed. The EVA also has channel 278 and covers palate arch 280 excepting the ruggae opening 282 .
The fourth and fifth shots of the softenable material 170 and soft EVA skin 270 may be combined in a single fourth shot of a low-density polyethylene having a short “D” hardness of approximately 45. It is believed that this is the first time that a mouthguard has been made out of a low-density polyethylene. A suitable material may be EXACT® Part No. 4023 from ExxonMobil Chemical. This material is ideal for the required softness. However, applicant has found that nucleating agents mixed with the low density polyethylene creates a slight shrinkage to assure that the encapsulating low-density polyethylene securely fits to the configuration of the mouth, teeth and gums. Such nucleating agents might be DIBENZYLIDINE SORBITOL of the polyol acetal chemical family sold by Milliken Chemical, 1440 Campton Road, Inman, S.C. 29349 under product name MILLAD® Part No. 3905. Another nucleating agent which creates slight shrinkage in the low-density polyethylene is from the sorbitol acetal family marketed under MILLAD® Part No. 3940 and has the chemical name bis(P-METHYLBENZYLIDENE) SORBITOL while another similar additive might be the MILLAD® Part No. 3988 known under the chemical name 3-4-DINEMETHYLBENZYLIDENE SORBITOL.
To fit the mouthguard 70 to the user's mouth, the mouthguard 70 is placed in hot water at about 211° F. (i.e., water that has been brought to a boil and taken off the heat) for about 15 seconds. The mouthguard is then removed from the hot water, and it will be very soft, but the framework 86 will hold the mouthguards general shape. Excess water is allowed to drain off the mouthguard 70 by holding it with a spoon or the like.
Next, the wearer carefully places the mouthguard in the mouth so that the interior portion of the appliance 70 touches or covers the eye teeth (the third set of teeth from the front) and extends backwardly toward the molars. Next, the wearer bites down firmly on the appliance and pushes the tongue against the roof of the mouth. The cross-cantilever connectors guide the upper molars 22 in position on plates 92 . With a strong sucking motion, the wearer draws out all air and water from the mouthguard 70 . The projections or knobs 116 of the traction pads 114 will index to the cusp 26 of the molars 22 .
With a thumb, the wearer presses the bridge 88 and arch 80 tight against the roof of the mouth and then uses his hands and fingers to press the outside of the cheeks against the appliance 70 as the softenable material 170 oozes inwardly and outwardly to custom form the lingual and buccal walls 172 and 174 respectively. Because there are no rigid lingual or buccal walls in the appliance 70 , the mouthguard 70 will fit any width of molar 22 or mouth.
The wearer retains the mouthguard in the mouth for at least one minute and, with the mouthguard still in the mouth, takes a drink of cold water. Next, the wearer removes the mouthguard 70 from the mouth and places it in cold water for about 30 seconds.
It is well known that illness, infection, tooth decay and/or periodontal disease is caused by bacteria, fungus, yeast, and virus. These microbials can grow and multiply on dental appliances when the appliances are being stored between uses as well as when the appliance is actually being worn or used.
Antimicrobial substances which are non-toxic and free of heavy metal for resisting the growth of the microbials may include chlorinated phenol (e.g. 5-CHLORO-2-(2,-4-DICHLOROPHENOXY)PHENOL), POLYHEXAMETHYLENE BIGUANIDE HYDROCHLORIDE (PHMB), DOXYCYCLINE, CHLORHEXIDINE, METRONIDAZOLE, THYMOL, EUCALYPOL and METHYL SALYCILATE. TRICLOSAN® from Siba Giegy of Switzerland is also available.
Dental appliances and mouthguards are suitably made of polymers. Incorporating the antimicrobial agent into the polymer during the manufacture of the mouthguard is achieved by incorporating the agent into the synthetic polymeric master batch. The antimicrobial agent is suitably placed into the batch in a concentration as high as 10% which will permit a let-down ratio resulting in the final concentration of the antimicrobial agent and the dental appliance of about 0.005 to about 2% by weight.
By encapsulating the antimicrobial agent into the polymer batch mix, the agents survive molten temperatures approximately or above 350° F. and thus the antimicrobial agent loses none of its biocidal properties in the formation of the mouthguard.
The present invention may be embodied in other specific forms without departing from the spirit or central attributes thereof; therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | A performance enhancing and force absorbing mouthguard adapted to fit the upper teeth of the mouth of an athlete wherein the mouthguard is quadruple or quintuple composite material of distinct materials. The first internal layer is a non-softenable flexible framework which will permit the mouthguard to hold its shape during fitting as well as to absorb and dissipate significant impact conveyed to the upper teeth. A hard, durable reverse bite plate wedge is thicker rearwardly and lowers the condyle from the temporomandibular joint in a fulcrum action to place the lower jaw in an optimum condition preventing impingement upon the nerves and arteries as well as spacing the upper and lower teeth apart. Elastomeric traction pads are on the bottom of the mouthguard and are grippingly engaged by the posterior teeth of the lower jaw. While the framework, wedge and traction pads are mechanically interlocked, a softenable material is placed over the mouthguard excepting the contact portions of the traction pads to encapsulate the mouthguard and to permit custom fitting. | 0 |
This application is the US national phase of PCT Application No. PCT/BE2013/000029 filed on Jun. 17, 2013, which claims priority to BE Patent Application No. 2012/403 filed on Jun. 18, 2012, the disclosures of which are incorporated in their entirety by reference herein.
The subject matter of this invention is an engine system that is more efficient in the use of fuels through simplifying the timing system of all types of internal combustion engines. The system does not necessitate camshafts or tappets nor transmission wheels, or transmission chain, nor gears, nor desmodromic timing, nor intermediate mechanical bearing or belt timing. This system enables lighter engines with higher efficiencies. The system eliminates the conventional timing transmission systems existing at present in internal combustion engines. The hydraulic direct timing system (or the other two types described hereinafter) that is the subject matter of the invention has a minimum resistance and a minimum transmission.
This system may be thought of as an information system exploiting the motion of the crankshaft to provide the engine timing. This is thanks to various types of devices, notably a rotor device attached to and fast with the crankshaft that, contained in a casing, by its movement actuates plungers or triggers electrical sensors, depending on the type, the latter transmitting their timing to the piston valves.
Compared to present engines, the systems make it possible to produce improved performance; that is, the system makes it possible to produce greater acceleration and lower fuel consumption with fewer cylinders. The quantity of fuel necessary to produce the same amount of work as the present system is much lower.
Problem and Technical Field: Timing in Internal Combustion Engines.
Present internal combustion engines necessitate relatively complex, costly and bulky timing systems, such as camshafts, tappets, transmission wheels, transmission chain, gears, desmodromic timing, intermediate mechanical bearing, belt timing.
Advantage of the Direct Timing System Relative to the Present State of the Art.
The engine starts with fewer turns of the starter motor. It starts more quickly than present engines. This enables a battery, electricity saving. This enables the use of a smaller and less powerful battery given the lower consumption of electricity on starting the engine. The pistons do not have to drive a camshaft as there is none in the system, which generates less friction and reduces the number of mechanisms: they are freer. The engine produces more power (horsepower) than existing systems. The engine has fewer transmission moving parts. With less transmission timing will be faster. The intake, compression, power, exhaust cycle is faster. This implies a saving in terms of fuel consumption. If the direct timing system suffers a fault in the hydraulic circuit, the valves will be closed automatically by the valve springs, eliminating the valves from the corresponding cycle. The system can operate with three cylinders. The location of the fault will be obvious given the loss of liquid in the pipes. Repair will not necessitate retuning the engine.
Cylinder Head Advantages.
The system enables the cylinder heads to be situated at a lower position compared to engines existing at present. As the cylinder head is lower the cooling liquid can enter at a higher pressure, which results in improved cooling. The low position of the cylinder head makes it more difficult to damage it. The system allows the use of smaller valves and springs. This enables a saving of materials in the construction of the cylinder heads, springs and valves.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic plan view of a front cover and related screws.
FIG. 2 is a diagrammatic side view of the front cover.
FIG. 3 is a diagrammatic plan view of a rear cover and a related screw.
FIG. 4 is another diagrammatic plan view of the rear cover and related screw.
FIG. 5 is a diagrammatic side view of the rear cover.
FIG. 6 is a diagrammatic plan view of a register.
FIG. 7 is a diagrammatic side view of the register.
FIG. 8 is a diagrammatic view of an interior of a casing.
FIG. 9 is another diagrammatic view of the interior of the casing.
FIG. 10 is a diagrammatic side view of the casing.
FIG. 11 is another diagrammatic side view of the casing.
FIG. 12 is a diagrammatic plan view of a hermetic seal for a cover.
FIG. 13 is a diagrammatic plan view of another hermetic seal for a cover.
FIG. 14 is a diagrammatic plan view of a register seal.
FIG. 15 is a diagrammatic view of a cam and a through bolt.
FIG. 16 is another diagrammatic view of the cam and an adjustment guide.
FIG. 17 is a diagrammatic plan view of a register seal.
FIG. 18 is a diagrammatic plan view of an oil seal.
FIG. 19 is a diagrammatic side view of the rear cover.
FIG. 20 is an exploded view of the casing.
FIG. 21 is a diagrammatic view of the entire assembly, partially exploded.
FIG. 22 is a diagrammatic side view of a lubrication system.
FIG. 23 is another diagrammatic side view of the lubrication system.
FIG. 24 is a diagrammatic plan view of the lubrication system.
FIG. 25 is a diagrammatic plan view of a strip.
FIG. 26 is another diagrammatic plan view of the strip.
FIG. 27 is a diagrammatic cross sectional view of a plunger.
FIG. 28 is a diagrammatic side view of the plunger.
FIG. 29 is a diagrammatic cross-sectional view of a pair of valves and associated plungers.
FIG. 30 is a diagrammatic cross-sectional view of the plunger.
FIG. 31 is a diagrammatic side view of the plunger.
FIG. 32 is a diagrammatic side view of a piston.
FIG. 33 is a diagrammatic side view of a spring.
FIG. 34 is a diagrammatic side view of a pair of washers.
FIG. 35 is a diagrammatic side view of a pair of piston rings.
FIG. 36 is a diagrammatic cross sectional view of the plunger.
FIG. 37 is a diagrammatic side view of a transmission pipe.
FIG. 38 is a diagrammatic cross sectional view of one embodiment of the transmission pipe.
FIG. 39 is a diagrammatic cross sectional view of another embodiment of the transmission pipe.
FIG. 40 is a diagrammatic cross sectional view of another embodiment of the transmission pipe.
DESCRIPTION
FIG. 1 :
The numbers and references between parentheses in the description and in the claims refer back to the encircled references in the figures.
Components of the System.
Direct Timing Components.
Rotor ( 1 ).
The rotor ( 1 ) actuates the mechanism that opens and closes the valves. The rotor consists of a mechanism fixed directly to the crankshaft ( 2 ) by four through-bolts ( 2 A). The mechanism is made up of two superposed cams ( 1 A, 1 B), curved at their ends where the movement of the pistons is timed with reference to the opening of the cylinder head valves ( 3 ) relative to the engine timing (intake, compression, power, exhaust). The contact portion of the two cams ( 1 A, 1 B) consists of an antifriction material. The rotor has a screw type adjustment guide ( 1 C). The rotor ( 1 ) also acts as a lubrication pump by virtue of its movement distributing oil onto the areas of contact between it and the rotor plungers ( 5 ).
Rotor Casing ( 4 ).
This consists of a casing ( 4 ) itself made up of two hermetically sealed covers: a front cover ( 4 A) and a rear cover ( 4 B) in which the rotor ( 1 ) is housed. A register ( 4 C) is attached to the front cover ( 4 A) by four 4 F type screws ( 4 F), sixteen screws ( 4 D) joining the two hermetically sealed covers ( 4 A and 4 B) around the rotor ( 4 ). Four screws ( 4 E) retain the rotor casing ( 4 ) on the engine block. Two screws ( 4 F) are used for topping up and for filling and draining oil. Two hermetic seals ( 4 G and 4 H) respectively join the front cover ( 4 A) and the rear cover ( 4 B) to the rotor casing ( 4 ). A register seal ( 41 ) joins the register ( 4 C) to the casing ( 4 ) of the rotor. The oil seal ( 4 J) is situated in the rear hermetically sealed cover ( 4 B). Said casing ( 4 ) contains eight plungers ( 5 ). The plungers, pushed by the rotor connected to the crankshaft, transmit movement to the cylinder head valves ( 3 ) via transmission pipes ( 7 ). The rotor casing ( 4 ) is filled with a quantity of oil approximating 15% to 25% of its volume. The register ( 4 C) is used to attach an accessory; namely the oil pump and indirect transmission systems (water pump, alternator, air-conditioner, power steering, servomotor).
Rotor Plungers ( 5 ).
A plunger comprises a piston ( 5 A), a plunger ( 5 B), a spring ( 5 C), two washers ( 5 D) and two cavities ( 5 E) in which are housed two piston rings ( 5 F). The contact portion of the piston of the plunger ( 5 B) is made of an antifriction material.
Valve Plungers ( 6 ).
These are the same as the rotor plungers, the only difference being the shape of the head of the plunger ( 6 A). The contact portion of the plunger ( 6 A) is made of an antifriction material.
Transmission Pipe ( 7 ).
A transmission pipe consists of a flexible tube ( 7 A) and an adjuster washer ( 7 B). There are eight pipes of the same type, each connecting a valve of a valve plunger ( 6 ) to a rotor plunger ( 5 ). The transmission pipes are filled with oil.
The pipes may use three different plunger systems:
1. Hydraulic plunger: the pipes are filled only with oil.
2. Ball plunger: the pipes are filled with oil and force-transmitting objects, which are balls ( 7 C), having a diameter corresponding to the inside diameter of the pipe.
3. Bullet plunger: the pipes are filled with oil and force-transmitting objects, which are bullet-shaped members ( 7 D) and balls ( 7 C), having a diameter corresponding to the inside diameter of the pipe.
Strip ( 8 ).
The strip is made up of eight cavities ( 8 A) in which are housed the valve plungers ( 6 ), each of which is attached by two screws ( 6 B) to the strip ( 8 ) The strip ( 8 ) includes sixteen holes ( 8 B) for attaching the valve plungers to the strip ( 8 ). The strip ( 8 ) is fixed by six screws ( 8 C) that fasten it to the cylinder head. The strip is perforated internally by a lubrication system ( 8 D) that has the function of lubricating the valve plungers ( 6 ).
Tuning of Hydraulic Direct Timing System.
Present engines are generally tuned in the following order that is retained in the hydraulic direct timing system:
In piston order (not shown in the drawings): 1, 3, 4, 2.
We use the same ignition order by opening the valves in the same order.
The Hydraulic Direct Timing Cycle.
The cycle of opening the valves is defined by the rotor. The cycle is the same as the cycle of a conventional four-stroke engine. In the first quarter-turn of the crankshaft (0 to 90°) two valves will open in the cylinder head: the intake valve of the piston 1 and the exhaust valve of the piston 3 . In the second quarter-turn of the crankshaft (90 to 180°) two valves will open in the cylinder head: the intake valve of the piston 3 and the exhaust valve of the piston 4 . In the third quarter-turn of the crankshaft (180 to 270°) two valves will open in the cylinder head: the intake valve of the piston 4 and the exhaust valve of the piston 2 . In the fourth quarter-turn of the crankshaft (270 to 360°) two valves will open in the cylinder head: the intake valve of the piston 2 and the exhaust valve of the piston 1 . This completes the cycle.
Adaptations.
The direct timing system is designed to be coupled to conventional indirect transmission systems such as alternator, water pump, air-conditioner, power steering, servomotor and the oil pump. The oil pump coupled to the direct timing system is situated off the crankshaft. This makes it possible to reduce the size of the crankcase, the oil pump being situated off the latter.
Electrical Direct Timing System.
An electric rotor system differs in the following respects.
Eight electrical sensors corresponding to the eight cylinder head valves are placed in the rotor casing.
In the electrical system the eight cylinder head valves are electromagnetic valves.
The eight electrical sensors replace the rotor plungers.
In this electrical system the rotor includes on its contact surface devices that can be detected by the sensors when they are at a predetermined distance from the latter.
The sensors are connected to a central unit (which can be a computer, an electronic system, etc.) that by centralizing the information sent by the sensors determines the position of the rotor and consequently commands opening of the electromagnetic cylinder head valves in real time, the electromagnetic cylinder head valves also being connected to the central unit. | The object of this invention is to simplify the timing system of all types of internal combustion engine. The system eliminates existing conventional timing trains. The hydraulic, mechanical or electrical/electronic direct timing systems that form the subject of the invention offer minimal resistance and minimal transmission. The piston strokes are given directly by the crankshaft by means of a system fixed thereto which via a mechanical or hydraulic or electrical or electronic system transmits the strokes to the cylinder valves. The system can be connected to all types of indirect transmission and has adjusting systems that allow it to be adapted to suit all types of internal combustion engine. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of application Ser. No. 12/323,976 filed on Nov. 26, 2008.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a method of improving dewatering efficiency, increasing sheet wet web strength, increasing sheet wet strength and enhancing filler retention in a papermaking process. Typically in a papermaking process chemicals are added in the wet end to assist in the dewatering of the slurry, increasing retention and improving wet or dry sheet strength. The wet end of the papermaking process refers to the stage in the papermaking process where the fiber is dispersed in the water in the slurry form. The fiber-water slurry then go through drainage and dewatering process to form a wet web. The solid content after this wet formation process is about 50%. The wet web is further dried and forms a dry sheet of paper mat. Paper mat comprises water and solids and is commonly 4 to 8% water. The solid portion of the paper mat includes fibers (typically cellulose based fibers) and can also include filler.
[0004] Fillers are mineral particles that are added to paper mat during the papermaking process to enhance the resulting paper's opacity and light reflecting properties. Some examples of fillers are described in U.S. Pat. No. 7,211,608. Fillers include inorganic and organic particle or pigments used to increase the opacity or brightness, reduce the porosity, or reduce the cost of the paper or paperboard sheet. Some examples of fillers include one or more of: kaolin clay, talc, titanium dioxide, alumina trihydrate, barium sulfate, magnesium hydroxide, pigments such as calcium carbonate, and the like.
[0005] Calcium carbonate filler comes in two forms, GCC (ground calcium carbonate) and PCC (precipitated calcium carbonate). GCC is naturally occurring calcium carbonate rock and PCC is synthetically produced calcium carbonate. Because it has a greater specific surface area, PCC has greater light scattering abilities and provides better optical properties to the resulting paper. For the same reason however, PCC filled paper mat produces paper which is weaker than GCC filled paper in dry strength, wet strength and wet web strength.
[0006] Filler is generally much smaller than fiber, therefore, filler has much larger specific surface area than fiber. One of the challenges people found to increase filler content in the sheet is that high filler content decreases the efficiency of wet end chemicals, such as dewatering aids, wet web strength aids and wet strength aids. This invention is to provide novel filler pretreatment, so that it reduced the adsorption of wet end chemicals onto filler surface, therefore, increased the efficiency of wet end chemicals such as dewatering aids, wet web strength aids and wet strength aids.
[0007] Paper wet web strength is very critical for paper producers because increased paper wet web strength would increase machine runnability and reduce sheet breaks and machine down time. Paper wet web strength is a function of the number and the strength of the bonds formed between interweaved fibers of the paper mat. Filler particles with greater surface area are more likely to become engaged to those fibers and interfere with the number and strength of those bonds. Because of its greater surface area, PCC filler interferes with those bonds more than GCC.
[0008] Paper dewatering efficiency is also very critical for paper producers because decreased dewatering efficiency in wet wed would increase steam demand for drying operation, reduce machine speed and production efficiency. Dewatering aids are widely used to improve dewatering efficiency for reducing energy consumption, increasing machine speed and production efficiency.
BRIEF SUMMARY OF THE INVENTION
[0009] At least one embodiment of the invention is directed towards a method of papermaking having improved sheet wet strength or wet web strength or increased drainage or filler retention through combining filler pretreatment and drainage aid or wet web strength aid or wet strength aid. The method comprises the steps of: providing a blend of filler particles, at least one drainage additive or one wet strength aid or one wet web strength aid, and cellulose fiber stock; treating the filler particles with a composition of matter, combining the filler particles with the cellulose fiber stock; and forming a paper mat by removing some of the water from the combination. At least 10% of the filler particles are the precipitated form of calcium carbonate (PCC) and at least 10% of the filler particles are the ground form of calcium carbonate (GCC). The cellulose fiber stock comprises a plurality of cellulose fibers and water. The composition of matter inhibits drainage aid or wet strength additive or wet web strength additive from adhering to the filler particles. In at least one embodiment, the cellulose fiber stock and the filler particles are combined to form a furnish and subsequently the filler particles are treated with the composition of matter.
[0010] At least one embodiment of the invention is directed towards a method in which the blend of filler particles further comprises one item selected from the list consisting of: calcium carbonate, organic pigment, inorganic pigment, clay, talc, titanium dioxide, alumina trihydrate, barium sulfate, magnesium hydroxide, and any combination thereof.
[0011] At least one embodiment of the invention is directed towards a method in which the composition of matter is an AcAm/DADMAC copolymer. At least one embodiment of the invention is directed towards a method in which the wet strength aid or wet web strength additive or drainage aid is glyoxylated Acrylamide/DADMAC copolymer. At least one embodiment of the invention is directed towards a method in which the wet web strength additive or wet strength aid or drainage aid and the composition of matter carry the same charge.
[0012] At least one embodiment of the invention is directed towards a method in which the calcium carbonate is in one form selected from the list consisting of dry calcium carbonate, dispersed slurry calcium carbonate, chalk, and any combination thereof. At least a portion of the calcium carbonate can be in a dispersed slurry calcium carbonate form, the dispersed slurry calcium carbonate further comprising at least one item selected from: polyacrylic acid polymer dispersants, sodium polyphosphate dispersants, Kaolin clay slurry, and any combination thereof. The blend of filler particles can be 50% GCC and 50% PCC. The composition of matter can be a coagulant and can be selected from the list consisting of: inorganic coagulants, organic coagulants, condensation polymerization coagulants, and any combination thereof. The coagulant can have a molecular weight range of between 200 and 1,000,000.
[0013] At least one embodiment of the invention is directed towards a method in which the composition of matter is a coagulant selected from the list consisting of alum, sodium aluminate, polyaluminum chlorides, aluminum chlorohydroxide, aluminum hydroxide chloride, polyaluminum hydroxychloride, sulfated polyaluminum chlorides, polyaluminum silica sulfate, ferric sulfate, ferric chloride, epichlorohydrin-dimethylamine (EPI-DMA), EPI-DMA ammonia crosslinked polymers, polymers of ethylene dichloride and ammonia, condensation polymers of multifunctional diethylenetriamine, condensation polymers of multifunctional tetraethylenepentamine, condensation polymers of multifunctional hexamethylenediamine condensation polymers of multifunctional ethylenedichloride, melamine polymers, formaldehyde resin polymers, cationically charged vinyl addition polymers, and any combination thereof.
[0014] At least one embodiment of the invention is directed towards a method in which the ratio of wet strength aid or drainage aid or wet web strength aid relative to the solid portion of the paper mat can be 0.3 to 5 kg of additive per ton of paper mat. At least some of the GCC particles can be treated with the composition of matter. At least one embodiment of the invention is directed towards a method in which none of the PCC particles are treated with the composition of matter. The filler particles can have a mass, which is up to 50% of the combined mass of the solid portion of the paper mat. The wet strength aid or wet web strength additive or drainage additive and the composition of matter can carry the same charge.
[0015] At least one embodiment of the invention is directed to a composition of matter for use in a papermaking process. The composition of matter comprises: cellulose, filler particles, a wet strength aid or wet web strength additive or drainage additive, and a coating surrounding at least some of the filler particles. The coating is constructed and arranged to prevent the wet strength aid or wet web strength additive or drainage aid from adhering to the filler particles. In at least one embodiment, at least some of the filler particles are calcium carbonate. In at least one embodiment, the filler particles are GCC, PCC, or a combination of the two. In at least one embodiment, the filler particles comprise at least 10% PCC and 10% GCC.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
[0017] FIG. 1 is a graph showing the improved wet strength of paper made according to the invention.
[0018] FIG. 2 is a graph showing the improved wet web strength of paper made according to the invention.
[0019] FIG. 3 is a second graph showing the improved ash content in the sheet according to the invention.
[0020] FIG. 4 is a third graph showing the improved filler retention according to the invention.
[0021] FIG. 5 is a graph showing the steam pressure reduction (drainage enhancement) according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] In at least one embodiment of the invention is a method of making paper which comprises filler. In at least one embodiment of the invention the method of papermaking comprises the steps of: creating a filler blend of PCC and GCC in which PCC comprises at least 10% by mass of the filler and GCC comprises at least 10% of the filler mass, pre-treating at least some of the filler particles with a coating that decreases the adhesion between a wet web strength additive or drainage aid or wet strength aid and the filler particles, and adding both the filler blend and the wet web strength additive or drainage aid or wet strength aid to the paper mat.
[0023] It has been known for some time that adding wet web strength additives or drainage aid or wet strength aid to paper mat increases the wet web strength of the resulting paper or enhances drainage or improves machine speed and runnability or enhance sheet wet strength. Some examples of wet strength aids, wet web strength additives and drainage aids are described in U.S. Pat. Nos. 7,125,469, 7,615,135 and 7,641,776.
[0024] Unfortunately it is not practical to add large amounts of wet strength aids or wet web strength additives or drainage aids to compensate for the weakness due to large amounts of filler in paper mat. One reason is because those additives are expensive and using large amounts of additives would result in production costs that are commercially non-viable. In addition, adding too much additive negatively affects the process of papermaking and inhibits the operability of various forms of papermaking equipment. Furthermore cellulose fibers can only adsorb a limited amount of wet strength aid or wet web strength additive or drainage aid. This imposes a limit on how much additive can be used. One reason why this is so is because wet strength aid or wet web strength additive or drainage aid tend to neutralize the anionic fiber/filler charges and when these charges are neutralized further adsorption of those additives is inhibited.
[0025] Adding filler to the paper mat also reduces the effectiveness of the wet strength aid or wet web strength additive or drainage aid. Those additives have a tendency to coat the filler particles. The more filler particles present, the more additive coats the filler particles, and therefore there is less wet strength aid or wet web strength additive or drainage available to bind the cellulose fibers together. Because there is a maximum amount of wet strength aid or wet web strength additive or drainage that can be added, more filler has always meant less effective strength additive. This effect is more acute with PCC than GCC because PCC's higher surface area becomes more coated with the additives than GCC.
[0026] In at least one embodiment of the invention at least some of the filler particles are pre-treated with a composition of matter to at least partially prevent the adherence of wet strength aid or wet web strength additive or drainage aid to the filler particles. The pre-treatment contemplates entirely coating some or all of one or more filler particles with the composition of matter. In the alternative, the pre-treatment contemplates applying the composition of matter to only a portion of one or more of the filler particles, or completely coating some filler particles and applying the composition of matter to only a portion of some other particles. In at least one embodiment the pre-treatment is performed with at least some of the compositions of matter described in U.S. Pat. No. 5,221,435 and in particular the cationic charge-biasing species described therein. In at least one embodiment the pre-treatment is performed with a diallyl-N,N-disubstituted ammonium halide-acrylamide copolymer described in U.S. Pat. No. 6,592,718.
[0027] While pre-treating filler particles is known in the art, prior art methods of pre-treating filler particles are not directed towards affecting the adhesion of the wet strength aid or wet web strength additive or drainage aid to the filler particles. In fact, many prior art pre-treatments increase the adhesion of the strength additive to the filler particles. For example, U.S. Pat. No. 7,211,608 describes a method of pre-treating filler particles with hydrophobic polymers. This pre-treatment however does nothing to the adhesion between the strength additive and the filler particles and merely repels water to counterbalance an excess of water absorbed by the strength additive. In contrast, the invention decreases the interactions between the wet strength aid or wet web strength additive or drainage aid and the filler particles and results in an unexpectedly huge increase in paper strength, sheet dewatering and machine runnability.
[0028] FIG. 1 shows wet tensile strength of a given paper versus the percentage of filler relative to the total solid portion of the paper mat used to produce the given paper. The results clearly illustrates that sheet had very weak wet strength without addition of wet strength aid 63700 (temporary wet strength aid). Velox could significantly increase sheet wet strength. Filler pretreatment alone did not increase sheet wet strength. However, filler pretreatment further enhance Velox performance which resulted in higher sheet wet strength.
[0029] FIG. 2 plots wet web tensile strength of a given paper versus the percentage of filler relative to the total solid portion of the paper mat used to produce the given paper. As shown in FIG. 2 , the relationship between increasing filler content and decreasing paper wet web strength is a linear relationship. Without the addition of Nalco dewatering aid (wet web strength aid) 63700, paper sheet had very poor wet web strength. Sheet wet web strength could be significantly improved by the using of Nalco dewatering aid 63700. Filler pretreatment alone had negligible effect on paper wet web strength. However, filler pretreatment could further boost the performance of Nalco dewatering aid 63700, and additional 20% wet strength improvement was achieved by the filler pretreatment at the lower ash content. As for the higher ash content, the performance of 63700 was boosted even higher than 20%. This is because the reduced effectiveness of the strength additive trapped against the filler particles was released by the filler pretreatment.
[0030] At least some of the fillers encompassed by this invention are well known and commercially available. They include any inorganic or organic particle or pigment used to increase the opacity or brightness, reduce the porosity, or reduce the cost of the paper or paperboard sheet. The most common fillers are calcium carbonate and clay. However, talc, titanium dioxide, alumina trihydrate, barium sulfate, and magnesium hydroxide are also suitable fillers. Calcium carbonate includes ground calcium carbonate (GCC) in a dry or dispersed slurry form, chalk, precipitated calcium carbonate (PCC) of any morphology, and precipitated calcium carbonate in a dispersed slurry form. The dispersed slurry forms of GCC or PCC are typically produced using polyacrylic acid polymer dispersants or sodium polyphosphate dispersants. Each of these dispersants imparts a significant anionic charge to the calcium carbonate particles. Kaolin clay slurries also are dispersed using polyacrylic acid polymers or sodium polyphosphate.
[0031] In at least one embodiment, the treating composition of matter is any one of or combination of the compositions of matter described in U.S. Pat. No. 6,592,718. In particular, any of the AcAm/DADMAC copolymer compositions described in detail therein are suitable as the treating composition of matter. An example of an AcAm/DADMAC copolymer composition is product# Nalco-4690 from Nalco Company of Naperville, Ill. (hereinafter referred to as 4690).
[0032] The treating composition of matter can be a coagulant. The coagulants encompassed in this invention are well known and commercially available. They may be inorganic or organic. Representative inorganic coagulants include alum, sodium aluminate, polyaluminum chlorides or PACs (which are also known as aluminum chlorohydroxide, aluminum hydroxide chloride, and polyaluminum hydroxychloride), sulfated polyaluminum chlorides, polyaluminum silica sulfate, ferric sulfate, ferric chloride, and the like and blends thereof.
[0033] Some organic coagulants suitable as a treating composition of matter are formed by condensation polymerization. Examples of polymers of this type include epichlorohydrin-dimethylamine (EPI-DMA), and EPI-DMA ammonia crosslinked polymers.
[0034] Additional coagulants suitable as a treating composition of matter include polymers of ethylene dichloride and ammonia, or ethylene dichloride and dimethylamine, with or without the addition of ammonia, condensation polymers of multifunctional amines such as diethylenetriamine, tetraethylenepentamine, hexamethylenediamine and the like with ethylenedichloride and polymers made by condensation reactions such as melamine formaldehyde resins.
[0035] Additional coagulants suitable as a treating composition of matter include cationically charged vinyl addition polymers such as polymers, copolymers, and terpolymers of (meth)acrylamide, diallyl-N,N-disubstituted ammonium halide, dimethylaminoethyl methacrylate and its quaternary ammonium salts, dimethylaminoethyl acrylate and its quaternary ammonium salts, methacrylamidopropyltrimethylammonium chloride, diallylmethyl(beta-propionamido)ammonium chloride, (beta-methacryloyloxyethyl)trimethyl ammonium methylsulfate, quaternized polyvinyllactam, vinylamine, and acrylamide or methacrylamide that has been reacted to produce the Mannich or quaternary Mannich derivatives. Preferable quaternary ammonium salts may be produced using methyl chloride, dimethyl sulfate, or benzyl chloride. The terpolymers may include anionic monomers such as acrylic acid or 2-acrylamido 2-methylpropane sulfonic acid as long as the overall charge on the polymer is cationic. The molecular weights of these polymers, both vinyl addition and condensation, range from as low as several hundred to as high as several million. Preferably, the molecular weight range should be from about 20,000 to about 1,000,000. In at least one embodiment, the pre-treatment is preformed by a combination of one, some, or all of any of the compositions of matter described as suitable compositions of matter for pre-treating the filler particles.
[0036] In at least one embodiment, the wet strength aid or wet web strength additive or drainage aids carries the same charge as the composition of matter suitable for treating the filler particles. When the two carry the same charge, the filler additive is less likely to adsorb wet strength aid, wet web strength additive or drainage aid on its surface. Wet strength aids, wet web strength additives or drainage aids encompassed by the invention include any one of the compositions of matter described in U.S. Pat. No. 4,605,702 and US Patent Application 2005/0161181 A1 and in particular the various glyoxylated Acrylamide/DADMAC copolymer compositions described therein. An example of a glyoxylated Acrylamide/DADMAC copolymer composition is product# Nalco 63700 (made by Nalco Company, Naperville, Ill.). Another example of is amine-containing polymers including allylamine/acrylamide copolymers and polyvinylamines; one more example is Polyamide-Polyamine-Epichlorohydrin (PAE)
[0037] In at least one embodiment, the fillers used are PCC, GCC, and/or kaolin clay. In at least one embodiment, the fillers used are PCC, GCC, and/or kaolin clay with polyacrylic acid polymer dispersants or their blends. The ratio of wet strength additive or wet web strength aid or drainage additive relative to solid paper mat can be 3 kg of additive per ton of paper mat.
[0038] The foregoing may be better understood by reference to the following example, which is presented for purposes of illustration and is not intended to limit the scope of the invention.
EXAMPLE 1
[0039] 1(i) Filler Pre-Treatment:
[0040] A blend of filler particles was obtained from a paper mill. The blend filler was a mixture of 50% PCC and 50% 100% GCC. The filler blend was diluted to 20% solid content with tap water. 200 mL of the diluted filler blend was placed in a 500 mL glass beaker. Stirring was conducted for at least 30 seconds prior to the addition of coagulant. The stirrer was a EUROSTAR Digital overhead mixer with a R1342, 50 mm, four-blade propeller (both from IKA Works, Inc., Wilmington, N.C.). A coagulant solution was slowly added after the initial 30 seconds of mixing under stirring with 800 rpm. The coagulant solution used was 4690. The dose of coagulant was 1 kg/ton based on dry filler weight. Stirring continued at 800 rpm until all the coagulant was added. Then the stirring speed increased to 1500 rpm for one minute.
[0041] 1(ii) Use of Filler:
[0042] Furnish was prepared by disintegrating commercial bleached hardwood dry lap. The mixture of 50% PCC and 50% GCC was added to pulp furnish to achieve different filler content in the sheet. 200 ppm Nalco 61067 was used as retention aid. For the pretreatment evaluation, filler mixture was pretreated using Nalco coagulant 4690 before filler was added into the furnish. During the handsheet preparation, 3 kg/ton Nalco 63700 was added to improve the sheet wet web strength. The result was shown in FIG. 2 . We tried to evaluate the effect of filler pretreatment on the press dewatering performance of 63700 by measuring sheet wet web strength. Handsheets were pressed to a certain solid content (50%) by controlling the same pressure level at 60 degree C., and the time required to completely break up wet sheet in water under the shear force of 1000 RPM was recorded to compare sheet wet web strength, which was expected to indirectly reflect press dewatering. The results showed in FIG. 2 indicated that sheet wet web strength could be significantly improved by the addition of 63700. Filler pretreatment could further boost sheet wet web strength by additional 20% at the lower ash content. As for the higher ash content, the performance of 63700 was even higher than 20%.
EXAMPLE 2
[0043] A machine trial was run in which a papermaking machine made GAB300 with machine speed of 900 m/min. A composition was provided whose cellulose fibers were 14% MXW; 3% coated broke; 17% SOW; 12% Uncoated Broke, 44% DIP and 10% ONP. The furnish also contained GCC. During the trial, all the wet end additives including 15/ton Nalco press dewatering aid 63700, retention aids, sizing agents, and cationic starches were kept constant.
1) Filler Retention Enhancement:
[0044] 4690 was gradually increased from 0.5 kg/ton to 2 kg/ton based on filler. It was found that online ash content was increased gradually with the addition of 4690 to the filler pipe as shown in FIG. 3 . Obviously, 0.7 ash point increase from 15.6% to 16.3% was obtained through filler pre-treatment. Historically, for the same grade production, recorded ash content of DCS was about 12% without using Nalco 63700. It should be pointed out that the ash content improvement was only contributed by filler ply. Therefore, ash content increase in filler ply was supposed to be about 1.4% because filler ply accounted for half basis weight of the final product. FIG. 4 showed the FPAR of filler ply. It clearly illustrated that FPAR was increased from 70% to 75%, which could explain why final ash content was significantly enhanced.
2) Steam Pressure Reduction:
[0045] It was also found that steam pressure of the pre-dryer was reduced through filler treatment as shown in FIG. 5 . Steam pressure was gradually decreased from 2.15 to 2 bar from 10:30 am to 2:00 pm. Even though press pressure of the first press section and press pressure of the second press section were reduced from 550 to 470 and 600 to 580 respectively, the steam pressure only went back to 2.05.
[0046] During the trial, the ash content increased from around 15.6% to 16.3% about 1 hour after the filler was pretreated, then was kept at the same level for several hours. On the other hand, the steam pressure kept decreasing for several hours until the press load was reduced. This seems to indicate that the steam reduction was not only from ash content increase. Moreover, the steam demand reduction of this trial was only from filler ply since 4690 was only applied for this ply, thus the total steam reduction caused by ash content increase alone should be less. Therefore, the results illustrated that filler pre-treatment could enhance 63700 performance as press dewatering agent or wet web strength aid.
[0047] A person of ordinary skill in the art will recognize that all of the previously described methods are also applicable to paper mat comprising other non-cellulose based fibrous materials, paper mats comprising a mixture of cellulose based and non-cellulose based fibrous materials, and/or synthetic fibrous based materials.
[0048] Changes can be made in the composition, operation, and arrangement of the method of the invention described herein without departing from the concept and scope of the invention as defined in the claims. While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments described herein. All patents, patent applications, and other cited materials mentioned anywhere in this application or in any cited patent, cited patent application, or other cited material are hereby incorporated by reference in their entirety. Furthermore this invention contemplates embodiments which exclude one, some, or all of the compositions, methods, components, elements, or other portions of any cited material.
[0049] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0050] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto. | The invention provides a method of improving dewatering efficiency, increasing sheet wet web strength, increasing sheet wet strength and enhancing filler retention in a papermaking process The method improves the efficiency of drainage aids or wet web strength aids or wet strength aid by coating at least some of the filler particles with a material that prevents the filler materials form adhering to a those additives. The drainage additive or wet web strength additive or wet strength aid holds the cellulose fibers together tightly and is not wasted on the filler particles. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/517,220, filed Oct. 31, 2003.
BACKGROUND OF THE INVENTION
[0002] The invention relates generally to osmotic pumps for delivering beneficial agents. More specifically, the invention relates to an osmotic pump having a membrane plug for controlling the delivery rate of a beneficial agent.
[0003] Osmotic pumps for delivering beneficial agents within the body of a patient are known in the art. For illustration purposes, FIG. 1A shows a cross-section of a prior-art osmotic pump 100 having an implantable capsule 102 with open ends 104 , 106 . A diffusion moderator (also called flow modulator) 108 is disposed in the open end 106 of the capsule 102 . The diffusion moderator 108 has a delivery path 110 that terminates at a delivery port 112 and allows fluid from the interior of the capsule 102 to be transported to the exterior of the capsule 102 . A membrane plug 114 is inserted in the open end 104 of the capsule 102 . The membrane plug 114 is made of a semipermeable material and forms a fluid-permeable barrier between the exterior and the interior of the capsule 102 . A piston 116 is disposed in the capsule 102 . The piston 116 defines two chambers 118 , 120 within the capsule 102 . The chamber 118 contains an osmotic agent 122 , and the chamber 120 contains a beneficial agent 124 .
[0004] When the osmotic pump 100 is implanted in a patient, fluid from the body of the patient enters the chamber 118 through the membrane plug 114 , permeates the osmotic agent 122 , and causes the osmotic agent 122 to swell. The swollen osmotic agent 122 pushes the piston 116 in a direction away from the membrane plug 114 , reducing the volume of the chamber 120 and forcing an amount of the beneficial agent 124 out of the capsule 102 through the diffusion moderator 108 into the body of the patient. The rate at which the osmotic pump 100 delivers the beneficial agent 124 to the body depends on the rate at which fluid permeates the membrane plug 114 .
[0005] Typically, the membrane plug 114 is made of a hydratable compound that must hydrate in order for the osmotic agent 122 to begin absorbing moisture. The time to hydrate the membrane plug 114 and the osmotic agent 122 delays the start of ejection of the beneficial agent 124 from the chamber 120 . During this startup phase, body fluid, usually water, can back-diffuse into the delivery port 112 of the diffusion moderator 108 and degrade the beneficial agent 124 or the vehicle carrying the beneficial agent 124 . Some vehicles when they combine with water can plug the delivery path 110 .
[0006] If the delivery path 110 or port 112 becomes plugged, for example, due to a lengthy startup, or if the piston 116 becomes stuck inside the capsule 102 , there will be pressure buildup in the chamber 118 , which may be sufficient to expel the membrane plug 114 from the capsule 102 .
[0007] Various methods have been proposed for avoiding expulsion of the membrane plug 114 from the capsule 102 . One method involves securing the membrane plug 114 to the capsule 102 using an adhesive. This method requires an additional operation to apply the adhesive to the membrane plug 114 and/or the capsule 102 , and the adhesive may affect the permeability of the membrane plug 114 . Another method for avoiding expulsion of the membrane plug 114 is to drill a hole in the end portion of the capsule 102 containing the membrane plug 114 . FIG. 1B shows a hole 126 drilled in the capsule 102 . As shown in FIG. 1B , the hole 126 is initially covered by the membrane plug 114 , but as the membrane plug 114 is forced out of the capsule 102 due to pressure buildup in the chamber 118 , the hole 126 will eventually become exposed, allowing pressure to be vented from the chamber 118 to the exterior of the capsule 102 . In this manner, the membrane plug 114 is prevented from becoming separated from the capsule 102 . This method requires an additional operation in the fabrication of the capsule 102 and increases the overall cost of the osmotic pump.
BRIEF SUMMARY OF THE INVENTION
[0008] In one aspect, the invention relates to an osmotic pump which comprises a capsule having at least one delivery port formed at a first end and a membrane plug retained in a second end of the capsule remote from the delivery port to provide a fluid-permeable barrier between an interior and an exterior of the capsule. The membrane plug has a columnar body and at least one slot formed in the columnar body to vent pressure from the interior to the exterior of the capsule when the columnar body extends a predetermined distance relative to the second end of the capsule, thereby preventing expulsion of the membrane plug from the second end.
[0009] In another aspect, the invention relates to a membrane plug for use with an osmotic pump having a delivery capsule. The membrane plug comprises a columnar body made of a semipermeable material and having an outer surface for engagement with an inner surface of the capsule. The columnar body is provided with at least one slot, which extends from a base of the columnar body to a non-basal point on the outer surface of the columnar body so that pressure can be selectively vented from an interior to an exterior of the capsule.
[0010] In yet another aspect, the invention relates to a membrane plug for use with an osmotic pump having a delivery capsule which comprises a columnar body made of a semipermeable material. The columnar body has an outer surface for engagement with an inner surface of the capsule and is provided with an orifice that allows fluid flow into the capsule until the orifice becomes occluded due to swelling of the semipermeable material.
[0011] Other features and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIGS. 1A and 1B are cross-sections of prior-art osmotic pumps.
[0013] FIG. 2A is an enlarged view of a membrane plug according to an embodiment of the invention.
[0014] FIG. 2B is an enlarged view of a membrane plug according to another embodiment of the invention.
[0015] FIG. 2C is a cross-section of a membrane plug according to another embodiment of the invention.
[0016] FIG. 3 shows an osmotic pump incorporating an embodiment of the membrane plug of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The invention will now be described in detail with reference to a few preferred embodiments, as illustrated in accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be apparent 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.
[0018] FIG. 2A shows a membrane plug 200 according to an embodiment of the invention. The membrane plug 200 can be inserted into an open end of an osmotic pump capsule (not shown) to control the rate at which fluid enters the capsule. The membrane plug 200 has a columnar body 202 . The outer diameter of the columnar body 202 is selected such that the columnar body 202 can fit into the capsule. In one embodiment, the columnar body 202 terminates in an enlarged end cap 204 . When the membrane plug 200 is inserted in the capsule, the end cap 204 acts as a stop member engaging an end of the capsule and achieving a repeatable position of the membrane plug 200 inside the capsule. In an alternative embodiment, the end cap 204 may be omitted, allowing the membrane plug 200 to be fully inserted into the capsule.
[0019] One or more slots 206 are formed in the columnar body 202 . In one embodiment, the slots 206 are longitudinal, extending from the base 208 of the columnar body 202 to a point 210 below the end cap 204 . In alternative embodiments, the slot(s) formed in the columnar body 202 may have other shapes. For example, a helical slot extending from the base 208 of the columnar body 202 to a point below the end cap 204 could be formed. Measured from the base 208 of the columnar body 202 , the extent or height (l o ) of the slot(s) 206 may be in a range from about 10 to 90% of the length (L) of the columnar body 202 , preferably in a range from about 20 to 80% of the length of the columnar body 202 , more preferably in a range from about 30 to 60% of the length of the columnar body 202 . In general, the extent or height (l o ) of the slot(s) 206 should be selected such that there is adequate (uninterrupted) sealing surface at the top portion 212 of the columnar body 202 . The depth and width of the slot(s) 206 can be variable. In general, the depth and width should be selected such that the structural integrity of the membrane plug 200 is not compromised in use. The depth and width of the slot(s) 206 should be sufficiently large to be reproducibly formed in the columnar body 202 and to prevent occlusion of the slot due to swelling of the membrane material when hydrated. The depth of the slot(s) 206 can be in a range from approximately 1 to 99% of the diameter of the columnar body 202 , preferably in a range from approximately 10 to 90% of the diameter of the columnar body 202 . The width of the slot(s) 206 can be in a range from approximately 1 to 99% of the diameter of the columnar body 202 , preferably in a range from approximately 10 to 90% of the diameter of the columnar body 202 .
[0020] Protrusions, such as ribs, ridges, threads, or the like, may be formed on the columnar body 202 to enhance sealing between the columnar body 202 and the osmotic pump capsule (not shown), as taught by Chen et al. in U.S. Pat. No. 6,113,938. FIG. 2B shows circumferential ribs 214 formed on the columnar body 202 with the slots 206 cutting through the ribs 214 . Preferably, the length of the slot(s) 206 is such that there are continuous ribs 214 in the top portion 212 of the columnar body 202 to ensure proper sealing between the top portion 212 and the inner surface of the osmotic pump capsule.
[0021] The membrane plug 200 is made of a semipermeable material that allows fluid, usually water, to pass into the interior of an osmotic pump capsule while preventing compositions within the capsule from passing out of the capsule. Semipermeable materials suitable for use in the invention are well known in the art. Semipermeable materials for the membrane plug 200 are those that can conform to the shape of the capsule upon wetting and that can adhere to the inner surface of the capsule. Typically, these materials are polymeric materials, which can be selected based on the pumping rates and system configuration requirements, and include, but are not limited to, plasticized cellulosic materials, enhanced PMMAs such as hydroxyethylmethacrylate (HEMA), and elastomeric materials such as polyurethanes and polyamides, polyether-polyamind copolymers, thermoplastic copolyesters, and the like.
[0022] FIG. 3 shows the membrane plug 200 used in an osmotic pump 300 . It should be noted that the internal structure of the osmotic pump 300 is presented for illustration purposes only and is not to be construed as limiting the present invention. The present invention is generally applicable to all osmotic pumps having any number of shapes, and to all such pumps administered in implantable osmotic delivery techniques.
[0023] The osmotic pump 300 includes an elongated cylindrical capsule 302 , which may be sized such that it can be implanted within a body. The capsule 302 has open ends 304 , 306 . The membrane plug 200 is inserted in the open end 304 , and a diffusion moderator (or flow modulator) 308 is inserted in the open end 306 . The diffusion moderator 308 includes a delivery path 310 which terminates in a delivery port 312 . Although not shown, the diffusion moderator 308 may also include a vent hole and optionally a fill hole, as taught by Peterson et al. in U.S. Pat. No. 6,524,305. In an alternative embodiment, the diffusion moderator 308 could be omitted, and the open end 306 could be replaced with a closed end having a delivery port. The diffusion moderator 308 (or delivery port) allows fluid from within the capsule 302 to be delivered to the exterior of the capsule 302 , while the membrane plug 200 allows fluid from the exterior of the capsule 302 to enter the interior of the capsule 302 .
[0024] Two chambers 314 , 316 are defined inside the capsule 302 . The chambers 314 , 316 are separated by a piston 318 , which is configured to fit within the capsule 302 in a sealing manner and to move longitudinally within the capsule 302 . The piston 318 may be made of an impermeable resilient material. As an example, the piston 318 may include annular ring shape protrusion(s) 319 that form a seal with the inner surface of the capsule 302 . An osmotic agent 320 is disposed in the chamber 314 adjacent the membrane plug 200 , and a beneficial agent 322 to be delivered to a body is disposed in the chamber 316 adjacent the diffusion moderator 308 . The piston 318 isolates the beneficial agent 322 from the environmental liquids that are permitted to enter the capsule 302 through the membrane plug 200 such that in use, at steady-state flow, the beneficial agent 322 is expelled through the delivery port 312 at a rate corresponding to the rate at which liquid from the environment of use flows into the osmotic agent 320 through the membrane plug 200 .
[0025] In operation, fluid enters the chamber 314 through the membrane plug 200 and permeates the osmotic agent 320 . The wetted osmotic agent 320 swells and pushes the piston 318 in a direction away from the membrane plug 200 , reducing the volume of the chamber 316 and forcing an amount of the beneficial agent 322 out through the diffusion moderator 308 . If the diffusion moderator 308 becomes plugged or the piston 318 becomes stuck, pressure will build up in the chamber 314 . This pressure buildup will force the membrane plug 200 in a direction away from the piston 318 . The membrane plug 200 will slide out of the capsule 302 until the slot(s) 206 are exposed. As soon as the slots 206 are exposed, pressure from the chamber 314 will escape to the exterior of the capsule 302 , thereby preventing further movement of the membrane plug 200 out of the capsule 302 . The membrane plug 200 may return to its original position after the pressure buildup in the chamber 314 has been vented.
[0026] In general, materials suitable for constructing the capsule 302 must be sufficiently rigid to withstand expansion of the osmotic agent 320 without changing its size or shape. Further, the materials should ensure that the capsule 302 will not leak, crack, break, or distort under stress to which it could be subjected during implantation or under stresses due to the pressures generated during operation. The capsule 302 may be formed of chemically inert biocompatible, natural or synthetic materials which are known in the art. The capsule material is preferably a non-bioerodible material which remains in the patient after use, such as titanium. However, the material of the capsule 302 may alternatively be a bioerodible material which bioerodes in the environment after dispensing of the beneficial agent. Generally, preferred materials for the capsule 302 are those acceptable for human implantation.
[0027] In general, typical materials of construction suitable for the capsule 302 according to the present invention include non-reactive polymers or biocompatible metals or alloys. The polymers include acrylonitrile polymers such as acrylonitrile-butadiene-styrene terpolymer, and the like; halogenated polymers such as polytetraflouroethylene, polychlorotrifluoroethylene, copolymer tetrafluoroethylene and hexafluoropropylene; polyimide; polysulfone; polycarbonate; polyethylene; polypropylene; polyvinylchloride-acrylic copolymer; polycarbonate-acrylonitrile-butadiene-styrene; polystyrene; and the like. Metallic materials useful for the capsule 302 include stainless steel, titanium, platinum, tantalum, gold, and their alloys, as well as gold-plated ferrous alloys, platinum-plated ferrous alloys, cobalt-chromium alloys and titanium nitride coated stainless steel.
[0028] A capsule 302 made from the titanium or a titanium alloy having greater than 60%, often greater than 85% titanium, is particularly preferred for the most size-critical applications, for high payload capability and for long duration applications, and for those applications where the formulation is sensitive to body chemistry at the implantation site or where the body is sensitive to the formulation. In certain embodiments, and for applications other than the fluid-imbibing devices specifically described, where unstable beneficial agent formulations are in the capsule 302 , particularly protein and/or peptide formulations, the metallic components to which the formulation is exposed must be formed of titanium or its alloys as described above.
[0029] The osmotic agent 320 may be in tablet form as shown or may have other shape, texture, density, and consistency. For example, the osmotic agent 320 may be in powder or granular form. The osmotic agent 320 may be, for example, a nonvolatile water soluble osmagent, an osmopolymer which swells on contact with water, or a mixture of the two.
[0030] In general, the present invention applies to the administration of beneficial agents, which include any physiologically or pharmacologically active substance. The beneficial agent 322 may be any of the agents which are known to be delivered to the body of a human or an animal such as medicaments, vitamins, nutrients, or the like. Drug agents which may be delivered by the present invention include drugs which act on the peripheral nerves, adrenergic receptors, cholinergic receptors, the skeletal muscles, the cardiovascular system, smooth muscles, the blood circulatory system, synoptic sites, neuroeffector junctional sites, endocrine and hormone systems, the immunological system, the reproductive system, the skeletal system, autacoid systems, the alimentary and excretory systems, the histamine system and the central nervous system. Suitable agents may be selected from, for example, proteins, enzymes, hormones, polynucleotides, nucleoproteins, polysaccharides, glycoproteins, lipoproteins, polypeptides, steroids, analgesics, local anesthetics, antibiotic agents, anti-inflammatory corticosteroids, ocular drugs and synthetic analogs of these species. An exemplary list of drugs that may be delivered using the osmotic pump is disclosed in U.S. Pat. No. 6,270,787. The list is incorporated herein by reference.
[0031] The beneficial agent 322 can be present in a wide variety of chemical and physical forms, such as solids, liquids and slurries. On the molecular level, the various forms may include uncharged molecules, molecular complexes, and pharmaceutically acceptable acid addition and base addition salts such as hydrochlorides, hydrobromides, sulfate, laurylate, oleate, and salicylate. For acidic compounds, salts of metals, amines or organic cations may be used. Derivatives such as esters, ethers and amides can also be used. A beneficial agent 322 can be used alone or mixed with other beneficial agents. The beneficial agent 322 may optionally include pharmaceutically acceptable carriers and/or additional ingredients such as antioxidants, stabilizing agents, permeation enhancers, etc.
[0032] FIG. 2C shows another embodiment of the membrane plug 200 . In this embodiment, at least one orifice 216 is formed in the columnar body 202 . When the membrane plug 200 is inserted at an end of an osmotic pump, such as osmotic pump ( 300 in FIG. 3 ), the orifice 216 allows fluid to pass through the membrane plug 200 to the osmotic agent ( 320 in FIG. 3 ) and permeate the osmotic agent ( 320 in FIG. 3 ) before the membrane plug 200 is fully hydrated. This has the effect of accelerating the startup phase of the osmotic pump. The size of the orifice 216 is such that fluid can flow through the columnar body 202 . The size of the orifice 216 is also such that upon adequate hydration/swelling of the columnar body 202 the orifice 216 becomes occluded, allowing the osmotic function of the system to be fully activated.
[0033] The diameter of the orifice 216 depends on the outside diameter of the columnar body 202 of the membrane plug 200 , the inside diameter of the capsule ( 302 in FIG. 3 ), and the percentage of fluid the membrane plug 200 material will absorb. The diameter of the orifice 216 may be selected based on the assumption that the membrane plug 200 material will expand the same percentage in all directions until it meets a constraint such as the capsule.
[0034] The volume, V, of the membrane plug 200 can be expressed as follows:
V=πL ( D/ 2) 2 (1)
where L is the length of the membrane plug 200 and D is the diameter of the columnar body 202 . Multiplying both sides of equation (1) by (1+b) 3 gives:
V (1+ b ) 3 =L (1 +b )( D (1+ b )/2) 2 π (2)
where b is the change in the linear dimension of the membrane plug 200 due to fluid absorption. Let c be the change in volume of the membrane plug 200 due to fluid absorption, then:
(1 +b ) 3 =1 +c (3)
[0035] If the outside diameter of the membrane plug 200 is the same as the inside diameter of the capsule ( 302 in FIG. 3 ), then the area of the orifice 216 at time 0 before the plug expands (A o,t= 0) must be less than the difference between the cross-sectional area of the plug at time 0 before the plug expands (A p,t=0 ) and the cross-sectional area of the plug at time 1 after the plug expands (A p,t=1 ). That is,
A o,t=0 <A p,t=1 −A p,t=0 (4)
where
A o,t=0 =( d/ 2) 2 π (5)
where d is the diameter of the orifice before the plug expands (t=0) and
A p,t=0 =( D/ 2) 2 π (6)
and
A p,t=1 =[D (1+b)/2] 2 π (7)
The following expression is obtained by combining equation (3) with equation (7):
A p,t=1 =( D/ 2) 2 (1 +c ) 2/3 π (8)
From equations (6) and (8), the difference between the cross-sectional area of the plug at time 0 and time 1 becomes:
A p,t=1 −A p,t=0 =( D/ 2) 2 [(1 +c ) 2/3 −1]π (9)
The following expression is obtained by substituting equations (5) and (9) into equation (4) and solving for d:
d <{square root}{square root over (( D ) 2 [(1 +c ) 2/3 −1])} (10)
Thus, for a membrane plug that expands 18% (c=18%) with a columnar diameter of 3 mm (D=3 mm) in a capsule with a diameter of 3 mm, d<1.02 mm. For this example, d is less than 35% of the diameter of the columnar body. Preferably, d is in a range from 0.8 to 33% of the diameter of the columnar body.
[0036] The invention typically provides the following advantages. The membrane plug of the invention has a built-in mechanism that prevents its expulsion from an osmotic pump capsule once inserted in the capsule. As a result, additional operations to glue the membrane plug to the capsule or drill holes in the capsule are avoided. Further, any compromise in the operation of the membrane plug due to gluing of the membrane plug to the capsule is avoided. The mechanism for preventing expulsion of the membrane plug from the capsule, i.e., the vent slot(s), can be formed in the membrane plug at the time that the membrane plug is fabricated. For example, if the membrane plug is formed by molding, the mold design would already account for the slot(s) in the membrane plug. Because this solution does not require an additional operation, it should not significantly increase the cost of the osmotic pump. The membrane plug can include an orifice that allows the osmotic agent to start hydrating even before the membrane plug is fully hydrated. This has the effect of accelerating the startup phase of the osmotic pump.
[0037] 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. | An osmotic pump includes a capsule having at least one delivery port formed at a first end and a membrane plug retained in a second end of the capsule remote from the delivery port to provide a fluid-permeable barrier between an interior and an exterior of the capsule. The membrane plug has a columnar body and at least one slot formed in the columnar body to vent pressure from the interior to the exterior of the capsule when the columnar body extends a predetermined distance relative to the second end of the capsule, thereby preventing expulsion of the membrane plug from the second end. | 0 |
BACKGROUND OF INVENTION
A large number of orders are processed in a normal work day in a modern photographic processing plant. To expedite the processing, orders containing film of a similar type and size are spliced together for developing. After developing, the film images are printed in an edge-to-edge relationship on a continuous strip of photo sensitive paper by a printer apparatus. The printer apparatus places indicia in the margin to indicate the cutting line between adjacent prints and a seond mark in the opposite margin to indicate the end of an order. The cutter apparatus senses the cutting indicia and separates individual prints from the strip. The separated prints are passed to an order packaging device which groups the prints in response to the end of order marks sensed by the cutter. Thus it may be seen that in a system of this type it is important to positively identify the cutting line between finished prints to provide a means to control an automatic print cutter apparatus.
To be a viable apparatus, the cutter must accommodate the numerous differences that are encountered when dealing with the work product of various photo printers in photographic processing plants. Among these differences is the cutting and end of order indicia configuration. These indicia may vary from a rectangle of approximately 0.030 × 0.093 inches to a circle of approximately 0.050 inch diameter depending on the manufacturer of the photo printer. Another variable frequently encountered is the placement of the control indicia from print to print. Experience has shown that deviation in indicia placement may be as large as 0.125 inch laterally from the sensing path center line. The indicia is usually in the form of punched holes or marks on the edge of the strip of prints. The sensing means of previous cutters has demonstrated a high sensitivity to both indicia placement and configuration due to a relatively narrow scanning angle afforded by a photosensitive transistor employed as the sensing element.
Another shortcoming of prior indicia sensors is that the sensor was attached to the cutter device photographic strip guide means. Thus, as adjustments were made in guide positioning to accommodate variations in the width of the photographic strip, the sensor position was likewise effected. The necessary realignment of the sensor was then accomplished by a trial and error procedure in which a highly experienced operator would loosen the sensor mounting screws and realign the sensor to pick up the indicia on the strip.
In the past phototransistors have been used as sensing elements. These elements have a very restricted scanning area which was thought to be an advantage because there would be less chance of a false indicia being sensed. However with the high speed equipment now in use this restricted sensing area has produced the problems outlined above.
The concept of using a wide angle sensing element provides an extremely simple solution to these problems and furthermore the discovery that a photovoltaic or solar cell as the sensing element produces the desired wide angle sensing area and provides the means for implementing this concept. In addition to the wide angle sensing capability of the photovoltaic cell the characteristic of such a cell is to provide a straight line or logarithmic energy producing ratio which is directly proportional to the area on which the radiation source is imposed. This is not true with the phototransistor sensors previously used with such equipment. Solar cell elements are normally used for the conversion of infrared energy to electrical current. However, in the application herein described this element is employed as a wide angle sensor of infrared energy and provides a substantial increase in sensing area and the width thereof when compared to the phototransistor of prior applications.
The invention also provides separation of the sensor mounting means from the photographic strip guide means. Thus, with different film sizes variations in the width of the photographic strip are encountered and the guide means may be repositioned accordingly without affecting placement of the sensor means. This invention also provides for micrometer type adjustments of the sensor means in planes both parallel and normal to the photographic strip for adjusting the sensor position for the various film sizes. These adjustments expedite the cutter set-up procedure. These enhancements are designed for retrofit into existing Pako Model 255 and 255B cutters.
The following is a description of the specific embodiment of this improvement illustrated in the accompanying drawings wherein like reference characters refer to similar parts throughout the views in which:
FIG. 1 is a perspective view of the Pako Model 255 cutter with the wide scanning angle sensor and improved adjusting means indicated;
FIG. 2 is a rear elevational view of the wide scanning angle sensor and transverse adjusting means with sections removed to illustrate the detail;
FIG. 3 is a top plan view of the wide scanning angle sensor illustrating the lateral and transverse adjustments as well as the photographic strip guide means with sections removed to illustrate detail;
FIG. 4 is a fragmentary right elevational view of the wide scanning angle sensor taken principally along viewing line 4--4 in FIG. 2. To illustrate the detail of the infrared emitter, the photovoltaic cell and the sensor electronics assembly detail;
FIG. 5 is an electrical schematic of the light emitting diodes and photovoltaic cell in the wide scanning angle sensor improvement;
FIG. 6 is an enlarged perspective view of the wide angle sensor and adjustment means;
FIG. 7 is a sectional view of the sensor lateral adjustments, taken substantially along viewing line 7--7 of FIG. 2, illustrating the V way; and
FIG. 8 is a sectional view of the sensor lateral adjustment taken substantially along viewing line 8--8 of FIG. 7, illustrating the adjusting mechanism and compression spring.
DETAILED DESCRIPTION
A wide scanning angle sensor with independent lateral and transverse axis adjustment means is shown attached to a Pako Model 255 cutter in FIG. 1. The sensor and adjustment means is illustrated in an enlarged scale in FIG. 6. With the wide angle sensor concept the only adjustment of the sensor that is necessary is to convert from one size film to another. The wide angle scanning characteristic of the sensor adapts to normal variations and inaccuracies in indicia configuration, size and placement in a continuous roll of prints which contain a large number of individual orders and from which the individual prints must be cut and separated into the respective orders.
Mounting guide rail 10 is attached to frame assembly 521-1059 as by mounting screws 12 engaging threaded holes provided in said frame assembly as illustrated in FIGS. 2 and 3. Frame assembly 521-1059 is best seen in Illustrated Parts List for Pako Model 244 cutters, Form 72-1R3 FIG. 1. Sensor mounting assembly 14 is attached to mounting guide rail 10 as by screws 16 engaging threaded holes in said guide rail. Fixed lateral slide block 18 as best illustrated in FIG. 2 is attached to sensor mounting assembly 14 as by screws 20. Said lateral slide block 18 is configured to provide a longitudinal V shaped as best illustrated in FIG. 7. Movable lateral slide block 22 provides a threaded hole and a longitudinal V shaped protrusion to engage the V shaped groove provided in fixed lateral slide block 18. Knurled head lateral sensor adjusting screw 24 engages a threaded hole provided in said movable slide block assembly 22 as seen in FIG. 8. Said lateral sensor adjusting screw 24 with compression spring 26 installed thereon is rotatably attached to the fixed lateral slide block 18 as by end plate 28 and mounting screws 30. Compression spring 26 is retained in a compressed state as by split snap ring 32 engaging an axial groove provided on lateral adjusting screw 24. The previously described assembly provides lateral adjustment of movable slide block 22 by rotation of said lateral sensor adjusting screw 24 while compression spring 26 maintains loading on said adjusting screw and movable slide block to remove end play and prevent tolerance buildup.
Movable lateral slide block 22 provides a transverse V shaped groove positioned as best illustrated in FIG. 2. Sensor mounting slide 34 provides a threaded hole and a V shaped protrusion to engage the V shaped groove provided in said fixed lateral slide block. Knurled head transverse sensor adjusting screw 36 engages the threaded hole provided in said sensor mounting 34. Said transverse sensor adjusting screw 36 with sensor mounting 34 and compression spring 38 installed as best shown in FIG. 3 is rotatably attached to said lateral slide block 22 as by end plates 40 and mounting screws 42. Compression spring 38 is retained in a compressed state between end plate 40 and sensor mounting plate 34 by split snap ring 44 engaging an axial groove provided in said transverse sensor adjusting screw 36. This assembly provides transverse adjustment of the sensor mount slide 34 by rotating knurled head transverse sensor adjusting screw 36 while compression spring 38 maintains loaded on said adjusting screw and said sensor mounting slide to remove end play and prevent tolerance buildup.
Sensor assembly 46 is positioned on said sensor mounting slide 34 as by locating screws 48 engaging a hole provided therein, and attached thereto as by sensor mounting screw 50. Infrared source D2 and photovoltaic cell BT2 and the sensor electronics illustrated in FIG. 5 are positioned within sensor assembly 46 and maintained therein as by molding with a resin compound as best illustrated in FIG. 4.
The inherent characteristics of the phototransistors previously used for the sensing elements are so limited in the scanning area as to prevent the same from operating successfully as a wide angle sensing element, even the use of a lens system. When used with the equipment presently being marketed. The wide angle sensing area required to produce the desired universal sensing function for a successful print cutting operation must be capable of providing a sensing area having a width of at least 0.250 inches when installed in its operative position. The photovoltaic cell herein designated at a BT2 meets these requirements and increases the width of the sensing area very substantially over the width permitted by the use of a phototransistor indicia sensing element.
Photographic strip guide 52 is attached as by thumb screws 54 engaging threaded holes provided in sensor mounting assembly 14. Guide 52 is adjusted while thumb screws 54 are in a loosened state.
The electronics for the improved hole sensor are illustrated in FIG. 5. All components are commercially available and are not critical to the design, however slight modifications in amplifier frequency compensation may be necessary if major changes are made. The quadruple differential amplifiers commercially available are type 4136 as supplied by Ratheon Semiconductor Division or equivalent, signal diodes are JEDEC type 1N4305 or equivalent, zener diode CR2 is a commercially available 12 volt device, resistors are 1/4 watt carbon composition, capacitors are ceramic with the exception of C6 which is a 35v electrolytic.
The electronics illustrated in FIG. 5 are mounted in sensor assembly 46 as illustrated in FIG. 4. Electrical interconnection is made by cable assembly 56 and plug 58 which is compatible with existing sockets on Pako Model 255 cutters.
The cathode of 12 volt zener diode CR2 is connected to NODE 4 and the anode connected to ground. Resistor R10 is connected between +25 volt source and NODE 4. The positive plate of electrolytic capacitor C6 is connected to NODE 4, the negative plate to ground. The interconnection of diode CR2, resistor R10 and capacitor C6 as previously described provide a +12 volt reference at 4 and is used throughout the electronics.
The anode of infrared emitting diode D2 is connected to the +25 supply contained in the paper cutter, the cathode of diode D2 is connected to a current resistor located within the paper cutter. Photovoltaic cell BT2 is connected with the positive terminal, connected to NODE 2, the negative terminal connected to ground. Resistor R2 is connected in parallel with said photovoltaic sensor. Capacitor C2 is connected between NODE 2 and the noninverting input of differential amplifier U2. The interconnection of devices BT2, R2 and C2 as previously described provide a translation of the output of photovoltaic cell BT2 to approximately +12.
Resistor R4 is connected between the non-inverting input of differential amplifier U2 and NODE 4. Resistor R6 is connected between the inverting input of differential amplifier U2 and NODE 4. Capacitor C4 with resistor R8 connected in parallel are connected between the output of differential amplifier U2 and the inverting input. The previously described interconnection of differential amplifier U2, resistors R4, R6 and R8 and capacitor C4 provide a shaping circuit to condition the translated output of photovoltaic cell BT2.
Resistor R12 is connected between the inverting input of differential amplifier U4 and NODE 4. Resistor R14 is connected between the noninverting input of differential amplifier U4 and NODE 4. Resistor R16 is connected between the output and inverting input of differential amplifier U4. The cathode of diode D4 is connected to the output of differential amplifier U4. The anode of diode D4 is connected to the inverting input of differential amplifier U4. Capacitor C8 is connected between the output of differential amplifier U2 and the noninverting input of differential amplifier U4. Components R12, R16, D4 and differential amplifier U4 provide a blanking function.
Resistor R20 is connected between NODE 4 and the noninverting input of differential amplifier U6. Resistor R22 is connected between NODE 4 and the inverting input of differential amplifier U6. Resistor R24 is connected between the noninverting input of differential amplifier U6 and ground. The cathode of diode D8 is connected to the noninverting input of differential amplifier U6, the anode to NODE 8. The anode of diode D10 is connected to ground and the cathode to NODE 8.
Capacitor C12 is connected between the input of differential amplifier U6 and NODE 8. Capacitor C10 is connected between the output of differential amplifier U4 and NODE 6. The anode of diode D6 is connected to NODE 6, the cathode of diode D6 is connected to NODE 4. Resistor R18 is connected between NODE 6 and the inverting input of differential amplifier U6. Components R20, R22, R24, diodes D8 and D10, capacitor C12 and differential amplifier U6 interconnected as previously described form a monostable multivibrator with a time constant of approximately 15 msec.
Resistor R26 is connected between the output of differential amplifier U6 and the inverting input of differential amplifier U8. The noninverting input of differential amplifier U8 is connected to NODE 4. The output of differential amplifier U8 is provided to switch S3 as best illustrated in FIG. 14 of the electrical diagrams for Pako Models 255 and 255B as previously described.
The end of order indicia are detected by a wide scanning angle sensor with independent axis adjustment capability as previously described, attached to the front frame assembly of the cutter. This assembly is identical to the improvement herein described, however configured to position the sensor and adjustment knobs appropriately for the front frame mounting. This reconfiguration requires fabricating a mounting guide rail similar to, but reversed from, component 10 illustrated in FIGS. 2 and 3. The lateral slide block assembly is assembled as shown attached to the reversed mounting guide rail. The transverse slide block assembly is then assembled with the adjusting screw and way subassembly reversed as allowed by the intrinsic symmetry of the components. Sensor assembly 46 is then attached to sensor mounting plate 34 in a reversed manner. The assembly is then attached to the front frame assembly 521-1059.
A cutter configured with two wide scanning angle sensors as described provides the capability to accommodate a roll of uncut prints with cutting indicia on either margin as would result if a roll of prints were inadvertently rolled backwards, for instance. The Pako Model 255 cutter provides switching capability to allow operator to choose which sensor will actuate the cutter. The other sensor will then become the end of order sensor. These switches are schematically illustrated in Electrical Diagrams for Pako Model 255 cutter, form 27-026R1 page 12.
It will, of course, be understood that various changes may be made in the form, details, arrangement and proportions of the parts without departing from the scope of this invention, which generally stated is set forth in the appended claims. | An improvement for use with an automatic print cutter mechanism which is actuated by sensing control indicia positioned along a continuous strip of photographic prints, said improvement comprising a wide scanning angle sensor capable of detecting said indicia of numerous configurations when same are misaligned with respect to the center line of said sensor and means for independent lateral and transverse adjustment of said sensor. | 1 |
This is a continuation application of our co-pending application of our co-pending application U.S. Ser. No. 580,901, filed Feb. 16, 1984, now U.S. Pat. No. 4,544,757.
BACKGROUND OF THE INVENTION
This invention relates to a process for the resolution of (±)-pyrano-[3,4-b]indole-1-acetic acids to obtain the separate corresponding (+) and (-) optical enantiomers.
The racemic (±)-pyranol[3,4-b]indole-1-acetic acids are well known anti-inflammatory and analogesic agents described by C. A. Demerson et al., U.S. Pat. No. 3,939,178, issued Feb. 17, 1976; C. A. Demerson et al., J. Med. Chem., 18, 189 (1975) and 19, 391 (1976).
The process of this invention involves the condensation of a racemic (±)-pyrano[3,4-b]indole-1-acetic acid with (-)-borneol to obtain a separable diasteroisomeric mixture of the corresponding esters and hydrolyzing the (+) and (-) diastereoisomeric esters. A limited number of esterifications of a racemic acid with an optically active alcohol to give diastereoisomeric esters are described, for example, P. H. Boyle, Quarterly Reviews, 25, 323 (1971). In addition, a few total synthesis of optically active acids using optically active alcohols are described, for example E. Wehinger et al., Abstr. Papers Am. Chem. Soc. 182 Meet. MEDI 64/1981; B. Laangstroem et al., Chem. Abstr. 91, 193607 p (1979) for Chem. Scr., 13, 49 (1979); and P. E. Krieger et al., J. Org. Chem., 43, 4447 (1978).
The above described uses of optically active alcohols are for specific synthesis of various acids in limited quantities. Such use of optically active alcohols are known to be of little importance for the general resolution of racemic acids, see P. H. Boyle, cited above, at p. 325. Usually the mixture of diastereoisomeric esters cannot be separated to obtain the individual enantiomers.
The process of this invention resulted from the discovery that a diastereoisomeric mixture of pyrano[3,4-b]indole-1-acetic acid (-)-borneol esters can be easily separated. This process gives individual (+) and (-)-enantiomers of a pyrano[3,4-b]indole-1-acetic acid in a commercially feasible operation and in high yield.
SUMMARY OF THE INVENTION
The process of this invention comprises:
(a) esterifying a racemic (±)pyrano[3,4-b]indole-1-acetic acid of formula I ##STR1## in which R 1 is lower alkyl, and R 2 and R 3 each is hydrogen, lower alkyl or halo with (-)-borneol to obtain a diastereoisomeric mixture of a corresponding compound of formula II ##STR2## in which R 1 , R 2 and R 3 are as defined above;
(b) separating the diastereoisomers;
(c) hydrolyzing the (+) or (-)-diastereoisomer of formula II under alkaline conditions; and
(d) isolating the corresponding (+) or (-)-enantiomer of formula I in which R 1 , R 2 and R 3 are as defined herein.
In a preferred process, (±)-1,8-diethyl-1,3,4,9-tetrahydropyrano[3,4-b]-indole-1-acetic acid is resolved with (-)-borneol to obtain (+)-1,8-diethyl-1,3,4,9-tetrahydropyrano[3,4-b]indole-1-acetic acid.
DETAILED DESCRIPTION OF THE INVENTION
The term "lower alkyl" as used herein means straight and branched chain alkyl radicals containing from one to five carbon atoms and includes methyl, ethyl, propyl, 1-methylethyl, butyl, 1,1-dimethylethyl and the like, unless stated otherwise.
The term "halo" as used herein means bromo, chloro, fluoro and iodo, unless stated otherwise.
The first step in the process for resolving a racemic compound of formula I in which R 1 , R 2 and R 3 are as defined herein involves the esterification of the compound of formula I with (-)-borneol to obtain the diastereoisomeric mixture of the corresponding compound of formula II in which R 1 , R 2 and R 3 are as defined herein. A number of the methods known in the art can be utilized for this esterification, for example, use of an acid chloride or bromide of the acid of formula I; acid catalyzed esterification; use of a dehydrating agent, i.e. a dialkylcarbodiimide; and use of a dehydrating agent in the presence of an esterification catalyst, i.e. N-hydroxysuccinimide, 2,4,5-trichlorophenol, 1-hydroxybenzotriazole and 4-dimethylaminopyridine. In the preferred method of esterification, the racemic compound of formula I is condensed with about 1.0 to 1.5 molar equivalents of (-)-borneol in the presence of about 1.0 to 1.5 molar equivalents of N,N'-dicyclohexylcarbodiimide and about 0.1 to 0.15 molar equivalents of 4-dimethylaminepyridine in an inert organic solvent, for example, diethyl ether, diisopropyl ether, chloroform or dimethylformamide. The condensation reaction is allowed to proceed at about 15° to 30° C. for about 10 to 30 hours. After a standard work-up, a diastereoisomeric mixture of the corresponding compounds of formula II are obtained. The diastereoisomeric mixture can be separated to obtain the individual diastereoisomers by using chromatography on a silica gel adsorbant with a suitable eluant. The chromatography can be conducted by using a thin layer of adsorbent on plates, a column of adsorbent at atmospheric pressure or a column of adsorbant under high pressure. A preferred eluant for the chromatography is about 3 to 10 percent ethyl acetate in hexane.
Each of the separated diastereoisomers of formula II is hydrolyzed under alkaline conditions to obtain the corresponding (+) or (-) enantiomer of formula In in which R 1 , R 2 and R 3 are as defined herein. Preferred conditions for the hydrolysis involve reacting the individual diastereoisomers of formula II with an aqueous solution of about two to five molar equivalents of an alkali hydroxide or carbonate, preferably sodium or potassium hydroxide, and a water miscible organic solvent, preferably methanol or ethanol at about 60° to 80° C. for one to ten hours. After hydrolysis is complete, the alkaline solution is acidified, preferably with a dilute mineral acid, and the individual enantiomers of formula I are extracted and purified.
The following examples illustrate further this invention:
EXAMPLE 1
1,8-Diethyl-1,3,4,9-tetrahydropyrano[3,4-b]indole-1-Acetic acid, (-)-borneol Esters
A mixture consisting of (±)-1,8-diethyl-1,3,4,9-tetrahydropyrano[3,4-b]-indole-1-acetic acid (100 g, 0.348 mol), (-)-borneol (64.46 g, 0.418 mol), 4-dimethylaminopyridine (5.09 g, 0.0417 mol) and N,N'-dicyclohexylcarbodiimide (86.24 g, 0.418 mol) in 1.5 liters of diethyl ether was stirred at 22° C. for 18 hours. The reaction was cooled in an ice-water bath and filtered. The filtrate was washed once with 5% aqueous sodium hydroxide, twice with 5% hydrochloric acid and twice with water. After drying over magnesium sulfate and evaporation of the solvent, 160.3 g of a semisolid was obtained. Filtration through 1.5 kg of silica gel using 10% ethyl acetate in hexane as eluant afforded 119.3 g of the mixture as a solid. Preparative high pressure liquid chromatography (using batches of 20-25 g) using Prepak 500 silica gel cartridges and 3% ethyl acetate in hexane as eluant separated the (+) and (-) esters of the title compound. Evaporation of the appropriate eluates gave 52.33 g of the (+)-diastereoisomer; mp 142°-143° C.; [α] D +47.4° (1% in ethanol); and Anal. Calcd for C 27 H 37 NO 3 : C, 76.56% H, 8.81% N, 3.31% and Found: C, 76.60% H, 8.71% N, 3.28%. The (-)-diastereoisomer (53.33 g) had mp 93°-96° C.; [α] D -61.4° (1% in ethanol); and Anal. Found: C, 76.71% H, 8.72% N, 3.21%.
EXAMPLE 2
Hydrolyses of Borneol Esters
The (-)-diastereoisomeric ester, obtained from Example 1, was dissolved in methanol (1 liter) containing potassium hydroxide (34.8 g) and water (260 ml). The mixture was refluxed while stirring for 3 hr. Most of the methanol was distilled off, water (500 ml) was added and the mixture was extracted with toluene. The aqueous phase was acidified with 6N hydrochloric acid and extracted with chloroform. The chloroform extracts were washed with water, dried and and solvent removed to afford crude (+)-enantiomer (32.5 g) which was purified by chromatography on 1 kg of silica gel impregnated with phosphoric acid by stirring the silica gel with a 1% solution of phosphoric acid in methanol, followed by air drying. Elution with 10% acetone in toluene gave the pure (+)-enantiomer. It was obtained as a solid by dissolving in benzene (100 ml) and pouring into cold petroleum ether (bp 30°-60° C., 1.2 liters) with stirring. Subsequent crystallization from benzene-petroleum ether (bp 30°-60° C.) gave the pure enantiomer, (+)-1,8-diethyl-1,3,4,9-tetrahydropyrano[3,4-b]indole-1-acetic acid (24.02 g): mp 138°-140° C.; [α] D +25.2° (3% in ethanol); and Anal. Calcd for C 17 H 21 NO 3 : C, 71.05% H, 7.37% N, 4.88% and Found: C, 71.14% H, 7.36% N, 4.81%. In the same manner, the (+)-diastereoisomeric ester, obtained from Example 1, gave (-)-1,8-diethyl-1,3,4,9-tetrahydropyrano[3,4-b]indole-1-acetic acid (21.46 g): mp 139°-141° C.; [+] D -25.6° (3% in ethanol); and Anal. Found: C, 71.09) H, 7.37% N, 4.84%.
EXAMPLE 3
Effect on Primary Inflammation of Adjuvant Induced Arthritis
The method used was a modification of that described by J. Wax et al., J. Pharmac. Exp. Ther., 192, 166 (1975). Groups of rats were injected intradermally in the left hindpaw (injected hindpaw) with 0.1 ml of a fine suspension of killed and dried Mycobacterium butyricum (Difco) at a concentration of 5 mg/ml in liquid paraffin (Freund's complete adjuvant). Drugs were administered immediately before the adjuvant, 24 h and 48 h after the adjuvant (day 0, 1 and 2). The injected hindpaw volume was measured before the adjuvant and 24 after the last drug administration (day 3). The difference between the hindleg volume before the adjuvant injection and the day 3 reading represented the edema volume. Rats showing an inhibition of hindpaw edema of 25% or more when compared to the mean edema volume of the control group (10 rats) were considered to exhibit an anti-inflammatory effect. The dose which produced a positive effect in half the rats (ED 50 ) was calculated by probit analysis. (D. J. Finney, Statistical Method in Biological Assay, MacMillan, N.Y., 1978). There were 10 to 20 rats per dose and 4 dose levels were used. An adjuvant-injected control group receiving water only was also included. Hindleg volume was determined by a mercury displacement method. Hindlegs were dipped in mercury up to the hairline and the amount displaced was read in grams on a direct reading balance. It represented the volume of the hingleg (13.6 g of mercury=1 ml). Male Charles River albino rats weighing 180 to 200 g were used. The results are expressed as ED 50's , the dose which reduces, by 25% the edema of primary adjuvant arthritis in 50% of the rats. In this model the ED 50 for (+)-1,8-diethyl-1,3,4,9-tetrahydropyrano[3,4-b]indole-1-acetic acid was 0.7±0.3 mg/kg, while the (-)-enantiomer was inactive. The ED 50 of the (±)-racemate in this test was 1.1±0.5 mg/kg. | Mixtures of racemic (+)pyrano[3,4-b]indole-1-acetic acids are resolved with (-)-borneol to obtain the substantially pure (+) and (-)-enantiomers. The resolution involves the formation of a mixture of the diastereoisomeric pyrano[3,4-b]indole-1-acetic acid, (-)-borneol esters, separation of the diastereoisomeric esters, and hydrolysis of the latter esters. | 2 |
[0001] The present application is based on Japanese Patent Application No. 2002-353560, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a polarizing plate used in an image display device such as a liquid crystal display device, an organic EL display device or a PDP and particularly to a polarizing plate used in a liquid crystal display device.
[0004] 2. Description of the Related Art
[0005] A polarizing plate used in an image display device (especially, a liquid crystal display device) is produced as follows. For example, after a polyvinyl alcohol (PVA) film is subjected to a dyeing process, a crosslinking process and a stretching process, the film is dried and laminated between protective layers each made of a transparent protective film such as a triacetyl cellulose (TAC) film. In the dyeing process, the polyvinyl alcohol (PVA) film is dyed with dichroic iodine or dichroic dye. In the crosslinking process, the film is crosslinked with boric acid, borax or the like. In the stretching process, the film is stretched uniaxially. (The dyeing, crosslinking and stretching processes need not be executed separately. Some processes may be executed simultaneously. The sequence of the processes is not particularly limited.)
[0006] Incidentally, it is preferable that a protective sheet not curled originally is used as each of the protective layers used for protecting the polarizing plate. When a film made of a material such as triacetyl cellulose (TAC) or polycarbonate is used as the protective sheet, generally, the film is however more or less curled because the film is produced by stretching. If the polarizing plate is curled largely, a portion different in optical characteristic such as in-plane light transmittance is produced by stress acting on the polarizing plate when the polarizing plate is bonded to a panel and used. This causes ununiformity of image display. If the polarizing plate is bonded to a liquid crystal cell in the condition that an adhesive surface of the polarizing plate to be bonded to the liquid crystal cell is curled concavely with respect to the liquid crystal cell, voids are held between the polarizing plate and the liquid crystal cell bonded to each other. For this reason, it is impossible to use the polarizing plate.
[0007] The aforementioned curl was heretofore suppressed by a method of adjusting the physical condition of the protective sheet (e.g., see Patent Document 1). In recent years, there was however a demand for a bigger size of the polarizing plate than ever. As the area of the polarizing plate increased, the amount of curl at edge sides increased inevitably. With the increase in the amount of curl in the polarizing plate, there arose again the case where the curl of the polarizing plate brought about the problem of lowering of work efficiency and in-plane variation in various kinds of optical characteristic because of the difficulty of bonding the polarizing plate to the panel. Therefore, an important issue is to suppress the curl of the polarizing plate more sufficiently.
[0008] [Patent Document 1]
[0009] Unexamined Japanese Patent Publication No. 2002-258049
SUMMARY OF THE INVENTION
[0010] An object of the invention is to provide a method for producing a polarizing plate in which curl of the polarizing plate can be reduced, mainly a method for producing a polarizing plate in which curl of a widthwise direction generated in a polarizing plate production process, i.e., curl of the widthwise direction of a raw material sheet of the polarizing plate can be reduced, a polarizing plate produced by the production method, and an image display device using the polarizing plate.
[0011] The inventors have made investigation earnestly to examine the problem. As a result, it has been found that the foregoing object can be achieved by the following method of producing a polarizing plate. Thus, the invention is accomplished.
[0012] The invention provides a method of producing a polarizing plate, comprising including the step of laminating a pair of curled protective sheets onto opposite surfaces of a polarizer respectively so that respective curling directions of the pair of curled protective sheets are reverse to each other.
[0013] Preferably, the pair of curled protective sheets have a laminating index L of not higher than 60 when the laminating index L is given by the expression:
L= ( a−b )/ a× 100
[0014] in which a and b are quantities of curl in the pair of protective sheets respectively on the assumption of a>b.
[0015] The invention also provides a polarizing plate produced by the production method on the basis of the laminating index L. The invention further provides a composite polarizing plate produced in the same manner as described above and having an optical layer laminated on the polarizing plate. The invention further provides an image display device using at least one of these polarizing plates.
[0016] The invention further provides a polarizing plate including a polarizer, and a pair of protective sheets laminated onto opposite surfaces of the polarizer respectively, wherein curling directions of the pair of protective sheets are reverse to each other when the pair of protective sheets are separated from the polarizing plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the accompanying drawings:
[0018] [0018]FIGS. 1A and 1B are combinations of a schematic view and a sectional view showing curling directions in the case where protective sheets are laminated on opposite surfaces of a polarizer in the invention;
[0019] [0019]FIGS. 2A and 2B are combinations of a schematic view and a sectional view showing curling directions in the case where protective sheets are laminated on opposite surfaces of a polarizer in a comparative example;
[0020] [0020]FIG. 3 is a schematic view showing a method for acquiring a curl amount measuring sample from a protective sheet in the invention; and
[0021] [0021]FIG. 4 is a schematic view showing a method for acquiring a curl amount measuring sample from a polarizing plate in the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] A polarizing plate according to the invention is basically configured so that a protective sheet is bonded, through a suitable adhesive layer made of a vinyl alcohol polymer etc., to one or each of opposite surfaces of a polarizer, for example, made of a dichroic substance-containing polyvinyl alcohol film.
[0023] The polarizer is produced by a swelling process, a dyeing process, a crosslinking process, a stretching process, etc. In the swelling process, for example, a polyvinyl alcohol film is immersed in water, and washed with water so that dirt or an antiblocking agent deposited on a surface of the polyvinyl alcohol film can be cleaned. In addition, the polyvinyl alcohol film is swollen so as to be effective in preventing ununiformity such as ununiform dyeing. In the dyeing process, the film is dyed in a bath containing a dichroic substance such as iodine or a dye such as a dichroic dye. In the crosslinking process, the film is crosslinked in a bath containing a crosslinking agent such as boric acid or borax. In the stretching process, the film is stretched by a scaling factor of from three times to seven times as large as its original length. The sequence of these processes is not particularly limited. Some processes may be carried out simultaneously. For example, the film may be stretched after dyed with iodine, the film may be stretched while dyed with iodine, or the film may be dyed with iodine after stretched. The film can be stretched even in an aqueous solution of boric acid or potassium iodide or in a water bath.
[0024] Any kind of material can be used as the polarizer without any particular limitation. Examples of the material of the polarizer include: a hydrophilic high-molecular film, such as a polyvinyl alcohol film, a partially formalized polyvinyl alcohol film or a partially saponified ethylene-vinyl acetate copolymer film, which film is stretched uniaxially after adsorbing a dichroic substance such as iodine or dichroic dye; and a polyenic oriented film such as a dehydrated film of polyvinyl alcohol or a dehydrochlorinated film of polyvinyl chloride. Especially, a polarizer made of a combination of a polyvinyl alcohol film and a dichroic substance such as iodine is preferred. The thickness of the polarizer is not particularly limited. Generally, the thickness of the polarizer is selected to be in a range of from 5 μm to 80 μm.
[0025] The polarizer may contain boric acid, zinc sulfate, zinc chloride, etc. as occasion demands. The polarizer may be immersed in an aqueous solution of potassium iodide or the like.
[0026] A material excellent in transparency, mechanical strength, thermal stability, moisture sealability, isotropy and so on is preferably used as the material for forming the protective sheet provided on one or each of opposite surfaces of the polarizer. Examples of the polymer for forming the protective sheet include: polyester polymer such as polyethylene terephthalate, and polyethylene naphthalate; cellulose polymer such as diacetyl cellulose, and triacetyl cellulose; acrylic polymer such as polymethyl methacrylate; styrene polymer such as polystyrene, and acrylonitrile-styrene copolymer (AS resin); and polycarbonate polymer. Examples of the polymer for forming the protective sheet further include: polyolefin polymer such as polyethylene, polypropylene, polyolefin having a cyclo or norbornene structure, and ethylene-propylene copolymer; vinyl chloride polymer; amide polymer such as Nylon, and aromatic polyamide; imide polymer; sulfone polymer; polyether-sulfone polymer; polyether-ether-ketone polymer; polyphenylene sulfide polymer; vinyl alcohol polymer; vinylidene chloride polymer; vinyl butyral polymer; allylate polymer; polyoxymethylene polymer; epoxy polymer; and blends of these polymers. The protective sheet can be also formed as a cured layer of a heat-curable or ultraviolet-curable resin such as an acrylic resin, an urethane resin, an acrylic urethane resin, an epoxy resin, or a silicone resin. Among those polymers, cellulose polymer is particularly preferable.
[0027] A polymer film described in Unexamined Japanese Patent Publication No. 2001-343529 (WO 01/37007) may be also used as the protective sheet. For example, the polymer film is made of a resin composition containing (A) a thermoplastic resin having substitutional and/or nonsubstitutional imide group as a side chain, and (B) a thermoplastic resin having substitutional and/or nonsubstitutional phenyl group and nitrile group as a side chain. As a specific example, there can be used a film of a resin composition containing an alternating copolymer of isobutene and N-methyl maleimide, and an acrylonitrile-styrene copolymer. As the film, there can be used a film made of an extruded mixture product of a resin composition.
[0028] The thickness of the protective sheet is not particularly limited. Generally, the thickness of the protective sheet is selected to be not larger than 500 μ, preferably in a range of from 1 μm to 300 μm, especially preferably in a range of from 5 μm to 200 μm. From the point of view of polarizing characteristic, durability, etc., it is preferable that a surface of the protective film is saponified with alkali or the like.
[0029] It is also preferable that the protective sheet is as colorless as possible. Hence, there can be preferably used a transparent protective film which is formed so that a retardation in a direction of thickness of the film is in a range of from −90 nm to +75 nm when the retardation is given by the expression:
Rth =[( nx+ny )/2− nz]·d
[0030] in which nx and ny are main refractive indices in planes of the film, nz is a refractive index in a direction of thickness of the film, and d is the thickness of the film.
[0031] When the transparent protective film which is formed so that the retardation (Rth) in the direction of thickness is in a range of from −90 nm to +75 nm is used, coloring (optical coloring) of the polarizing plate caused by the transparent protective film can be substantially eliminated. More preferably, the retardation (Rth) in the direction of thickness is selected to be in a range of from −80 nm to +60 nm, especially in a range of from −70 nm to +45 nm.
[0032] Two protective sheets different in characteristic may be bonded to opposite surfaces of the polarizer respectively. Examples of the characteristic include thickness, material, light transmittance, tensile modulus of elasticity, and presence of an optical layer. The characteristic is not limited to the examples.
[0033] In a production method according to the invention, two curled protective sheets as a sample extracted at a certain point of time before lamination are laminated onto opposite surfaces of a polarizer respectively so that curling directions of the protective sheets are reverse to each other as shown in FIG. 1A or 1 B. It is found that if the protective sheets are laminated onto opposite surfaces of the polarizer respectively so that curling directions of the protective sheets are equal to each other as shown in FIG. 2A or 2 B, the amount of curl of a polarizing plate after lamination becomes larger than that in the case where the protective sheets are laminated onto opposite surfaces of the polarizer respectively so that curling directions of the protective sheets are reverse to each other as shown in FIG. 1A or 1 B.
[0034] [0034]FIG. 1A shows a lamination where convex curled surfaces (the curling direction is a direction coming closer to the polarizer) of two protective sheets are opposed to each other. FIG. 1B shows a lamination where concave curled surfaces (the curling direction is a direction moving away from the polarizer) of two protective sheets are opposed to each other.
[0035] The amount of curl of each protective sheet is measured as follows. As shown in FIG. 3, five samples 21 each having a size of 3 mm wide and 35 mm long are punched out from a raw protective sheet 20 so that the length of 35 mm in each sample 21 is taken in a widthwise direction 4 of the raw protective sheet 20 . After left in a conditioning space under 25±2%RH for 24 hours, each sample 21 is taken out from the conditioning space. Within 2minutes, each sample 21 is put on a flat surface. In the condition that an end of each sample 21 is held by 5 mm, a spatial distance raised from the flat surface is measured. All the five samples 21 are measured in the same manner as described above, so that an average of five measured values is calculated as the amount of curl of the protective sheet.
[0036] The amount of curl of the polarizing plate is measured as follows. As shown in FIG. 4, three samples 31 each having a size of 25 cm square are punched out from a raw material sheet 30 of the polarizing plate in a widthwise direction 4 so that an absorption axis 6 of the raw material sheet 30 is inclined at an angle of 45° to each side of each sample 31 . Each sample 31 is put on a flat surface. Spatial distances raised from the flat surface are measured at two top points of the sample 31 in the widthwise direction 4 . All the three samples 31 are measured in the same manner as described above, so that an average of six measured values is calculated as the amount of curl of the polarizing plate.
[0037] The amount of curl of the protective sheet measured as described above is evaluated on the basis of a laminating index L given by the expression:
L= ( a−b )/ a× 100
[0038] in which a and b are amounts of curl of two protective sheets respectively on the assumption of a>b.
[0039] Although the amount of curl is approximately proportional to the length of the protective sheet, the laminating index L can be decided regardless of the length of the protective sheet. In the invention, the laminating index L is preferably not higher than 60 and more preferably not higher than 40. If the laminating index L is higher than 60, the amount of curl of the polarizing plate increases even in the case where the laminating method according to the invention is used.
[0040] The extracting method used at the time of measuring the amount of curl need not be used when the polarizing plate is actually cut out. That is, the polarizing plate can be cut out so that each side of the polarizing plate is inclined at an optional angle of from 0° to 180° with respect to the absorption axis.
[0041] In practice, the polarizing plate according to the invention can be used after any kind of optical layer is laminated on the polarizing plate. The optical layer is not particularly limited if it satisfies required optical characteristic. For example, a surface of the transparent protective film to which the polarizer is not bonded (i.e., a surface on which the adhesive layer is not provided) may be subjected to a hard coating treatment, an anti-reflection treatment or a surface treatment for anti-sticking, diffusion or anti-glare. For example, a method of laminating an oriented liquid crystal layer on the surface of the transparent protective film may be used for the purpose of compensating the viewing angle. A layer of an optical film such as a reflecting plate, a semi-transmissive plate, a phase retarder (inclusive of a wave plate (λ plate) such as a half-wave plate or a quarter-wave plate), a viewing angle compensating film, or a luminance-enhancing film used for forming a liquid crystal display device may be used as the optical layer. Or a laminate of two or more layers of such optical films may be used as the optical layer. Especially, there may be preferably used a reflection type or semi-transmission type polarizing plate made of a laminate of the polarizing plate and a reflecting plate or semi-transmissive reflecting plate, an elliptic or circular polarizing plate made of a laminate of the polarizing plate and a phase retarder, a wide viewing angle polarizing plate made of a laminate of the polarizing plate and a viewing angle compensating layer or film, or a luminance-enhancing type polarizing plate made of a laminate of the polarizing plate and a luminance-enhancing film. The optical layer or optical film may be laminated onto the transparent protective film after or before the transparent protective film is bonded to the polarizer.
[0042] The hard coating treatment is carried out for preventing a surface of the polarizing plate from being scratched. For example, the hard coating treatment can be achieved by a method in which a cured film excellent in hardness, lubricity, etc. as obtained from a suitable ultraviolet-curable resin such as an acrylic resin or a silicone resin is added to a surface of the transparent protective film. The anti-reflection treatment is carried out for preventing a surface of the polarizing plate from reflecting external light. For example, the anti-reflection treatment can be achieved by a method of forming an anti-reflection film according to the related art. The anti-sticking treatment is carried out for preventing the polarizing plate from being stuck closely to an adjacent layer.
[0043] The anti-glare treatment is carried out for preventing visibility of light transmitted through the polarizing plate from being disturbed by external light reflected in a surface of the polarizing plate. For example, the anti-glare treatment can be achieved by a technique in which a fine irregular structure is given to a surface of the transparent protective film by a suitable method such as a surface roughening method using sandblasting or embossing, or a method of mixing transparent fine particles. For example, transparent fine particles with a mean particle size of 0.5 μm to 50 μm can be used as the fine particles contained in the transparent protective film for forming the fine irregular surface structure. Examples of the transparent fine particles include: inorganic fine particles of silica, alumina, titania, zirconia, tinoxide, indiumoxide, cadmium oxide, antimony oxide, etc. which may be electrically conductive; and organic fine particles of a crosslinked or non-crosslinked polymer. When the fine irregular surface structure is formed, the amount of fine particles used is generally in a range of from about 2 parts by weight to about 70 parts by weight, preferably in a range of from 5 parts by weight to 50 parts by weight, with respect to 100 parts by weight of a transparent resin for forming the fine irregular surface structure. The anti-glare layer may serve also as a diffusing layer (having a viewing angle enlarging function, etc.) for diffusing light transmitted through the polarizing plate to enlarge the viewing angle etc.
[0044] Incidentally, the optical layer such as an anti-reflection layer, an anti-sticking layer, a diffusing layer or an anti-glare layer may be provided in the transparent protective film per se or may be provided as a matter separate from the transparent protective film.
[0045] The process of bonding the polarizer and the transparent protective film to each other is not particularly limited. For example, the bonding process can be carried out through an adhesive agent made of a vinyl polymer or an adhesive agent at least made of an aqueous crosslinking agent of a vinyl alcohol polymer containing boric acid or borax, glutaric aldehyde or melamine, and oxalic acid. The adhesive layer may be formed as a dried layer of an applied aqueous solution. The aqueous solution can be prepared so that other additives and a catalyst such as acid are mixed with the aqueous solution if necessary.
[0046] The reflection type polarizing plate is a polarizing plate provided with a reflecting layer. For example, the reflection type polarizing plate is used for forming a liquid crystal display device of the type of performing display by reflecting incident light coming from the viewing side (display side). The reflection type polarizing plate has an advantage in that reduction in thickness and size of the liquid crystal display device can be attained easily because a built-in light source such as a backlight unit can be dispensed with. The reflection type polarizing plate can be formed by a suitable method such as a method of providing a reflecting layer of a metal or the like on a surface of the polarizing plate through a transparent protective layer or the like if necessary.
[0047] As a specific example, the reflection type polarizing plate may be formed so that a sheet of foil or a deposited film of a reflective metal such as aluminum is provided on a surface of a matted transparent protective film to thereby form a reflecting layer on the transparent protective film. The reflection type polarizing plate may be also formed so that a reflecting layer having a fine irregular structure is formed on a fine irregular surface structure which is formed in such a manner that fine particles are mixed with the transparent protective film. The reflecting layer having the fine irregular structure has an advantage in that incident light is diffused by irregular reflection to prevent directivity and glaring appearance to thereby suppress ununiformity in brightness and darkness. The transparent protective film containing fine particles also has an advantage in that incident light and reflected light thereof is diffused when transmitted through the transparent protective film to thereby suppress ununiformity in brightness and darkness more perfectly. The reflecting layer having the fine irregular structure corresponding to the fine irregular surface structure of the transparent protective film can be formed by a technique in which a metal is directly provided on a surface of the transparent protective film by a suitable vapor deposition or plating method such as a vacuum vapor deposition method, an ion plating method or a sputtering method.
[0048] In place of direct provision of the reflecting plate on the transparent protective film of the polarizing plate, the reflecting plate may be used as a reflecting sheet constituted by a suitable film according to the transparent film and a reflecting layer provided on the suitable film. Incidentally, the reflecting layer is generally made of a metal. Accordingly, the reflecting surface of the reflecting layer may be preferably coated with a transparent protective film or a polarizing plate from the point of view of preventing lowering of reflectance due to oxidation and, accordingly, long duration of initial reflectance and avoidance of separate provision of a protective layer.
[0049] Incidentally, the semi-transmission type polarizing plate can be obtained in such a manner that the aforementioned reflecting layer is provided as a semi-transmission type reflecting layer such as a half mirror capable of reflecting part of light and transmitting the other part of light. The semi-transmission type polarizing plate is generally provided on the rear side of a liquid crystal cell to thereby make it possible to form a liquid crystal display device of the type in which image display is performed on the basis of reflection of incident light given from the viewing side (display side) when the liquid crystal display device is used in a relatively bright environment and in which image display is performed by using a built-in light source such as a backlight unit provided in the back side of the semi-transmission type polarizing plate when the liquid crystal display device is used in a relatively dark environment. That is, the semi-transmission type polarizing plate is useful for the formation of a liquid crystal display device of the type which can be used in a bright environment while energy consumed by a light source such as a backlight unit is saved and which can be also used in a relatively dark environment by using the built-in light source.
[0050] The elliptically or circularly polarizing plate as a laminate of the polarizing plate and a phase retarder will be described below. The phase retarder is used for converting linearly polarized light into elliptically or circularly polarized light, converting elliptically or circularly polarized light into linearly polarized light or changing the direction of polarization of linearly polarized light. Particularly as the phase retarder for converting linearly polarized light into elliptically or circularly polarized light or converting elliptically or circularly polarized light into linearly polarized light, there is used a so-called quarter-wave plate (also referred to as λ/4 plate). A half-wave plate (also referred to as λ/2 plate) is generally used for changing the direction of polarization of linearly polarized light.
[0051] The elliptically polarizing plate is used effectively for compensating for (preventing) coloring (blue or yellow) caused by birefringence of a liquid crystal layer of a super-twisted nematic (STN) liquid crystal display device to achieve monochrome display free from the coloring. An elliptically polarizing plate of the type capable of controlling three-dimensional refractive indices can be preferably used because coloring generated at the time of obliquely viewing a screen of a liquid crystal display device can be compensated for (prevented). The circularly polarizing plate is used effectively for adjusting the color tone of an image on a reflection type liquid crystal display device, for example, for color image display. The circularly polarizing plate also has an anti-reflection function.
[0052] Examples of the phase retarder include: a birefringent film of a uniaxially or biaxially stretched high-molecular material; an oriented film of a liquid crystal polymer; and a film provided with an oriented layer of a liquid crystal polymer supported by the film. For example, the process of stretching the high-molecular material can be carried out by a roll stretching method, a long gap alignment stretching method, a tenter stretching method, a tubular stretching method, etc. The stretching scale is generally in a range of from about 1.1 times to about 3 times in the case of uniaxial stretching. The thickness of the phase retarder is not particularly limited either. Generally, the thickness of the phase retarder is in a range of from 10 μm to 200 μm, preferably in a range of from 20 μm to 100 μm.
[0053] Examples of the high-molecular material include: high-molecular substances such as polyvinyl alcohol, polyvinyl butyral, polymethyl vinyl ether, polyhydroxyethyl acrylate, hydroxyethyl cellulose, hydroxypropyl cellulose, methyl cellulose, polycarbonate, polyallylate, polysulfone, polyethylene terephthalate, polyethylene naphthalate, polyether-sulfone, polyphenylene sulfide, polyphenylene oxide, polyallyl sulfone, polyvinyl alcohol, polyamide, polyimide, polyolefin, polyvinyl chloride, and cellulose polymer; and various kinds of co-orter-polymers, graft copolymers and blends of these high-molecular substances. The high-molecular material forms an oriented matter (stretched film) when stretched.
[0054] Examples of the liquid crystal polymer include various kinds of main-chain or side-chain polymers having conjugate linear atom groups (mesogen groups) introduced into its main chain or side chain for donating liquid crystal orienting characteristic. Specific examples of the main-chain liquid crystal polymer include polymers each having such a structure that mesogen groups are connected by a spacer portion for donating flexing characteristic, that is, a nematic liquid crystal polyester polymer, a discotic polymer, and a cholesteric polymer. Specific examples of the side-chain liquid crystal polymer include polymers each of which has polysiloxane, polyacrylate, polymethacrylate or polymalonate as a main chain skeleton, and a mesogen portion of a nematic orientation-donating para-substitutional cyclic compound unit through a spacer portion of conjugate atom groups as a side chain. Each of these liquid crystal polymers can be produced, for example, by a method in which a liquid crystal polymer solution is spread on a rubbed surface of a thin film of polyimide, polyvinyl alcohol or the like formed on a glass plate or on an oriented surface of obliquely deposited silicon oxide and then heated.
[0055] The phase retarder can have a suitable retardation according to the purpose of use such as the purpose of compensating for coloring caused by the birefringence of various kinds of wave plates and liquid crystal layers, the viewing angle, and so on. The phase retarder may be made of a laminate of at least two kinds of phase retarders in order to control optical characteristic such as retardation.
[0056] The elliptically polarizing plate or the reflection type elliptically polarizing plate is provided as a laminate using a suitable combination of at least one polarizing plate or reflection type polarizing plate and at least one phase retarder. The (reflection type) elliptically polarizing plate may be formed in such a manner that at least one (reflection type) polarizing plate and at least one phase retarder are laminated and stuck successively and separately in the process of production of a liquid crystal display device. Or the (reflection type) elliptically polarizing plate may be provided as an optical film in advance. The (reflection type) elliptically polarizing plate provided as an optical film is excellent in stability of quality and efficiency in laminating work, so that there is an advantage in that efficiency in production of a liquid crystal display or the like can be improved.
[0057] The viewing angle compensating film is a film provided for widening the viewing angle so that an image can be seen relatively sharply even in the case where a screen of a liquid crystal display device is viewed not perpendicularly but slightly obliquely. Examples of the viewing angle compensating phase retarder include: a phase retarder; an oriented film of a liquid crystal polymer etc.; and a transparent substrate having an oriented layer of a liquid crystal polymer etc. supported thereon. Although the general phase retarder is made of a polymer film uniaxially stretched in an in-plane direction so as to have birefringence, the phase retarder used as the viewing angle compensating film is made of a polymer film biaxially stretched in an in-plane direction so as to have birefringence or a bidirectionally stretched film such as a polymer film or a gradient oriented film uniaxially stretched in an in-plane direction and further stretched in a direction of thickness so as to have birefringence with the refractive index controlled in the direction of thickness. Examples of the gradient oriented film include: a polymer film stretched and/or shrunk under action of shrinking force of a heat-shrinkable film due to heating after the heat-shrinkable film is bonded to the polymer film; and a film of a liquid crystal polymer oriented obliquely. Polymers listed above in the description of the phase retarder can be used as materials for forming the phase retarder used as the viewing angle compensating film. A suitable polymer can be selected and used from the point of view of prevention of coloring caused by on the retardation in a liquid crystal cell according to change in viewing angle and enlargement of the viewing angle with good visibility.
[0058] To achieve a wide viewing angle with good visibility, there can be preferably used an optically compensating phase retarder which is formed in such a manner that an optically anisotropic layer made of an oriented layer of a liquid crystal polymer, especially made of an obliquely oriented film of a discotic liquid crystal polymer, is supported by a triacetyl cellulose film.
[0059] The polarizing plate provided as a laminate of a polarizing plate and a luminance-enhancing film is generally used in a state in which it is provided on the rear side of a liquid crystal cell. The luminance-enhancing film exhibits characteristic of reflecting part of light such as linearly polarized light having a predetermined axis of polarization or circularly polarized light having a predetermined direction but transmitting the other part of light when natural light is incident on the luminance-enhancing film from a backlight unit of a liquid crystal display device or by reflection in the rear side. The polarizing plate provided as a laminate of a polarizing plate and a luminance-enhancing film is provided so that part of light having a predetermined polarized state is transmitted and the other part of light not having the predetermined polarized state is not transmitted but reflected when light emitted from a light source such as a backlight unit is incident on the polarizing plate. Light reflected by a surface of the luminance-enhancing film may be returned by a reflection layer provided on the rear side of the luminance-enhancing film so that the light can be made incident on the luminance-enhancing film again. As a result, the light can be partially or wholly transmitted as light having the predetermined polarized state to attain increase in the amount of light transmitted through the luminance-enhancing film. Moreover, polarized light difficult to be absorbed to the polarizer can be supplied to attain increase in the amount of light allowed to be used for liquid crystal image display. In this manner, luminance can be improved. That is, if light emitted from a backlight unit on the rear side of a liquid crystal cell is made incident on the polarizer without use of any luminance-enhancing film, the light can be little transmitted through the polarizer because a large part of light having a direction of polarization not coincident with the axis of polarization of the polarizer is absorbed to the polarizer. That is, though the amount of light transmitted varies according to the characteristic of the polarizer used, about 50% of light is generally absorbed to the polarizer to decrease the amount of light allowed to be used for liquid crystal image display to thereby darken an image. The luminance-enhancing film does not transmit light having a direction of polarization which will be absorbed to the polarizer, that is, the luminance-enhancing film once reflects such light. The reflected light is returned by a reflecting layer provided on the rear side of the luminance-enhancing film so that the light can be made incident on the luminance-enhancing film again. While this operation is repeated, the direction of polarization of light reflected and returned between the luminance-enhancing film and the reflecting layer can be changed to allow the light to be transmitted through the polarizer. Only polarized light having the direction of polarization changed in this manner is supplied to the polarizer. Accordingly, light emitted from a backlight unit or the like can be effectively used for image display on a liquid crystal display device, so that the screen of the liquid crystal display device can be made bright.
[0060] A diffusing plate may be provided between the luminance-enhancing film and the reflecting layer. Light of a polarized state reflected by the luminance-enhancing film advances toward the reflecting layer. The diffusing plate provided between the luminance-enhancing film and the reflecting layer diffuses light transmitted through the diffusing plate evenly while eliminating the polarized state to a non-polarized state. That is, the polarized state is restored to a natural light state. The light of the non-polarized state, that is, the natural light state advances toward the reflecting layer and is reflected by the reflecting layer. The reflected light is transmitted through the diffusing plate again, so that the light is made incident on the luminance-enhancing film again. This operation is repeated. When the diffusing plate for restoring the polarized state to its original natural light state is provided as described above, a screen of uniform brightness can be provided so that ununiformity of brightness of the display screen can be reduced while brightness of the display screen can be retained. It is conceived that a display screen of uniform brightness can be provided because of moderate increase in the number of repetitions in reflection of initial incident light in addition to the diffusing function of the diffusing plate when the diffusing plate for restoring the polarized state to its original natural light state is provided.
[0061] Examples of the luminance-enhancing film that can be used suitably include: a film exhibiting characteristic of transmitting linearly polarized light having a predetermined axis of polarization but reflecting the other part of light, such as a multi-layer dielectric thin film or a multi-layer thin film having layers different in refractive index anisotropy; and a film exhibiting characteristic of reflecting either left-handed circularly polarized light or right-handed circularly polarized light but transmitting the other part of light, such as an oriented film of a cholesteric liquid crystal polymer or a film substrate having an oriented liquid crystal layer of a cholesteric liquid crystal polymer supported thereon.
[0062] Accordingly, when light transmitted through a luminance-enhancing film of the type of transmitting linearly polarized light having a predetermined axis of polarization is made incident on the polarizing plate having its axis of polarization coincident with the predetermined axis polarization, the light can be efficiently transmitted through the polarizing plate while absorption loss due to the polarizing plate is suppressed. On the other hand, in a luminance-enhancing film of the type of transmitting circularly polarized light in the same manner as in a cholesteric liquid crystal layer, although light can be made incident on the polarizer as it is, it is preferable from the point of view of suppression of absorption loss that the circularly polarized light is converted into linearly polarized light by a phase retarder so that the linearly polarized light can be made incident on the polarizing plate. Incidentally, when a quarter-wave plate is used as the phase retarder, circularly polarized light can be converted into linearly polarized light.
[0063] A phase retarder functioning as a quarter-wave plate in a wide wavelength range such as a visible light wavelength range can be obtained, for example, by a method of laminating a retardation layer functioning as a quarter-wave plate for monochromatic light with a wavelength of 550 nm and a retardation layer exhibiting another retardation characteristic such as a retardation layer functioning as a half-wave plate. Therefore, the phase retarder disposed between the polarizing plate and the luminance-enhancing film may contain one retardation layer or two or more retardation layers.
[0064] Incidentally, when the cholesteric liquid crystal layer is formed as an arrangement structure in which two layers or three or more layers different in reflection wavelength are laminated in combination, the cholesteric liquid crystal layer can be obtained as a layer reflecting circularly polarized light in a wide wavelength range such as a visible light wavelength range. As a result, circularly polarized light transmitted through the cholesteric liquid crystal in a wide wavelength range can be obtained.
[0065] In the invention, the polarizing plate may be formed as a laminate of a polarizing plate and two or three or more optical layers in the same manner as in the polarized light separating type polarizing plate. Therefore, the polarizing plate may be a reflection type elliptically polarizing plate or semi-transmission type elliptically polarizing plate formed by combination of the reflection type polarizing plate or semi-transmission type polarizing plate and the phase retarder.
[0066] Although an optical film, which is a laminate of the polarizing plate and the optical layers, can be also formed by a method of laminating the optical layers successively and separately in the process of production of a liquid crystal display device or the like, an optical film formed by lamination in advance is excellent in stability of quality, efficiency in assembling work, and so on, and brings an advantage in that the process of production of a liquid crystal display device or the like can be improved. Suitable bonding means such as a pressure-sensitive adhesive layer can be used for lamination. When the polarizing plate and another optical layer are bonded to each other, the optical axes thereof can be disposed to form a suitable angle in accordance with aimed retardation characteristic.
[0067] A pressure-sensitive adhesive layer can be provided on the polarizing plate or laminated optical member in the invention so that the polarizing plate or laminated optical member can be bonded to another member such as a liquid crystal cell by the pressure-sensitive adhesive layer. The pressure-sensitive adhesive layer is not particularly limited. For example, the pressure-sensitive adhesive layer can be made of a suitable pressure-sensitive adhesive agent such as an acrylic resin according to the related art. From the point of view of prevention of a foaming phenomenon and a peeling phenomenon due to moisture absorption, prevention of lowering of optical characteristic and warping of a liquid crystal cell due to difference between thermal expansion coefficients, and hence formability of an image display device high in quality and excellent in durability, it is preferable that the pressure-sensitive adhesive layer is low in coefficient of moisture absorption and excellent in heat resistance. The pressure-sensitive adhesive layer may contain fine particles so as to exhibit light-diffusing characteristic. The pressure-sensitive adhesive layer may be provided on a necessary surface as occasion demands. For example, referring to the polarizing plate composed of a polarizer and at least one protective film in the invention, the pressure-sensitive adhesive layer may be provided on one or each of opposite surfaces of a protective layer as occasion demands.
[0068] When the pressure-sensitive adhesive layer is exposed in the surface, the pressure-sensitive adhesive layer may be preferably temporarily covered with a separator for the purpose of preventing contamination until the pressure-sensitive adhesive layer is put into practical use. The separator can be formed by a method in which a releasing coat of a suitable releasing agent such as a silicone releasing agent, a long-chain alkyl releasing agent, a fluorine releasing agent or molybdenum sulfide is provided on a suitable thin film according to the transparent protective film as occasion demands.
[0069] Incidentally, each of layers such as a polarizer, a transparent protective film, an optical layer and a pressure-sensitive adhesive layer for forming the polarizing plate and the optical member may be given ultraviolet-absorbing power by a suitable method such as a method of treating the layer with an ultraviolet-absorbing agent such as a salicylic ester compound, a benzophenone compound, a benzotriazole compound, a cyanoacrylate compound or a nickel complex salt compound.
[0070] The polarizing plate according to the invention can be preferably used for forming an image display device such as a liquid crystal display device, an organic EL display device or a PDP.
[0071] The polarizing plate according to the invention can be preferably used for forming various kinds of devices such as a liquid crystal display device. For example, the polarizing plate can be used in a reflection type, semi-transmission type or transmission-reflection double type liquid crystal display device in which the polarizing plate is disposed on one or each of opposite surfaces of a liquid crystal cell. A substrate for the liquid crystal cell may be a plastic substrate or a glass substrate. The liquid crystal cell used for forming the liquid crystal display device can be selected optionally. For example, there may be used any suitable type of liquid crystal cell such as an active matrix drive type liquid crystal cell represented by a thin-film transistor type liquid crystal cell or a passive matrix drive type liquid crystal cell represented by a twisted nematic liquid crystal cell or a super-twisted nematic liquid crystal cell.
[0072] When polarizing plates or optical members are provided on opposite surfaces of the liquid crystal cell respectively, the polarizing plates or optical members may be the same or may be different. For formation of the liquid crystal display device, one or two or more layers of suitable parts such as a prism array sheet, a lens array sheet, a light-diffusing plate and a backlight unit may be disposed in a suitable position or positions.
[0073] Next, an organic electroluminescence device (organic EL display device) will be described. Generally, in the organic EL display device, a transparent electrode, an organic emitting layer and a metal electrode are laminated successively on a transparent substrate to thereby form an emitter (organic electroluminescence emitter). The organic emitting layer is provided as a laminate of various organic thin films. For example, there are known configurations of various combinations such as a laminate of a hole injection layer made of a triphenylamine derivative or the like and a luminous layer made of an organic fluorescent solid substance such as anthracene, a laminate of the luminous layer and an electron injection layer made of a perylene derivative or the like, and a laminate of the hole injection layer, the luminous layer and the electron injection layer.
[0074] The organic EL display device emits light on the basis of the following principle. When a voltage is applied between the transparent electrode and the metal electrode, holes and electrons are injected into the organic emitting layer. In the organic emitting layer, these holes and electrons are recombined to generate energy for exciting the fluorescent substance. When the excited fluorescent substance is restored to its normal state, light is radiated from the fluorescent substance. The mechanism of hole-electron recombination in the middle of the aforementioned principle is the same as that of a general diode. As expected from this fact, both electric current and luminous efficiency exhibit strong nonlinearity resulting from rectifiability with respect to the applied voltage.
[0075] In the organic EL display device, at least one electrode must be transparent to take out light emitted from the organic emitting layer. Generally, a transparent electrode made of a transparent electrical conductor such as indium tin oxide (ITO) is used as an anode. On the other hard, it is important that a substance small in work function is used as a cathode to make electron injection easy to improve luminous efficiency. Generally, a metal electrode made of Mg-Ag, Al-Li or the like is used as the cathode.
[0076] In the organic EL display device configured as described above, the organic emitting layer is formed as a very thin film about 10 nm thick. Accordingly, like the transparent electrode, the organic emitting layer transmits light approximately perfectly. As a result, light incident on a surface of the transparent substrate, transmitted through both the transparent electrode and the organic emitting layer and reflected by the metal electrode at the time of non-emitting operation comes to the surface side of the transparent substrate again. Accordingly, when viewed from the outside, a display surface of the organic. EL display device looks like a mirror surface.
[0077] In an organic EL display device including an organic electroluminescence emitter having an organic emitting layer for emitting light by application of a voltage, a transparent electrode provided on a front surface side of the organic emitting layer, and a metal electrode provided on a rear surface side of the organic emitting layer, a polarizing plate may be provided on the front surface side of the transparent electrode and a retardation film may be provided between the transparent electrode and the polarizing plate.
[0078] The retardation film and the polarizing plate have a function of polarizing light which comes from the outside and is reflected by the metal electrode. The polarizing function is effective in preventing the mirror surface of the metal electrode from being visually recognized from the outside. Particularly when the retardation film is constituted by a quarter-wave plate while the angle in direction of polarization of light between the polarizing plate and the phase retarder is adjusted to π/4, the mirror surface of the metal electrode can be shaded perfectly.
[0079] That is, only a linearly polarized light component of external light incident on the organic EL display device is transmitted through the polarizing plate. Generally, the linearly polarized light is converted into elliptically polarized light by the retardation film. Particularly when the retardation film is constituted by a quarter-wave plate while the angle in direction of polarization of light between the polarizing plate and the phase retarder is adjusted to π/4, the linearly polarized light is converted into circularly polarized light by the retardation film.
[0080] The circularly polarized light is transmitted through the transparent substrate, the transparent electrode and the organic thin film and then reflected by the metal electrode. The reflected light is transmitted through the organic thin film, the transparent electrode and the transparent substrate again and converted into linearly polarized light by the retardation film again. The linearly polarized light cannot be transmitted through the polarizing plate because it is perpendicular to the direction of polarization of the polarizing plate. As a result, the mirror surface of the metal electrode can be shaded perfectly.
[0081] According to the invention, a polarizing plate little curled and a method for producing the polarizing plate are provided as follows. Directions and amounts of curl of two curled protective sheets are measured before lamination of the two curled protective sheets onto a polarizer. The two curled protective sheets are laminated onto opposite surfaces of the polarizer respectively so that the curling directions of the two curled protective sheets are reverse to each other. In this manner, a polarizing plate little curled is obtained.
[0082] The invention will be described below more specifically on the basis of the following Examples and Comparative Examples but the invention is not limited to the Examples and Comparative Examples.
EXAMPLE 1
[0083] A polyvinyl alcohol (PVA) film (made by Kuraray Co., Ltd., degree of polymerization: 2400) was stretched to three times in a first bath (aqueous solution containing iodine and KI at 30° C.) and then stretched to six times as a total stretching factor in a second bath (aqueous solution containing boric acid and KI at 55° C.) to thereby obtain a polarizer. Then, two protective sheets (protective sheets a and b) each made of an 80 μm-thick triacetyl cellulose (TAC) film were bonded to opposite surfaces of the polarizer respectively by a PVA adhesive agent so that curling directions of the two protective sheets were reverse to each other as shown in FIG. 1A. Then, the polarizer with the two protective sheets was dried at 50° C. for 5 minutes. Thus, a polarizing plate was produced. The laminating index in this case was 60 . As a result, the amount of curl of the polarizing plate after lamination was 8 mm. The curl of the polarizing plate obtained was small.
EXAMPLE 2
[0084] A polarizing plate was produced in the same manner as in Example 1 except that two protective sheets having a laminating index of 40 were bonded to opposite surfaces of the polarizer respectively so that curling directions of the two protective sheets were reverse to each other as shown in FIG. 1B. As a result, the amount of curl of the polarizing plate after lamination was 4 mm. The curl of the polarizing plate obtained was small.
EXAMPLE 3
[0085] A polarizing plate was produced in the same manner as in Example 1 except that two protective sheets having a laminating index of 30 were bonded to opposite surfaces of the polarizer respectively so that curling directions of the two protective sheets were reverse to each other as shown in FIG. 1A. As a result, the amount of curl of the polarizing plate after lamination was 2 mm. The curl of the polarizing plate obtained was very small.
EXAMPLE 4
[0086] A polarizing plate was produced in the same manner as in Example 1 except that two protective sheets having a laminating index of 20 were bonded to opposite surfaces of the polarizer respectively so that curling directions of the two protective sheets were reverse to each other as shown in FIG. 1A. As a result, the amount of curl of the polarizing plate after lamination was 0 mm. The curl of the polarizing plate obtained was zero.
EXAMPLE 5
[0087] A polarizing plate was produced in the same manner as in Example 1 except that two protective sheets having a laminating index of 80 were bonded to opposite surfaces of the polarizer respectively so that curling directions of the two protective sheets were reverse to each other as shown in FIG. 1A. As a result, the amount of curl of the polarizing plate after lamination was 14 mm. The curl of the polarizing plate obtained was relatively small.
COMPARATIVE EXAMPLE 1
[0088] A polarizing plate was produced in the same manner as in Example 1 except that two protective sheets having a laminating index of 80 were bonded to opposite surfaces of the polarizer respectively so that curling directions of the two protective sheets were equal to each other as shown in FIG. 2A. As a result, the amount of curl of the polarizing plate after lamination was 21 mm. The curl of the polarizing plate obtained was conspicuous.
COMPARATIVE EXAMPLE 2
[0089] A polarizing plate was produced in the same manner as in Example 1 except that two protective sheets having a laminating index of 60 were bonded to opposite surfaces of the polarizer respectively so that curling directions of the two protective sheets were equal to each other as shown in FIG. 2A. As a result, the amount of curl of the polarizing plate after lamination was 23 mm. The curl of the polarizing plate obtained was conspicuous.
COMPARATIVE EXAMPLE 3
[0090] A polarizing plate was produced in the same manner as in Example 1 except that two protective sheets having a laminating index of 40 were bonded to opposite surfaces of the polarizer respectively so that curling directions of the two protective sheets were equal to each other as shown in FIG. 2A. As a result, the amount of curl of the polarizing plate after lamination was 28 mm. The curl of the polarizing plate obtained was conspicuous.
COMPARATIVE EXAMPLE 4
[0091] A polarizing plate was produced in the same manner as in Example 1 except that two protective sheets having a laminating index of 20 were bonded to opposite surfaces of the polarizer respectively so that curling directions of the two protective sheets were equal to each other as shown in FIG. 2B. As a result, the amount of curl of the polarizing plate after lamination was 38 mm. The curl of the polarizing plate obtained was conspicuous.
[0092] (Method for Measuring Amount of Curl of Protective Sheet)
[0093] The amount of curl of each protective sheet was measured as follows. As shown in FIG. 3, five samples 21 each having a size of 3 mm wide and 35 mm long were punched out from a raw protective sheet 20 so that the length of 35 mm in each sample 21 was taken in a widthwise direction 4 of the raw protective sheet 20 . After left in a conditioning space under 25±2%RH for 24 hours, each sample 21 was taken out from the conditioning space. Within 2minutes, each sample 21 was put on a flat surface. In the condition that an end of each sample 21 was held by 5 mm, a spatial distance raised from the flat surface was measured. All the five samples 21 were measured in the same manner as described above, so that an average of five measured values was calculated as the amount of curl of the protective sheet.
[0094] (Method for Measuring Amount of Curl of Polarizing plate)
[0095] The amount of curl of the polarizing plate was measured as follows. As shown in FIG. 4, three samples 31 each having a size of 25 cm square were punched out from a raw material sheet 30 in a widthwise direction 4 so that an absorption axis 6 of the raw material sheet 30 was inclined at an angle of 45° to each side of each sample 31 . Each sample 31 was put on a flat surface. Spatial distances raised from the flat surface were measured at two top points of the sample 31 in the widthwise direction 4 . All the three samples 31 were measured in the same manner as described above, so that an average of six measured values was calculated as the amount of curl of the polarizing plate.
TABLE 1 Amount of Curl Amount of Curl Amount of Curl of Laminating Laminating of Protective of Protective Polarizing plate Condition Method Index Sheet a [mm] Sheet b [mm] [mm] and Evaluation Example 1 60 1.0 0.4 8 ♯ Example 2 40 1.0 0.6 4 ♭ Example 3 30 1.0 0.7 2 ♭ Example 4 20 0.5 0.4 0 ♭ Example 5 80 1.0 0.2 14 Δ Comparative 80 1.0 0.2 21 X Example 1 Comparative 60 1.0 0.4 23 X Example 2 Comparative 40 1.0 0.6 28 X Example 3 Comparative 20 1.0 0.8 38 X Example 4
[0096] As is obvious from the results shown in Table 1, the amount of curl of the polarizing plate produced as a laminate by the production method described in any one of Examples 1 to 5 according to the invention is small. It is to be understood that the problem of curl can be solved by the production method according to the invention.
[0097] As described above, in the method of producing a polarizing plate according to the invention, curling directions of two protective sheets laminated onto opposite surfaces of a polarizer respectively can be adjusted to suppress the amount of curl of the polarizing plate to thereby improve work efficiency in bonding the polarizing plate to a panel and optical characteristic such as variation in in-plane transmittance. Furthermore, when the laminating index concerned with the amounts of curl of the protective sheets is reduced, a polarizing plate little curled can be obtained. There can be provided a polarizing plate produced by the production method and an image display device using the polarizing plate. | A method of producing a polarizing plate, including the step of laminating a pair of curled protective sheets onto opposite surf aces of a polarizer respectively so that respective curling directions of the pair of curled protective sheets are reverse to each other, wherein the laminating index of the pair of protective sheets is selected to be not higher than 60 in order to restrain the polarizing plate from being curled. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to agricultural planter units, and more particularly relates to row marker lift controls having automatic sequencing mechanisms which alternately cause each row marker to be lifted and lowered.
Automatic row marker lift mechanisms are well known in the art. Those mechanisms employ mechanical as well as electric and hydraulic means to raise and lower the row marker. These mechanisms are mounted on the implements structure or toolbar and include lever members, cable means and other bulky exposed elements that limit the ability to mount tools or other necessary parts on the implement. The mechanisms are exposed to weather, foreign matter and provide moving elements posing safety hazzards. Many mechanisms provide duplicate systems including separate hydraulic lift cylinders that increase cost and maintenance and reduce usable toolbar space.
Actuation of the row marker movement has been tied to tractor movement, planter or grain drill earth engagement, electrical signals, and the hydraulic system.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide a simple and yet reliable and inexpensive row marker lift mechanism for a planter or other farm implement.
More specifically, it is proposed to provide a row marker lift mechanism concealed in a housing mounted within the implement toolbar. This mechanism includes a powered extensible and retractable link, and the preferred embodiment utilizes a simple single-acting hydraulic cylinder having each cylinder end slidably engaged in channels of the housing. Each end of the hydraulic cylinder is connected to one row marker lift cable. A detent means is included within the housing and acts to alternately engage and lock each end of the hydraulic cylinder so its respective row marker is held in a raised position. When one end of the single-acting hydraulic cylinder is immovably locked, the other end will be free to float and its respective row marker will be in an operating position. An actuating mechanism serves to cause the detent means to alternately engage and release each end of the hydraulic cylinder as it expands so that its respective row marker is held in a raised position while the other row marker is down and operatively engaging the ground.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear view of the device installed within the toolbar of a planter, each end of the link coupled to a row marker assembly.
FIG. 2 is an exploded perspective of the device.
FIG. 3 is an enlarged end view of the device installed within a toolbar.
FIG. 4 is a top view of the device.
FIG. 5 is an enlarged view of the device taken along lines 5--5 as illustrated in FIG. 6.
FIG. 6 is a side elevation of the device with the left end of the link locked and the right end of the link free to move.
FIG. 7 is a side elevation of the device illustrating the device as the right end of the hydraulic cylinder is being moved to the right.
FIG. 8 is a side elevation of the device illustrating the right end of the link locked and the left end of the link free to move.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The restraining device or lift control mechanism is illustrated herein in combination with row markers and a planter unit, see FIG. 1.
The chosen embodiment, while employing a hydraulic cylinder, can also utilize electrical motors or other powered extensible and retractable links. The lift control mechanism includes a detent lever which alternately restrains movement of each end of the powered link or hydraulic cylinder. Each end of the hydraulic cylinder, when immovably locked by the detent lever, will cause its respective row marker to be held in a raised position. Correspondingly, each row marker will be free to move when its respective hydraulic cylinder end is not so restrained by the detent lever.
Referring now to the drawings, and in particular FIG. 1, it can be seen that the device is compact and contained within a rectangularly-shaped housing 10 wherein the extensible and retractable link or hydraulic cylinder is positioned. As shown in FIG. 2, the housing includes base members 12, vertical sides 14 in parallel coplanar relationship with each other, and an end plate 16 secured to one end of the side plates 14. The end plate 16 extends beyond one side plate and includes two openings 18 wherein bolts 20 are positioned to mount the housing 10 within the implement's toolbar 22 as is illustrated in FIG. 3. At the other end of the housing is a brace member 24 which positions the unit within the implement toolbar.
Referring again to FIG. 2, it will be seen that spaced slightly below the upper edge of each housing side plate 14, and extending along the length of each side plate are two sets of rectangularly shaped channel openings 26. To the center portion of one side plate 14 is secured a mounting pin 28 having a hole 30 drilled perpendicular to its center axis.
Within the housing 10 is positioned a single-acting hydraulic cylinder 32. To the cylinder's right or base end is secured a rectangular block, hereafter designated the right block 34. To the cylinder's left or rod end is also secured a rectangular block hereafter designated the left block 36. Each block 34 and 36 has a rectangularly-shaped opening 38 therein perpendicular to the hydraulic cylinder center line. Through the upper surface of each block 34 and 36 is an opening 40. Complementarily shaped guide blocks 42 and 44 with openings 46 perpendicular to their horizontal axis are matingly positioned within their respective hydraulic cylinder block opening 38 and secured thereto by cotter pins.
As is best illustrated in FIG. 4, a portion 48 of each inserted guide block 42 and 44 extends beyond its respective block. Each protruding portion 48 is slidably positioned within a housing channel opening 26 and will move along the path defined by the channel openings 26 in the side plates 14 as the powered link extends or retracts.
Included within the housing 10 is a detent means for alternately restraining inwardly movement of the end portions of the powered link or hydraulic cylinder 32 and an actuating mechanism for causing the detent means to alternately engage and release each end of the link section. The detent means is comprised of an elongated lever member 50 having notched end portions 52 and a circular opening 54. The actuating mechanism includes an elongated lever member 56 having raised or hooked portions 58 at each end, an L-shaped force-transmitting member 60 secured to one side of the center portion of the detent lever 50, and a biasing pin 62 with spring 70 shiftably positioned between the actuating lever 56 and the L-shaped member 60. One leg of the L-shaped force-transmitting member 60 is secured to the center portion of the detent lever 50 and the other leg of said L-shaped member 60 has a slotted opening 64 wherein said biasing pin 62 is shiftably positioned.
The lift control device is compactly assembled within the rectangular housing 10, see FIGS. 4 and 5. As assembled the detent lever 50 is rockably mounted through its hole 54 on the mounting pin 28. This lever 50 is mounted such that the slotted leg of the L-shaped member 60 extends inwardly towards the actuating lever 56 and is positioned horizontal with and parallel to said housing base. The actuating lever 56 is slidably mounted through a slotted opening 66 therein on the same mounting pin 28. To secure the two lever members on the mounting pin 28, a cotter key is inserted through the hole 30 in the mounting pin 28 after the levers 50 and 56 are pivotally mounted.
Referring now to FIG. 6, it will be noted that the biasing pin 62 extends between the actuating lever 56 and the L-shaped member 60. The lower end of the biasing pin 62 is pivotally secured through the circular hole 68 of the actuating lever 56. The upper portion of the biasing pin 62 is shiftably positioned through the slotted opening 64 of the L-shaped member 60. A helical spring 70 is axially aligned with the biasing pin 62 and is positioned around the pin 62. When the biasing pin 62 is secured between the L-shaped member 60 and the actuating lever 56, the spring 70 abutts at its upper end the lower surface of the L-shaped member's horizontal leg, and at its other end the flange 72 of the biasing pin 62.
Secured to the top surface of each hydraulic cylinder block 34 and 36 are upstanding walls 74 and 75, each having openings 76 therein. Through holes 76 are secured the cables 78 and 80 which lift and lower each row marker 82 and 84. As is illustrated in FIG. 1, the cable 78 attached to the hydraulic cylinder left block end 36 lifts and lowers the right row marker 82, and the cable 80 attached to the hydraulic cylinder right block 34 lifts and lowers the left row marker 84.
The lift device functions such that one row marker is locked in the raised transport position when the other row marker is down. As the operator activates the hydraulic system to raise the lowered row marker to a transport position, the locked hydraulic cylinder end block will hold the row marker in a raised position until the lowered marker is raised and locked. At this time the marker originally held is a raised position will be lowered as the detent lever 50 disengages its respective hydraulic cylinder end.
Assuming that the right row marker 82 is raised and the left row marker 84 is lowered, the elements of the restraining device will occupy those positions illustrated in FIG. 6. With the structural elements in these positions, the operation of the device will be as follows. The left block 36 of the hydraulic cylinder is locked between the left end of the detent lever 50 and the housing channel end 85. In this position, the detent lever 50 is rockably disposed clockwise about the pivotal axis 86 of the pin 28 such that its left end is raised and its right end is lowered. The inner face 88 of the hydraulic cylinder left block 36 is abutting the outer surface 94 of the detent lever 50 left end and the outer face 89 of the left block 36 is abutting its respective housing channel outer wall 85.
The actuating lever 56 is positioned to the left and its pivotal axis 86 is located within the right end of the slot 66. Since the actuating lever 56 is as far to the left as it can be moved, the bias pin 62 lower end has been moved to the left of the pivotal axis 86 and the top of bias pin 62 rests on the right edge of the slotted hole 64 in the L-shaped member 60.
An explanation of the forces exerted by the bias pin follows. As the helical spring 70 is compressed between the lower surface of the L-shaped horizontal leg and the bias pin flange 72, a force is transmitted to each surface the bias pin 62 contacts. Accordingly, the bottom of the bias pin transfers a downwardly acting force to the actuating lever 56 at the location where the pin 62 is inserted through the actuating lever 56. Where the parts of the device are in the positions as shown in FIG. 6, a force will be exerted on the actuating lever 56 at a point laterally removed from the lever's pivot axis 86 and a counterclockwise moment force shown by the arrow 90 will be exerted on the actuating lever 56 causing the actuating lever 56 to drop and contact the base plate 12. Thus, as the bias pin 62 exerts the counterclockwise force on the actuating lever 56, the left end of the lever 56 is forced downwardly whereat the hooked end 58 is below the bottom surface of the rectangular portion of the hydraulic cylinder left block 36. Accordingly the actuating lever's 56 right end 59 will be in a raised position. When the bias pin 62 transmits a force to the left on the actuating lever 56, it also transmits a clockwise force to the right portion of the leg of the L-shaped member 60. That force is exerted at the edge 92 of the slotted surface. Since this force is exerted at a point lateral to and at the right of the pivotal axis 86 of the detent lever 50, the detent lever 50 occupies a position clockwise about its pivotal axis 86, whereat its right-hand portion is lowered and its left-hand portion is raised.
With the levers 50 and 56 as above described, the left row marker 84 will be in the lowered position, and the right end 34 of the hydraulic cylinder will be as far to the left as the housing channel 26 permits it to be moved, this situation is illustrated in FIGS. 6, 4 and 1.
Assume now that the operator wants to raise the left row marker 84 and lower the right row marker 82. Accordingly, the right end 34 of the hydraulic cylinder must be extended to raise the left row marker 84 and the left end 36 of the hydraulic cylinder released to permit the right row marker 82 to descend.
To raise the left row marker 84, the operator will actuate the hydraulic system to cause the single-acting hydraulic cylinder 32 to expand. From FIG. 7, it can be seen that as the right end 34 of the hydraulic cylinder moves to the right, the left end 36 of the hydraulic cylinder is prevented from moving to the left by the housing channel wall 85. As the right end 34 of the hydraulic cylinder moves to the right, it slides along the top surface of the levers 56 and 58 and its outer vertical surface 104 will contact the inner vertical surface 100 of the right hooked portion 59 on the actuating lever 56 causing the actuating lever 56 to be slidably moved over the mounting pin 28 to the right. As this actuating lever 56 slides to the right, the top of its left end raised or hooked portion 58 will be lower than the bottom of the hydraulic cylinder left block 36. As the acutating lever member 56 is slidably moved over the mounting pin 28 and crosses its center balance point, the lower end of the bias pin 62 is moved to the right of the pivotal axis 86, the helical spring 70 is compressed and the top of the biased pin 62 shiftably forced to the left end of the slotted opening 64 in the horizontal leg of the L-shaped member 60 (see FIG. 8). The forces now exerted by the bias pin 62 on the actuating lever 56 and detent lever 50 are reversed from those forces which prevailed when the restraining device was as illustrated in FIG. 6 and consequently the actuating lever 56 will tend to rotate clockwise and the detent lever 50 will tend to rotate counterclockwise. However, as shown in FIG. 7, counterclockwise rotation of the detent lever 50 does not occur until the inner vertical surface 96 of the right block 34 of the hydraulic cylinder has moved beyond the vertical face 98 of the detent lever 50.
After the right block 34 has moved to the right, the detent lever 50 rotates counterclockwise, and its left end will drop downwardly, thereby disengaging the hydraulic cylinder left end 36 whereby gravity will cause the right row marker to descend and the left block 36 to slidably move to the right. Meanwhile, the actuating lever left hooked portion 58 has, as the hydraulic cylinder left end rectangular block 36 passed over it, emerged at the left of the sliding hydraulic cylinder left block 36 and its right end 59 will rotate downwardly disengaging the outer side 104 of the hydraulic cylinder right block 34. The hydraulic cylinder right block 34 is now immovably locked and prevented from moving to the left by the detent lever's right end vertical surface 98, and is also prevented from moving to the right since it has reached the end of the housing channel 26. At this time the left row marker 84 is raised and the right row marker 82 is descending since the left end of the hydraulic cylinder is able to slidably move to the right. The right row marker 82 is now operational and the left end of the single-acting hydraulic cylinder can "float" to allow the right row marker 82 to move up or down to follow varying ground contours. | A device for alternately restraining movement of each end of a powered extensible and retractable link having first and second sections. The device is contained within a housing which can be inserted into a toolbar and attached to row marker assemblies to alternately lift and lower each row marker. Included as part of the device is a housing having channels therein for guiding linear movement of the link sections, a detent lever for alternately restraining movement of each link section and an actuating mechanism which causes the detent lever to alternately engage and release each link section. | 0 |
RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 11/410,736 filed on Apr. 25, 2006, which is a continuation of U.S. patent application Ser. No. 11/087,483 filed on Mar. 22, 2005, now U.S. Pat. No. 7,032,892, which is a continuation of U.S. patent application Ser. No. 10/456,247 filed on Jun. 5, 2003, now U.S. Pat. No. 6,896,244, which is a continuation of U.S. patent application Ser. No. 09/976,380 filed on Oct. 11, 2001, now abandoned, which is a continuation-in-part of U.S. Design patent application Ser. No. 29/067,042 filed on Feb. 27, 1997, which claims priority of Canadian Industrial Design Application No. 1996-2618 filed on Nov. 26, 1996.
TECHNICAL FIELD
[0002] The present invention relates to hardware for use in the construction of gates and, more specifically, to gate hardware adapted to brace the vertical and horizontal support members of a wooden gate and rotatably connect these members to a fixed structural member.
BACKGROUND OF THE INVENTION
[0003] Gates are often used to allow selective access through a wall or fence. Conventionally, gates are constructed as follows. Two vertical support members and two horizontal support members are fastened together in a rectangular shape to form what will be referred to herein as a gate box. Fence boards or the like are fastened to the support members, and one of the vertical support members is rotatably attached by two or more hinge assemblies to a structural member such as a wall or post.
[0004] Using conventional gate building techniques, fasteners such as nails or screws are driven through one support member into another support member to form the corners of the gate box. Over time, the force of gravity and wood shrinkage will cause these fasteners to loosen, allowing the gate box to sag out of its desired rectangular shape.
[0005] Accordingly, metal L-brackets, wooden brace members, triangular pieces of plywood, and the like are often fastened to the adjacent ends of the support members to strengthen the inside corners of the gate box. In other situations, a wire is placed in tension between the upper proximal and lower distal corners of the gate box to support the lower distal corner of the gate box and thereby reduce sagging of the gate. Such bracing techniques are somewhat effective but also commonly employ fasteners that are susceptible to failure and can be relatively time consuming to implement.
[0006] Another problem with conventional gate building techniques is that fasteners such as nails or screws are similarly used to attach the hinge assemblies to the vertical support member adjacent to the structural member. The loads are transferred to the gate through the screws placed in tension. As the wood shrinks and the gate is opened and closed, the fasteners under tension tend to loosen and may eventually fail.
[0007] As the hinge fasteners loosen, the entire gate assembly may sag relative to the hinge assemblies and thus the structural member, even if the gate box maintains its rectangular shape. The use of braces at the corners of the gate box will worsen sagging at the hinges because the materials and hardware used for bracing increase the weight of the gate; this increased weight increases the forces of gravity on the fasteners used to attach the hinge assemblies to the proximal vertical support member.
[0008] The Applicant is aware of a product sold in Canada as early as approximately 1993 under the tradename “Artistic Steel Gate Frames”. The Artistic Steel Gate Frame product comprises distal and proximal brace members, with hinges being attached to the proximal brace member. A gate assembly constructed using the Artistic product would use upper and lower horizontal wooden support members, but would not use vertical support members. Instead, the distal and proximal brace members would form the structure of the vertical sides of the gate. Accordingly, the brace members of the Artistic product were sold in a plurality of sizes, with each size corresponding to a given distance between the upper and lower horizontal support members.
[0009] One problem with the Artistic product is that this system requires the manufacturer to produce and keep in inventory, and the retailer to stock, multiple sizes of brace members.
[0010] In addition, the end user is limited to one of these multiple sizes of brace members; one could not create a gate assembly having a custom distance between the upper and lower horizontal support members.
[0011] From the foregoing, it should be clear that one object of the present invention is to create bracket systems and methods that are strong, that are easy and inexpensive to use, and which allow significant flexibility in the final design of the gate assembly.
SUMMARY OF THE INVENTION
[0012] The present invention is a bracket system or method for forming gate assemblies. The bracket system comprises at least two brace members that are rigidly attached to hinge assemblies. The brace members are adapted to be attached to support members to form two corners of a gate box functioning as the structural portion of the gate assembly. The hinge assemblies are adapted to be rigidly attached to a fence post to allow the gate assembly to pivot relative to the fence post. Gate assemblies of arbitrary height and width can be formed using the bracket system of the present invention
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a gate frame system of the present invention comprising distal brace members and proximal brace assemblies;
[0014] FIG. 2 is an exploded, front elevation view of a gate assembly incorporating the gate frame system of FIG. 1 ;
[0015] FIG. 3 is a partial cut-away, front elevation view of the gate assembly of FIG. 2 attached to a fence post;
[0016] FIG. 4 is a front elevation view of the distal brace member depicted in FIG. 1 ;
[0017] FIG. 5 is a side elevation view of the distal brace member depicted in FIG. 1 ;
[0018] FIG. 6 is a bottom plan view of the distal brace member depicted in FIG. 1 ;
[0019] FIG. 7 is a top plan view of the distal brace member depicted in FIG. 1 ;
[0020] FIG. 8 is a front elevation view of the proximal brace member depicted in FIG. 1 ;
[0021] FIG. 9 is a side elevation view of the proximal brace member depicted in FIG. 1 ;
[0022] FIG. 10 is a bottom plan view of the proximal brace member depicted in FIG. 1 ; and
[0023] FIG. 11 is a top plan view of the proximal brace member depicted in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring initially to FIG. 1 , depicted therein is a gate bracket system 20 constructed in accordance with, and embodying, the principles of the present invention. Referring for a moment to FIGS. 2 and 3 , the gate bracket system 20 is adapted to form a gate box 22 to be used as part of a gate assembly 24 ; the gate assembly 24 is in turn to be connected to a structural member such as a fence post 26 ( FIG. 3 ) of a larger structure such as a fence 28 .
[0025] The exemplary gate assembly 24 comprises in addition to the bracket system 20 distal and proximal vertical support members 30 and 32 , upper and lower horizontal support members 34 and 36 , and a plurality of fence members 40 . The exemplary support members 30 - 36 are conventional wooden two-by-fours, but other materials and sizes may be used as the support members 30 - 36 . The exemplary fence members 40 are also conventionally made out of wood, but other materials and various sizes of any type of material may be used to form the fence members 40 .
[0026] The support members 30 - 36 and fence members 40 do not form a part of the present invention. A description of the construction and operation of these members 30 - 40 is not necessary to describe how to make and use the present invention and is included herein simply to illustrate the environment in which the present invention operates.
[0027] The fence post 26 is conventionally a wooden four-by-four, but other materials and sizes may be used to form the structural member to which the gate assembly 24 is rotatably attached. For example, rather than a fence post 26 , the structural member may be a wall of a structure. The fence post 26 and fence 28 also are or may be conventional and are not part of the present invention. As with the support and fence members 30 - 40 introduced above, a description of the construction and operation of the post 26 and fence 28 is not necessary to describe how to make and use the present invention. The fence post 26 and fence 28 are described herein simply to illustrate the environment in which the present invention operates.
[0028] The gate bracket system 20 of the present invention comprises first and second distal brace members 50 and 52 and first and second brace assemblies 54 and 56 . The first brace assembly 54 in turn comprises a first proximal brace member 60 and a first hinge assembly 62 , while the second brace assembly comprises a second proximal brace member 64 and a second hinge assembly 66 .
[0029] The exemplary brace members 50 , 52 , 60 , and 64 each comprise a horizontal portion 70 , a vertical portion 72 , and a brace portion 74 . An outer end 72 a of the vertical portions 72 is rigidly connected to an attachment region 70 a of the horizontal portions 70 . The exemplary brace portion 74 is preferably rigidly connected at an angle between bracing regions 70 b and 72 b of the horizontal and vertical portions 70 and 72 , respectively.
[0030] The choice of materials and shapes of the materials are not essential to any particular implementation of the present invention. The primary requirements of the brace members 50 , 52 , 60 , and 64 are that these members each define a horizontal support surface 80 and a vertical support surface 82 such that these surfaces rigidly extend from each other at a right angle. In the exemplary system 20 , the horizontal support surfaces 80 are formed on the horizontal portions 70 and the vertical support surfaces 82 are formed on the vertical portions 72 .
[0031] A plurality of fastener holes 90 are formed in the brace members 50 , 52 , 60 , and 64 ; the fastener holes 90 are adapted to allow fasteners 92 to attach, in a conventional manner, the brace members 50 , 52 , 60 , and 64 to the support members 30 - 36 . The fasteners 92 are preferably self-tapping screws but can be nails, bolts, or the like. The fasteners 92 are not part of the gate bracket system 20 of the present invention per se but, as will be described in further detail below, are used to combine the bracket system 20 with the support members 30 - 36 to form the gate assembly 24 .
[0032] The exact number and location of the fastener holes 90 is not critical to any given implementation of the present invention. In a broadest form of the bracket system 20 , the fastener holes 90 can be formed anywhere along the horizontal portions 70 and vertical portions 72 . The only requirement for the number and spacing of these holes is that the fasteners 92 extend through these holes 90 and into the support members to rigidly secure the brace members to the support members.
[0033] Given the foregoing general understanding of the present invention, the distal bracket members 50 and 52 and the proximal bracket assemblies 54 and 56 of the present invention will now be described in further detail with reference to FIGS. 4-11 .
[0034] The attachment and bracing regions 70 a and 70 b of the horizontal portions 70 of the exemplary bracket members 50 , 52 , 60 , and 64 are formed located generally as follows.
[0035] The horizontal portions 70 have an outer end 70 c and an inner end 70 d . The exemplary attachment regions 70 a are located between approximately 15-30%, and preferably approximately 20%, of the distance between the horizontal portion ends 70 c and 70 d as measured from the outer ends 70 c . The bracing regions 70 b are located between approximately 80-95%, and preferably approximately 88%, of the distance between the horizontal portion ends 70 c and 70 d as measured from the outer ends 70 c.
[0036] The horizontal portions 70 further define spacing regions 70 e (between the attachment regions 70 a and the outer ends 70 c ), inner regions 70 f (between the bracing regions 70 b and the inner ends 70 d ), and intermediate regions 70 g (between the attachment regions 70 a and the bracing regions 70 b ).
[0037] The length of the spacing regions 70 e is determined such that the vertical support members 34 and 36 fit snugly between the vertical portions 72 and the outer ends 70 c . In the case of the proximal bracket assemblies 54 and 56 , the length of the spacing regions 70 e allows the vertical support members 34 and 36 to fit snugly between the vertical portions 72 of the third and fourth bracket members 60 and 64 and the first and second hinge assemblies 62 and 66 , respectively. When, as is typical, two-by-four dimensional lumber is used to form the vertical support members, the length of the spacing regions 70 e will be approximately 3 1/2″, or slightly greater to allow for variations in the true dimensions of the lumber.
[0038] The vertical portions 72 each comprise the outer ends 72 a discussed above and an inner end 72 c . The bracing regions 72 b are located approximately 85% of the distance between the horizontal portion ends 72 a and 72 c as measured from the outer ends 72 a . The vertical portions 72 thus each define a main region 72 d between the outer end 72 a and the bracing region 72 b and an inner end region 72 e between the bracing region 72 b and the inner end 72 c.
[0039] In the horizontal portions 70 of the exemplary brace members 50 , 52 , 60 , and 64 , first, second, and third fastener holes 90 a , 90 b , and 90 c are formed in the spacing regions 70 e , inner regions 70 f , and intermediate regions 70 g , respectively. The first, second, and third fastener holes are spaced approximately 15%, 46%, and 96%, respectively, of the distance between the horizontal portion ends 70 c and 70 d as measured from the outer ends 70 c.
[0040] In the vertical portions 72 of the exemplary brace members 50 , 52 , 60 , and 64 , fourth and fifth fastener holes 90 d and 90 e are formed in the main region 72 d and a sixth fastener hole 90 f is formed in the inner end region 72 e . The fourth, fifth, and sixth fastener holes 90 d , 90 e , and 90 f are spaced approximately 15%, 46%, and 96% of the distance between the horizontal portion ends 72 a and 72 c as measured from the outer ends 72 a.
[0041] The fastener holes 90 of the exemplary brace members 50 , 52 , 60 , and 64 are formed along a horizontal center line A of the horizontal portion 70 and a vertical center line B of the vertical portion 72 .
[0042] The exemplary horizontal and vertical portions 70 and 72 are made of flat pieces of rigid metal, but other relatively rigid materials and shapes that function in a similar manner may be used. For ease of manufacturing, the exemplary horizontal and vertical portions 70 and 72 are identical in length, and the fastener holes 90 are formed at identical locations therein; only one part thus needs to be fabricated and stocked to form the exemplary brace members 50 , 52 , 60 , and 64 .
[0043] The brace portion 74 is typically round or flat metal stock, but other shapes and materials may be used. For example, the brace portion 74 may be a triangular web of flat material that extends between the horizontal and vertical portions 70 and 72 . In this case, the entire brace member may be cast of metal or injection molded from plastic. If a triangular web or similar brace portion is used, it may be necessary to form the fastener holes 90 such that they are offset from the horizontal and vertical centerlines A and B.
[0044] From the foregoing, it should be clear that the exemplary brace members 50 , 52 , 60 , and 64 are identical, which is preferred for manufacturing purposes. However, these brace members 50 , 52 , 60 , and 64 need not be identical to practice the present invention in its broadest form.
[0045] The first and second hinge assemblies 54 and 56 are or may be conventional and will be described herein only to the extent necessary for a complete understanding of the present invention.
[0046] As is conventional, the hinge assemblies 54 and 56 each comprise a gate plate 120 and a post plate 122 . These plates define hinge projections 124 that receive a hinge pin (not shown). The hinge pin allows the gate and post plates 120 and 122 to rotate relative to each other about a hinge axes C and D defined by the hinge assemblies 54 and 56 .
[0047] The outer ends 70 c of the horizontal portions 70 of the first and second brace members 60 and 64 are rigidly connected to the gate plates 120 . In particular, the horizontal center lines A of the horizontal portions 70 of these brace members 60 and 64 are tangential to circles centered about the hinge axes C and D, respectively. The vertical center lines B of the vertical portions of the brace members 60 and 64 are parallel to the hinge axes C and D, respectively.
[0048] An array of fastener holes 90 is formed in the post plate 122 to allow this plate to be rigidly attached to the fence post 26 . Preferably four fastener holes 90 are formed in the post plate 122 . The drawing depicts fastener holes 90 in the gate plate 120 ; these holes 90 in the plate 120 need not be used, but will be present if off-the-shelf hinge assemblies 62 and 66 are used.
[0049] The process of combining the bracket system 20 with the support members 30 - 36 to form the gate box 22 will now be described with reference to FIG. 2 .
[0050] Initially, as is conventional, the support members 30 - 36 are cut to the desired lengths. The length vertical support members 30 and 32 generally correspond to the height of the gate assembly 24 , while the length of the horizontal support members 34 and 36 closely correspond to the width of the gate assembly 24 . The minimum lengths of the support members 30 - 36 are determined by the horizontal portions 70 and vertical portions 72 of the brace members 50 , 52 , 60 , and 64 ; in particular, the support members 30 - 36 must be at least twice as long as the lengths of the horizontal and vertical portions 70 and 72 to prevent overlapping of the horizontal portions 70 or vertical portions 72 of adjacent brace members.
[0051] The first and second distal brace members 50 and 52 and first and second brace assemblies 54 and 56 are arranged such that: (a) horizontal and vertical support surfaces 80 a and 82 a of the first distal brace member 50 define first and second support surfaces of the bracket system 20 ; (b) horizontal and vertical support surfaces 80 b and 82 b of the second distal brace member 50 define third and fourth support surfaces of the bracket system 20 ; (c) horizontal and vertical support surfaces 80 c and 82 c of the first proximal brace member 60 define third and fourth support surfaces of the bracket system 20 ; and (d) horizontal and vertical support surfaces 80 d and 82 d of the second proximal brace member 54 define third and fourth support surfaces of the bracket system 20 .
[0052] The fasteners 92 are then inserted through the fastener holes 90 of the brace members 50 , 52 , 60 , and 64 and into the support members 30 - 36 to form the gate box 22 . In particular, fasteners 92 are driven through the holes 90 and into the support members 30 - 36 such that: (a) the upper horizontal support member 30 is drawn tight against the first and fifth support surfaces defined by the first distal brace member 50 and second proximal brace member 60 ; (b) the lower horizontal support member 32 is drawn tight against the second and sixth support surfaces defined by the second distal brace member 52 and fourth proximal brace member 64 ; (c) the distal vertical support member 34 is drawn tight against the third and fourth support surfaces defined by the first and second distal brace members 50 and 52 ; and (d) the proximal vertical support member 36 is drawn tight against the seventh and eight support surfaces defined by the first and second proximal brace members 60 and 64 .
[0053] The exact order of the attachments described in the preceding paragraph is not critical to the present invention in its broadest form. However, with the brace members 50 , 52 , 60 , and 64 described herein, fasteners 92 are preferably driven through at least the first fastener holes 90 a formed in the spacing regions 70 e of the horizontal portions 70 before fasteners 92 are driven through the fastener fourth, fifth, or sixth fastener holes 90 d - e of the vertical portions 72 . Otherwise, the vertical support members 34 and 36 may block access to the first fastener holes 90 a . Preferably, fasteners 92 are driven through the first through third fastener holes 90 a - c before fasteners are driven through the fifth through sixth fastener holes 90 d - e.
[0054] With the gate box 22 formed as described above, the hinge axes C and D will be substantially aligned. The gate box 22 so formed may thus then be attached to the fence post 26 by fasteners 92 extending through the fastener holes 90 in the post plate 122 and into the post 26 . When the post plates 122 are rigidly connected to the post 26 , the gate box 22 pivots relative to the fence post 26 about the hinge axes C and D.
[0055] The gate assembly 24 may be formed before or after the gate box 22 is attached to the fence post 26 by attaching the fence members 40 to at least one, and preferably at least two, of the support members 30 - 36 of the gate box 22 .
[0056] Given the foregoing, it should be clear that the present invention may be embodied in forms other than those depicted and described herein. The scope of the present invention should thus be determined by the claims appended hereto and not the preceding detailed description of the preferred embodiment. | A bracket system for forming gate assemblies comprising at least two brace members that are rigidly attached to hinge assemblies. The brace members are adapted to be attached to support members to form two corners of a gate box functioning as the structural portion of the gate assembly. The hinge assemblies are adapted to be rigidly attached to a fence post to allow the gate assembly to pivot relative to the fence post. Gate assemblies of arbitrary height and width can be formed using the bracket system. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of European patent application 00810933.2, filed Oct. 10, 2000, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
The invention relates to a radio frequency receiver according to the preamble of the independent claim.
It has been known to provide electronic circuits with power save or control units for switching the circuits off when they are not used. When switching the circuits off, it may be required or desirable that their settings are saved. E.g. when switching a TV off by a remote control, its current loudness settings should be preserved. For this purpose, a control voltage controlling the loudness is stored in a digital memory, from where it is fed to an D/A-converter when the device is switched back on. This, however, requires additional circuitry.
Furthermore, it has been know to preserve energy in radio frequency receivers by switching the receiver section on and off, in particular in receivers of digital data with a know time structure. In such receivers, the settings of the receiver section, e.g. the control voltage of a VCO in a PLL, are usually lost during power-off periods. When these components are switched back on, some time passes before the settings have been re-established.
BRIEF SUMMARY OF THE INVENTION
Hence, the problem to be solved by the present invention is to provide an RF receiver of the type mentioned above that maintains its settings while being switched off without requiring additional complicated circuitry.
Now, in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the radio receiver is manifested by the features that it comprises circuit elements a setting of which is controlled by at least one control voltage, a control unit for switching off the circuit elements during power-off periods, and a storage for storing the control voltage while the circuit elements are switched off, wherein the storage comprises a storage capacitor storing the control voltage.
In a further aspect of the invention, the radio frequency receiver comprises a frequency downconverter for downconverting an incoming signal to an intermediate frequency, an oscillator circuit being connected to the downconverter, a frequency of said oscillator being controlled by a control voltage, a control unit for switching off the oscillator during power-off periods, and a capacitor for storing the control voltage while the oscillator is switched off.
To store the setting, the corresponding control voltage is stored in a storage capacitor. This obviates the need for providing a digital memory and a D/A-converter. Since the control voltage needs not be converted to digital information and back, circuitry remains simple and power consumption is reduced.
For a reliable storage of the control voltage, a discharge time of the capacitor during switch-off should be much larger than a typical switch-off time.
To increase storage time, an electronic switch can be provided for disconnecting the capacitor from at least part of the circuit elements while they are switched off. Alternatively or in addition to that, an active hold circuit can be used for maintaining the voltage over the capacitor.
The technology described here is particularly useful for RF receivers. When part of an RF receiver is switched off for reducing power consumption or during periods of high electronic noise from a radio transmitter in the same appliance, its settings can be maintained using capacitive storage.
In particular, RF receivers usually comprise down-converters, where the incoming signal is mixed to a reference frequency. The reference frequency is usually generated by a VCO in a PLL. If such a circuit is switched off and back on, it requires some time to regain stable reference frequency unless the voltage controlling the VCO is stored.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings, wherein:
FIG. 1 shows a circuit diagram of an RF receiver,
FIG. 2 part of the automatic gain control circuit, and
FIG. 3 part of the PLL circuit.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the invention is an RF-receiver shown in FIG. 1 . The receiver shown here is used for receiving the signal of GPS satellites at 1575.42 MHz, but the same technique can be applied to other type of radio receivers, in particular for digital signals.
The receiver comprises an antenna 1 with low noise amplifier 2 and an input filter 3 . The signal from input filter 3 is fed to a frequency mixer 4 , which mixes the carrier at 1575.42 MHz with a frequency of 1554.96 MHz to generate a downconverted first IF signal at 20.46 MHz. The first IF signal is filtered in a first IF filter 5 and fed to a second mixer 6 , where it is mixed with a frequency of 16.368 MHz to generate a second downconverted IF signal at 4.092 MHz. The second IF signal is fed through a second IF filter 7 and to a adjustable amplifier 8 . The output of adjustable amplifier 9 is fed to an A/D-converter 9 which generates a digital value of two bits SGN and MAG giving the sign and magnitude of the signal. The magnitude bit is analyzed by an adjustable gain control (AGC) 10 to set the gain of adjustable amplifier 8 .
The design of AGC 10 is shown in FIG. 2 . It comprises a switch control unit 20 controlling a switch 21 . In a first state, switch 21 connects a capacitor C 1 via a current source 22 to the positive supply voltage Vdd. In a second state, switch 21 connects capacitor C 1 via a current source 23 to the negative supply voltage or ground. In a thirds state, switch 23 is in high impedance state. The voltage U 1 over C 1 is fed as a control voltage to the high impedance input of a buffer 24 , the output of which controls amplifier 8 , wherein a lower voltage U 1 corresponds to a higher amplification in amplifier 8 .
In normal operation, if MAG is 1, switch 21 is in its first state and, if MAG is 0, switch 21 is in its second state, i.e. the voltage over capacitor C 1 is proportional to the average value of MAG. If the average value of MAG is large, voltage U 1 increases, thereby decreasing the amplification of adjustable amplifier 8 and vice versa. The gain loop is adjusted such that it tries to hold MAG at an average value of 0.33, thereby holding the average signal strength at a desired value.
The circuit of FIG. 1 further comprises a Quartz oscillator 11 operating at 16.368 MHz. It generates the reference frequency for second mixer 6 . Furthermore, it provides a frequency base for a PLL. The PLL comprises a phase and frequency comparator 12 for comparing the Quartz oscillator frequency divided by 16 to the PLL's frequency divided by 1520. The output of comparator 12 is fed to a low pass filter comprising storage capacitors C 2 , C 3 , the voltage U 2 over which is the control voltage for the resonance frequency of a tank circuit 13 of a VCO 14 . By this arrangement, the VCO's frequency is kept at 1554.96 MHz, the reference frequency for first mixer 4 .
The design of the part of the PLL that drives capacitors C 2 , C 3 is shown in FIG. 3 . It comprises a switch control unit 26 controlling a switch 27 . In a first state, switch 27 connects capacitors C 2 , C 3 via a current source 29 to the positive supply voltage Vdd. In a second state, switch 27 connects capacitors C 2 , C 3 via a current source 30 to the negative supply voltage or ground. In a third state, switch 27 is in high impedance state. If the comparator finds that the VCO's frequency is too low, switch 27 is primarily set to its first state, thereby increasing voltage U 2 over the capacitors, while, if the VCO's frequency is too high and for decreasing voltage U 2 , switch 27 is primarily in its second state.
The circuit of FIG. 1 comprises a control or power save unit 15 . The purpose of this power save unit is to temporarily switch off the circuits of the RF receiver for conservation of power. The position and length of the switch-off periods can e.g. be selected according to a known temporal structure of the incoming signal or according to requirements of the user of the RF receiver.
Power save unit 15 switches off power supply to mixers 4 , 6 , amplifiers 2 , 8 , ADC 9 and AGC 10 , as well as to the PLL (comparator 12 , VCO 14 and frequency dividers) by issuing a control signal PWR SAVE. Typical power-off periods may e.g. have a duration between 1 ms and several seconds.
After a power-off period, power to the circuits of the RF receiver is switched back on and the RF receiver should become operational quickly. Without special provisions, the start-up time of the receiver would be limited by the time it takes for the circuit to re-establish its dynamic settings. These settings are the amplification of adjustable amplifier 8 as well as the frequency of the PLL. To reduce the start-up time, the circuit of FIG. 1 is designed to store these settings as control voltages U 1 , U 2 over the capacitors C 1 and C 2 or C 3 . While power is off, the load impedance offered by the circuits to these capacitors is high enough to make the discharge time of the capacitors much longer than a typical power-off period. A typical power-off period is e.g. limited by a few seconds, while the discharge time is e.g. 100 times as large.
It must be noted that the capacitors C 1 , C 2 and C 3 serve two purposes. First they act as low pass filters or integraters in their corresponding feed-back loops (ACG and PLL), second they store the setting of the loop during power-off.
To achieve high discharge times, switches 21 and 27 are both set to their third, high impedance state while the signal PWR SAVE indicates that the circuit is switched off.
To reach even higher discharge times, the capacities of the capacitors can be increased where possible. In addition or alternatively to this, active hold circuits can be used to maintain the voltage of the capacitors during power-off periods. In such a circuit, the storage capacitor can e.g. be arranged in the negative feedback loop between the amplifier output and its inverting input.
The LNA 2 , the frequency mixers 4 , 6 , the filters 5 , 7 , the amplifier 8 and the AGC 10 form the analogue section of the receiver of FIG. 1 . In the shown embodiment, the settings of this section are stored during power-off periods by saving the control voltages for the amplifier 8 and the VCO.
By storing the control voltages in the capacitors, the circuit can be switched back on quickly because its settings are maintained.
The principle described here can be used in other electronic circuits having settings that can be controlled by control voltages. In such circuits, the control voltages can be stored in suitable capacitors while power is shut down. The technique shown here is especially suited for PLL circuits in any application or for storing the amplification setting or setpoint of an adjustable RF or LF amplifier. It can also be used for storing the settings of any feedback loops.
In the embodiment described above, power save unit 15 is controlled automatically, i.e. the time and duration of the switch-off periods are not directly determined by the user. However, power save unit 15 could also be controlled by the user directly.
While there are shown and described presently preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practised within the scope of the following claims. | An RF receiver or another type of electronic circuit contains circuit elements a setting of which is controlled by at least one control voltage. Furthermore, a control unit is provided for switching off the circuit elements during power-off periods. While the circuit elements are switched off, the control voltage is stored in storage capacitors, which allows to start the circuit up quickly after a switch-off period. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a method for preparing hydroxyalkyl-functionalized polyphenylene ether which is obtained by functionalizing of the terminal phenolic hydroxyl group of a polyphenylene ether.
More specifically, the hydroxyalkyl-functionalized polyphenylene ether according to the method of the present invention can be considered to have effects, when blended with the other resin, etc., of heightening solubility between resins by reacting with functional groups of a resin to be blended and increasing strength of a composition as compared with a non-functionalized polyphenylene ether resin. Further, it is available for a precursor of a graft or block copolymer.
A polyphenylene ether resin is an extremely available thermoplastic resin having excellent heat resistance, mechanical characteristics, electric characteristics, water resistance, acid resistance, alkali resistance and self-extinguishing properties. Thus, it has been planning to use for many applications as an engineering plastic material. However, this resin has high melt viscosity which relates to high glass transition temperature, and thus, poor in molding property. Further, it has a disadvantage that impact resistance is poor as an engineering plastic.
In order to solve these problems, a polyolefin or an engineering plastic is blended with the polyphenylene ether, but the polyphenylene ether is essentially poor in compatibility with these polymers. Also, the resulting composition is weak and lowered in mechanical strength and impact strength whereby such a composition cannot be practically used. For solving the problem, a compatibilizing agent has been used, but many of the compatibilizing agents are a graft or block copolymer of the both polymers. When these copolymers are to be synthesized, a terminal phenolic hydroxyl group of the polyphenylene ether resin can be considered to react with a functional group in the other polymer.
However, the kinds of functional groups of the other polymers capable of reacting with the terminal phenolic hydroxyl group are limited so that utilizable range is restricted naturally. Thus, many functionalized polyphenylene ethers have been proposed in order to heighten reactivity of the polyphenylene ether resin. In Japanese Provisional Patent PCT Publications No. 500456/1987, No. 500803/1988 and No. 503391/1988, examples of some hydroxyalkyl group-functionalized polyphenylene ethers have been mentioned, but many steps of reactions are required for preparing the same and a melting reaction at a high temperature should be employed in many cases. Also, even when the modification can be carried out under relatively moderate reaction conditions, there is the problem that expensive acid chloride should necessarily be used. Further, in Japanese Provisional Patent Publication No. 128021/1988, there is disclosed a method in which a polyphenylene ether and ethylene oxide or propylene oxide are reacted to hydroxyalkylate the terminal of the polyphenylene ether. However, this method involves the problems that the reaction should be carried out under high pressure, control of an added number of ethylene oxide or propylene oxide is difficult and a uniform product can hardly be obtained.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method for preparing a hydroxyalkyl-functionalized polyphenylene ether under advantageous reaction conditions which are improved method of the conventional ones.
The present inventors have found that by functionalizing the terminal phenolic hydroxyl group of a polyphenylene ether with a functionalizing agent in the presence or absence of an organic solvent and in the presence of a basic catalyst, a modified polyphenylene ether can be obtained extremely easily to accomplish the present invention.
That is, the present invention comprising reacting a polyphenylene ether represented by the formula: ##STR2## wherein Q 1 each represents a halogen atom, a primary or secondary alkyl group, a phenyl group, an aminoalkyl group, a hydrocarbonoxy group or a halohydrocarbonoxy group; Q 2 each represents a hydrogen atom, a halogen atom, a primary or secondary alkyl group, a phenyl group, a haloalkyl group, a hydrocarbonoxy group or a halohydrocarbonoxy group; and m is an integer of 10 or more,
with a functionalizing agent in the presence or absence of an organic solvent capable of dissolving the polyphenylene ether and in the presence of a basic catalyst, and (1) the functionalizing agent comprises a glycidol represented by the following formula: ##STR3## and a hydroxyalkyl-functionalized polyphenylene ether is represented by the following formula: ##STR4## wherein Q 1 , Q 2 and m have the same meanings as defined above, and n is an integer of 1 to 10;
(2) the functionalizing agent comprises an epihalohydrin represented by the following formula: ##STR5## wherein X represents a halogen atom, and a hydroxyalkyl-functionalized polyphenylene ether obtained by hydrolyzing a terminal glycidylated polyphenylene ether is represented by the following formula: ##STR6## wherein Q 1 , Q 2 and m have the same meanings as defined above;
(3) the functionalizing agent is an alkylene carbonate represented by the formula: ##STR7## wherein R represents a hydrogen atom or an alkyl group having 1 to 8 carbon atoms,
and a hydroxyalkyl-functionalized polyphenylene ether is represented by the formula: ##STR8## wherein Q 1 , Q 2 , m and R have the same meanings as defined above;
and (4) the functionalizing agent is a halogenated alkyl alcohol represented by the formula:
X--R.sup.1 --OH (II.sub.D)
wherein X represents a halogen atom, and R 1 represents an alkylene group having 1 to 10 carbon atoms,
and a hydroxyalkyl-functionalized polyphenylene ether is represented by the following formula: ##STR9## wherein Q 1 , Q 2 , m and R 1 have the same meanings as defined above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an infrared absorption spectrum of hydroxyalkyl-functionalized polyphenylene ether (cast film prepared from a chloroform solution) obtained in Example 1.
FIG. 2 is an infrared absorption spectrum of hydroxyalkyl-functionalized polyphenylene ether (cast film prepared from a chloroform solution) obtained in Example 4.
FIG. 3 is an infrared absorption spectrum of hydroxyalkyl-functionalized polyphenylene ether (cast film prepared from a chloroform solution) obtained in Example 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polyphenylene ether to be used in the present invention is a homopolymer or a copolymer having a structural unit represented by the following formula: ##STR10## Preferred examples of the primary alkyl group of Q 1 and Q 2 may include methyl, ethyl, n-propyl, n-butyl, n-amyl, isoamyl, 2-methylbutyl, n-hexyl, 2,3-dimethylbutyl, 2-, 3- or 4-methylpentyl and heptyl groups. Examples of the secondary alkyl group may include isopropyl, sec-butyl and 1-ethylpropyl groups. In many cases, Q 1 is preferably an alkyl group or a phenyl group, particularly preferably an alkyl group having 1 to 4 carbon atoms and Q 2 is a hydrogen atom.
Preferred homopolymer of the polyphenylene ether may include, for example, those comprising a 2,6-dimethyl-1,4-phenylene ether unit. Preferred copolymer may include a random copolymer comprising the combination of the above and a 2,3,6-trimethyl-l,4-phenylene ether unit. Many suitable homopolymers or random copolymers are described in patents and literatures. For example, it is preferred to use a polyphenylene ether containing a molecular constitutional component which improves characteristics of a molecular weight, a melt viscosity and/or impact strength. They may include, for example, polyphenylene ethers in which a vinyl monomer such as acrylonitrile or vinyl aromatic compound including styrene, or a polymer such as a polystyrene or an elastomer thereof are grafted on the polyphenylene ether.
A molecular weight of the polyphenylene ether is generally preferably those in which an intrinsic viscosity in chloroform at 30° C. is 0.2 to 0.8 dl/g or so.
The polyphenylene ether can be usually prepared by oxidation coupling reaction of the above monomers. As for the oxidation coupling polymerization reaction of the polyphenylene ether, many catalyst systems have been known. Selection of the catalyst is not specifically limited and either of the conventionally known catalysts can be used. Such catalysts may include at least one of a compound of a heavy metal such as copper, manganese and cobalt generally in combination with the other various substances. The functionalizing agent (II A ) to be used in the present invention is glycidol, and specific examples of the functionalizing agent (II B ) of epihalohydrin may include epichlorohydrin, epibromohydrin and epiiodohydrin.
Also, preferred examples of the functionalizing agent of the alkylene carbonate represented by the formula (II C ) may include ethylene carbonate and propylene carbonate.
Further, preferred examples of the functionalizing agent of the halogenated alkyl alcohol represented by the formula (II D ) may include 2-chloroethanol, 3-chloro-l-propanol, 1-chloro-2-propanol, 4-chloro-1-butanol, 5-chloro-1-pentanol, 6-chloro-l-hexanol, 2-bromoethanol, 3-bromo-l-propanol, 1-bromo-2-propanol, 1-bromo-2-butanol and 2-iodoethanol.
Of these functionalizing agents represented by the formulae (II A ) to (II D ), (II A ) and (II B ) are preferred since they can add 2 or more alcoholic hydroxyl groups having different reactivity to one mole of the terminal phenolic hydroxyl group of the polyphenylene ether, particularly glycidol of the formula (II A ) is preferred.
For effecting the method of the present invention, the polyphenylene ether (III) is reacted with any one of glycidol (II A ), the epihalohydrin (II B ), the alkylene carbonate (II C ) or the halogenated alkyl alcohol (II D ) as the functionalizing agent in the presence or absence of an organic solvent and in the presence of a basic catalyst.
The organic solvents to be used in the present invention may include an aromatic hydrocarbon such as benzene, toluene and xylene; a halogenated hydrocarbon such as chloroform and carbon tetrachloride; a halogenated aromatic hydrocarbon such as chlorobenzene and dichlorobenzene; and a heterocyclic compound such as N-methyl-2-pyrrolidone, and the like.
As the basic catalyst mentioned above, there may be mentioned an alcoholate such as sodium methoxide, sodium ethoxide and potassium t-butoxide; an alkali metal hydroxide such as sodium hydroxide and potassium hydroxide; and an alkali metal carbonate such as sodium carbonate and potassium carbonate, and the like.
A reaction ratio of the polyphenylene ether and the functionalizing agent to be used in the method of the present invention is 1 to 50 moles, preferably 1 to 20 moles of the functionalizing agent based on one mole of the terminal phenolic hydroxyl group of the polyphenylene ether. However, in the case that the functionalizing agent can also act as a reaction solvent, the amount is not limited by those as mentioned above and it may be used with a larger excess amount.
The basic catalyst is preferably used in an amount of 1 to 30 parts by weight based on 100 parts by weight of the polyphenylene ether.
The reaction is practiced in a temperature range of 50° to 200° C. under an inert atmosphere such as nitrogen or argon. Preferred temperature range is a temperature range not exceeding a boiling point of the reaction solvent to be used.
When epihalohydrin is used as the functionalizing agent, a glycidylated polyphenylene ether is obtained in a first step reaction and then the material is hydrolyzed as a second step reaction. The second step reaction is carried out by adding 5 to 100 parts of water to 1 part by weight of the glycidylated polyphenylene ether formed in the first step reaction and adding 0.01 to 0.1 part by weight of a water soluble acid such as sulfuric acid, perchloric acid and acetic acid as a catalyst to react them at a temperature range of 20° to 100° C.
EXAMPLES
In the following, the present invention will be described in more detail by referring to examples.
Incidentally, the reaction ratio of the terminal phenolic hydroxyl group of the polyphenylene ether was calculated by determining an amount of the terminal phenolic hydroxyl group before and after the reaction in accordance with the method described in Journal of Applied Polymer Science; Applied Polymer Symposium, vol. 34 (1978), pp. 103 to 117.
The Case Where Glycidol is Used as the Functionalizing Agent
An average added number (n in the general formula (IA)) in the case of using glycidol as the functionalizing agent is estimated by the following equation. ##EQU1## wherein W 1 and R each represent a weight of a terminal modified polyphenylene ether isolated after completion of the reaction and a terminal reaction ratio of the same, respectively; and W 0 and Mn each represent a weight of a polyphenylene ether used in the reaction and a number average molecular weight of the same, respectively.
EXAMPLE 1
200 ml of toluene was added to 20 g of poly(2,6-dimethyl-1,4-phenylene ether) (intrinsic viscosity measured at 30° C. in chloroform was 0.31 dl/g), and the mixture was completely dissolved by stirring in a nitrogen atmosphere at 100° C. To the solution were added 5 g of sodium ethoxide and 10 ml of methanol, and then 3 g of glycidol was added dropwise over 20 minutes. Stirring was further continued at 100° C. for 7 hours. The reaction mixture was poured into 600 ml of methanol to precipitate a hydroxyalkyl-functionalized polyphenylene ether as a product. The formed product was collected by filtration and washed twice with methanol and dried at 80° C. under reduced pressure. The yield was 21.5 g.
This hydroxyalkyl-functionalized polyphenylene ether showed an absorption derived from a hydroxyl group at 3,380 cm -1 of an infrared absorption spectrum as shown in FIG. 1. When the determination of the terminal phenolic hydroxyl group was practiced, it had been found that 90% was reacted.
The above results show that, when the calculation formula of the above formula (IV) is used, to the terminal group of the polyphenylene ether used for the reaction, 6.7 in average of glycidols are bound.
EXAMPLE 2
In the same manner as in Example 1, the reaction was practiced except for using 0.6 g of sodium ethoxide as the catalyst and 2 ml of methanol and replacing the used amount of glycidol with 0.7 g. The formed modified polyphenylene ether was 20.3 g and the reaction ratio of the terminal group was 85 %.
The above results show that, when the calculation formula of the above formula (IV) is used, to the terminal group of the polyphenylene ether used for the reaction, 1.4 in average of glycidols are bound.
APPLICATION EXAMPLE 1
200 ml of xylene was added to 5 g of the terminal modified polyphenylene ether obtained in Example 1 and 5 g of a polypropylene modified with maleic anhydride (maleic anhydride content: 1.3% by weight, number average molecular weight Mn=43,200, weight average molecular weight Mw=125,000), and the mixture was reacted under a nitrogen atmosphere at 110° C. for 4 hours. The reaction mixture was poured into 800 ml of methanol to precipitate a polymer, and the polymer was collected by filtration. Further, the polymer was washed twice with each 800 ml of methanol and dried at 80° C. under reduced pressure to obtain 9.6 g of a polymer.
Subsequently, 3.3 g of the resulting polymer was extracted by a Soxhlet apparatus using 300 ml of chloroform as a solvent. As the result, unreacted polyphenylene ether extracted as a chloroform soluble component was 1.3 g. From this fact, the content of the polyphenylene ether in the resulting polyphenylene ether-polypropylene copolymer was found to be 17.5 % by weight.
The Case Where Epihalohydrin is Used as the Functionalizing Agent
EXAMPLE 3
To 350 g of poly(2,6-dimethyl-l,4-phenylene ether) (intrinsic viscosity measured at 30° C. in chloroform was 0.40 dl/g) was added 5 liters of epichlorohydrin, and the mixture was dissolved by stirring in a nitrogen atmosphere at 100° C. To the solution were added 70 g of sodium ethoxide and 300 ml of methanol over 20 minutes, and stirring was further continued at 100° C. for 4 hours. After the reaction mixture was cooled to room temperature, 10 liters of methanol was added to precipitate a modified polyphenylene ether as a product. After the product was collected by filtration, it was successively washed with 10 liters of methanol, then with each 10 liters of pure water twice and with 10 liters of methanol again. The resulting modified polyphenylene ether was dried at 80° C. under reduced pressure to obtain 351 g of a glycidylated polyphenylene ether.
When the terminal group was determined, it was found that 99% of the terminal phenolic hydroxyl group was reacted.
To 10 g of the resulting glycidylated polyphenylene ether were added 100 ml of pure water and 0.5 g of conc. sulfuric acid and the mixture was refluxed under heating for 5 hours. The reaction mixture was poured into one liter of methanol to precipitate the formed hydroxyalkyl-functionalized polyphenylene ether. Next, the product was dissolved again in 200 ml of chloroform and poured into one liter of methanol to effect reprecipitation and purification. The product was dried at 80° C. under reduced pressure to obtain 10 g of hydroxyalkyl group-functionalized polyphenylene ether (n=1 in the formula (I A ), i.e. which corresponds to the formula (I B )).
The Case Where Alkylene Carbonate is Used as the Functionalizing Agent
EXAMPLE 4
In 400 ml of chlorobenzene was dissolved 40 g of poly(2,6-dimethyl-1,4-phenylene ether) (intrinsic viscosity measured at 30° C. in chloroform was 0.40 dl/g). Subsequently, 4.4 g of ethylene carbonate and 0.4 g of potassium carbonate were added to the solution and the mixture was further continued to stir at 120° C. for 8 hours.
After the reaction mixture was cooled, it was gradually poured into 1.5 liters of methanol to precipitate the formed functionalized polyphenylene ether. The precipitated polymer was collected by filtration, washed with 1.5 liters of pure water and then washed twice with each 1.5 liters of methanol. The polymer was dried at 80° C. under reduced pressure to obtain 38.5 g of a hydroxyethylated polyphenylene ether.
An infrared absorption spectrum of the hydroxyethylated polyphenylene ether is shown in FIG. 2, it shows an absorption considered to be derived from a hydroxyl group at around 3600 cm -1 . Also, from the determination of the terminal phenolic hydroxyl group before and after the reaction, it can be found that 50% of the terminal group was reacted.
EXAMPLE 5
In 200 ml of xylene was dissolved 20 g of poly(2,6-di-methyl-1,4-phenylene ether) (intrinsic viscosity measured at 30° C. in chloroform was 0.30 dl/g). Subsequently, 20.0 g of propylene carbonate and 0.3 g of potassium carbonate were added to the solution and the mixture was further continued to stir at 132° C. for 7 hours. The reaction mixture was gradually poured into one liter of methanol and the formed functionalized polyphenylene ether was precipitated. The precipitated polymer was collected by filtration, washed with one liter of pure water and then washed twice with each one liter of methanol. The polymer was dried at 80° C. under reduced pressure to obtain 19.0 g of a 2-hydroxypropylated polyphenylene ether.
This 2-hydroxypropylated polyphenylene ether showed an absorption considered to be derived from a hydroxyl group at the neighbor of 3600 cm -1 of an infrared absorption spectrum. Also, from the determination of the terminal phenolic hydroxyl group before and after the reaction, it can be found that 49 % of the terminal group was reacted.
APPLICATION EXAMPLE 2
200 ml of xylene was added to 17.1 g of the hydroxyethylated polyphenylene ether obtained in Example 4 and 5 g of a polypropylene modified with maleic anhydride (maleic anhydride content: 1.3 % by weight, number average molecular weight Mn=43,200, weight average molecular weight Mw=125,000), and the mixture was reacted under a nitrogen atmosphere at 130° C. for 7 hours. The reaction mixture was poured into 1.2 liters of methanol to precipitate a polymer, and the polymer was collected by filtration. Further, the polymer was washed twice with each 1.2 liters of methanol and dried at 85° C. under reduced pressure and heating to obtain 21.4 g of a polymer.
Subsequently, 2.54 g of the resulting polymer was extracted by a Soxhlet apparatus using 300 ml of chloroform as a solvent. As the result, unreacted polyphenylene ether extracted as a chloroform soluble component was 1.83 g. From this fact, the content of the polyphenylene ether in the resulting polyphenylene ether-polypropylene copolymer was found to be 19.7 % by weight.
The Case Where Halogenated Alkyl Alcohol is Used as the Functionalizing Agent
EXAMPLES 6 TO 10
In a reactor were charged poly(2,6-dimethyl-l,4-phenylene ether) (intrinsic viscosity measured at 30° C. in chloroform was 0.31 dl/g), a functionalizing agent shown in Table 1, sodium ethoxide and a reaction solvent with amounts as shown in Table 1, and the mixture was reacted by stirring under heating and nitrogen atmosphere. After completion of the reaction, the reaction mixture was poured into a large amount of methanol to precipitate the formed modified polymer. Subsequently, the modified polymer obtained by filtration was washed with water and with methanol twice. The polymer was dried at 85° C. under heating and reduced pressure to obtain hydroxyalkyl-functionalized polyphenylene ether. The results are shown in Table 1.
These functionalized polyphenylene ethers showed absorptions considered to be derived from a hydroxyl group at a neighbor of 3600 cm -1 of an infrared absorption spectrum, respectively. An infrared absorption spectrum of the hydroxyethylated polyphenylene ether (a cast film prepared from a chloroform solution) obtained in Example 6 is shown in FIG. 3.
TABLE 1__________________________________________________________________________ Reaction Reaction TerminalFunctionalizing Amount PPE.sup.1) EtONa Solvent temperature Time Yield reactionExampleagent used (g) (g) (ml) (°C.) (hr) (g) ratio (%)__________________________________________________________________________6 2-chloroethanol 200 ml 17.5 1.7 -- 80 4 16.5 42.27 3-chloropropanol 50.0 g 20.0 1.5 100.sup.2) 95 7 19.4 69.38 4-chlorobutanol 200 ml 20.0 2.0 50.sup.2) 93 7 18.6 38.79 2-bromoethanol 20.0 g 20.0 1.5 -- 105 7 18.8 27.310 2-chloroethanol 50.0 g 20.0 2.0 200.sup.3) 108 7 19.1 45.3__________________________________________________________________________ .sup.1) PPE: Polyphenylene ether .sup.2) Toluene .sup.3) Nmethyl-2-pyrrolidone
APPLICATION EXAMPLE 3
100 ml of xylene was added to 5.0 g of the hydroxyethylated polyphenylene ether obtained in Example 6 and 2.0 g of a polypropylene modified with maleic anhydride (maleic anhydride content: 8.1% by weight, number average molecular weight Mn=39,000, weight average molecular weight Mw=221,000), and the mixture was reacted under a nitrogen atmosphere at 128° C. for 7 hours. The reaction mixture was poured into one liter of methanol to precipitate a polymer, and the polymer was collected by filtration. Further, the polymer was washed with one liter of methanol and dried at 85° C. under reduced pressure and heating to obtain 6.8 g of a polymer.
Subsequently, 1.29 g of the resulting polymer was extracted by a Soxhlet apparatus using 250 ml of chloroform as a solvent to remove unreacted polyphenylene ether. As the result, an amount of the polyphenylene ether extracted by chloroform was 0.80 g. From this fact, the content of the polyphenylene ether in the resulting polyphenylene etherpolypropylene copolymer was found to be 24.5% by weight.
As shown in the above Examples, the method for preparing the polyphenylene ether in which the terminal group is hydroxyalkyl-functionalized of the present invention is extremely easy, and the resulting product can be easily copolymerized with a treated polypropylene as shown in Application examples 1 to 3. | Disclosed is a method for preparing a hydroxyalkyl-functionalized polyphenylene ether which comprises reacting a polyphenylene ether represented by the formula: ##STR1## wherein Q 1 each represents a halogen atom, a primary or secondary alkyl group, a phenyl group, an aminoalkyl group, a hydrocarbonoxy group or a halohydrocarbonoxy group; Q 2 each represents a hydrogen atom, a halogen atom, a primary or secondary alkyl group, a phenyl group, a haloalkyl group, a hydrocarbonoxy group or a halohydrocarbonoxy group; and m is an integer of 10 or more,
with a functionalizing agent in the presence or absence of an organic solvent capable of dissolving the polyphenylene ether and in the presence of a basic catalyst. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to the field of civil engineering, particularly to fit in prefabricated blocks suitable for the raising of pillars and walls.
BACKGROUND OF THE INVENTION
[0002] The technical field, to which this invention refers, is continuously searching for obtaining firmness, stability, and high resistance in the prefabricated pieces destined to raise walls, as well as in the resulting walls.
[0003] In parallel, the mentioned technical field has been known world-wide in the use of fit in prefabricated pieces of different designs in order to prevent the use of the mortar mixture.
[0004] Additionally, in many cases, the use of larger amounts of elements for the raising of walls has been avoided so the task becomes as simple as possible to be attainable by workers without qualification or even by the future occupants of the house.
[0005] The proposed solutions in the matter of prefabricated pieces that do not require the use of a mortar mixture provided until the moment did not offer the firmness, stability and high resistance at a satisfactory level. At the same time, the proposed solutions in the matter of fit in prefabricated pieces had demonstrated that the use of elements to help in the construction as metal supports or beams had not being totally avoided.
[0006] Additionally, the proposed solutions until this moment have not allowed obtaining a suitable finish in spaces destined to openings, doors and windows, or an easy encounter to right angle walls.
[0007] The present invention proposes an alternative to solve these problems.
[0008] It is presented a fit in prefabricated block and its derived and complementary pieces for the task of raising pillars and walls without the need of a mortar mixture or plaster, being the block and the derived and complementary pieces prefabricated in a Portland cement mortar reinforced with steel fiber. The resulting pillars and walls of the fit in blocks and complementary derived pieces do not require structural elements as metal supports or beams.
[0009] The mortar mixture absence allows affirming that the blocks and the derived and complementary pieces are self-locking. The absence of additional structural elements, such as supports or metal beams, allows affirming that the pillars and walls are free-standing.
[0010] The pieces derived from the design of the block that complement it in the task of raising the pillars and walls are: a lintel beam which can also be used as a career beam or crown beam; a head block; and a semi-block.
[0011] All these prefabricated pieces are made in Portland cement mortar reinforced with steel fibers and are fit in between them.
[0012] The block and complementary derived pieces interact in a way that is described next, providing a technical alternative for the solution of the described technical problems. By the interaction of these elements, pillars and walls having firmness, stability, and high resistance and free-standing capacity are constructed, obtaining a suitable finish in spaces destined to openings, doors and windows, as well as a suitable encounter between the right angle walls that offer a solid mechanical entailment between the convergent walls.
SUMMARY OF THE INVENTION
[0013] The present invention relates to a prefabricated block in Portland cement mortar reinforced with steel fiber fit in self-locking form, suitable for the raising of firm pillars and walls, stable and of high resistance, for interior or exterior.
[0014] It is also an objective of the present invention to provide three pieces derived from the design of the block that complements the block in the task of raising the pillars and walls. They are: lintel beam, head block, and semi-block.
[0015] The block and the complementary derived pieces interact allowing the raising of the pillars and walls by a dry method.
[0016] To the effects of the present invention, it is understood by dry method the one that allows raising a pillar or wall without the use of a mortar mixture, and without the necessity of other different structural elements.
[0017] The fact that neither the blocks nor the complementary derived pieces need the mortar mixture to raise pillars and walls allows describing the block and the derived complementary pieces as self-locking.
[0018] The fact that the pillars and the walls do not need additional structural elements to provide the necessary raising capacity allows describing the pillars and walls as free-standing.
[0019] Additionally, the high resistance design that the prefabricated material grants to the blocks and the derived complementary pieces does not require plaster neither in the pillars nor in the walls, which carries advantages that are detailed in this document.
DESCRIPTION WITH REFERENCE TO THE DRAWINGS
[0020] FIG. 1 —illustrates a perspective view of the block in which the parallelepiped of rectangular base ( 1 ) and the two towers that overpass it ( 2 ) are shown. In the same figure a top view is shown where the hollow interiors of the towers ( 3 ) can be seen.
[0021] FIG. 2 —illustrates a front view, longitudinal section, lateral view, and cross sectional view of the block showing the parallelepiped of rectangular base ( 1 ) of which the two towers ( 2 ) overpass.
[0022] The longitudinal and cross-sectional sections, show the two hollow volumes of the towers ( 3 ), and the two hollow volumes symmetrically placed inside the parallelepiped of rectangular base each one with two segments of straight prismatic form of square base, having each one of them different segment dimensions ( 4 , 5 ).
[0023] FIG. 3 —illustrates a vertical view, front view, and lateral view of the semi-block ( 6 ) showing a single tower ( 2 ).
[0024] FIG. 4 —illustrates an inferior view of the head block ( 7 ) where the accesses to the two hollow volumes symmetrically placed are appraised ( 8 ); superior view ( 7 a ), horizontal ( 7 b ) and lateral ( 7 c ) of the head block.
[0025] In same FIG. 4 , a longitudinal section and a cross-sectional view of the head block ( 7 ) allow to appreciate the hollow volumes ( 8 ) and the solid superior part ( 9 ).
[0026] FIG. 5 —illustrates a perspective view of the lintel beam ( 10 ) and of its two ends ( 11 ).
[0027] FIG. 6 —illustrate a vertical view of the lintel beam ( 10 ).
[0028] FIG. 7 —illustrates a cross sectional view of one of the ends ( 11 ).
[0029] FIG. 8 —illustrates a horizontal view of the lintel beam ( 10 ).
[0030] FIG. 9 —illustrates a longitudinal view of the lintel beam ( 10 ) showing the stirrups ( 12 ), the main reinforcement ( 13 ) and the secondary reinforcement ( 14 ).
[0031] FIG. 10 —Illustrates a vertical view of a pillar of square section ( 15 ) where two blocks ( 1 ) are placed one next to the other.
[0032] FIG. 11 —illustrates a front view of a pillar of square section ( 15 ) showing the alternative disposition of layers of two blocks ( 1 ) that link with the superior layers when turning ninety degrees their direction.
[0033] FIG. 12 —illustrates a lateral view of a pillar of square section ( 15 ) where can be appraised just like in FIG. 11 .
[0034] FIG. 13 —illustrates a perspective view of the superior part of a pillar of square section ( 15 ).
[0035] FIG. 14 —illustrates a wall ( 16 ) constructed on the basis of the present system with the use of the block ( 1 ), semi-block ( 6 ), head block ( 7 ), lintel beam ( 10 ). The pieces used are observed at the foot of the representation. Also, a pillar of square section ( 15 ) is shown.
DESCRIPTION OF THE INVENTION
Block
[0036] The basic piece is constituted by a block. From the form of this piece, the other three mentioned pieces are derived.
[0037] The block basically comprises a parallelepiped of rectangular base whose length is double its width and its height is a third of the length, with two small identical towers that overpass its superior face.
[0038] The block comprises the parallelepiped and the towers that overpass the block. Nevertheless, in this chapter, for the single effects to give clarity to the description that follows, reference to the parallelepiped and the towers will be made separately.
[0039] The parallelepiped has in its interior two hollow volumes disposed symmetrically. Each one of the hollow volumes is made up of two segments of square base straight prismatic form placed one on top of the other, having each one of the segments different dimensions. The superior and inferior ends of the segments are opened.
[0040] The system to fit in the blocks between them is similar to the male/female system. The inferior segments of each one or both hollow volumes in the parallelepiped are predicted to function like the cavities or female elements in this system.
[0041] Both hollow volumes provide the block a favorable contribution to thermal insulation that is desirable in a wall designed to serve as a closing outer wall.
[0042] The weight of the block is lightened, allowing easy work manipulation; thus, the approximated weight of the block may be 6.5 kg, for an example, in which the rectangular base blocks have a length of 30 cm, width of 15 cm and a height of 10 cm, obtaining in addition a wall with its own weight of approximately 217 kg/m 2 in walls of 15 cm, comparable to the weight of a plastered solid brick wall of the same thickness.
[0043] The two towers that overpass the superior face of the described parallelepiped are symmetrically arranged and have a square base straight prismatic form. Each one of the towers is equipped with an interior hollow volume also with straight prismatic form of square base, being the hollow volumes symmetrically located. The superior and inferior ends of the hollow prism are open.
[0044] The inferior ends of the hollow volumes of the towers are in communication with the superior ends of the hollow volumes of the parallelepiped, so that each one of the hollow volumes of the towers is continued in each one of the hollow volumes of the parallelepiped.
[0045] The main function of the towers is to serve as a mechanical bond between the blocks constituting the male element in the mentioned male/female system. Each one of the blocks is fit in with another by introducing the towers of one of them in the inferior segments of the hollow volumes of the parallelepiped.
[0046] The fit in system allows to eliminate the necessity of a mortar mixture because their effects are replaced by the first, conferring to the wall, at the same time, stability and a monolithism similar to the obtained in a traditional wall with the use of a mortar mixture. It is for this reason that the block is called self-locking.
[0047] This fit in system allows in addition eliminating the necessity of additional structural elements, such as supports or metal beams, destined to equip the walls with the necessary raising capacity. The pillars and the walls that are constructed are by design free-standing for important wall height and with capacity to support reinforced concrete slabs with usual design overloads. Without damage to it, in the case of being needed as a structural reinforcement destined to other aims, this one can be implemented by adding reinforcement and concrete in the continuous hollow columns that are formed in the walls as a product of placing the blocks in successive layers.
[0048] The two towers allow an average adult worker to take the block comfortably with a single hand, which facilitates its manipulation and positioning in the work area.
[0049] As the blocks are fit into one another, walls can be perfectly raised saving in manual labor from the qualitative point of view. Non-specialized workers and people who work under the modality of auto-construction or mutual aid can execute the walls with professional finishing.
[0050] A result of the block design and placing them in successive layers is the formation of pillars and walls with continuous vertical hollow columns in its interior.
[0051] Another result of both is the greater yield per time because walls can be raised with a non-possible speed by other methods.
[0052] The pillars and walls do not need any fresh element that sets; they have high resistance which, along with the characteristics already mentioned, makes them suitable to offer immediately raising capacity.
[0053] In a preferable embodiment, the pillars are of square section with free-standing capacity, which is obtained by providing alternatively successive layers of two blocks that are linked to successive superior layers when turning ninety degrees their orientation. In the walls with free-standing capacity, somewhat, the standing capacity is obtained when successive block layers are placed and the link with the superior successive layers is made without the need to turn the direction of such.
[0054] Another result of the block design and alternatively intercalating in the junction of the walls encounter the blocks so they are simultaneously fit in both walls; its right angle walls are obtained that allow achieving, at the same time, in the considered corner a monolithism of equal order of the one of each wall itself.
[0055] The corners are conformed in the same hollow columns that are in the rest of the walls. These hollow columns can be used to produce reinforced concrete pillars in their interior if it is considered useful to the effects of providing additional stability.
[0056] Also, it is distinguishable to the facility to implement the installation of lights, water, or other services by means of interior canals that use the vertical hollow spaces of the walls.
[0057] The link between the blocks with each other causes the block to be set under compression forces, supported fundamentally by the mortar, and flexion and cut that are essentially supported by the steel fibers that integrate the mortar matrix. The content of steel fiber additionally confers a high resistance to impacts.
Lintel Beam
[0058] For the effects to totally allow the raising of walls with prefabricated elements a lintel beam is introduced.
[0059] The lintel beam is a piece having a cross-sectional section identical to the block, the length is equivalent to a multiple of the block length and the longitudinal section is equal to the one obtained by placing several aligned blocks. The volume is equivalent to the volume of combining several blocks in which the hollow openings symmetrically placed have been filled up; thus, they are parallelepipeds having a solid rectangular base with solid towers that overpass them, joined among them.
[0060] Its reinforcement is equivalent to that of a traditional beam.
[0061] The ends of the lintel beam have the same form of a block which confers a type of uniform fit in for the whole structure. These ends are those that link the lintel beam to the masonry allowing a fit in with the rest of the wall.
[0062] Its function is double: they can serve as lintel beam in openings; but, in addition, placing them in series, can function as career beam or crown beam, according to the case.
[0063] They may be prefabricated of several lengths being advisable to limit them, for simplicity as well as for economy, in addition to the inherent conditioning to the work manipulation and design factors.
[0064] The lintel beam has main reinforcement, secondary reinforcement, and stirrups according to the usual design hypotheses in reinforced concrete, and they are made with the same material of the blocks including the steel fibers.
Head Block
[0065] To the effects of having a space of windows and doors that are adapted to the rapidity and convenience of the raising of walls according to this system, the piece of the head block is introduced.
[0066] This piece allows to easily construct a ledge, as well as to finish off the crowning of a wall or a crown beam in a uniform way offering a smooth surface when it is required for construction reasons.
[0067] It is prefabricated with the same material of the above identified block.
[0068] It derives from the design of the block because starting from the block design, the towers are eliminated and the rectangular base parallelepiped is provided with a solid superior face.
[0069] The solid superior face is obtained by filling the superior prismatic segments of the hollow volumes of the mentioned parallelepiped.
[0070] It is linked by means of the inferior face where they are the two cavities or female elements constituted by the prismatic hollow volumes symmetrically placed that are equivalent to the inferior segments of the hollow volumes of the rectangular parallelepiped that forms part of a block.
[0071] The head block is fit in an inferior block by means of the previously mentioned male/female, because the towers of the inferior block are fit in the cavities that are opened in the inferior face of the head block.
Semi-Block
[0072] In addition, a semi-block is added which, along with the lintel beam, allows forming a space suitable to tie down windows or doors by means of suitable adherences.
[0073] It is a piece derived from the block.
[0074] Starting from a block as it has been described; a transversal cross-sectional section is performed as previously described to obtain two identical semi-blocks.
[0075] The semi-blocks are fit in blocks in order to complete the lateral closing of the wall in those places where they need to be implementing, for example, spaces destined to windows and doors, or joining of walls.
[0076] Next to the lintel beam, the semi-block allows producing a space suitable for armor of windows or doors by means of suitable adherences, for example, wall anchor.
Characteristic of the Wall
[0077] The dosage of the elements of the mortar—cement, water, and sand including its mesh—allows obtaining a wall of texture comparable to texture of a plastered wall, that along with its resistance, allows leaving out the plaster for interior as well as for exterior.
[0078] The mentioned texture and consistency grant a suitable impermeability, making it only necessary to perform the sealing of the superficial junctions that form in the ornament between the pieces, with cement mortar or a suitable pastine. This sealing may be applied by a person that does not have any technical skill in a similar way to the enforcement of joints, for example, ceramics pieces or floor tiles.
[0079] The morphology of these pieces and link also grant facility and monolithism in the execution of the walls joints and the corners in right angle that prevail at general level.
[0080] From the point of view of the work schedule, it is obtained a shortening of the same by way of eliminating the necessary of habitual waiting times that assure a minimum structural resistance in traditional resistant elements, as well as to eliminate delays due to the incidence of the adverse weather in outdoor work.
[0081] The use of the block and the pieces derived from it, with the characteristics described for the raising of pillars and inner and outer walls, constitutes an integral constructive system. This system assures the fast emergence of complementary elements like doors, windows, or ceilings.
[0082] In addition, it is to emphasize the remarkable resistance to impact that confers the steel fiber content, important point for a wall that is designed to be without interior or exterior plaster.
A WORKING EMBODIMENT
[0083] Next a working embodiment is described without meaning in anyway some limitation in the reach of this request for patent, since it is possible to always give other measures to the block and other pieces obtaining the same results as long as the proportion between the measures is maintained.
Block
[0084] In a preferred form to obtain an easily manageable volume by the workers, by its dimensions as well as by its weight, and considering a suitable wall width, the rectangular base parallelepiped has a length of 30 cm, a width of 15 cm, and a height of 10 cm, whereas the towers has a length of 10 cm, a width of 10 cm and a height of 4.5 cm.
[0085] From the inferior face of the rectangular base parallelepiped it is possible to access the two cavities or female elements constituted by the prismatic inferior segments of the hollow volumes symmetrically placed. Each one of these prismatic segments has a length of 11 cm, a width of 11 cm, and a height of 5 cm.
[0086] Between the internal faces of the inferior segments of both hollow volumes there is a separation of 4 cm. From the external faces of the inferior segments of both hollow volumes there is a separation of 2 cm with respect to the lateral faces of the parallelepiped.
[0087] The prismatic superior segments of the hollow volumes symmetrically placed have a length of 7 cm, a width of 7 cm, and a height of 5 cm.
[0088] The towers measure 10 cm in length, 10 cm width, and 4.5 cm in height, whereas the inner hollow volumes measure 7 cm in length, 7 cm in width, and 4.5 cm in height.
[0089] The towers symmetrically placed in the superior face of the block have a separation among them of 5 cm, and each one of them moved away 2.5 cm of the respective lateral faces of the parallelepiped. The thickness of the walls of the towers is of 1.5 cm.
[0090] The described measures constitute a preferred example by the inventor without for that reason limiting the reach of this request of patent. The mentioned measures can change if the proportions are maintained.
[0091] When placing the blocks one next to another, and one fit in the other as a male/female, layers or rows of blocks are formed that allow to raise as an example columns, inner or outer walls.
[0092] The fit in between pieces allows forming square pillars of 30 cm of side with standing capacity, this is obtained by alternatively placing layers of two blocks that link with the superior layers when turning ninety degrees their direction.
[0093] The height of the pillars and the walls is a multiple of the height of the block. In the above mentioned example it is a multiple of 10 cm. This is particularly useful in the case of using foundation stall, in which case the pillars may be placed as an additional ceiling support.
Lintel Beam
[0094] For the case of rectangular base block type of a length of 30 cm, a width of 15 cm, and a height of 10 cm, the beams may be made with a section of 15 cm of base by 10 cm of height, which limits the amount of reinforcement to be placed.
[0095] Its weight must be so that it allows to manipulate it and to place it in the wall with facility, to such effects, in a manufacture example for the previously mentioned case, is considered to prefabricate the lintel beams of two lengths, that is to say: of 1.20 m for lintels of doors, and 1.50 ms for lintels of windows. The fact that the beam door lintel has 1.20 m allows a free light of 90 cm to the effects to locate the door and the frame. The length of the lintel beam of window of 1.50 m allows that the width of the window with the frame is 1.20 m.
[0096] In the case of the beams section lintels 15 cm by 10 cm and 1.50 cm of overall length, its total weight is approximately of 65 kg, which allows that two workers position it in work area without greater difficulty.
Head Block
[0097] Starting from the design of the block, and having eliminated the towers, the superior hollow segments of the parallelepiped that are filled up have a length of 7 cm, width of 7 cm and a height of 5 cm.
[0098] From the inferior face of the head block it is possible to access the two cavities or female elements constituted by the prismatic hollow volumes symmetrically placed. Each one of these volumes has a length of 11 cm, width of 11 cm, and a height of 5 cm.
Semi-Block
[0099] Starting from the block as it has been described; a cross-sectional section is performed in the block to obtain two identical semi-blocks.
[0100] Consequently, starting from the measures previously described for the block it is possible to easily deduce the measures of the semi-block.
INDUSTRIAL APPLICATION
[0101] The blocks are feasible products to be produced exclusively at industrial level by means of matrix or molds, which facilitates the necessary quality control and made possible the desirable scale economies.
[0102] The semi-blocks, which can be obtained by sectioning blocks with common equipment, are feasible industrially prefabricated by means of matrices or molds.
[0103] The head block and the beams can only be prefabricated industrially by means of matrices or molds obtaining the desirable standardization. | The present invention refers to a prefabricated fit in blocks and derived and complementary pieces in cement mortar reinforced with steel fiber for raising of pillars and walls with no need to use mortar mixture or plasters. Pillars and resulting walls of the fit in of blocks and derived and complementary pieces do not require additional structural elements. | 4 |
This patent application is a U.S. national stage application of PCT international application PCT/EP2008/009287 filed on Nov. 4, 2008 which claims priority of German patent document 10 2007 053 023.6-43 filed on Nov. 5, 2007.
FIELD OF THE INVENTION
The present invention relates to a coating composition consisting of oxide compounds, to a method for producing said oxide compounds, and to the use thereof.
BACKGROUND OF THE INVENTION
Oxide layers, in particular ceramic and especially aluminum oxide (Al 2 O 3 ), are used as coating material for a multiplicity of applications which impose stringent demands in respect of heat stability and heat shock stability or resistance to wear, oxidation or hot corrosion, thermal stability and electrical insulation.
Such layers can act as a diffusion barrier for ions and have high chemical stability and radiation resistance. They are therefore used in many fields. Thus, by way of example, aluminum oxide serves as an insulation material in the field of microelectronics. Owing to its chemical resistance and biocompatibility, it is also used in the field of medicine. Coatings comprising oxides are a good option for protecting surfaces against oxidation or hot corrosion, for example. This high chemical stability coupled with highly advantageous mechanical properties make oxides an ideal material for protective layers.
In this case, the production of suitable oxide compounds constitutes a major challenge; particularly the production of suitable oxide compounds having high homogeneity and purity is difficult. Thus, by way of example, aluminum oxide is present either as an amorphous phase or in various crystalline modifications with different properties. Said modifications have the more advantageous properties for protective coatings, since amorphous phases are normally softer. Crystalline aluminum oxide can be present in various modifications, of which only α-Al 2 O 3 (corundum) is thermodynamically stable. The others, so-called transition aluminum oxides, such as γ, δ, η, θ, χ, χ′-Al 2 O 3 and Al 2 O 3 -KII, are metastable and can be irreversibly converted into α-Al 2 O 3 . Above 1200° C., corundum is the only stable modification. In this case, corundum is also the hardest modification of aluminum oxide. The low ionic conductivity and its high thermodynamic stability make it an important coating against oxidations.
The prior art discloses a variety of methods for producing coatings and films composed of aluminum oxide, such as, for example, chemical vapor deposition (CVD), physical vapor deposition (PVD), hydrothermal synthesis, sputtering or the sol-gel method.
U.S. Pat. No. 6,521,203 describes the production of α-Al 2 O 3 by calcination of aluminum hydroxide, produced by hydrolysis of aluminum isopropoxide, at a temperature of 700 to 1300° C. However, this method does not permit the production of thin coatings.
U.S. Pat. No. 5,302,368 describes the production of coatings by applying a dispersion of aluminum hydroxide and/or a transition aluminum oxide in aqueous medium. After adjusting the slurry and spray drying, the dry powder is calcined in the presence of a chlorine-containing substance at 1100° C. to 1500° C.
For industrial applications for depositing oxide layers, chemical vapor deposition (CVD) at high temperatures, normally around 1000° C., is normally used since this technique affords the possibility of coating even complex geometries in conjunction with well-controllable thickness of the coating.
U.S. Pat. No. 5,654,035 describes such a process wherein the body to be coated is brought into contact at high temperature with a hydrogen carrier gas and a hydrolyzing or oxidizing agent, said hydrogen carrier gas containing one or more aluminum halides. In addition, U.S. Pat. No. 6,713,172 describes the application of this method for coating cutting tools, once again at high temperatures of approximately 1000° C.
U.S. Pat. No. 7,238,420 describes a nanotemplate composed of relatively pure and fully crystalline α-Al 2 O 3 on a metal alloy. In the production method disclosed, crystalline α-Al 2 O 3 is produced with the aid of CVD directly on the surface of the alloy. For this purpose, the latter is pretreated before the deposition with a CO 2 /H 2 mixture at high temperatures of 1000° C. to 1200° C.
All the methods described require high temperatures. The latter not only limit the possible substrates but can also lead to thermal flaws in the coating. Thus, the oxide coatings and the substrate often have different coefficients of thermal expansion of film and substrate, which leads to thermally induced flaws in the coating.
In order to avoid the high temperatures, major efforts have been undertaken to develop methods which make it possible to deposit oxide layers at lower temperatures, for example physical vapor deposition (PVD).
U.S. Pat. No. 5,683,761 describes a method for depositing α-Al 2 O 3 with the aid of electron beam PVD. However, the substrate has to be heated to approximately 1000° C. Therefore, the deposition of pure oxide, in this case α-Al 2 O 3 , also requires high temperatures.
Variants of the CVD method, such as plasma assisted/enhanced chemical vapor deposition (PACVD/PECVD) or metal organic chemical vapor deposition (MOCVD) likewise afford the possibility of using lower temperatures.
Thus, Pradhan et al. (Surf. Coat. Tech. 176 (2004) 382-384) describes that the use of metallo-organic aluminum compounds leads to the formation of crystalline aluminum oxide at low temperatures (higher than 550° C.). Only amorphous films were obtained at lower temperatures.
Although MOCVD methods afford many advantages, such as, for example, lower temperatures, simple processes, uniform coatings or the use of a single precursor, they also lead to carbon-like impurities in the coating.
The degree of crystallinity and the crystalline phases within the deposited oxide layer are very important for the mechanical properties thereof. A pure phase having high thermal and mechanical stability is distinctly preferred to a mixture of different phases. However, this necessitates a suitable heat treatment of the coated substrate which leads not only to the transformation into the desired phase but additionally to a densification of the coating, which is likewise of great importance for the mechanical stability of the layer. Such a heat treatment often requires temperatures of greater than 1200° C., which are not suitable for many substrates.
In order to avoid the heating of the entire coated substrate, a local heat treatment is appropriate. In this context, lasers have already been used successfully for the treatment of such ceramic materials (laser sintering). In this case, the coating is heated in a small region with the aid of a laser beam. These methods are used precisely in the field of oxide ceramics since they absorb in the range of the CO 2 lasers used. In this case, one particular problem is the formation of thermally induced flaws during the resolidification and cooling of the material. They result from the brittleness of the ceramics and from the high temperature gradient between the region of action and the surrounding material, and also the different coefficients of thermal expansion of coating and substrate.
Thus, Triantafyllids et al. (Appl. Surf, Sci. 186 (2002) 140-144) and WO 2007/102143 describe the occurrence of thermally induced cracks during laser sintering. Such defects naturally influence the density and stability of the coating and the homogeneity of the phase transformation.
These effects can be reduced by adding binders to the oxide compounds, e.g. the aluminum oxide particles. Thus, U.S. Pat. No. 6,048,954 describes such a binder composition for inorganic particles having a high melting point. Although such binders increase the densification of the coating, they can only be employed for pulverulent materials and the binder and also the residues thereof have to be removed after the laser sintering or even remain in the oxide layer.
Since the efficiency of laser sintering is highly dependent on the absorption of the material to be sintered, absorption is an important criterion. In this case, the binder can also contribute to the absorption. Thus, U.S. Pat. No. 6,007,764 describes the use of a mixture of absorbent and ceramic particles in order to improve the absorption. Zheng et al. (Mat. Lett. 60 (2006) 1219-1223) use polystyrene-coated aluminum oxide particles in order to optimize the absorption for CO 2 lasers. Said particles exhibited better absorption and therefore also more uniform heating and a reduced temperature gradient. However, organic material always remains as a residue in the coating.
DE 10 2006 013 484 A1 describes the production of an element/element oxide composite material, that is to say a material containing an element and the corresponding element oxide, in this case nanowires comprising a metal core and an oxide sheath.
The disadvantage of most methods for producing oxide layers resides in the high temperatures of the method. In the case of the laser sintering methods, the essential disadvantages are that only very specific lasers in a certain wavelength range, usually CO 2 lasers, are suitable for being used; the precursors used do not absorb other wavelengths. This causes high temperature gradients and leads to a higher loading of the substrate and to thermally induced cracks and defects. Therefore, the addition of additional binders is often necessary in order to increase the absorption of the laser energy and to achieve a high quality of the coating. However, residues of said binders remain in the coating. Moreover, the production of high-quality and fault-free coatings requires a high degree of experience since influencing of the underlying substrate or excessive heating has to be avoided.
Problem
The present invention addresses the problem of overcoming the disadvantages of the prior art in the production of oxide layers as a coating composition. The problem addressed by the invention is, in particular, that of specifying a method which makes it possible to produce suitable oxide compounds as a coating composition.
SUMMARY OF INVENTION
This problem is solved by the invention with the features of the independent claims. Advantageous developments of the inventions are characterized in the dependent claims. The wording of all the claims is hereby incorporated by reference in the content of this description. The invention also encompasses all expedient and in particular mentioned combinations of independent and/or dependent claims.
Individual method steps are described in greater detail below. The steps need not necessarily be carried out in the order indicated, and the method to be portrayed can also have further steps that are not mentioned.
In order to solve the stated problem, a method for producing oxide layers is proposed, which comprises the following method steps:
a) application of an element/element oxide composite structure on the substrate b) (brief) local heating of the element/element oxide composite structure, preferably by means of a laser.
The method according to the invention surprisingly yields oxide layers which have few to no defects and high hardness and densification. The composite structure is designated as a composite structure since it consists both of the element and of the element oxide.
The coating according to the invention of the surface with the element/element oxide composite structure is preferably carried out according to the metal organic chemical vapor deposition (MOCVD) method. In this method, metallo-organic precursors are converted into the vapor phase and thermolytically decomposed, the nonvolatile decomposition product generally depositing at or on the substrate. The precursors used in the invention have the general formula
El(OR) n H 2
wherein El denotes Al, Ga, In, Tl, Si, Ge, Sn, Pb or Zr, and R represents an aliphatic or alicyclic hydrocarbon radical, and n has the value 1 or 2.
The aliphatic and alicyclic hydrocarbon radical is preferably saturated and has, for example, a length of 1 to 20 carbon atoms. Alkyl or unsubstituted or alkyl-substituted cycloalkyl are preferred. The alkyl radical preferably has 2 to 15 carbon atoms, preferably 3 to 10 carbon atoms, and can be linear or branched, where branched alkyl radicals are preferred. Examples that may be mentioned here include: ethyl, n-propyl, n-butyl and the corresponding higher linear homologs, isopropyl, sec-butyl, neopentyl, neohexyl and the corresponding higher isoalkyl and neoalkyl homologs or 2-ethylhexyl. The alicyclic rings can comprise 1, 2 or more rings, each of which can be substituted by alkyl. The alicyclic radical preferably comprises 5 to 10, particularly preferably 5 to 8, carbon atoms. Examples that may be mentioned here include: cyclopentyl, cyclohexyl, methylcyclohexyl, norbornyl and adamantyl.
Oxide compounds which form ceramic oxides are preferably used according to the invention.
Particular preference is given to aluminum alkoxydihydrides having branched alkoxy radicals having 4 to 8 carbon atoms, in particular aluminum tert-butoxydihydride. The production of such compounds is described in DE 19529241. They can be obtained for example by reacting aluminum hydride with the corresponding alcohol in a molar ratio of 1:1, wherein the aluminum hydride can be prepared in situ by reacting an alkali metal aluminum hydride with an aluminum halide. Furthermore, the production of such compounds is also described by Veith et al. (Chem. Ber. 1996, 129, 381-384), where it is also shown that the compounds of the formula El(OR)H 2 can also comprise dimeric forms.
The compounds are preferably converted into the vapor phase and thermolytically decomposed, the nonvolatile decomposition product generally being formed at or on a substrate in the form of the element/element oxide composite structure. Appropriate substrates for applying the coating include all customary materials, for example metal, ceramic, alloys, quartz, glass or glass-like materials, which are preferably inert with respect to the starting and end products. The thermolysis can be carried out e.g. in a furnace, at an inductively heated surface or at a surface situated on an inductively heated sample carrier. Only conductive substrates such as, for example, metals, alloy or graphite can be used in the case of inductive heating. In the case of substrates having a low conductivity, an electrically conductive substrate carrier or furnace should be used in the case of inductive heating. The substrate can therefore be either a surface of the reaction space or a substrate positioned therein. The reactor space used can have any desired configuration and consist of any customary inert material, for example Duran or quartz glass. Reactor spaces having hot or cold walls can be used. The heating can be effected electrically or by other means, preferably with the aid of a radiofrequency generator. The furnace and also the substrate carrier can have any desired forms and sizes corresponding to the type and form of the substrate to be coated; thus, the substrate can be for example a plate, plane surface, tubular, cylindrical, parallelepipedal or have a more complex form.
It may be advantageous to purge the reactor space a number of times with an inert gas, preferably nitrogen or argon, before the precursor is introduced. Moreover, it may be advantageous to apply an interim vacuum, if appropriate, in order to render the reactor space inert.
Furthermore, it may be advantageous, before the metallo-organic precursor is introduced, to heat the substrate to be coated, for example metal, alloy, semiconductor, ceramic, quartz, glass or glass-like, to above 500° C. in order to clean the surface.
The desired element/element oxide composite structure preferably arises at temperatures of more than 400° C., particularly preferably more than 450° C. Preference is given to temperatures of not more than 1200° C., in particular not more than 600° C., e.g. from 400° C. to 1200° C., and preferably from 450° C. to 650° C., especially preferably 450° C. to 600° C. The substrate on or at which the thermolysis takes place is accordingly heated to the desired temperature. In this case, the production of the element/element oxide composite structure according to the invention is independent of the substrate material used and the constitution thereof.
The (metallo-organic) compound or the precursor can be introduced into the reactor from a supply vessel, which is preferably temperature-regulated to a desired evaporation temperature. Thus, it can be temperature-regulated for example to a temperature of between −50° C. and 120° C., preferably between −10° C. and 40° C. The thermolysis in the reactor space is generally effected at a reduced pressure of 10 −6 mbar to atmospheric pressure, preferably in a range of 10 −4 mbar to 10 −1 mbar, preferably 10 −4 mbar to 10 −2 mbar. In order to generate the vacuum, a vacuum pump system can be connected to the reactor on the outlet side. All customary vacuum pumps can be used; a combination of rotary vane pump and turbomolecular pump or a rotary vane pump is preferred. It is expedient for the supply vessel for the precursor to be fitted on the side of the reactor space and the vacuum pump system on the other side.
When the substrate is heated by induction, e.g. electrically conductive metal laminae or films having a size measured in square centimeters can be arranged as substrate in a reaction tube composed of Duran or quartz glass. Upon adaptation of the dimensions of the apparatus, substrate areas in the range from square decimeters through to several square meters are likewise possible. The supply vessel with the precursor, temperature-regulated to the desired evaporation temperature, is connected to the reaction tube on the inlet side and a vacuum pump system is connected to said reaction tube on the outlet side. The reaction tube is situated in a radiofrequency induction field that is used to heat the substrate laminae or films to the desired temperature. After the desired pressure has been set and a precursor has been introduced, the substrate is covered with the element/element oxide composite structure.
It is advantageous to regulate the flow rate of the precursor using a valve. The valve can be controlled manually or automatically. Depending on the desired thickness of the coating, the duration of the addition of the precursor can be from a few minutes up to several hours.
The morphology of the element/element oxide composite structure can be controlled by varying one or more process parameters selected from substrate temperature, gas pressure, precursor feed temperature, precursor flow (amount of precursor introduced per unit time) and vapor deposition time.
In a further development, the element/element oxide composite structure obtained can be subjected to a treatment with a mixture, a solution and/or a suspension of organic and/or inorganic substances.
In a further configuration of the invention, the substrate can be coated with the element/element oxide composite structure only in desired regions, which also restricts the treatment by local heating to said regions.
After cooling, the element/element oxide composite structure is locally heated, particularly preferably with the aid of a laser. This process is also referred to as sintering. In this case, the element/element oxide composite structure is converted into the desired element oxide structure. This alteration can also comprise conversion into one or more modifications of a crystal structure; the formation of a single modification of the element oxide is particularly preferred in this case.
As a particular advantage of the invention, the element/element oxide composite structure has a better thermal conductivity than the pure element oxide and, as a result, leads to a reduced temperature gradient during the local heating. This reduces the cracks induced thereby.
In one advantageous development of the invention, the elemental component of the element/element oxide composite structure can function as a binder by virtue of the fact that it melts during heating and can thus fill cracks and pores that have possibly arisen in the element/element oxide composite structure as a result of the heating. As a result, it is not necessary to add a separate binder, which might lead to undesired residues.
In one advantageous development of the invention, the element/element oxide composite structure is not completely converted into the corresponding element oxide at the heating location. The degree of conversion can be controlled very accurately by control of the laser intensity and the duration of action. This makes it possible to selectively produce regions having a specific structure and morphology, and thus for example to produce nanowires, nanoparticles and fractal surfaces.
In a further advantageous development of the invention, the element/element oxide composite structure is completely converted into the corresponding element oxide at the heating location. The degree of conversion can be controlled up to complete conversion by control of the laser intensity and the duration of action. By melting the metallic component of the element/element oxide composite structure, it is possible to produce particularly defect-free and uniform oxide layers.
A further major advantage of the present invention is the possibility of being able to choose the wavelength of the laser from a large wavelength range. The element/element oxide composite structure produced can be a broadband absorber and thus absorb light from a very broad wavelength range. The wavelength of the laser can lie in the range from UV to electromagnetic waves, preferably in the range of 300 nm to 15 μm, particularly preferably in the range of 500 nm to 11 μm, even more advantageously, but without restriction to lasers having the wavelengths of 488 nm, 514 nm, 532 nm, 635 nm, 1064 nm or 10.6 μm. Continuous (CW) or pulsed lasers can be used.
Preferably, the laser energy used, depending on the wavelength used and the element/element oxide composite structure, is between 1 milliwatt per square centimeter and a number of watts per square centimeter, preferably between 1 milliwatt per square centimeter and 10 watts per square centimeter, particularly preferably between 1 mW/cm 2 and 5 W/cm 2 .
One particular advantage of the invention is the realization of very small penetration depths of the laser. Thus, the penetration depth, with the use of a pulsed laser, for example, can be reduced to a range of less than approximately 400 nm, preferably less than approximately 300 nm, particularly preferably less than approximately 200 nm, especially preferably less than approximately 100 nm. This enables not only the production of very thin layers, but also particularly mild treatment of the substrate. The layer thickness of the element oxide layer produced can accordingly lie between approximately 400 nm and approximately 10 nm, preferably between approximately 300 nm and approximately 10 nm, particularly preferably between approximately 200 nm and approximately 10 nm, especially preferably between approximately 100 nm and approximately 10 nm. Theoretically, it would even be possible to produce just a few monolayers of element oxide, that is to say just a few layers of atoms. Furthermore, the small penetration depth protects a temperature-sensitive substrate against thermal energy input and, in addition, mechanical stresses at the interface between coating and substrate are avoided. Thus, it is also possible to use substrates which themselves absorb the laser wavelength used. Moreover, it is also possible to convert only the surface of an element/element oxide composite structure having a relatively large layer thickness.
A further particular advantage of the invention resides in the possibility of being able to produce not only particularly thin but also particularly hard oxide layers, which particularly preferably afford a high degree of protection against corrosion as a result of low permeability.
A further advantageous development of the invention involves measuring the light absorption of the element/element oxide composite structure at the treatment location, during the heating or between a plurality of sintering processes. As a result of the conversion of the element/element oxide composite structure into the desired element oxide, it is possible to alter the absorption for example of light in the visible range, at the heating location. From this alteration, it is possible to produce a specific degree of conversion by adapting method parameters such as, for example, but without restriction to, laser intensity, wavelength, time of action of the laser, repetitions of the heating. After the desired degree has been achieved, the heating can be ended at this location.
In a particularly advantageous configuration of the invention, the wavelength of the laser is chosen in such a way that it is reflected by a pure element oxide layer. As a result, after complete conversion of the element/element oxide composite structure has been effected, at the heating location, no further absorption of the laser light takes place since the element oxide then present does not absorb said light. As a result, the conversion can be stopped “automatically” upon the pure element oxide being attained, since no further heating by the laser occurs. An “overheating” of the element oxide layer, which can lead to defective positioning, for example as a result of the formation of granulation, in the element oxide layer, is avoided as a result.
Moreover, the substrate lying below the layer can be treated mildly in this way. At the same time, this development permits the use of higher laser intensities than were possible in conventional methods with the same layer thickness and substrate.
Lasers having wavelengths in the visible range of light are particularly preferably chosen for this configuration of the present invention. The local heating using lasers having this wavelength range is possible by virtue of the absorption properties of the element/element oxide composite structure according to the invention.
As an alternative, the “overheating” of the oxide layer produced can also be used to set a specific porosity as a result of the targeted production of defects.
A further advantage of the present invention resides in the possibility of carrying out the heating locally, that is to say not only with mild treatment of the underlying substrate but also just in desired regions of the element/element oxide composite structure, if, by way of example, such a coating is desired only on the outer side of the substrate. On the other hand, it is likewise possible to treat the entire surface of the substrate, particularly preferably by line-by-line scanning with the aid of a computer-controlled laser scanner.
A further advantage of the present invention resides in the possibility of producing a specific desired structure on the surface of the substrate by targeted proportional or complete conversion of the element/element oxide composite structure. The possibility of using lasers having shorter wavelengths enables structures having a significantly higher resolution than with the CO 2 lasers used heretofore, theoretically limited by half of the wavelength used.
Furthermore, the local heating according to the invention can be carried out with the aid of a computer-controlled laser scanner, preferably with a focusing optical unit in order to focus the laser beam better.
The present invention furthermore relates to a coating composition, in particular producible by the abovementioned method according to the invention, comprising oxide layers having a high to complete oxide proportion, which are produced by thermolytic decomposition of metallo-organic compounds of the formula El(OR) n H 2 , wherein El denotes Al, Ga, In, Tl, Si, Ge, Sn, Pb or Zr, and R represents an aliphatic or alicyclic hydrocarbon radical, and n has the value 1 or 2, at a temperature of more than 400° C. with the formation of an element/element oxide composite structure, and the element/element oxide composite structure produced is converted into the oxide compound by brief local heating, preferably by means of a laser (sintering).
Preferably, the proportion of the oxide compound in the coating composition is at least 80%, preferably at least 95%, particularly preferably almost 100%.
Preferably, the oxide compound is a ceramic oxide, and aluminum or gallium oxide is particularly preferred, especially preferably aluminum oxide and most preferably aluminum oxide as α-Al 2 O 3 (corundum).
According to the invention, the coating composition can have a high hardness; by way of example, a hardness of approximately 28 GPa can be achieved in the case of aluminum oxide.
Furthermore, the coating compositions according to the invention are distinguished by high adhesion to the substrate. As a further advantage, the coating compositions according to the invention have a low diffusion coefficient for ions, and also a low permeability to water. By virtue of these properties, they are suitable, in particular, as protection of the substrate against corrosion or wear and abrasion.
Furthermore, the invention relates to the use of the coating composition according to the invention for coating substrates composed of e.g. metal, semiconductor, alloy, ceramic, quartz, glass or glass-like materials. This merely represents a choice of the possible substrates, and in no way a restriction. Generally, the coating composition according to the invention can be applied to (almost) all substrates. Suitable substrates are known to the person skilled in the art.
The diversity of the method according to the invention with regard to the conversion of the element/element oxide composite structure permits numerous applications. According to the invention, it is possible to produce very hard, wear-resistant protective layers for components exposed to a high degree of erosion and wear. The possibility of producing highly defect-free layers enables the protective layers to be used for electrical or thermal insulation. Furthermore, applications in the field of medicine, in particular as a coating for implants, are also possible. Surfaces structured in a targeted manner according to the invention are suitable for example in the field of catalysis, filtration or lithography through to storage media, such as information storage.
Furthermore, the element/element oxide composite structure according to the invention is suitable, owing to its absorption properties, for producing surfaces with absorption of a broad wavelength range. For example for light energy absorbing coatings for solar cells, light protective coatings, solar collectors and the like.
Furthermore, the invention comprises a device for carrying out the local heating preferably with the aid of a laser, preferably with a computer-controlled laser scanner, particularly preferably with an optical unit that focuses the laser beam.
A further advantageous development of the device according to the invention comprises the possibility of measuring the light absorption of the element/element oxide composite structure at the treatment location, during the heating or between a plurality of sintering processes. This can be done by measuring the intensity of the reflection of the laser at the heating location or by measuring the intensity of the reflection at the heating location using some other light source having a suitable wavelength during sintering or between a plurality of sintering processes. This permits complete automation of the method according to the invention.
Further details and features will become apparent from the following description of preferred exemplary embodiments in conjunction with the dependent claims. In this case, the respective features can be realized by themselves or as a plurality in combination with one another. The possibilities for solving the problem are not restricted to the exemplary embodiments. Thus, by way of example, range indications always encompass all—unmentioned—intermediate values and all conceivable sub-intervals.
XRD Analysis: X-ray Diffraction Analysis
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 photograph of an untreated Al/Al 2 O 3 composite structure
FIG. 2 photograph of a treated Al/Al 2 O 3 composite structure (5 watt laser 5 mm/sec);
FIG. 3 photograph of a treated Al/Al 2 O 3 composite structure (10 watt laser; 2 mm/sec);
FIG. 4 absorption spectrum of an Al/Al 2 O 3 composite structure (thickness: 200-400 nm)
FIG. 5 X-ray diffraction analysis (XRD) of different Al/Al 2 O 3 composite structures on stainless steel
FIG. 6 X-ray diffraction analysis (XRD) of different Al/Al 2 O 3 composite structures on titanium
FIG. 7 photograph of an Al/Al 2 O 3 composite structures treated partially and with increasing energy
FIG. 8 examination of the water permeability of different Al/Al 2 O 3 composite structures
FIG. 9 measurement of the hardness of an α-Al 2 O 3 layer produced according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The series of images in FIGS. 1 to 3 clearly shows the influence of the action of the laser depending on the duration of action, in this case given by the speed at which the laser was moved across the sample.
In detail, FIG. 1 shows an untreated Al/Al 2 O 3 composite structure before the laser treatment. Neither a uniform surface nor a structuring of the surface can be discerned.
FIG. 2 shows an Al/Al 2 O 3 composite structure after brief laser treatment. This gives rise to the formation of new morphologies and structures, in this case to nanowires and fractal structures.
FIG. 3 shows an Al/Al 2 O 3 composite structure treated to complete conversion. Only a small number of defects can be discerned and the surface appears to be uniform.
FIG. 4 shows the broad absorption of the Al/Al 2 O 3 composite structure (thickness: 200-400 nm). The absorption in a broad wavelength range permits the use of lasers in a broad wavelength range.
FIG. 5 and FIG. 6 show an X-ray diffraction analysis of different Al/Al 2 O 3 composite structures which were treated for different periods of time on two different substrates. It is clearly possible to discern the arising and the increase of the signals of the α-Al 2 O 3 crystal structure, while the signals of the metallic aluminum decrease. This shows an increasing crystallization and formation of α-Al 2 O 3 .
FIG. 7 shows the selective conversion in specific regions depending on the energy. On the Al/Al 2 O 3 composite structure shown, strip-shaped regions were produced with the treatment intensity increasing toward the left, said regions being separated in each case by untreated strips, in accordance with the method according to the invention. It is clearly possible to discern the precise resolution and the accuracy with which the method according to the invention enables the targeted production of structures on surfaces.
FIG. 8 shows the water permeability of differently treated Al/Al 2 O 3 composite structures. While the untreated Al/Al 2 O 3 composite structure (top, squares) exhibits a high permeability to water and is therefore not suitable as protection against corrosion, the completely converted Al/Al 2 O 3 composite structure according to the invention exhibits no permeability (bottom, triangles). By contrast, an Al 2 O 3 coating having defects (middle, circles) has a significantly higher permeability. This shows how important it is to precisely control the conversion conditions for the production of durable and secure protective layers.
FIG. 9 shows the measurement of the hardness of a completely converted Al/Al 2 O 3 composite structure with the aid of nano intendation. A hardness of 28 (+/−2) GPa was measured in this case.
EXEMPLARY EMBODIMENTS
a) Production of the Element/Element Oxide Composite Structure
The precursor aluminum tert-butoxydihydride (Al(tBu)H 2 ) was deposited onto a metallic substrate (steel, copper, nickel or platinum) or alternatively onto glass or ceramics in a CVD apparatus under argon at a temperature of 600° C. The furnace was heated inductively, wherein a conductive sample holder was used in the case of glass. The pressure in the reactor was approximately 6.0×10 −2 mbar. The volatile decomposition products of the precursor (including hydrogen and isobutene) were detected by a connected mass spectrometer. For an Al/Al 2 O 3 composite structure having a layer thickness of approximately 1 μm, the duration of the inflow of precursor was approximately 10 minutes. Larger thicknesses were able to be obtained with a longer duration (30 to 90 minutes). The Al/Al 2 O 3 composite structure obtained is dark to black in coloration owing to its absorption.
b) Local Heating
The local heating was carried out with the aid of a laser. Firstly, an air-cooled CO 2 laser having a wavelength of 10.6 μm was used, which laser was focused by means of a biconvex ZnSe lens having a focal length of 120 mm. The exposure diameter was 10-12 mm and the conversion width of the laser on the substrate was approximately 20-25 μm. The intensity of the laser was varied between 1 W/cm 2 and 5 W/cm 2 . This laser is absorbed by the Al/Al 2 O 3 composite structure and the aluminum oxide layer.
An argon ion laser having wavelengths in the range of visible light was furthermore used, which laser was focused with the aid of a biconvex lens having the focal length of 120 mm. The exposure diameter was 10-12 mm and the conversion width of the laser on the substrate was approximately 20-25 μm. The wavelengths of 514 nm, 488 nm, and also a wavelength range of 450 nm to 532 nm (mixed line) were used for the irradiation of the Al/Al 2 O 3 composite structure. The intensity was varied between 0.4 W/cm 2 and 2 W/cm 2 . This laser is absorbed only by the Al/Al 2 O 3 composite structure and not by the aluminum oxide layer obtained upon complete conversion.
A pulsed laser was used in the case of fragile substrates, in particular in the case of some glasses and ceramics. In this case, it was possible to treat thin, and very thin layers of Al/Al 2 O 3 composite structure without influencing the substrate. Lasers having the wavelengths of 266 nm, 355 nm, 532 nm or 1064 nm were used for this purpose. The intensity was kept low and was 200 joules for a pulse length of 4-8 ns. The exposure diameter was 10-12 mm and the conversion width of the laser on the substrate was approximately 20-25 μm. The treatment was carried out both with an individual pulse and with a repetition of pulses with a rate of 10 Hz. A small penetration depth of the laser of just 200-300 nm was able to be achieved as a result. This permitted the production of very thin oxide layers (<300 nm and even <200 nm) with particularly high protection against corrosion and having a hardness of 28 (+/−2) GPa.
LIST OF THE CITED LITERATURE
U.S. Pat. No. 6,521,203
U.S. Pat. No. 5,302,368
U.S. Pat. No. 5,654,035
U.S. Pat. No. 6,713,172
U.S. Pat. No. 5,683,761
U.S. Pat. No. 7,238,420
U.S. Pat. No. 6,048,954
U.S. Pat. No. 6,007,764
WO 2007/102143
DE 10 2006 013 484 A1
DE 19529241
Pradhan et al. “Crystallinity of Al 2 O 3 films deposited by metalorganic chemical vapour deposition”, Surface and Coating Technology, 176, (2004), 382-384
Triantafyllids et al. “Surface treatment of alumina-based ceramics using combined laser sources”, Applied Surface Science, 186, (2002), 140-144
Zheng et al. “Effect of core-shell composite particles on the sintering behaviour and properties of nano-Al 2 O 3 /polystyrene composite prepared by SLS”, Materials Letters, 60, (2006), 1219-1223 | The invention relates to a coating composition consisting of an oxide compound. The invention also relates to a method for producing a coating composition consisting of an oxide compound and to a method for coating substrates composed of metal, semiconductor, alloy, ceramic, quartz, glass or glass-type materials with coating compositions of this type. The invention further relates to the use of a coating composition according to the invention for coating metal, semiconductor, alloy, ceramic, quartz, glass and/or glass-type substrates. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an apparatus for capturing game or pests and, more particularly, but not by way of limitation to an apparatus that employs a snare.
2. Description of the Related Art
Trapping is the use of a device to remotely catch an animal and is employed for a variety of reasons, including hunting, pest control, and wildlife management. In particular, traps are effective in protecting livestock and agriculture from pests and predators such as coyotes and feral hogs.
Due to an exploding population and the lack of natural predators, feral hogs have become a problem in the United States. Feral hogs are omnivores and are opportunistic when it comes to food sources eating crops as well as livestock. In addition, to reach tubers and worms, feral hogs root the soil changing the soil's mineral properties as well as water infiltration rates, which has a negative impact on agriculture and vegetation.
Traps have become an effective way to control the feral hog population and limit their impact on agriculture, livestock, and the environment. Many different methods are used to trap feral hogs including box traps, corrals, and snares. Box traps and corrals are expensive, immobile, and may become less effective over time. Specifically, the feral hogs often learn from their keen sense of smell not to approach the box trap or corral. Conversely, snares are inexpensive, portable, and may be placed on trails and pathways that are used by feral hogs. Moreover, the snare and the triggering system for the snare can be buried to make the snare harder to detect for feral hogs and other pests or game. In addition, multiple snares may be employed in a given area to increase their effectiveness.
Accordingly, a game snare that is inexpensive, portable, and that can be buried would be useful.
SUMMARY OF THE INVENTION
In accordance with the present invention, a snare system comprises a trap body including an aperture, a trigger plate assembly disposed within the trap body, a snare assembly placeable about the trap body, and at least one snare release assembly operatively linked with the trap body.
The trap body includes a wall defining an opening and having an inner surface and an outer surface, a lip atop the wall that defines the aperture, at least one release slot in the wall, at least one hinge bracket disposed within the trap body that aligns with the release slot, and a bottom plate. A base secures to the bottom plate to cover the opening of the trap body.
The trigger plate assembly includes a trigger plate and legs coupled with the trigger plate. The trigger plate assembly inserts within the opening of the wall such that the legs abut the lip and the trigger plate aligns with the aperture. The trigger plate assembly is accessible through the aperture of the trap body and movable between an armed position and an activated position. In the armed position the legs abut the lip and the trigger plate aligns with the aperture.
The snare assembly includes a wire having a first end formed into a loop and second end. The snare assembly further includes a stop secured to the wire adjacent the loop and a swivel stop that receives the wire therethrough and couples with the second end of the wire to form a snare. The snare assembly still further includes a biasing member disposed over the wire between the stop and the swivel stop. The biasing member biases the swivel stop from a loading position to a capture position.
The snare release assembly includes a snare release coupled with the hinge bracket of the trap body that moves between a normally charged position and a release position. In addition, the snare release disengages the snare assembly from the trap body when the trigger plate assembly moves from the armed position to the activated position. The snare release assembly further includes an actuator coupled with the snare release and a biasing member coupled with the snare release.
The snare release includes a trigger tab and a snare tab. The trigger tab engages with the actuator and a first member of the biasing member. The snare tab engages with a coil of the biasing member and couples with the hinge bracket of the trap body. A second member of the biasing member abuts the inner surface of the wall of the trap body such that the biasing member biases the snare release into the normally charged position, whereby a portion of the snare tab extends through the release slot of the trap body. The portion of the snare tab extending through the release slot and the trap body form a pocket for receiving the snare assembly therein. Furthermore, in the normally charged position, the actuator contacts the trigger plate assembly to maintain the trigger plate assembly in the armed position.
When a force is applied to the trigger plate, the trigger plate overcomes the biasing member and moves the snare release from the normally charged position to the release position. As a result, the portion of the snare release extending through the release slot pivots to eliminate the pocket and release the snare assembly from the trap body. Upon release from the trap body, the biasing member of the snare assembly biases the swivel stop from the loading position to the capture position thereby ensnaring an animal's limb.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view illustrating a snare system according to the preferred embodiment.
FIG. 2 is an exploded view illustrating the snare system.
FIG. 3 is a bottom view in perspective illustrating the snare system.
FIG. 4 is a bottom view illustrating the snare system.
FIG. 5 is a cross-sectional side view illustrating the snare system in an armed position.
FIG. 6 is a cross-sectional side view illustrating the snare system in a release position.
FIG. 7 is a perspective view illustrating the snare system capturing an animal's limb.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Figures are not necessarily to scale, and some features may be exaggerated to show details of particular components or steps.
FIGS. 1-3 illustrate a snare system 10 . The snare system 10 includes a snare assembly 100 , a trigger plate assembly 200 , a trap body 300 , a snare release system 400 , and a base 500 . The snare assembly 100 includes a wire 110 , a swivel stop 120 that moves between a loading position and a capture position, a biasing member 130 , a stop 140 , and retaining clips 151 and 152 . The wire 110 can be any suitable material, however, in the preferred embodiment the wire 110 is a steel cable. The swivel stop 120 includes a first member 121 and a second member 122 . The first member 121 includes an aperture 123 that receives a second end of the wire 110 therethrough and the second member 122 includes an aperture 124 that receives and secures the second end of the wire 110 . In particular, the second end of the wire 110 passes through the aperture 123 of the first member 121 and inserts into the aperture 124 of the second member 122 . After the wire 110 inserts into aperture 124 of the second member, the wire 110 secures to the second member 122 using any suitable means such as a threaded nut. Once the wire 110 secures to the second member 122 , the wire 110 forms a snare 105 .
The stop 140 includes an aperture 145 that receives the first end of the wire 110 such that the wire 110 passes through the aperture 145 . After passing through the aperture 145 , the stop 140 secures to the wire 110 using any suitable means such as a friction fit created through crimping. Furthermore, once the first end of the wire 110 passes through the aperture 145 of the stop 140 , the wire 110 forms a loop 150 that is maintained by the retaining clips 151 and 152 . The loop 150 allows the snare assembly 100 to secure to an immobile object such as a tree, fence post, or stake.
The biasing member 130 inserts over the wire 110 such that a first end of the biasing member 130 abuts the stop 140 and a second end of the biasing member 130 abuts the first member 121 of the swivel stop 120 . The biasing member 130 biases the swivel stop 120 from the loading position to the capture position. In the preferred embodiment, the biasing member 130 is a spring.
The snare assembly 100 assembles in the following manner. The aperture 145 of the stop 140 receives the first end of the wire 110 such that the wire 110 passes through the aperture 145 . After passing through the aperture 145 , the stop 140 secures to the wire 110 at a desired distance from the loop 150 . Furthermore, once the first end of the wire 110 passes through the aperture 145 of the stop 140 , the wire 110 forms the loop 150 wherein the retaining clips 151 and 152 are placed onto the wire 110 to maintain the loop 150 . The biasing member 130 inserts over the wire 110 at the second end until the first end of the biasing member 130 abuts the stop 140 . Thereafter, the second end of the wire 110 inserts through the first member 121 and into the second member 122 of the swivel stop 120 . In particular, the second end of the wire 110 inserts through the aperture 123 of the first member 121 until the second end of the biasing member 130 abuts the first member 121 . Furthermore, the second end of the wire 110 inserts and secures into aperture 124 of the second member 122 using any suitable means such as a threaded nut. After inserting through the aperture 123 of the first member 121 and securing to the second member 122 , the wire 110 forms the snare 105 .
The snare assembly 100 operates in the following manner. The loop 150 secures to an immobile object such as a tree, fence post, or stake. The biasing member 130 through engagement with the swivel stop 120 and the stop 140 biases the swivel stop 120 from the loading position to capture position. In particular, as the biasing member 130 biases the swivel stop 120 from the loading position to the capture position, the swivel stop 120 guided by the aperture 123 moves along the wire 110 such that the diameter of the snare 105 is reduced thereby allowing the capture of an animal's limb. Operation of snare assembly 100 in combination with the other components of the snare system 10 will be described in greater detail herein.
The trigger plate assembly 200 includes a trigger plate 210 and legs 211 - 214 . The trigger plate 210 connects to the legs 211 - 214 using any suitable means such as welding. The trigger plate assembly 200 inserts within the trap body 300 and moves between an armed position and an activated position. Specifically, when an animal steps on the trigger plate 210 of the trigger plate assembly 200 , the trigger plate assembly 200 moves from the armed position to the activated position. The legs 211 - 214 guide and maintain the trigger plate assembly 200 within the trap body 300 as the trigger plate assembly 200 moves between the armed position and the activated position. The movement of the trigger plate assembly 200 between armed position and the activated position will be explained in greater detail herein.
The trap body 300 includes a wall 301 defining an opening 304 and having an inner surface 302 and an outer surface 305 , a lip 307 atop the wall 301 that defines an aperture 310 , release slots 315 in the wall 301 , and a bottom plate 320 that allows the trap body 300 to secure to the base 500 . The trap body 300 further includes hinge brackets 311 - 314 that connect to the lip 307 , the inner surface 302 of the wall 301 , or both using any suitable means such as spot welding. The hinge brackets 311 - 314 align with a respective release slot 315 and include apertures 330 that allow the securing of the snare release system 400 . The outer surface 305 of the wall 301 receives the snare assembly 100 when moved to the loading position.
The hinge brackets 311 - 314 receive the snare release system 400 . In particular, a portion of the snare release system 400 secures within the hinge brackets 311 - 314 and allows the snare release system 400 to pivot within the hinge brackets 311 - 314 . In addition, the release slots 315 of the trap body 300 receive a portion of the snare release system 400 that moves within the release slots 315 to release the snare assembly 100 from the trap body 300 . The snare release system 400 is activated by the trigger plate assembly 200 resulting in a portion of the snare release system 400 pivoting within the hinge brackets 311 - 314 and a portion of the snare release system 400 moving upwards within the release slots 315 to release the snare assembly 100 from the outer surface 305 of the wall 301 . Once the snare assembly 100 is released from the outer surface 305 , the swivel stop 120 of the snare assembly 100 moves from the loading position to the capture position thereby reducing the diameter of the snare 105 and allowing the capture of an animal's limb.
The snare release system 400 includes snare release assemblies 401 - 404 . The snare release assemblies 401 - 404 are identical and each includes a snare release 410 , an actuator 415 which is a screw in the preferred embodiment, a biasing member 420 , and a retaining clip 425 . The snare release 410 includes a snare tab 411 and a trigger tab 412 . The snare tab 411 includes an aperture 413 and the trigger tab 412 includes an aperture 414 . The aperture 413 of the snare tab 411 receives the retaining clip 425 and the aperture 414 of the trigger tab 412 is threaded to receive the actuator 415 . The biasing member 420 includes a first member 431 , a second member 432 , and a coil 433 . The first member 431 of the biasing member 420 forms a loop 435 .
The snare assemblies 401 - 404 assemble and install within the hinge brackets 311 - 314 of the trap body 300 in the following manner. The loop 435 of the biasing member 420 is placed onto the trigger tab 412 . The actuator 415 inserts through the loop 435 of the biasing member 420 and through the aperture 414 of the trigger tab 412 . The actuator 415 maintains the biasing member 420 engaged with the trigger tab 412 . The snare assemblies 401 - 404 are placed within the hinge brackets 311 - 314 of the trap body 300 and the retaining clip 425 inserts through the apertures 330 of the hinge brackets 311 - 314 , the aperture 413 of the snare tab 411 , and the coil 433 of the biasing member 420 . Insertion of the retaining clip 425 through the apertures 330 of the hinge brackets 311 - 314 , the aperture 413 of the snare tab 411 , and the coil 433 of the biasing member 420 allows the snare assemblies 401 - 404 to pivot within the hinge brackets 311 - 314 . Furthermore, the retaining clip 425 is bendable to allow retention of the snare assemblies 401 - 404 within the hinge brackets 311 - 314 .
After the snare assemblies 401 - 404 secure within the hinge brackets 311 - 314 , a portion of the snare releases 410 of the snare assemblies 401 - 404 extends through the release slots 315 of the trap body 300 , the biasing members 420 abut the inner surface 302 of the wall 301 , and the actuators 415 reside against the trigger plate assembly 200 . Specifically, the snare tabs 411 of the snare assemblies 401 - 404 insert through a respective release slot 315 of the trap body 300 , the second members 432 of the biasing members 420 abut the inner surface 302 of the wall 301 , and the actuators 415 reside against the trigger plate 210 of the trigger plate assembly 200 . Once the actuators 415 of the snare release assemblies 401 - 404 reside against the trigger plate 210 , the biasing members 420 of the snare assemblies 401 - 404 bias the trigger plate assembly 200 into the armed position. Likewise, the biasing members 420 of the snare assemblies 401 - 404 bias the snare releases 410 of the snare assemblies 401 - 404 into a normally charged position that allows placement of the snare assembly 100 around the trap body 300 in the loading position.
The snare releases 410 move between the normally charged position and a release position that disengages the snare assembly 100 from the trap body 300 . Specifically, in the normally charged position, the snare tab 411 of the snare release 410 pivots away from the lip 307 to form a pocket 501 with the outer surface 305 of the wall 301 . The pocket 501 receives the snare 105 of the snare assembly 100 . Conversely, in moving to the release position, the snare tab 411 pivots towards the lip 307 to eliminate the pocket 500 and remove the snare 105 of the snare assembly 100 from the outer surface 305 of the trap body 300 . As described above, removing the snare 105 of the snare assembly 100 from the outer surface 305 of the trap body 300 moves the swivel stop 120 of the snare assembly 100 from the loading position to the capture position.
The snare system 10 assembles in the following manner. As illustrated in FIG. 3 , the trap body 300 is aligned such that the opening 304 of the wall faces upward and the lip 307 and aperture 310 faces downward. The trigger plate assembly 200 then inserts within the trap body 300 . Specifically, the trigger plate assembly 200 inserts within the opening 304 of the wall 301 such that the legs 211 - 214 reside against the inner surface 302 of the wall 301 and the trigger plate 210 aligns with the lip 307 and the aperture 310 . The snare release assemblies 401 - 404 are then installed and secured within the trap body 300 as described above. Once the snare release assemblies 401 - 404 are installed and secured within the trap body 300 , the biasing members 420 of the snare assemblies 401 - 404 bias the trigger plate assembly 200 into the armed position. Likewise, the biasing members 420 of the snare assemblies 401 - 404 bias the snare releases 410 of the snare assemblies 401 - 404 into the normally charged position. The base 500 then connects to the bottom plate 320 of the trap body 300 using any suitable means such as bolts thereby sealing the trigger plate assembly 200 and the snare assemblies 401 - 404 within the trap body 300 . After the trigger plate assembly 200 and the snare assemblies 401 - 404 seal within the trap body 300 , the snare assembly 100 is ready for placement on the trap body 300 .
FIGS. 4-6 illustrate the trapping of an animal using the snare system 10 . The operator locates a suitable position for the snare system 10 . Once a suitable position is found, the trap body 300 is placed on the ground or buried such that the aperture 310 of the trap body 300 and the trigger plate 210 of the trigger plate assembly 200 is facing upward. As described above, the biasing member 420 of the snare assemblies 401 - 404 biases the snare release 410 of the snare assemblies 401 - 404 into the normally charged position and the trigger plate assembly 200 into the armed position. The loop 150 of the snare assembly 100 secures to an immobile object such as a tree, fence post, or stake. The swivel stop 120 of the snare assembly 100 is moved into the loading position and the snare 105 is placed over the outer surface 305 of the trap body 300 and into the pocket 500 formed by the snare release 410 of the snare release assemblies 401 - 404 and the outer surface 305 of the trap body 300 .
When an animal such as a feral hog, coyote, or the like steps on the trigger plate 210 of the trigger plate assembly 200 , pressure from the animal's weight overcomes the biasing members 420 of the snare assemblies 401 - 404 causing the trigger plate assembly 200 to move from the armed position to the activated position and the snare releases 410 of the snare assemblies 401 - 404 to move from the normally charged position to the release position. In particular, in moving from the armed position to the activated position, the trigger plate assembly 200 acting through the actuators 415 applies a force to the trigger tab 412 causing the snare releases 410 to move from the normally charged position to the release position. In moving to the release position, the snare tabs 411 of the snare releases 410 pivot towards the lip 307 to eliminate the pocket 500 and remove the snare 105 of the snare assembly 100 from the outer surface 305 of the trap body 300 . Once the snare 105 is removed from the trap body 300 , the biasing member 130 biases the swivel stop 120 of the snare assembly 100 from the loading position to the capture position. As illustrated in FIG. 6 , the swivel stop 120 guided by the aperture 123 moves along the wire 110 such that the diameter of the snare 105 is reduced capturing the animal's limb.
Although the present invention has been described in terms of the foregoing embodiment, such description has been for exemplary purposes only and, as will be apparent to those of ordinary skill in the art, many alternatives, equivalents, and variations of varying degrees will fall within the scope of the present invention. That scope, accordingly, is not to be limited in any respect by the foregoing description; rather, it is defined only by the claims that follow. | A snare system includes a trap body including an aperture, a trigger plate assembly disposed within the trap body such that the trigger plate assembly is accessible through the aperture, a snare assembly placeable about the trap body, and at least one snare release assembly operatively linked with the trap body. The trigger plate assembly is movable between an armed position and an activated position. The snare release assembly normally biases the trigger plate assembly into the armed position. Furthermore, the snare release assembly disengages the snare assembly from the trap body when the trigger plate assembly moves from the armed position to the activated position. Upon disengagement from the trap body, the snare assembly moves to capture an animal's limb. | 0 |
FIELD OF INVENTION
This invention relates to an illuminated bag having a chemiluminescent wand and particularly relates to an illuminated bag for receiving halloween treats.
BACKGROUND OF THE INVENTION
Various attempts have heretofore been made in order to provide bags or containers which include a light source in order to announce the presence of individuals who are travelling at night. These illuminating devices may be used in a variety of situations but are particularly important at halloween when small children are travelling from door to door at night.
For example, U.S. Pat. No. 4,802,071 teaches a battery powered lantern which is used by a child to collect halloween treats where the outer shell simulates a jack-o-lantern and improves the child's ability to see and to be seen at night.
Moreover, U.S. Pat. No. 4,698,732 teaches a bucket shaped container which has an open top for collecting items and a bottom portion for receiving a light such as a flash light. The flash light is held in position by a press fit against the edge of the opening and extends between the interior and exterior of the container.
Moreover, U.S. Pat. No. 5,143,440 relates to a lunch pail wherein the lunch pail box includes an upper housing pivotly mounted to a lower housing with the illumination chamber positioned on the top wall of the upper housing. Moreover, U.S. Pat. No. 607,897 relates to a flexible bag having a closed end and an open end with a transverse case connected at the closed end of the bag and providing with a slot or opening in one side thereof wherein such slot or opening is adapted to be closed by the bag when the later is rolled around the case.
Furthermore, U.S. Pat. No. 2,334,680 relates to a purse which has a light source along the bottom thereof.
Moreover, chemiluminescent wands have heretofore been used in order to provide light by means of mixing two chemicals. For example, U.S. Pat. No. 3,576,987 illustrates a chemiluminescent wand having a first chemical in an inner frangible tube and a second chemical in an outer flexible casing which encompasses the inner tube wherein the chemicals when mixed by deforming the outer casing and fracturing the inner to generate a chemiluminescent.
Such chemiluminescent wands have been used to provide luminescent fishing lures as disclosed in U.S. Pat. No. 3,861,071 as well as illuminated under water writing tablets as shown in U.S. Pat. No. 5,083,242.
It is an object of this invention to provide an improved illuminated bag which includes a chemiluminescent wand so as to enhance the visibility of a user at night and particularly relates to an improved halloween container.
It is an aspect this invention to provide a bag with a chemiluminescent wand for illuminating said bag, said bag having: an open top end and sealed bottom end and sealed opposite side ends; a transparent pouch spaced substantially parallel from one of said sealed ends, an opening into said pouch, said chemiluminescent wand disposed within said pouch for illumination upon activating said chemiluminescent wand.
It is a further aspect of this invention to provide a bag for receiving halloween treats said bag having a chemiluminescent wand for illuminating said bag comprising: a folded web of transparent material presenting a folded closed bottom and an open top with sealed opposite side ends thereof defining said bag for receiving said treats; a bottom seal spaced substantially parallel from said folded bottom defining a pouch; an opening into said pouch for receiving said chemiluminescent wand within said pouch, said chemiluminescent wand having a first chemical in an inner frangible tube and a second chemical in an outer flexible casing encompassing said inner tube, wherein said chemicals when mixed by deforming said outer casing and fracturing said inner tube generate a chemiluminescent so as to illuminate said bag.
DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention shall now be described in relation to the following drawings:
FIG. 1 is a front elevational view of the illuminated bag.
FIG. 2 is a side elevational view of the illuminated bag.
DESCRIPTION OF THE INVENTION
Like parts will be given numbers throughout the figures.
FIG. 1 generally illustrates the illuminated bag 2 which has an open end 4 and a closed end 6 and two opposite side ends 8 and 10, respectively. One of the ends has associated therewith a pouch 12. In the embodiment described in FIGS. 1 and 2 the pouch 12 is associated with the bottom end 6 although the pouch 12 in accordance with the invention herein could also be associated with either of the side ends 8 or 10.
In the embodiment shown in FIG. 1 and 2 the bag 2 presents a front panel 14 and a rear panel 16. In particular, the bag 2 as shown in FIGS. 1 and 2 comprises a folded web of transparent material which presents a folded closed bottom 18 and open top 4 with sealed opposite sides 8 and 10 thereof defining the bag for receiving halloween treats.
The bag 2 also includes a bottom seal 20 which is spaced substantially parallel from the folded bottom 18 for defining a pouch 12.
The web transparent material can comprise of plastic or the like. The side ends 8 and 10 and bottom seal 20 are produced in a manner well known to those persons skilled in the art by means of heat sealing or the like so as to join the front and rear panels 14 and 16 to define the bag 2.
The pouch 12 will include an opening 22 for inserting the chemiluminescent wand 24 within the pouch. The pouch 12 may have the opening 22 heat sealed closed as illustrated at 26 or such opening 22 may be left open. Alternatively the wand 24 may be inserted in an opening 38 as illustrated in FIG. 2. The opening 38 would be provided prior to heat sealing the pouch 12. In other words, one side 10 is heat sealed all the way down the side, while the other side 8 would be heat sealed, but the heat sealing would stop at the pouch 12, such that openings 38 would be provided to receive the wand 12. Thereafter the wand 12 would be heat sealed in.
The pouch 12 may also includes opposite seals 26 and 28 which are substantially parallel to the side seals 8 and 10, respectively so as to securely retain the chemiluminescent wand 24 within the pouch 12. The upper end 4 also includes a handle 30 which may be reinforced by material 32.
Moreover, the handle area may be comprises of a double layer of transparent web material which is folded over at 36 and then heat sealed as represented by numeral 34 so as to increase the carrying capacity of the handle.
Accordingly, the user of the bag 2 may use the bag in a conventional manner and when in use at night the user may activate the chemiluminescent wand 24 so as to enhance the visibility of the transparent pouch 12 as well as the user of the bag 2.
In particular, the chemiluminescent wand has a first chemical and an inner frangible tube and a second chemical in an outer flexible casing which encompasses the inner tube wherein the chemicals when mixed by deforming the outer casing and fracturing the inner tube generate a chemiluminescent.
Therefore, the bag 2 as described herein is well suited for use at halloween when children go door to door to pick up the treats. Accordingly, the chemiluminescent wand in the bag 2 may be activated so as to generate an illumination which will enhance the safety of the child since the chemiluminescent wand will light up the area around the child as well as announce the presence of the child to passing vehicles.
Although the preferred embodiment as well as the operation and use have specifically been described in relation to the drawings, it should be understood the variations in the preferred embodiment could be achieved by a man skilled in the art without departing from the spirit of the invention. Accordingly, the invention should not be understood to be limited to the exact form revealed by the drawings. | An illuminated bag having an open end and a closed end, a transparent pouch associated with the closed end, and chemiluminescent wand disposed within the pouch for illumination upon activating the chemiluminescent wand. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the priority date of U. S. Provisional patent application Ser. No. 60/708,125 filed Aug. 12, 2006.
BACKGROUND AND FIELD OF THE INVENTION
[0002] The invention relates to the use of “smart card” storage of data, and more specifically to the use of “smart cards” to store medical test result information.
SUMMARY
[0003] Automated blood pressure (ABP) machines and other types of non-invasive medical self-monitoring equipment, e.g., automated glucose monitors, cholesterol monitors, blood oxygen monitors are either purchased or leased by pharmacies, corporate work sites, health clubs and other customers. For the purpose of this discussion, these customers will be referred to as “Locations”.
[0004] The Locations provide ABP and other medical self-monitoring machines as a service to their customers, employees, members, etc. For the purpose of this discussion, we will refer to these customers, employees, and members using the ABP or other medical self-monitoring machines as the “End User”. Such Locations often offer the End User the option to use a memory card or a Smart Card to record and track their blood pressure history over time.
[0005] As used in this patent, the term “memory card” includes any device that is generally the size of credit card (2″×3.25″) with power, ground, input and output ports or terminals and an array of memory cells arranged in rows and columns. Such memory cells are typically made of flash memory which are static memory devices that retain their information when electrical energy to the card is removed. Smart Cards include memory arrays of flash memory cells and have a microprocessor or other control or logic circuitry. One purpose of the microprocessor or other circuitry is to provide security for the data on the card. Such Smart Cards have encryption and decryption keys or stored programs that secure the card from unwanted access.
[0006] Each time the End User uses the memory card or Smart Card in the machine, the blood pressure reading, pulse rate, and the date of the measurement are recorded on the card. The ABP machine then prints out a history of the End User's most recent results (as many as 10 results), and provides a calculated average blood pressure and pulse rate for the End User.
[0007] Similar monitoring, data collection, data compilation, and data presentation opportunities exist for other forms of medical self-monitoring equipment. A printed history of the End User's most recent results for any such monitoring process is important as it provides the End User with information to share with physicians, pharmacists, and other health care professionals. Recorded ABP information assists the health care professional in evaluating the End User's blood pressure history and the effectiveness of any End User hypertension control program. Recorded glucose levels, cholesterol levels, blood oxygen levels, and other records of medical monitoring for the End User can likewise assist health care professionals in their care of that End User.
[0008] The invention enables the providers of automated blood pressure readings and other non-invasive physiological test data, such as pharmacies, corporate work sites, health clubs and other customers, to charge an annual fee for the use of a memory card or Smart Card to record the non-invasive physiological test data and make the data available for health consultations. The invention's software, installed in an automated blood pressure system or other medical self-monitoring system with one or more memory card or Smart Card interface devices, uses a custom-formatted end-user memory card for keeping track of the user's non-invasive physiological test data and the dates these readings were taken. The software also uses a recharge memory card for controlling the provider's recharging of the end-user memory card. The invention's processing reactivates the end-user memory card or Smart Card after it expires, and updates the contents of the recharge memory card in order to track the number of recharges provided.
[0009] The invention's apparatus and methods also apply to non-medical systems for recording readings and verifying usability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A shows the processing flow of steps for updating a Recharge Card using a single-port card reader.
[0011] FIG. 1B shows the processing flow of steps for recharging a User Smart Card using a single-port card reader.
[0012] FIG. 1C shows the processing flow of steps for correcting the Recharge Count on a Recharge Card using a single-port card reader.
[0013] FIG. 2A shows the processing flow of steps for updating a Recharge Card using a dual-port card reader.
[0014] FIG. 2B shows the processing flow of steps for recharging a User Smart Card and correcting the Recharge Count on a Recharge Card using a dual-port card reader.
[0015] FIG. 3A shows the format of the data stored on the User Smart Card prior to encryption. A memory map of the encrypted card is not shown as the encryption techniques are well known in the art.
[0016] FIG. 3B shows the format of the data stored on the Recharge Card.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In its basic embodiment, the invention is both an apparatus and a process, developed initially for the PharmaSmart Model PS-2000 blood pressure machine and similar machines made by others. The PS-2000 is equipped to use blood pressure Smart Cards to store blood pressure readings for the End User. It is likely that millions of these blood pressure Smart Cards will eventually be in circulation in North America and in other parts of the world. The invention provides the option for Locations to: 1) generate additional revenues by charging the End User an annual fee for use of the Smart Card, and 2) provide End User with at least one annual blood pressure consultation.
[0018] The use of the invention is as follows. The Location issues a Smart Card to the End User. The first time the End User uses the Smart Card in the ABP machine, it electronically “stamps” a recharge date onto the Smart Card. The recharge date is a fixed or variable date, but preferably is one (1) year from the date of first use in the machine. This means the End User has a full year of use of the Smart Card before it will require a recharge. If the card is not recharged by the recharge date, it will no longer work in the ABP machine.
[0019] At any time, the Location may purchase recharge credits directly from manufacturer of the ABP machine. These credits are loaded onto a unique “Recharge Smart Card”, and shipped directly to the Location. Upon the End User's request, the Location personnel can use the Recharge Smart Card to recharge the End User's card for an additional year. In order to do this the Location personnel must have both the Recharge Smart Card and the End User Smart Card in hand. They then simply insert the Recharge Smart Card into the ABP machine and follow the instructions provided on the machine's display. Once completed, an updated recharge date is electronically “stamped” onto the End User Smart Card providing another full year of use of the Smart Card. Each time the Location personnel recharges an End User Smart Card, the Recharge Smart Card is debited one (1) recharge credit. Once all of the recharge credits are used, the Location personnel discards the Recharge Smart Card and, as required, may order an additional Recharge Smart Card from the ABP machine manufacturer.
[0020] The ABP machine manufacturer may charge Locations a fee for each recharge credit they order, and the Location, in turn, can charge the End User an annual fee for the User Smart Card.
[0021] FIGS. 1A through 1C show a combined flow chart presenting specific software design and operational details of the Smart Card recharge process as performed using a single-port card reader. There are three overall parts of the recharge process: 1) updating the Recharge Card, 2) updating the User Smart Card, and 3) restoring the Recharge Card to an earlier state when a User Smart Card update has not been completed. FIG. 1A shows the basic steps of the updating of a Recharge Card. Refer to FIG. 3A for the data memory map for the data fields stored on the User Smart Card (User Type ‘00’) and to FIG. 3B for the data fields stored on the Recharge Card (User Type ‘E0’).
[0022] 1. The operator inserts ( 10 ) the Recharge Card in the card reader.
[0023] 2. The system presents ( 20 ) the BPM utility menu to the operator.
[0024] 3. The operator selects ( 30 ) the “Recharge Smart Card” option from the menu.
[0025] 4. The system reads ( 40 ) the Recharge Card contents. If the card is not a valid PharmaSmart card of any type, the system displays ( 42 ) a message to that effect and prompts the user to use a PharmaSmart Recharge card.
[0026] 5. If the card is a valid PharmaSmart card but not a Recharge Card, the system displays ( 44 ) a message to that effect and prompts the user to use a PharmaSmart Recharge card.
[0027] 6. If the card is a valid PharmaSmart Recharge Card, the system decrements ( 50 ) the card's Recharge Count, and displays the number of recharges remaining on the card.
[0028] 7. The system ejects the Recharge Card and prompts ( 60 ) the operator to insert the User Smart Card.
[0029] Once the Recharge Smart Card is decremented one credit, the User Smart Card updating process begins. See FIG. 1B for the steps:
[0030] 1. The operator inserts ( 70 ) the User Smart Card.
[0031] 2. If the card is not a valid PharmaSmart card of any type, the system displays ( 72 ) a message to that effect and prompts the user to use a PharmaSmart user Smart Card.
[0032] 3. If the card is a valid PharmaSmart card but not a User Smart Card, the system displays ( 74 ) a message to that effect and prompts the user to use a PharmaSmart User Smart Card.
[0033] 4. If the card is a valid PharmaSmart User Smart Card, the system advances ( 80 ) the card's Expiration Date by 365 days, or if the Expiration Date has passed, sets a new Expiration Date 365 days from the User Smart Card's update.
[0034] 5. The system notifies ( 90 ) the operator of the successful update and displays the total number of days until the User Smart Card will require another recharge.
[0035] 6. The system ejects ( 100 ) the User Smart Card.
[0036] 7. The system updates ( 110 ) its management report data.
[0037] 8. The system displays ( 120 ) the BPM Utility Menu.
[0038] During the User Smart Card update, the operator may decide that the recharge process cannot be completed. If the process is not completed, the Recharge Card and the User Smart Card are left in states that are mutually inconsistent. The Recharge Card indicates that a recharge has been done, while the User Smart Card has not been recharged. Consequently, the inconsistency should be corrected. The Recharge Card should be incremented one Recharge Credit.
[0039] See FIG. 1C . The steps:
[0040] 1. The system prompts ( 130 ) the operator to insert the Recharge Card.
[0041] 2. The system reads the Recharge Card contents. If the card is not a valid PharmaSmart card of any type, the system displays ( 142 ) a message to that effect and prompts the operator to use a PharmaSmart Recharge card.
[0042] 3. If the card is a valid PharmaSmart card but not a Recharge Card, the system displays ( 144 ) a message to that effect and prompts the operator to use a PharmaSmart Recharge card.
[0043] 4. If the card is a valid PharmaSmart Recharge Card, the system increments ( 150 ) the card's Recharge Credits by one credit, and displays the number of Recharge Credits remaining on the card.
[0044] 5. The system updates ( 160 ) its management report data.
[0045] 6. The system displays ( 170 ) the BPM Utility Menu.
[0046] In an alternative embodiment of the system, a dual-port card reader allows the Recharge Card to remain accessible to the system while the User Smart Card is being updated. In this alternative dual-port embodiment, Step 4 of FIG. 1C is done as part of the process of FIG. 1A after the operator has interrupted the User Smart Card update, and the entire process is simplified as shown in FIGS. 2A and 2B . This alternative dual-port embodiment, while more expensive in hardware terms, has the advantage of eliminating all manual steps for correcting the inconsistency between the Recharge Card and the User Smart Card.
[0047] FIG. 2A shows the basic steps of the updating of a Recharge Card:
[0048] 1. The operator inserts ( 10 ) the Recharge Card in the Recharge card reader slot.
[0049] 2. The system presents ( 20 ) the BPM utility menu to the operator.
[0050] 3. The operator selects ( 30 ) the “Recharge Smart Card” option from the menu.
[0051] 4. The system reads ( 40 ) the Recharge Card contents. If the card is not a valid PharmaSmart card of any type, the system displays ( 42 ) a message to that effect and prompts the user to use a PharmaSmart Recharge card.
[0052] 8. If the card is a valid PharmaSmart card but not a Recharge Card, the system displays ( 44 ) a message to that effect and prompts the user to use a PharmaSmart Recharge card.
[0053] 9. If the card is a valid PharmaSmart Recharge Card, the system decrements ( 50 ) the card's Recharge Count, and displays the number of recharges remaining on the card.
[0054] 10. The system prompts ( 60 ) the operator to insert the expired User Smart Card in the User Smart Card card reader slot.
[0055] Once the Recharge Smart Card is updated, the User Smart Card updating process begins. See FIG. 2B for the steps:
[0056] 1. The operator inserts ( 70 ) the User Smart Card in the User Smart Card reader slot.
[0057] 2. If the card is not a valid PharmaSmart card of any type, the system displays ( 72 ) a message to that effect and prompts the user to use a PharmaSmart user card.
[0058] 3. If the card is a valid PharmaSmart card but not a User Smart Card, the system displays ( 74 ) a message to that effect and prompts the user to use a PharmaSmart User Smartcard.
[0059] 4. If the card is a valid PharmaSmart User Smart Card, the system advances ( 80 ) the card's Expiration Date by 365 days, or if the Expiration Date has passed, sets a new Expiration date 365 days from the User Smart Card's update.
[0060] 5. If the operator has interrupted the User Smart Card update process without change to the User Smart Card's Expiration Date, the system increments ( 150 ) the Recharge Card's Recharge Count, displays the number of recharges remaining on the card.
[0061] 6. If the operator has completed the User Smart Card update process successfully, the system notifies ( 90 ) the operator of the successful update and displays the new expiration date placed on the card.
[0062] 7. The system ejects ( 100 ) the User Smart Card.
[0063] 8. The system ejects ( 100 ) the Recharge Card
[0064] 9. The system updates ( 110 ) its management report data.
[0065] 10. The system displays ( 120 ) the BPM Utility Menu.
[0066] Regarding Step 2. identifying a valid PharmaSmart card, the format defined in FIG. 3 contains values in ‘Security Code’, ‘Smart Card Version Number’, ‘User Type’, ‘Pharmacy Code’, and ‘Expiration Date’ that may be used in combination in ways well-known in the art to identify the card as a valid PharmaSmart card.
[0067] Regarding Step 3. distinguishing between the Recharge Card and the User Smart Card, the formats of the Recharge Card and the User Smart Card are the same, as shown in FIG. 3 , except that the Recharge Card contains an ‘E0’ code in the User Type field, while the User Smart Card contains a ‘00’ in the User Type field. Also, since the Recharge Card is not used for storing readings, the ‘Number of Readings on Card’, ‘Next Reading Inserted Here’, and the ‘30 Latest Readings’ on the Recharge Card will not contain valid data unless such data is added by another application.
[0068] See FIGS. 3A and 3B . The User Type field may contain codes that identify other special-purpose card formats as needed for conventional technical and developmental purposes. FIG. 3A shows a map of the memory card. Such cards may be used in the invention but they do not provide security for the data on the card. But they are less expensive than the more secure Smart Cards and can store the same user data that is stored on a Smart Card.
[0069] In a general embodiment providing for storage and analysis of non-invasive physiological test data and other medical monitoring information, the invention's User Smart Card records values from automated equipment for reading blood glucose level, blood cholesterol level, or other testable medical parameter values. The range of testable medical parameter values expands constantly as new technologies enable rapid, reliable, low-powered monitoring techniques to be packaged and made available to an End User.
[0070] The User Smart Card records the non-invasive physiological test data that the user took over the course of a year. The user can use the User Smart Card to access this entire history at any Location, and print out the most recent 10 entries or all of them. The average of the printed entries is given with the printout. The date of each reading is also recorded on the User Smart Card and printed alongside each entry, allowing the user or a physician to identify trends in the data. Additionally, at the user's request, the data from the User Smart Card can be loaded into the computer system of a pharmacy or doctor's office, allowing health care workers quick access to the user's non-invasive physiological test data.
[0071] At a Location, the user can print out the entire history of non-invasive physiological test data stored on the user Smart Card. Additionally, at a pharmacy or physician's office this data can be submitted for a consultation on the patient's condition. When the User Smart Card is recharged, an option is given to allow the user to submit his data to a pharmacy for a consultation.
[0072] Tests now performed in a laboratory, such as blood enzyme levels for such critical markers as creatine phosphokinase (CPK), will eventually be capable of being performed properly and inexpensively in a manner similar to that now used for blood pressure monitoring. Furthermore, evaluations requiring significant analysis and processing of data, such as the classification of cardiac arrhythmias requiring medical attention, may become capable of being performed in a consumer setting as well.
[0073] Finally, numerous drugs, such as the COX-2 inhibitors, can produce varied deleterious effects on small subsets of their users. The monitoring of blood markers for adverse or allergic reactions to such drugs presents another field of application for the present invention.
[0074] To record the values captured, the invention substitutes different value sets and ranges for different types of reading and different sensitivity requirements. For example, readings of blood glucose levels when fasting range from the 60-100 range (excellent) to above 180 (poor), but after a meal the range rises so that the 110-140 range represents an excellent level, while above 220 represents a poor level of blood glucose (source of values: University of Massachusetts Medical School Web page concerning self-monitoring of blood glucose levels using the lancet). Ranges for different classes of monitored values are represented in the invention using range classifications, biasing of values, elimination of non-significant digits of precision, and other techniques well-known in the art for compressing data values for storage in limited memory space.
[0075] In a secure embodiment, the invention incorporates conventional anti-tampering hardware and software components in the User Smart Card and the Recharge Card to prevent an End User, a Location employee, or a thief from using a conventional standalone card reader to alter the contents of the User Smart Card or the Recharge Card.
[0076] In the secure embodiment, the invention applies encryption to the contents of the card, rendering the contents of the card unreadable by any process except the decryption of the encrypted values. The Location employee (for the Recharge Card) or the End User (for the User Smart Card) reads and updates the card's contents by furnishing the decryption key for the card. The specific encryption techniques used are well-known in the art and so are not described here.
[0077] Any attempt to read the card's contents using a conventional standalone card reader triggers the execution of software which breaks open one or more fuses on the card, rendering the card useless. While such measures do not prevent fraudulent misuse of the card, they make such misuse considerably more difficult.
[0078] The operation, contents, encryption, and decryptions of the invention's Recharge Card are the same for all classes of data to be collected.
[0079] The invention offers additional embodiments usable in non-medical contexts for any application that gathers, stores, and recalls a limited number of data values on a rechargeable basis as described hereinabove. Two such applications are:
[0080] 1. Transit systems, wherein the invention charges a User Smart Card with travel credit increments deductible by the user at entry into each stage of a journey on a transit system using the invention. At each stage of the journey, the invention notes the time and location of the user's entry for travel, and deducts one or more credit increments as appropriate for the stage on which the user is embarking. The user may afterwards obtain from the Smart Card a record of travel for business or evidentiary reasons.
[0081] 2. Libraries and lending systems, wherein the invention charges a User Smart Card with lending credit increments deductible by the user when borrowing a book, film, music score, or other item of rental or lease goods or equipment. Different items borrowed may result in different numbers of credit increments being deducted. The invention stores the time and date of lending or rental and the time and date of return of the item on the User Smart Card. | Enabling the providers of automated blood pressure readings, such as pharmacies, corporate work sites, health clubs and other customers, to charge a fee for the long-term use of a memory card to record non-invasive physiological test data and make the data available for health consultations. In an automated blood pressure system with one or more memory-card interface devices, a custom-formatted end-user memory card keeps track of the user's non-invasive physiological test data, and a recharge memory card controls the provider's recharging of the end-user memory card after the end-user memory card expires. The contents of the recharge memory card are updated in order to track its use by the provider of the readings. | 6 |
FIELD OF THE INVENTION
The present invention relates to cyclopentane heptan(ene) acyl sulfonamide, 2-alkyl or 2-arylalkyl, or 2-heteroarylalkenyl derivatives as therapeutic agents, e.g. such agents are potent ocular hypotensives that are particularly suited for the management of glaucoma.
BAKCGROUND OF THE INVENTION
DESCRIPTION OF RELATED ART
Ocular hypotensive agents are useful in the treatment of a number of various ocular hypertensive conditions, such as post-surgical and post-laser trabeculectomy ocular hypertensive episodes, glaucoma, and as presurgical adjuncts.
Glaucoma is a disease of the eye characterized by increased intraocular pressure. On the basis of its etiology, glaucoma has been classified as primary or secondary. For example, primary glaucoma in adults (congenital glaucoma) may be either open-angle or acute or chronic angle-closure. Secondary glaucoma results from pre-existing ocular diseases such as uveitis, intraocular tumor or an enlarged cataract.
The underlying causes of primary glaucoma are not yet known. The increased intraocular tension is due to the obstruction of aqueous humor outflow. In chronic open-angle glaucoma, the anterior chamber and its anatomic structures appear normal, but drainage of the aqueous humor is impeded. In acute or chronic angle-closure glaucoma, the anterior chamber is shallow, the filtration angle is narrowed, and the iris may obstruct the trabecular meshwork at the entrance of the canal of Schlemm. Dilation of the pupil may push the root of the iris forward against the angle, and may produce pupilary block and thus precipitate an acute attack. Eyes with narrow anterior chamber angles are predisposed to acute angle-closure glaucoma attacks of various degrees of severity.
Secondary glaucoma is caused by any interference with the flow of aqueous humor from the posterior chamber into the anterior chamber and subsequently, into the canal of Schlemm. Inflammatory disease of the anterior segment may prevent aqueous escape by causing complete posterior synechia in iris bombe, and may plug the drainage channel with exudates. Other common causes are intraocular tumors, enlarged cataracts, central retinal vein occlusion, trauma to the eye, operative procedures and intraocular hemorrhage.
Considering all types together, glaucoma occurs in about 2% of all persons over the age of 40 and may be asymptotic for years before progressing to rapid loss of vision. In cases where surgery is not indicated, topical b-adrenoreceptor antagonists have traditionally been the drugs of choice for treating glaucoma.
Certain eicosanoids and their derivatives have been reported to possess ocular hypotensive activity, and have been recommended for use in glaucoma management. Eicosanoids and derivatives include numerous biologically important compounds such as prostaglandins and their derivatives. Prostaglandins can be described as derivatives of prostanoic acid which have the following structural formula:
Various types of prostaglandins are known, depending on the structure and substituents carried on the alicyclic ring of the prostanoic acid skeleton. Further classification is based on the number of unsaturated bonds in the side chain indicated by numerical subscripts after the generic type of prostaglandin [e.g. prostaglandin E 1 (PGE 1 ), prostaglandin E 2 (PGE 2 )], and on the configuration of the substituents on the alicyclic ring indicated by α or β [e.g. prostaglandin F 2α (PGF 2β )].
Prostaglandins were earlier regarded as potent ocular hypertensives, however, evidence accumulated in the last decade shows that some prostaglandins are highly effective ocular hypotensive agents, and are ideally suited for the long-term medical management of glaucoma (see, for example, Bito, L. Z. Biological Protection with Prostaglandins , Cohen, M. M., ed., Boca Raton, Fla., CRC Press Inc., 1985, pp. 231-252; and Bito, L. Z., Applied Pharmacology in the Medical Treatment of Glaucomas Drance, S. M. and Neufeld, A. H. eds., New York, Grune & Stratton, 1984, pp. 477-505. Such prostaglandins include PGF 2α , PGF 1α , PGE 2 , and certain lipid-soluble esters, such as C 1 to C 2 alkyl esters, e.g. 1-isopropyl ester, of such compounds.
Although the precise mechanism is not yet known experimental results indicate that the prostaglandin-induced reduction in intraocular pressure results from increased uveoscleral outflow [Nilsson et.al., Invest. Ophthalmol. Vis. Sci . (suppl), 284 (1987)].
The isopropyl ester of PGF 2α has been shown to have significantly greater hypotensive potency than the parent compound, presumably as a result of its more effective penetration through the cornea. In 1987, this compound was described as “the most potent ocular hypotensive agent ever reported” [see, for example, Bito, L. Z., Arch. Ophthalmol . 105, 1036 (1987), and Siebold et.al., Prodrug 5 3 (1989)].
Whereas prostaglandins appear to be devoid of significant intraocular side effects, ocular surface (conjunctival) hyperemia and foreign-body sensation have been consistently associated with the topical ocular use of such compounds, in particular PGF 2α and its prodrugs, e.g., its 1-isopropyl ester, in humans. The clinical potentials of prostaglandins in the management of conditions associated with increased ocular pressure, e.g. glaucoma are greatly limited by these side effects.
In a series of co-pending United States patent applications assigned to Allergan, Inc. prostaglandin esters with increased ocular hypotensive activity accompanied with no or substantially reduced side-effects are disclosed. The co-pending U.S. Ser. No. 596,430 (filed Oct. 10, 1990), relates to certain 11-acyl-prostaglandins, such as 11-pivaloyl, 11-acetyl, 11-isobutyryl, 11-valeryl, and 11-isovaleryl PGF2c. Intraocular pressure reducing 15-acyl prostaglandins are disclosed in the co-pending application U.S. Ser. No. 175,476 (filed Dec. 29, 1993). Similarly, 11,15-9,15 and 9,11-diesters of prostaglandins, for example 11,15-dipivaloyl PGF 2α are known to have ocular hypotensive activity. See the co-pending patent applications U.S. Ser. Nos. 385,645 (filed Jul. 7, 1989, now U.S. Pat. No. 4,994,274), Ser. No. 584,370 (filed Sep. 18, 1990, now U.S. Pat. No. 5,028,624) and Ser. No. 585,284 (filed Sep. 18, 1990, now U.S. Pat. No. 5,034,413). The disclosures of all of these patent applications are hereby expressly incorporated by reference.
SUMMARY OF THE INVENTION
The present invention concerns a method of treating ocular hypertension which comprises administering to a mammal having ocular hypertension a therapeutically effective amount of a compound of formula I
wherein a hatched line represents the α configuration, a triangle represents the β configuration, a straight line, e.g. at the 9, 11 or 15 position, represents either the α or β configuration, a dotted line represents the presence or absence of a double bond; a wavy line represents a cis or trans bond;
X is O, S, NH or (CH 2 ) n ;
n is 0 or an integer of from 1 to 4;
Y is C 1 -C 5 n-alkyl, C 3 -C 7 cycloalkyl, phenyl, furanyl, thienyl, pyridinyl, thiazolyl, benzothienyl, benzofuranyl, naphthyl, or substituted derivatives thereof, wherein the substituents maybe selected from the group consisting of C 1 -C 5 alkyl, halogen,
CF 3 , CN, NO 2 , N(R 2 ) 2 , CO 2 R 2 and OR 2 ;
Z is (CH 2 ) n or a covalent bond;
R is C 1 -C 6 lower alkyl, benzyl, or Z—CF 3 or mesylate or triflate;
R 1 is H, R 2 or COR 2 ; and
R 2 is H or C 1 -C 5 lower alkyl or 9, 11 or 15 esters thereof.
In a still further aspect, the present invention relates to a pharmaceutical product, comprising
a container adapted to dispense its contents in a metered form; and
an ophthalmic solution therein, as hereinabove defined.
Finally, certain of the compounds represented by the above formula, disclosed below and utilized in the method of the present invention are novel and unobvious.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a schematic of the chemical synthesis of certain compounds of the invention as disclosed in Examples 5 and 6.
FIG. 2 is a schematic of the chemical synthesis of certain compounds of the invention as disclosed in Examples 39, 41, 43 and 45.
FIG. 3 is a schematic of the chemical synthesis of certain compounds of the invention as disclosed in Examples 40, 42, 44 and 46.
FIG. 4 is a schematic of the chemical synthesis of certain compounds of the invention as disclosed in Examples 47 and 48.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the use of cyclopentane heptan(ene) acyl sulfonamide, 2-alkyl or 2-arylalkyl, or 2-heteroarylalkenyl derivatives as therapeutic agents as ocular hypotensives. The compounds used in accordance with the present invention are encompassed by the following structural formula I:
A preferred group of the compounds of the present invention includes compounds that have the following structural formula II:
Another preferred group includes compounds having the formula III:
In the above formulae, the substituents and symbols are as hereinabove defined.
In the above formula:
X is preferably CH 2 .
Y is preferably selected from the group consisting of n-propyl, thienyl and halo or lower C 1 to C 4 alkyl substituted derivatives of thienyl.
Z is preferably a covalent bond.
R is preferably selected from the group consisting of methyl, ethyl, n-propyl, n-butyl, benzyl, CF 3 , mesylate or triflate.
R 1 is preferably selected from the group consisting of H, methyl, ethyl, acetyl or pivaloyl.
R 2 is preferably H.
The above compounds of the present invention may be prepared by methods that are known in the art or according to the working examples below. The compounds, below, are especially preferred representatives, of the compounds of the present invention.
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}methanesulfonarnide
Ethanesulfonic acid {(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
Ethanesulfonic acid {(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((R)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
Propane-1-sulfonic acid {(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
Propane-1-sulfonic acid {(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((R)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
Butane-1-sulfonic acid {(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
Butane-1-sulfonic acid {(Z)-7-[(1R,2R,3R,5 S)-3,5-dihydroxy-2-((R)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}N-methylmethanesulfonamide
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}N-ethylmethanesulfonamide
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxy-5-phenylpent-1-enyl)cyclopentyl]-hept-5-enoyl}methanesulfonamide
2,2-Dimethylpropionic acid (1R,2R,3R,5S)-4-hydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-3-((Z)-7-methanesulfonylamino-7-oxohept-2-enyl)cyclopentyl ester
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}-1,1,1-trifluoromethanesulfonamide
N-{(E)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxy-5-phenylpent-1-enyl)-cyclopentyl]hept-5-enoyl}methanesulfonamide
Ethanesulfonic acid ((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(4-bromo-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)amide
N-((Z)-7-{(1R,2R,3R,5S)-2-((S)-(E)-5-(5-Bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}methanesulfonamide
Ethanesulfonic acid ((Z)-7-{(1R,2R,3R,5S)-2-((S)-(E)-5-(5-bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}amide
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-Bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}-1,1,1-trifluoromethanesulfonamide
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-Chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}methanesulfonamide
Ethanesulfonic acid ((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}amide
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-Chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}-1,1,1-trifluoromethanesulfonamide
N-((Z)-7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl)cyclopentyl}hept-5-enoyl)methanesulfonamide
Ethanesulfonic acid ((Z)-7-{(1R,2R,3R,5S)-3,5-dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl]cyclopentyl}hept-5-enoyl)amide
N-((Z)-7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl]cyclopentyl}hept-5-enoyl)-1,1,1-trifluoromethanesulfonamide
N-((Z)-7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl)cyclopentyl}heptanoyl)methanesulfonamide
Ethanesulfonic acid ((Z)-7-{(1R,2R,3R,5S)-3,5-dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl]cyclopentyl}heptanoyl)amide
N-((Z)-7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl]cyclopentyl}heptanoyl)-1,1,1-trifluoromethanesulfonamide
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-Chlorothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}methanesulfonamide
Ethanesulfonic acid ((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-chlorothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}amide
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-Chlorothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}-1,1,1-trifluoromethanesulfonamide
N-((Z)-7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(5-iodothiophen-2-yl)pent-1-enyl)cyclopentyl}heptanoyl)methanesulfonamide
Ethanesulfonic acid ((Z)-7-{(1R,2R,3R,5S)-3,5-dihydroxy-2-[((S)-(E)-3-hydroxy-5-(5-iodothiophen-2-yl)pent-1-enyl]cyclopentyl}heptanoyl)amide
N-((Z)-7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(5-iodothiophen-2-yl)pent-1-enyl]cyclopentyl}heptanoyl)-1,1,1-trifluoromethanesulfonamide
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-Bromothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}methanesulfonamide
Ethanesulfonic acid ((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}amide
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-Bromothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}-1,1,1-trifluoromethanesulfonamide
Acetic acid ({(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-cyclopentyl]hept-5-enoyl}methanesulfonylamino)methyl ester
2,2-Dimethylpropionic acid ({(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-cyclopentyl]hept-5-enoyl}methanesulfonylamino)methyl ester
Acetic acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl ester
2,2-Dimethylpropionic acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl ester
Acetic acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl ester
2,2-Dimethylpropionic acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-chloro-5-methyl-thiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methane-sulfonyl-amino]methyl ester
Acetic acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl ester
2,2-Dimethylpropionic acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl ester
{3-[(1R,2S,3R)-3-Hydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-5-oxocyclopentyl-sulfanyl]propylsulfanyl}acetic acid methyl ester
{3-[(1R,2S,3R)-3-Hydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-5-oxocyclopentyl-sulfanyl]propylsulfanyl}acetic acid
{3-[(1R,2S,3R)-3-Hydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-5-oxocyclopentyl-sulfanyl]propylsulfanyl}acetic acid isopropyl ester
(3-{(1R,2S,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-propylcyclobutyl)but-1-enyl]-5-oxocyclopentylsulfanyl}propylsulfanyl)acetic acid methyl ester
(3-{(1R,2S,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-propylcyclobutyl)but-1-enyl]-5-oxocyclopentylsulfanyl}propylsulfanyl)acetic acid
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}benzenesulfonamide
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-Chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}benzenesulfonamide
Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, or a pharmaceutically acceptable acid addition salt thereof, as an active ingredient, with conventional ophthalmically acceptable pharmaceutical excipients, and by preparation of unit dosage forms suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.0001 and about 5% (w/v), preferably about 0.001 to about 1.0% (w/v) in liquid formulations.
For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 6.5 and 7.2 with an appropriate buffer system. The formulations may also contain conventional, pharmaceutically acceptable preservatives, stabilizers and surfactants.
Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenyhnercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose and purified water.
Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
In a similar vein, an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene.
Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place or in conjunction with it.
The ingredients are usually used in the following amounts:
Ingredient
Amount (% w/v)
active ingredient
about 0.001-5
preservative
0-0.10
vehicle
0-40
tonicity adjustor
1-10
buffer
0.01-10
pH adjustor
q.s. pH 4.5-7.5
antioxidant
as needed
surfactant
as needed
purified water
as needed to make 100%
The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate the application to the eye. Containers suitable for dropwise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution.
The invention is further illustrated by the following non-limiting Examples, which are summarized in the reaction schemes of FIGS. 1 through 3 wherein the compounds are identified by the same designator in both the Examples and the Figures.
EXAMPLE 1
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-5 enyl)cyclopentyl]-hept-5-enoyl}methanesulfonamide
Prepared in accordance with the procedures described in Schaaf, T. K., Hess, H.-J. J. Med. Chem . 1979, 22, 1340-1346.
Alternatively, the title compound could be synthesized from tris-THP-prostaglandin F 2α methyl ester as follows (see Scheme 1):
Step 1: Saponification of the Ester
Lithium hydroxide (6.8 mL of a 1.0 N solution in H 2 O, 6.8 mmol) was added to a solution of tris-THP-prostaglandin Flu methyl ester (1.05 g, 1.69 mmol) in THF (16 mL). After stirring 18 h at room temperature the reaction mixture was concentrated in vacuo. The residue was diluted with H 2 O, acidified with 1 N HCl and extracted with CH 2 Cl 2 (2×). The combined extracts were washed with brine, dried (Na 2 SO 4 ) filtered and concentrated in vacuo. Purification by flash column chromatography (silica gel, 33% EtOAc/Hex) afforded 940 mg (92%) of tris-THP PGF 2α .
Step 2: Preparation of the Tris-THP Acylsulfonamide
Tris-THP PGF 2α (495 mg, 0.816 mmol), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDCI) (220 mg, 1.15 mmol), 4-dimethyl-aminopyridine (DMAP) (125 mg, 1.02 mmol) and methanesulfonamide (235 mg, 2.47 mmol) were dissolved in DMF (3.4 mL) and the resulting solution was stirred at room temperature under an atmosphere of nitrogen. After 16 h the solution was diluted with EtOAc and washed with 1 N aqueous HCl (3×) and brine (1×), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification by flash column chromatography (silica gel, 45% EtOAc/Hex) afforded 468 mg (84%) of tris-THP PGF 2α methanesulfonamide.
Step 3: Deprotection of the Tris-THP Acylsulfonamide
Pyridiniump-toluenesulfonate (PPTs) (20 mg, 0.080 mmol) was added to a solution of tris-THP PGF 2α methanesulfonamide (468 mg, 0.684 mmol) in MeOH (6.5 mL). The solution was heated at 45° C. under an atmosphere of nitrogen. After 16 h, the reaction mixture was cooled then concentrated in vacuo to afford a crude oil. Flash column chromatography (silica gel, EtOAc, then 2% MeOH in EtOAc) gave 152 mg (51%) of the title compound.
EXAMPLE 2
Ethanesulfonic acid {(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide and ethanesulfonic acid {(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((R)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
The title compounds were prepared in accordance with the procedures described in Schaaf, T. K., Hess, H.-J. J. Med. Chem . 1979, 22, 1340-1346, with the following exceptions: methanesulfonamide was replaced with ethanesulfonamide; the bicyclic lactol was used as a 1:1 mixture of epimeric 15R and 15S alcohols (prostaglandin numbering used, see Scheme 2); the 15R and 15S alcohols were separated during chromatography at the end of the synthetic sequence to afford the title compounds.
EXAMPLE 3
Propane-1-sulfonic Acid {(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide and Propane-1-sulfonic Acid {(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((R)-(F,)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
The title compounds were prepared in accordance with the procedures described in Schaaf, T. K., Hess, H.-J. J. Med. Chem . 1979, 22, 1340-1346, with the following exceptions: methanesulfonamide was replaced with propane-1-sulfonamide; the bicyclic lactol was used as a 1:1 mixture of epimeric 15R and 15S alcohols (prostaglandin numbering used, see Scheme 2); the 15R and 15S alcohols were separated during chromatography at the end of the synthetic sequence to afford the title compounds.
EXAMPLE 4
Butane-1-sulfonic Acid {(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide and Butane-1-sulfonic Acid {(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((R)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}amide
The title compounds were prepared in accordance with the procedures described in Schaaf, T. K., Hess, H.-J. J. Med. Chem . 1979, 22, 1340-1346, with the following exceptions: methanesulfonamide was replaced with butane-1-sulfonamide; the bicyclic lactol was used as a 1:1 mixture of epimeric 15R and 15S alcohols (prostaglandin numbering used, see Scheme 2); the 15R and 15S alcohols were separated during chromatography at the end of the synthetic sequence to afford the title compounds.
EXAMPLE 5
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}-N-methyhnethanesulfonamide
Methyl iodide (38 μL, 0.61 mmol) and DBU (45 μL, 0.30 mmol) were added to a solution of N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]hept-5-enoyl}methanesulfonamide (44 mg, 0.10 mmol) in acetone (1.5 mL). After stirring for 2.5 h at room temperature, the reaction was diluted with EtOAc, washed with water (2×) and brine then concentrated in vacuo to afford the title compound. See FIG. 1 .
EXAMPLE 6
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}-N-ethylmethanesulfonamide
The title compound was prepared in accordance with the procedure of example 5, replacing methyl iodide with ethyl iodide.
EXAMPLE 7
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxy-5-phenylpent-1-enyl)cyclopentyl]hept-5-enoyl}methanesulfonamide
Step 1: Global Silylation of 17-phenyl PGF 2α
2,6-Lutidine (0.940 mL, 8.07 mmol) and tert-butyldimethylsilyl chloride (1.22 g, 8.07 mmol) were added to a solution of 17-phenyl PGF 2α (521 mg, 1.34 mmol) in DMF (13.4 mL). After stirring overnight at room temperature, the reaction was diluted with EtOAc then washed with water (3×) and brine (2×) and concentrated in vacuo. Purification of the residue by flash column chromatography (silica gel, 5% EtOAc/Hex) afforded 1.06 g (93%) of tetra-TBDMS-17-phenyl PGF 2α .
Step 2: Preparation of the Tris-TBDMS Acid
A solution of potassium carbonate (345 mg, 2.50 mmol) in H 2 O (3.5 mL) was added to a solution of tetra-TBDMS-17-phenyl PGF 2α (1.06 g, 1.25 mmol) in MeOH (15.6 mL) and TBF (5.2 mL). After 1 h, the reaction mixture was acidified with 1 N HCl and extracted with CH 2 Cl 2 (3×). The combined extracts were dried (Na 2 SO 4 ), filtered and concentrated in vacuo to afford 912 mg (100%) of tris-TBDMS-17-phenyl PGF 2α .
Step 3: Preparation of the Tris-TBDMS Acylsulfonamide
Methanesulfonamide (519 mg, 6.25 mnol), DMAP (153 mg, 1.25 mmol) and DCC (1.29 g, 6.25 mmol) were added to a solution of tris-TBDMS-17-phenyl PGF 2α (912 mg, 1.25 mmol) in CH 2 Cl 2 (100 mL). The solution was stirred at room temperature overnight, then concentrated in vacuo. The residue was diluted with EtOAc and the solid urea by-product was removed by filtration. The filtrate was concentrated in vacuo and the residue was purified twice by flash column chromatography (silica gel, 25% EtOAc/Hex) to afford 176 mg (17%) of the tris-TBDMS acylsulfonamide.
Step 4: Desilylation of the Tris-TBDMS Acylsulfonamide
Hydrogen fluoride-pyridine (288 μL) was added to a solution of the compound obtained in step 1 above (176 mg, 0.241 mmol) in THF (3.6 mL) at 0° C. under N 2 . After 2 h, additional HF-pyridine (288 μL) was added and stirring was continued at 0° C. After 1 h, additional HF-pyridine (288 μL) was added and stirring was continued at 0° C. for 40 min, then the reaction mixture was allowed to warm to room temperature. The solution was then diluted with EtOAc and neutralized with saturated NaHCO 3 . The layers were separated and the aqueous phase was extracted with CHCl 3 (2×). The combined organic layers were concentrated in vacuo. The residue was purified by flash chromatography (silica gel, 5% MeOH/EtOAc) to afford 22 mg (20%) of the title compound. This method of this Example is shown in Scheme 3.
EXAMPLE 8
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}-1,1,1-trifluoromethanesulfonamide
Step 1: Global Silylation of PGF 2α
In accordance with the procedure described in example 7, step 1, the use of PGF 2α gave tetra-TBDMS-PGF 2α
Step 2: Preparation of the Tris-TBDMS Acid
In accordance with the procedure described in example 7, step 2, the use of tetra-TBDMS-PGF 2α gave tris-TBDMS-PGF 2α .
Step 3: Preparation of the Tris-TBDMS Acylsulfonamide
In accordance with the procedure described in example 7, step 3, the use of tris-TBDMS-PGF 2α and trifluoromethanesulfonamide afforded tis-TB1DMS-PGF 2α trifluoromethanesulfonamide.
Step 4:: Desilylation of the Tris-TBDMS Acylsulfonamide
In accordance with the procedure described in example 7, step 4, the use of tris-TBDMS-PGF 2α trifluoromethanesulfonamide gave the title compound.
EXAMPLE 9
2,2-Dimethylpropionic Acid (1R,2R,3R,4S)-4-hydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-3-((Z)-7-methanesulfonamino-7-oxohept-2-enyl)cyclopentyl Ester
Step 1: Preparation of 11-Pivaloyl PGF 2α Methyl Ester
Pyridine (2.3 mL, 28.5 mmol) and trimethylacetyl chloride (879 μL, 7.14 mmol) were added to a solution of PGF 2α methyl ester (2.63 g, 7.14 mmol) in CH 2 Cl 2 (100 mL) at 0° C. After 2 h, the reaction was allowed to warm to room temperature. After another 1.5 h, the solution was washed with 10% citric acid (2×) and brine then concentrated in vacuo. The crude residue was purified by flash column chromatography (silica gel, 30% EtOAc/Hex) to afford 1.27 g (41%) of 11-Pivaloyl PGF 2α methyl ester.
Step 2: Preparation of 9,15-bis-TBDMS-11-PivaloylPGF 2α Methyl Ester
2,6-Lutidine (1.36 μL, 11.6 mmol) and tert-butyldimethylsilyl chloride (1.75 g, 11.6 inmol) were added to a solution of 11-Pivaloyl PGF 2 , methyl ester (1.27 g, 2.91 mmol) in DMF (30 mL). After stirring overnight at room temperature, the reaction was diluted with EtOAc then washed with water (3×) and brine and concentrated in vacuo. Purification of the residue by flash column chromatography (silica gel, 10% EtOAc/Hlex) afforded 1.84 g (95%) of 9,15-bis-TBDMS-11-Pivaloyl PGF 2α methyl ester.
Step 3: Saponification of9,15-bis-TBDMS-11-Pivaloyl PGF 2α Methyl Ester
Lithium hydroxide (5.5 mL of a 0.5 N solution in H 2 O, 2.75 mmol) was added to a solution of 9,15-bis-TBDMS-11-Pivaloyl PGF 2α methyl ester (1.82 g, 2.73 mmol) in THF (5.5 mL) and the solution was heated at 50° C. overnight. The reaction mixture was cooled and acidified with 10% aqueous HCl, then extracted with CHCl 3 (3×). The extracts were concentrated in vacuo affording 949 mg (53%) of 9,1 5-bis-TBDMS-11-Pivaloyl PGF 2α .
Step 4: Preparation of 9,15-bis-TBDMS-11-Pivaloyl PGF 2α Methanesulfonamide
In accordance with the procedure described above for example 7, step 3, the use of 9,15-bis-TBDMS-11-Pivaloyl PGF 2α gave 9,15-bis-TBDMS-11-Pivaloyl PGF 2α methanesulfonamide.
Step 5: Desilylation of 9,15-bis-TBDMS-11-Pivaloyl PGF 2α Methanesulfonamide
In accordance with the procedure described in example 7, step 4, the use of 9,15-bis-TBDMS-11-Pivaloyl PGF 2α methanesulfonamide gave the title compound. The method of this Example is shown in Scheme 4.
EXAMPLE 10
N-{(E)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxy-5-phenylpent-1-enyl)cyclopentyl]hept-5-enoyl}methanesulfonamide
Step 1: Preparation of Tris-TBDMS-17-phenyl PGF 2α Methyl Ester
2,6-Lutidine (2.27 μL, 19.5 mmol) and tert-butyldimethylsilyl chloride (2.94 g, 19.5 mmol) were added to a solution of 17-phenyl PGF 2α methyl ester (1.30 g, 3.25 nmmol) in DMF (32.5 mL). After stirring overnight at room temperature, the reaction was diluted with EtOAc then washed with water (3×) and brine and concentrated in vacuo. Purification of the residue by flash column chromatography (silica gel, 5% EtOAc/Hex) afforded 1.86 g (77%) of tris-TBDMS-17-phenyl PGF 2α methyl ester.
Step 2: Preparation of 5-(E)-tris-TBDMS-17-phenyl PGF 2α Methyl Ester
Phenyl disulfide (54 mg, 0.25 mmol) was added to a solution of tris-TBDMS-17-phenyl PGF 2α methyl ester (1.86 g, 2.5 mmol) in benzene (20 mL). The solution was irradiated overnight, then concentrated in vacuo to afford 5-(E)-tris-TBDMS-17-phenyl PGF 2α methyl ester, which was used without further purification.
Step 3: Saponification of 5-(E)-tris-TBDMS-17-phenyl PGF 2α Methyl Ester
Lithium hydroxide (5.0 mL of a 0.5 N solution in H 2 O, 2.5 mnuol) was added to a solution of 5-(E)-tris-TBDMS-17-phenyl PGF 2α methyl ester (879 mg, 1.18 mmol) in THF (5.0 mL). The solution was heated to 50° C. overnight. The reaction mixture was cooled and acidified with 3 N HCl then extracted with CHCl 3 (3×). The extracts were concentrated in vacuo to afford 5-(E)-tris-TBDMS-17-phenyl PGF 2α which was used without further purification.
Step 4: Preparation of5-(E)-tris-TBDMS-17-phenyl PGF 2α Acylsulfonamide
In accordance with the procedure described in example 7, step 3, the use of 5-(E)-tris-TBDMS-17-phenyl PGF 2α afforded 5-(E)-tris-TBDMS-17-phenyl PGF 2α acylsulfonamide
Step 5: Desilylation of 5-(E)-tris-TBDMS-17-phenyl PGF 2α Acylsulfonamide
In accordance with the procedure described in example 7, step 4, the use of 5-(E)-tris-TBDMS-17-phenyl PGF 2α acylsulfonamide gave the title compound. The method of the Example is shown in Scheme 5.
EXAMPLE 11
5 (Z)-7-[(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Bromo-4-methylthiophen-2-yl)-3-(tetrahydropyran-2-yloxy)pent-1-enyl]-3,5-bis(tetrahydropyran-2-yloxy)cyclopentyl]hept-5-enoic Acid (5a)
Step 1: Preparation of Enone 2a
To a suspension of sodium hydride (60% oil dispersion, 100 mg, 2.50 mmol) in THF (6 mL) at 0° C. was added a solution of dimethyl 4-(5-(2-bromo-3-methyl)thienyl)-2-oxobutylphosphonate (856 mg, 2.41 mmol) in THF (4 mL+2 mL). After 15 min at 0° C., a solution of aldehyde 1 (877 mg, 2.01 mmol) in THF (4 mL+2 mL) was added. After 30 min at 0° C., the reaction was allowed to warm to room temperature. After 2 h at room temperature, the reaction was quenched with saturated aqueous NH 4 Cl and extracted with EtOAc. The organic phase was washed with saturated aqueous NaHCO 3 and brine, then dried (MgSO 4 ), filtered and concentrated in vacuo. Purification of the residue by flash column chromatography (silica gel, 25% EtOAc/Hex) gave 1.15 g (86%) of enone 2a.
Step 2: Preparation of 15S Alcohol (3a)
Absolute ethanol (3.75 mL of a 1.0 M solution in THF, 3.75 mmol) was slowly added to a solution of lithium aluminum hydride (3.75 mL of a 1.0 M solution in THF, 3.75 mL). A solution of (S)-1,1′-bi-2-naphthol (1.08 g, 3.77 mmol) in THF (15 mL) was then added dropwise. After 30 min, a cloudy heterogeneous mixture persisted.
The freshly prepared BINAI-H mixture was cooled to −85° C., then a solution of enone 2a (500 mg, 0.75 mmol) in THF (15 mL) was added dropwise. After 1 h at −85° C., the reaction mixture was warmed to −78° C. After 1 h at −78° C., the reaction was quenched with methanol, allowed to warm to room temperature and then 1 N HCl was added. THF was removed by concentration in vacuo, then the aqueous remainder was extracted with EtOAc (2×). The combined extracts were washed with brine then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. The residue dissolved in CH 2 Cl 2 , then (S)-1,1′-bi-2-naphthol was precipitated by addition of hexane. The solid was removed by filtration (800 mg of (S)-1,1′-bi-2-naphthol was recovered) and the filtrate was concentrated in vacuo. Purification of the residue by flash column chromatography (silica gel, 25% EtOAc/Hex) gave 215 mg (43%) of alcohol 3a.
Step 3: Preparation of Tris-THP Ester (4a)
Dihydropyran (300 μL, 3.29 mmol) and PPTs (25 mg, 0.10 mmol) were added sequentially to a solution of alcohol 3a (755 mg, 1.13 mmol) in CH 2 Cl 2 (4 mL). The reaction mixture was stirred overnight at room temperature, then concentrated in vacuo. The residue was diluted with EtOAc, washed with 1 N HCl, water, saturated aqueous NaHCO 3 and brine, then dried (MgSO 4 ), filtered and concentrated in vacuo. The resulting product 4a was taken on without further purification. If desired, further purification by flash column chromatography (silica gel, 25% EtOAc/Hex) could be carried out.
Step 4: Saponification of Ester (4a)
Lithium hydroxide (4.5 mL of a 1.0 N solution in water, 4.5 mmol) was added to a solution of ester 4a (approx 1.13 mmol) in THF (11 mL). The reaction was stirred overnight at room temperature then concentrated in vacuo. The aqeous remainder was diluted with water then acidified with 1 N HCl and extracted with CH 2 Cl 2 (2×). The combined extracts were washed with brine, dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the residue by flash column chromatography (silica gel, 40% EtOAc/Hex) gave 750 mg (900/%) of acid 5a. The method of this Example is shown in Scheme 6.
EXAMPLE 12
(Z)-7-[(1R,2R,3R,5S)-2-[(S)-(E)-5-(4-Chloro-5-methylthiophen-2-yl)-3-(tetrahydropyran-2-yloxy)pent-1-enyl]-3,5-bis(tetrahydropyran-2-yloxy)cyclopentyl]hept-5-enoic Acid (5b)
In accordance with the procedures described above for the synthesis of 5a, the use of dimethyl 4-(5-(3-chloro-2-methyl)thienyl)-2-oxobutylphosphonate gave acid 5b.
EXAMPLE 13
(Z)-7-[(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Chlorothiophen-2-yl)-3-(tetrahydropyran-2-yloxy)pent-1-enyl]-3,5-bis(tetrahydropyran-2-yloxy)cyclopentyl]hept-5-enoic Acid (5c)
The synthesis of 5c was carried out in accordance with the procedures described above for the synthesis of 5a, with the following exceptions: dimethyl 4-(5-(2-chloro)thienyl)-2-oxobutylphosphonate) was used in place of dimethyl 4-(5-(2-bromo-3-methyl)thienyl)-2-oxobutylphosphonate and a different reduction method was used in step 2, as described below.
Step 2: Preparation of the 15S Alcohol (3c)
Sodium borohydride (85 mg, 2.25 mmol) was added in one portion to a solution of enone 2c (1.32 g, 2.17 mmol) in MeOH (21 mnL) at 0° C. After 3 h, the reaction was concentrated in vacuo then partitioned between saturated aqueous NH 4 Cl and EtOAc. The phases were separated and the aqueous phase was extracted with EtOAc. The combined organic phases were dried (MgSO 4 ), filtered and concentrated in vacuo. Purification of the residue by flash column chromatography (3×, silica gel, 25% EtOAc/Hex) afforded 335 mg (25%) of the faster eluting 15R alcohol and 183 mg (14%) of 3e.
EXAMPLE 14
(Z)-7-[(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Iodothiophen-2-yl)-3-(tert-butyldimethylsilanyloxy)pent-1-enyl]-3,5-bis(tetrahydropyran-2-yloxy)cyclopentyl]hept-5-enoic Acid (5d)
In accordance with the procedures described above for the synthesis of 5a, the use of dimethyl 4-(5-(2-iodo)thienyl)-2-oxobutylphosphonate gave enone 2d and alcohol 3d (steps 1 and 2, respectively). Further manipulation of alcohol 3d is as follows:
Step 3: Preparation of 15-TBDMS-bis-THP 4d
tert-Butyldimethylsilyl triflate (0.70 mL, 3.06 mmol) was added to a solution of alcohol 3d (718 mg, 1.02 mmol) and 2,6-lutidine (0.60 mL, 5.11 mmol) in CH 2 Cl 2 (6.0 mL) at 0° C. The reaction was warmed to room temperature and stirred for 12 h. The reaction was quenched with 1 N NaOH and extracted with EtOAc. The organic phase was washed with 1 N HCl, saturated aqueous NaHCO 3 and brine then dried (MgSO 4 ), filtered and concentrated in vacuo. Purification of the residue by flash column chromatography (20% EtOAc/Hex) afforded 613 mg (74%) of 4d.
Step 4: Saponification of Ester 4d
In accordance with the procedure described above for the synthesis of 5a, ester 4d gave acid 5d. The method of this Example is shown in Scheme 7.
EXAMPLE 15
(Z)-7-[(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Bromothiophen-2-yl)-3-(tetrahydropyran-2-yloxy)pent-1-enyl]-3,5-bis(tetrahydropyran-2-yloxy)cyclopentyl]hept-5-enoic Acid (5e)
In accordance with the procedures described above for the synthesis of 5a, the use of dimethyl 4-(5-(2-bromo)thienyl)-2-oxobutylphosphonate gave acid 5e.
EXAMPLE 16
(Z)-7-[(1R,2R,3R,5S)-2-[(S)-(E)-5-(2-Methylthiophen-3-yl)-3-(tetrahydropyran-2-yloxy)pent-1-enyl]-3,5-bis(tetrahydropyran-2-yloxy)cyclopentyl]hept-5-enoic Acid (5f)
In accordance with the procedures described above for the synthesis of 5a, the use of dimethyl 4-(3-(2-methyl)thienyl)-2-oxobutylphosphonate gave acid 5f.
EXAMPLE 17
N-((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonamide (9a)
Step 1: Preparation of the Tris-THP Acylsulfonamide (6a)
Acid 5a (100 mg, 0.135 mmol), EDCI (36 mg, 0.19 mmol), DMAP (20 mg, 0.16 nunol) and methanesulfonamide (39 mg, 0.41 mmol) were dissolved in DMF (0.6 mL) and the resulting solution was stirred at room temperature under an atmosphere of nitrogen. After 15 h the solution was diluted with EtOAc and washed with 1 N aqueous HCl (3×) and brine (1×), then dried (Na2SO4), filtered and concentrated in vacuo. The crude product (6a), judged to be >90% pure by 1 H NMR, was used directly in the next step.
Step 2: Deprotection of the Tris-THP Acylsulfonamide (6a)
A solution of 6a (approx. 0.135 mmol) in MeOH (1.1 mL) was treated with PPTs (4 mg, 0.016 mmol). The solution was heated at 45° C. under an atmosphere of nitrogen. After 16 h, the reaction mixture was cooled then concentrated in vacuo to afford a crude oil. Flash column chromatography (silica gel, EtOAc, then 2% MeOH in EtOAc) gave 24 mg (31% for 2 steps) of 9a. The method of this Example is shown in Scheme 8.
EXAMPLE 18
Ethanesulfonic Acid ((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)Amide (10a)
Step 1: Preparation of the Tris-THP Acylsulfonainide (7a)
Acid 5a (100 mg, 0.135 mmol), EDCI (36 mg, 0.19 mmol), DMAP (20 mg, 0.16 mmol) and ethanesulfonamide (45 mg, 0.41 mmol) were dissolved in DMF (0.6 mL) and the resulting solution was stirred at room temperature under an atmosphere of nitrogen. After 24 h the solution was diluted with EtOAc and washed with 1 N aqueous HCl (3×) and brine (1×), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. The crude product (7a), judged to be >90% pure by 1 H NMR, was used directly in the next step.
Step 2: Deprotection of the Tris-THP Acylsulfonamide (7a)
A solution of 7a (approx. 0.135 mmol) in MeOH (1.1 mnL) was treated with PPTs (4 mg, 0.016 mmol). The solution was heated at 45° C. under an atmosphere of nitrogen. After 16 h, the reaction mixture was cooled then concentrated in vacuo to afford a crude oil. Flash column chromatography (silica gel, EtOAc, then 2% MeOH in EtOAc) gave 20 mg (26% for 2 steps) of 10a. The method of this Example is also shown in Scheme 8.
EXAMPLE 19
N-((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)-1,1,1-trifluoromethanesulfonamide (11a)
Step 1: Preparation of the Tris-THP Acylsulfonamide (8a)
Acid 5a (100 mg, 0.135 mmol), EDCI (36 mg, 0.19 mmol), DMAP (20 mg, 0.16 mmol) and trifluoromethanesulfonamide (61 mg, 0.41 mmol) were dissolved in DMF (0.6 mL) and the resulting solution was stirred at room temperature under an atmosphere of nitrogen. After 15 h the solution was diluted with EtOAc and washed with 1N aqueous HCl (3×) and brine (1×), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. The crude product (8a), judged to be >90% pure by 1 H NMR, was used directly in the next step.
Step 2: Deprotection of the Tris-THP Acylsulfonamide (8a)
A solution of 8a (approx. 0.135 mmol) in MeOH (1.1 mL) was treated with PPTs (4 mg, 0.016 mmol). The solution was heated at 45° C. under an atmosphere of nitrogen. After 16 h, the reaction mixture was cooled then concentrated in vacuo to afford a crude oil. Flash column chromatography (silica gel, EtOAc, then 2% MeOH in EtOAc) gave 45 mg (54% for 2 steps) of acylsulfonamide 11a. The method of this Example is also shown in Scheme 8.
EXAMPLE 20
N-((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(4-Chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonamide (9b)
In accordance with the procedures described above for the synthesis of 9a, the use of acid 5b gave 9b.
EXAMPLE 21
Ethanesulfonic Acid ((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(4-chloro-5-30 methylthiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)amide (10b)
In accordance with the procedures described above for the synthesis of 10a, the use of acid 5b (41 mg, 0.059 mmol) afforded 9 mg (29% for 2 steps) of 10b.
EXAMPLE 22
N-((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(4-Chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)-1,1,1-trifluoromethanesulfonamide (11b)
In accordance with the procedures described above for the synthesis of 11a, the use of acid 5b (41 mg, 0.059 mmol) gave the desired product lib along with an impurity. The impure product was then suspended in CH 2 Cl 2 and extracted with 1N NaOH. The organic phase was discarded and the basic aqueous phase was acidified to pH 1 with 1N HCl. The aqueous phase was extracted with EtOAc (3×), then the combined organic extracts were dried (Na 2 SO 4 ), filtered and concentrated in vacuo to afford 15 mg (44% for 2 steps) of 11b.
EXAMPLE 23
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-Chlorothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}methanesulfonamide (9c)
The synthesis of 9c was carried out in accordance with the procedures described above for the synthesis of 9a, with the following exceptions: acid 5c (50 mg, 0.073 mmol) was used in place of acid 5a; intermediate 6c was purified by flash column chromatography (silica gel, 45% EtOAc/Hex) to give 43 mg (77%); and a different hydrolysis method (step 2) was used, as described below.
Purified 6e (43 mg, 0.057 mmol) was dissolved in THF (0.1 ML), H 2 O (0.1 mL) and acetic acid (0.4 mL). The mixture was heated at 35° C. under nitrogen for 42 h. The mixture was cooled and diluted with EtOAc, washed with water and brine, then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification by flash column chromatography (silica gel, EtOAc, then 2% MeOH in EtOAc) gave 9 mg (31%) of 9c.
EXAMPLE 24
Ethanesulfonic Acid ((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-chlorothiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)amide (10c)
In accordance with the procedures described above for the synthesis of 10a, the use of acid 5c (100 mg, 0.15 mmol) gave 24 mg (31% for 2 steps) of 10c.
EXAMPLE 25
N-((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Chlorothiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)-1,1,1-trifluoromethanesulfonamide (11c)
In accordance with the procedures described above for the synthesis of 11b, the use of acid 5c (100 mg, 0.15 mmol) gave 33 mg (40% for 2 steps) of lie.
EXAMPLE 26
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-Iodothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}methanesulfonamide (9d)
In accordance with the procedures described above for the synthesis of 9a, the use of acid 5d (45 mg, 0.056 mmol) gave 15 mg (45% for 2 steps) of 9d.
EXAMPLE 27
Ethanesulfonic Acid ((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-iodothiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)Amide (10d)
In accordance with the procedures described above for the synthesis of 10a, the use of acid 5d (45 mg, 0.056 inmol) gave 10 mg (29% for 2 steps) of 10d.
EXAMPLE 28
N-((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Iodothiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)-1,1,1-trifluoromethanesulfonarnide (11d)
In accordance with the procedures described above for the synthesis of 11b, the use of acid 5d (45 mg, 0.056 mmol) gave 20 mg (55% for 2 steps) of lid.
EXAMPLE 29
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-Brornothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}Methanesulfonamide (9e)
The syntheisis of 9e was carried out in accordance with the procedures described above for the synthesis of 9a, with the following exceptions: acid 5e (200 mg, 0.28 mmol) was used in place of acid 5a; intermediate 6e was purified by flash column chromatography (silica gel, 45% EtOAc/hex) to afford 180 mg (81%) of 6e; deprotection of 6e (36 mg, 0.045 mmol) afforded 13 mg (53%) of 9e.
EXAMPLE 30
Ethanesulfonic Acid ((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-bromothiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)amide (10e)
In accordance with the procedures described above for the synthesis of 10a, the use of acid 5e (45 mg, 0.062 mmol) gave 7 mg (20% for 2 steps) of 10e.
EXAMPLE 31
N-((Z)-7-{(1R,2R,3R,5S)-2-[(S)-(E)-5-(5-Bromothiophen-2-yl)-3-hydroxypent-1-enyl]-3,5-dihydroxycyclopentyl}hept-5-enoyl)-1,1,1-trifluoromethanesulfonamide (11e)
In accordance with the procedures described above for the synthesis of 11b, the use of acid 5e (45 mg, 0.062 mmol) gave 22 mg (59% for 2 steps) of 11e.
EXAMPLE 32
N-((Z)-7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl)cyclopentyl}hept-5-enoyl)methanesulfonamide (9f)
In accordance with the procedures described above for the synthesis of 9a, the use of acid 5f (200 mg, 0.30 mmol) gave 52 mg (37% for 2 steps) of 9f.
EXAMPLE 33
Ethanesulfonic Acid ((Z)-7-{(1R,2R,3R,5S)-3,5-dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl]cyclopentyl}hept-5-enoyl)amide (10f)
In accordance with the procedures described above for the synthesis of 10a, the use of acid 5f (200 mg, 0.30 mmol) afforded 110 mg (73% for 2 steps)of 10f.
EXAMPLE 34
N-((Z)-7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl]cyclopentyl}hept-5-enoyl)-1,1,1-trifluoromethanesulfonamide (11f)
According to the procedures above for 11a, the use of acid 5f (11 mg, 0.17 mmol) gave 51 mg (56% for 2 steps) of 11f.
EXAMPLE 35
7-[(1R,2R,3R,5S)-2-[(S)-(E)-5-(2-Methylthiophen-3-yl)-3-(tetrahydropyran-2-yloxy)pent-1-enyl]-3,5-bis(tetrahydropyran-2-yloxy)cyclopentyl]Heptanoic Acid (13)
Step 1: Preparation of the Partially Saturated Ester 12
Dienyl ester 4f (160 mg, 0.24 mmol) was dissolved in THF (1.0 mL) then tris(triphenylphosphine)rhodium(I) chloride (55 mg, 0.059 mmol) was added. The reaction was evacuated and purged under an atmosphere of hydrogen. After sstirring for 24 h the reaction was concentrated in vacuo. Purification of the crude residue by flash column chromatography (silica gel, 20% EtOAc/hex) afforded 151 mg (94%) of 12.
Step 2: Saponification of Ester 12
A solution of ester 12 (151 mg, 0.22 mmol) in THF (2.2 mL) was treated with lithium hydroxide (0.9 mL of a 1.0N solution in H 2 O, 0.9 mmol). After 20 h stirring at room temperature, the reaction mixture was concentrated in vacuo, diluted with H 2 O and acidified to pH 3 with 1N HCl. The aqueous mixture was extracted with EtOAc (2×), then the combined extracts were dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the crude residue by flash column chromatography (silica gel, 33% EtOAc/hex) afforded 130 mg (88%) of 13. The method of the Example is shown in Scheme 9.
EXAMPLE 36
N-(7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl)cyclopentyl}heptanoyl)methanesulfonamide (14)
In accordance with the procedures given above for the synthesis of 9a, the use of acid 13 (37 mg, 0.056 mmol) gave 13 mg (48% for 2 steps) of 14. The method of the Example is also shown in Scheme 9.
EXAMPLE 37
Ethanesulfonic Acid (7-{(1R,2R,3R,5S)-3,5-dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl]cyclopentyl}heptanoyl)amide (15)
In accordance with the procedures given above for the synthesis of 10a, the use of acid 13 (37 mg, 0.056 mmol) gave 9 mg (32% for 2 steps) of 15.
EXAMPLE 38
N-(7-{(1R,2R,3R,5S)-3,5-Dihydroxy-2-[((S)-(E)-3-hydroxy-5-(2-methylthiophen-3-yl)pent-1-enyl]cyclopentyl}heptanoyl)-1,1,1-trifluoromethanesulfonamide (16)
In accordance with the procedures given above for the synthesis of 11b, the use of acid 13 (37 mg, 0.056 mmol) gave 14 mg (46% for 2 steps) of 16.
EXAMPLE 39
Acetic Acid ({(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-cyclopentyl]hept-5-enoyl}methanesulfonylamino)methyl Ester (17g)
Step 1: Preparation of the THP-protected Prodrug
Diisopropropylethylamine (0.23 mL, 1.32 mmol) and bromomethyl acetate (0.11 mL, 1.12 mmol) were added sequentially to a solution of 6g (110 mg, 0.161 mmol) in DMF (1.0 mL) and the resulting solution was stirred at room temperature under an atmosphere of nitrogen overnight. The solution was concentrated in vacuo. Purification of the crude residue by flash column chromatography (silica gel, 35% EtOAc/hex) afforded 109 mg (90%) of the THP protected prodrug.
Step 2: Deprotection of the THP-protected Prodrug
A solution of the THP-protected prodrug (109 mg, 0.144 mmol) in MeOH (1.5 mL) was treated with PPTs (8 mg, 0.032 mmol). The solution was heated at 45° C. under an atmosphere of nitrogen. After 16 h, the reaction mixture was cooled then concentrated in vacuo to afford a crude oil. Flash column chromatography (silica gel, EtOAc, then 2% MeOH in EtOAc) gave 47 mg (65%) of 17g. See FIG. 2 .
EXAMPLE 40
2,2-Dimethylpropionic Acid ({(Z)-7-[(1R,2R,3R,5S)-3,5-dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)-cyclopentyl]hept-5-enoyl}methanesulfonylamino)methyl Ester (18g)
Step 1: Preparation of the THP-protected Prodrug
Diisopropropylethylamine (0.25 mL, 1.44 mmol), sodium iodide (187 mg, 1.25 mmol) and chloromethyl pivalate (0.18 mL, 1.25 mmol) were added sequentially to a solution of 6g (121 mg, 0.177 mmol) in DMF (1.1 mL) and the resulting mixture was stirred at room temperature under an atmosphere of nitrogen overnight. The reaction mixture was diluted with EtOAc, washed with brine (3×), dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the crude residue by flash column chromatography (silica gel, 25% EtOAc/hex) afforded 94 mg (67%) of the THP protected prodrug.
Step 2: Deprotection of the THP-protected Prodrug
A solution of the crude THP-protected acylsulfonamide derivative (93 mg, 0.117 mmol) in MeOH (1.2 mL) was treated with PPTs (7 mg, 0.028 mmol). The solution was heated at 45° C. under an atmosphere of nitrogen. After 24 h, the reaction mixture was cooled then concentrated in vacuo to afford a crude oil. Flash column chromatography (silica gel, 100% EtOAc, then 2% MeOH in EtOAc) gave 47 mg (65%) of 18g. See FIG. 3 .
EXAMPLE 41
Acetic Acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl Ester (17a)
In accordance with the procedures given above for the synthesis of 17g, the use of 6a (70 mg, 0.086 mmol) gave 21 mg (38% for 2 steps) of 17a. See FIG. 2 .
EXAMPLE 42
2,2-Dimethylpropionic Acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromo-4-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl Ester (18a)
In accordance with the procedures given above for the synthesis of 18g, the use of 6a (78 mg, 0.95 mmol) gave 28 mg (43% for 2 steps) of 18a. See FIG. 3 .
EXAMPLE 43
Acetic Acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl Ester (17b)
In accordance with the procedures given above for the synthesis of 17g, the use of 6b (60 mg, 0.078 mmol) gave 28 mg (61% for 2 steps) of 17b. See FIG. 2 .
EXAMPLE 44
2,2-Dimethylpropionic Acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-chloro-5-methyl-thiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methane-sulfonyl-amino]methyl Ester (18b)
In accordance with the procedures given above for the synthesis of 18 g, the use of 6b (60 mg, 0.078 mmol) gave 33 mg (67% for 2 steps) of 18b. See FIG. 3 .
EXAMPLE 45
Acetic Acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}hept-5-enoyl)methanesulfonyl-amino]methyl Ester (17e)
In accordance with the procedures given above for the synthesis of 17g, the use of 6e (72 mg, 0.090 mmol) gave 35 mg (63% for 2 steps) of 17e. See FIG. 2 .
EXAMPLE 46
2,2-Dimethylpropionic Acid [((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(5-bromothiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl}Hept-5-enoyl)methanesulfonyl-amino]methyl Ester (18e)
In accordance with the procedures given above for the synthesis of 18g, the use of 6e (72 mg, 0.090 mmol) gave 38 mg (64%Yo for 2 steps) of 18e. See FIG. 3 .
EXAMPLE 47
N-{(Z)-7-[(1R,2R,3R,5S)-3,5-Dihydroxy-2-((S)-(E)-3-hydroxyoct-1-enyl)cyclopentyl]-hept-5-enoyl}benzenesulfonamide (19g)
Step 1: Preparation of the Tris-THP Benzenesulfonamide
Tris-TIAP PGF 2α (150 mg, 0.255 mmol), EDCI (69 mg, 0.36 mmol), DMAP (37 mg, 0.30 mmol) and benzenesulfonamide (120 mg, 0.763 mmol) were dissolved in DMF (1.2 mL) and the resulting solution was stirred at room temperature under an atmosphere of nitrogen. After 15 h the solution was diluted with EtOAc and washed with 1 N aqueous HCl (3x) and brine (1×), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo to afford a crude oil. Flash column chromatography (silica gel, 40% EtOAc/Hex) gave 150 mg (79%) of tris-THP PGF 2α benzenesulfonamide.
Step 2: Deprotection of the Tris-THP Benzenesulfonamide
A solution of tris-THP PGF 2α benzenesulfonarnide (150 mg, 0.201 mmol) in MeOH (2.0 mL) was treated with PPTs (10 mg, 0.040 mmol). The solution was heated at 45° C. under an atmosphere of nitrogen. After 16 h, the reaction mixture was cooled then concentrated in vacuo to afford a crude oil. Flash column chromatography (silica gel, EtOAc, then 2% MeOH in EtOAc) gave 48 mg (48% for 2 steps) of 19g. See FIG. 4 .
EXAMPLE 48
N-((Z)-7-{(1R,2R,3R,5S)-2-[((S)-(E)-5-(4-Chloro-5-methylthiophen-2-yl)-3-hydroxypent-1-enyl)-3,5-dihydroxycyclopentyl]hept-5-enoyl}benzenesulfonamide (19b)
In accordance with the procedures given above for the synthesis of 19g, the use of 5b (125 mg, 0.175 mmol) gave 50 mg (49% for 2 steps) of 19b. See FIG. 4 .
The effects of the compounds of this invention on intraocular pressure are also provided in the following tables. The compounds were prepared at the said concentrations in a vehicle comprising 0.1% polysorbate 80 and 10 mM TRIS base. Dogs were treated by administering 25 μl to the ocular surface, the contralateral eye received vehicle as a control. Intraocular pressure was measured by applanation pneumatonometry. Dog intraocular pressure was measured immediately before drug administration and at 6 hours thereafter.
Compounds 9a, 9b, 9c, 9e, 10a, 18a, and 19b were examined and showed a pronounced ocular hypotensive effect in dogs.
Com-
pound #
IOP max % decrease time (Hr)
IOP max mmHg time (Hr)
9a
−13.6% (72 hr): 0.03%
−2.8 (72 hr): 0.03%
9b
−26.5 (96 hr): 0.03%
−4.9 (96 hr): 0.03%
9c
−23.8% (102 hr): 0.03%
−4.2 (102 hr): 0.03%
9e
−11.7% (100 hr): 0.03%
−2.0 (100 hr): 0.03%
10a
−24.9% (4 hr): 0.03%
−5.1 (4 hr): 0.03%
18a
−22.0% (24 hr): 0.03%
−3.9 (24 hr): 0.03%
19b
−13.0% (74 hr): 0.03%
−2.6 (74 hr): 0.03%
The foregoing description details specific methods and compositions that can be employed to practice the present invention, and represents the best mode contemplated. However, it is apparent for one of ordinary skill in the art that further compounds with the desired pharmacological properties can be prepared in an analogous manner, and that the disclosed compounds can also be obtained from different starting compounds via different chemical reactions. Similarly, different pharmaceutical compositions may be prepared and used with substantially the same result. Thus, however detailed the foregoing may appear in text, it should not be construed as limiting the overall scope hereof; rather, the ambit of the present invention is to be governed only by the lawful construction of the appended claims. | The present invention provides a method of treating ocular hypertension or glaucoma which comprises administering to an animal having ocular hypertension or glaucoma therapeutically effective amount of a compound represented by the general formula I;
wherein a hatched line represents the α configuration, a triangle represents the β configuration, a straight line, e.g. at the 9, 11 or 15 position represents either the α or β configuration, a dotted line represents the presence or absence of a double bond; a wavy line represents a cis or trans bond;
X is O, S, NH or (CH 2 ) n ;
n is 0 or an integer of from 1 to 4;
Y is C 1 -C 5 n-alkyl, C 3 -C 7 cycloalkyl, phenyl, furanyl, thienyl, pyridinyl, thiazolyl, benzothienyl, benzofaranyl, naphthyl, or substituted derivatives thereof, wherein the substituents maybe selected from the group consisting of C 1 -C 5 alkyl, halogen, CF 3 , CN, NO 2 , N(R 2 ) 2 , CO 2 R 2 and OR 2 ;
Z is (CH 2 ) n or a covalent bond;
R is C 1 -C 6 lower alkyl or Z—CF 3 or mesylate or triflate;
R 1 is H, R 2 or COR 2 ;and
R 2 is H or C 1 -C 5 lower alkyl or 9, 11 or 15 esters thereof. | 2 |
This application is a Continuation-In-Part of U.S. non-provisional patent application Ser. No. 14/300,981 filed on Jun. 10, 2014, which is a Continuation of U.S. non-provisional patent application Ser. No. 14/057,086 filed on Oct. 18, 2013, and they are included herein in their entirety by reference.
COPYRIGHT NOTICE
A portion of the disclosure of this patent contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a method of production of a cured pickle product by fermentation. In particular, the present invention is directed to a method of producing a fermentation cured pickle product quickly, without the traditional fermentation length.
Description of Related Art
Fermented pickle products, such as cucumbers and the like, are popular the world over because of the flavor and appearance that distinguishes them from other types of pickle products.
Commercially produced pickles are fermented in a brine solution of about 6% sodium chloride in large open-top tanks as large as 40,000 liters. The salt in this type of fermentation serves more than one function. For one, it is used to prevent freezing of outside tanks in northern climates. However, the most important function is that the sodium chloride brine solution selects for salt tolerant bacteria, such as Lactobacillus plantarm . Salt tolerant bacteria are normally used for fermentations of this type. Salt-tolerant bacteria help maintain the firm texture of the fermented product while the products are stored up to a year in fermentation tanks. It also provides salty flavor in the products made from the fermented fruit. Open tanks have the problem of allowing undesirable microbes and other items to enter the fermentation easily.
Fermentation of fruits, vegetables, and produce reduces sugars in the vegetable and in the brine from about 2% down to less than about 0.1% sugar. In the pickle industry, fermentation of a vegetable is typically considered complete when sugar test strips of the fermentation brine are negative, indicating less than about 0.1% residual sugar remains. Sugar concentration in the fermentation brine equalizes with the sugar concentration in the vegetable, making end of fermentation measurement easy by measuring the sugar in the brine solution. Also, pH of the fermentation brine typically goes down to about 2.9-3.9, also indicating a completed fermentation process. Those in the industry are familiar with methods for testing for fermentation completion.
With traditional fermentation, vegetables can take from about three to four weeks to finish the fermentation process sufficiently for commercial sale. This limits the amount of equipment-produced pickles to several batches per year in optimal conditions. Tank yard operations in the traditional fermenting process involve a large amount of labor and capital, with respect to maintaining the tank yard for these extended processing times. An additional continuing issue for commercial pickle production is the disposal of the salt in a manner that meets current disposal standards, with some local governments severely restricting the amount of salt which can be disposed of. Recycling of the brine from each fermentation batch has shown some benefit in sodium chloride reduction. However, during recycling, the intermingling of brines from different sources, batches, etc., with more diverse microbial content, presents a carryover of “off” or unwanted flavors in the finished product.
Calcium chloride is well known in the pickling process for having an effect when added to the conventional pickling process in that it increases the firmness of the preserved fruit, especially with cucumbers. Calcium chloride is considered more environmentally friendly than sodium chloride, and the disposal of calcium chloride as a waste product is less of an issue. Whole cucumber pickles have been utilized in a process involving only calcium chloride, and the results of this calcium chloride process indicated that a similar result, in terms of fermentation time, can be obtained without use of sodium chloride. Since no time difference was observed between the calcium chloride process and the sodium chloride process, the processes used did nothing to deal with the length of time it takes to ferment pickles and the problems with low equipment use turnover.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to the discovery of a process of fermenting pickles with calcium chloride such that the pickling time is greatly reduced and the turnover rate of fermentation tanks is much higher. By cutting, slicing, or piercing the produce prior to the pickling process, greatly reduced fermentation times are achieved.
Accordingly, in one embodiment the present invention relates to an accelerated method of pickling fresh produce in a solution without sodium chloride comprising the steps of:
a) exposing at least a portion of the internal flesh of the fresh produce by at least one method of the group consisting of piercing, cutting, slicing, and dicing; and b) adding the fresh produce to a fermentation container containing a solution without sodium chloride, the solution comprising; a pickling fermentation culture, and calcium chloride of about 0.5% to about 2.0% on w/w basis of the water; and c) fermenting the produce with the solution at a temperature of about 25° C. to about 35° C. for about five days or less until fermentation is complete, wherein the end of fermentation is measured by sugar concentration in the solution being reduced to less than about 0.1%.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example of the mechanical arrangement of the method of the present invention.
FIG. 2 is an example of cucumbers that have been sliced, cut (diced) and pierced.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible to embodiment in many different forms, there is shown in the drawings, and will herein be described in detail, specific embodiments, with the understanding that the present disclosure of such embodiments is to be considered as an example of the principles and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawings. This detailed description defines the meaning of the terms used herein and specifically describes embodiments in order for those skilled in the art to practice the invention.
DEFINITIONS
The terms “about” and “essentially” mean ±10 percent.
The terms “a” or “an”, as used herein, are defined as one or as more than one. The term “plurality”, as used herein, is defined as two or as more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
The term “comprising” is not intended to limit inventions to only claiming the present invention with such comprising language. Any invention using the term comprising could be separated into one or more claims using “consisting” or “consisting of” claim language and is so intended.
References throughout this document to “one embodiment”, “certain embodiments”, and “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.
The term “or” as used herein is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means any of the following: “A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.
The drawings featured in the figures are for the purpose of illustrating certain convenient embodiments of the present invention, and are not to be considered as limitations thereto. The term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function and that one skilled in the art could select from these or their equivalent in view of the disclosure herein and use of the term “means” is not intended to be limiting.
Normally, the fermentation of produce in a brine solution takes on the order of several weeks to several months to complete on a commercial scale. As used herein the term “accelerated” refers to completion of the pickling process in five days or less. In one embodiment, in three days or less, in another embodiment, two days or less (48 hours or less) and, in one embodiment, completion is within 1, 2, 3, 4, 5, 6, or 7 days. In one example, cubed cucumbers using sodium chloride fermentation would take 8-14 days to complete fermentation (i.e. all sugars fermented). In the present invention, the same cubed cucumbers would be completely fermented in 48 hours, reducing the fermentation time to ⅕ the original time.
As used herein the term “pickling” in the claims refers to the brine fermentation curing of vegetables in a solution of calcium chloride of a concentration of about 0.5% to about 2.0% on a w/w basis of the water in the brine. In addition, a suitable pickling culture such as Lactobacillus plantarum , or the like bacteria, is utilized or added to create the fermentation. In one embodiment of the invention, the brine consists essentially of calcium chloride and no other brining ingredients. The brine, in one embodiment, can also contain herbs and spices, as well as known yeast and mold inhibitors known in the art of food processing. For example, potassium sorbate inhibits both yeast and molds and could be utilized. In one embodiment, potassium sorbate is added in a concentration of about 0.1%.
As used herein the phrase “exposing at least a portion of the internal flesh of the fresh produce” refers to the act of cutting, slicing, dicing, piercing or the like, such that a physical exposure of the internal flesh of the vegetable occurs and the brine can come into contact with the exposed flesh. One can expose as little or as much as desired, but larger amounts of exposed flesh, as provided by slicing, for example, give the greatest exposure to the flesh. “Slices” refers generally to slices 3/16 inches thick or thinner. Thick slices are greater than about 3/16 inches and can be ½ inch thick or larger. Piercing refers to whole produce that has been punctured multiple times, and dicing can be regular shapes ½ inch thick or less. Cutting refers to cuts in the whole produce or cutting into chunks.
Once the flesh is exposed, the exposed vegetable is optionally water washed for a time sufficient to allow for a reduction in the sugars present in the fresh produce. Fermentation time, with this washing step, is much reduced, as opposed to fermentation time without the washing step. The time, in general, for the wash is roughly three minutes. One skilled in the art can determine the optimum soak time depending on the particular vegetable and the amount of interior flesh that is exposed, the size of the vegetable, and the like, in view of this disclosure. Once the washing step is completed, the wash water is removed by means known in the art. In one embodiment, it is done by use of a hydrosieve. Fresh water is removed before beginning the fermentation step (optionally the wash water is utilized in the fermentation step).
The produce is then added to a fermentation tank, then covered with water and enough calcium chloride added to make a solution of about 0.5% to about 2% w/w, as described above. In one embodiment, the solution is made isotonic. Since this method is designed primarily for commercial size production, the fermentation vessel in one embodiment is at least 19,000 liters (though any size big enough to fit a single piece of a produce or larger will work), and the tank is filled with produce to a level of about 45% produce and 55% solution, though the range is from about 30/70 to 70/30 volume basis. In addition, the culture and mold and yeast inhibitors are added as well. In one embodiment, the tank has a closed top to prevent entry of random bacteria and other unwanted items. The solution is brought to a temperature ideal for the lactobacillus fermentation, which is between 25° to 35° Celsius, and held for a length of fermentation time as described above. The fermentation is complete when sugar concentration in the brine is measured (e.g. by glucose test strip) at about 0.1% or less. Generally, all produce fermentation can be completed in about five days or less. In most cases, sliced produce can be completely fermented in 2-3 days, and a dice of 3/16 inches or less of produce can be completely fermented in two days or less.
Now referring to the drawings, FIG. 1 shows a commercial production arrangement 1 using the method of the present invention. In this view, a commercial step for exposing the flesh of the produce 10 is done at the cutter/dicer 2 . The produce is then transferred to the shaker screen 3 , which removes small unwanted pieces and debris while transferring the produce to a wet tank 4 for the soaking step as described above. Next, water transfer pump 5 transfers the water and produce to the commercial fermentation tank 8 after the wash water is optionally removed via a hydrosieve 9 positioned right before the produce enters the fermentation tank 8 . The appropriate amount of calcium chloride, the fermentation culture flavorings, water and the like are added to the tank. A heat exchanger 11 keeps the fermentation at the appropriate temperature, e.g. 30 degrees C. for the desired time, and then water and produce are removed via fermentation tank drain 12 to the bottom of the fermentation tank 8 via gravity once the pickles are fermented to a brine sugar content of 0.1% or less.
FIG. 2 shows cucumbers that have been sliced 20 , pierced 21 , and diced 22 for their addition to the fermentation process of the present invention.
Those skilled in the art to which the present invention pertains may make modifications resulting in other embodiments employing principles of the present invention without departing from its spirit or characteristics, particularly upon considering the foregoing teachings. Accordingly, the described embodiments are to be considered in all respects only as illustrative, and not restrictive, and the scope of the present invention is, therefore, indicated by the appended claims rather than by the foregoing description or drawings. Consequently, while the present invention has been described with reference to particular embodiments, modifications of structure, sequence, materials and the like apparent to those skilled in the art still fall within the scope of the invention as claimed by the applicant. | The fermentation of cucumbers and other vegetables into pickles is traditionally a long term process. By exposing the flesh of the vegetable and pickling with calcium chloride instead of sodium chloride, a faster fermentation pickle is achieved with no decrease in quality. | 0 |
CROSS-REFERENCE TO RELATED PATENT APPLICATION
This application claims priority from Korean Patent Application No. 10-2004-0073919, filed on Sep. 15, 2004, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
The present invention relates to a hydroformylation reaction catalyst composition including a bidentate phosphorus compound and a process for hydroformylation reaction using the same. More particularly, the present invention relates to a process for hydroformylation reaction of olefins to prepare aldehydes which includes stirring a transition metal catalyst modified with a nitrogen-containing bidentate phosphorus compound ligand, an olefin compound, and a mixed gas of carbon monoxide and hydrogen, under high temperature and pressure condition.
DESCRIPTION OF THE RELATED ART
Generally, hydroformylation reaction, also well known as an oxo reaction, is a process in which an olefin reacts with a synthesis gas (CO/H 2 ) in the presence of a metal catalyst and a ligand to produce a linear (normal) or branched (iso) aldehyde which has one more carbon atom than the olefin. The oxo reaction was originally discovered in 1938 by a German scientist, Otto Roelen. About 8,400,000 tons of aldehydes (including alcohol derivatives) were produced by oxo reaction and consumed around the world in 2001 ( SRI report , November 2002, 682. 7000A). Aldehydes produced by the oxo reaction are oxidized or reduced to their corresponding derivatives, acids or alcohols. In addition, aldehydes can also be converted to long alkyl chain-containing acids or alcohols through aldol condensation and then oxidation or reduction. The alcohols and acids thus produced are used as solvents, additives, materials of various plasticizers, etc.
Currently, cobalt and rhodium catalysts are mainly used in an oxo process. The N/I (ratio of linear (normal) to branched (iso) isomers) selectivity of aldehydes varies according to the type of ligand used and operating conditions. To date, a rhodium-catalyzed, low-pressure oxo process has been adopted in at least 70% of oxo plants worldwide.
In addition to cobalt (Co) and rhodium (Rh), iridium (Ir), ruthenium (Ru), osmium (Os), platinum (Pt), palladium (Pd), iron (Fe), nickel (Ni), etc. can be used as a central metal of an oxo catalyst. However, since it is known that the descending order of catalytic activity is as follows: Rh>>Co>Ir, Ru>Os>Pt>Pd>Fe>Ni, most processes and studies have been focused on rhodium and cobalt. A ligand of the oxo catalyst may be phosphine (PR 3 , R═C 6 H 5 , n-C 4 H 9 ), phosphine oxide (O═P(C 6 H 5 ) 3 ), phosphite, amine, amide, isonitrile, etc. However, there are few ligands superior to triphenylphosphine (TPP) considering catalytic activity, stability, and costs. Thus, a rhodium catalyst modified with a TPP ligand is used in most oxo processes. Furthermore, it is known that a TPP ligand is used in an amount of 100 eq. or more based on rhodium metal present in the rhodium complex catalyst to increase catalyst stability.
The Eastman Kodak Company and the Union Carbide Company (now a subsidiary of the Dow Chemical Company) developed a bidentate phosphine ligand imparting high activity and N/I selectivity to a catalyst, respectively. (U.S. Pat. Nos. 4,694,109 and 4,668,651). It is known that a bisphosphite ligand developed by the Dow Chemical Company has been used in some plants.
U.S. Pat. No. 6,653,485 discloses an asymmetric reaction using a chiral biaryl phosphine or phosphinite ligand and a transition metal catalyst. Even though this patent discloses that a nitrogen-containing bidentate phosphorous compound can be used as the ligand, it is silent about the actual application of the nitrogen-containing bidentate phosphorous compound in hydroformylation reaction.
The industrial importance of normal aldehydes is currently remarkably increasing. Thus, a catalyst composition that exhibits a high selectivity to normal-aldehyde or iso-aldehyde, and high catalytic activity at high temperature is needed.
SUMMARY OF THE INVENTION
The present invention provides a catalyst composition including a bidentate ligand and a transition metal catalyst which exhibits high catalytic activity and N/I selectivity.
The present invention also provides a process for hydroformylation reaction of an olefin compound to prepare an aldehyde which includes stirring the catalyst composition, the olefin compound, and a gas mixture of of carbon monoxide and hydrogen, under high temperature and pressure condition.
The present invention also provides a compound used as the bidentate ligand.
The present invention also provides a process for preparing the compound used as the bidentate ligand.
According to an aspect of the present invention, there is provided a catalyst composition including:
(a) a bidentate ligand represented by formula 1 below; and
(b) a transition metal catalyst represented by formula 2 below:
wherein,
R 1 and R 2 are each a substituted or unsubstituted alkyl group of 1-20 carbon atoms, a substituted or unsubstituted alkoxy group of 1-20 carbon atoms, a substituted or unsubstituted cycloalkane or cycloalkene of 5-20 carbon atoms, a substituted or unsubstituted aryl group of 6-36 carbon atoms, a substituted or unsubstituted heteroalkyl group of 1-20 carbon atoms, a substituted or unsubstituted heteroaryl group of 4-36 carbon atoms, or a substituted or unsubstituted hetero ring group of 4-36 carbon atoms;
Ar 1 -Ar 2 is a bisaryl compound; and
R 3 is an alkyl group of 1-20 carbon atoms, an aryl group of 6-20 carbon atoms, a triarylsilyl group, a trialkylsilyl group, a carboalkoxy group represented by —CO 2 R where R is an alkyl group of 1-20 carbon atoms or an aryl group of 6-20 carbon atoms, a carboaryloxy group, an aryloxy group, an alkoxy group, an alkylcarbonyl group, an arylcarbonyl group, an amide, a halogen, or a nitrile group, and
M(L 1 ) l (L 2 ) m (L 3 ) n (2)
wherein,
M is a transition metal;
L 1 , L 2 and L 3 are each hydrogen, CO, acetylacetonato, cyclooctadiene, norbornene, chlorine, or triphenylphosphine; and
l, m, and n are each an integer of 0 to 5, and the sum of l, m and n is not zero.
According to another aspect of the present invention, there is provided a process for hydroformylation reaction of an olefin compound to prepare an aldehyde which includes stirring the catalyst composition, the olefin compound, and a gas mixture of of carbon monoxide and hydrogen, under high temperature and pressure condition.
The olefin compound may be a compound represented by formula 3 below:
wherein,
R 4 and R 5 are each hydrogen, an alkyl group of 1-20 carbon atoms, fluorine (—F), chlorine (—Cl), bromine (—Br), trifluoromethyl (—CF 3 ), or a phenyl group of 6-20 carbon atoms that may be unsubstituted or substituted by one to five substituents selected from the group consisting of a nitro group (—NO 2 ), fluorine (—F), chlorine (—Cl), bromine (—Br), a methyl group, an ethyl group, a propyl group, and a butyl group.
According to still another aspect of the present invention, there is provided a compound represented by formula 1 below:
wherein,
R 1 , R 2 , R 3 , and Ar 1 —Ar 2 are as defined above.
According to yet another aspect of the present invention, there is provided a process for preparing the compound of formula 1, the process including:
reacting a compound represented by formula 4 below with a base to obtain an amine salt; and
reacting the amine salt with a compound represented by XPR 1 R 2 where X is a halogen and R 1 and R 2 are as defined above to obtain a bidentate compound with a direct phosphorus-nitrogen bond:
wherein,
R 3 and Ar 1 —Ar 2 are as defined above.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a catalyst composition including a bidentate ligand and a transition metal catalyst.
The bidentate ligand represented by formula 1 may be a bidentate ligand in which R 1 and R 2 are each a phenyl group, a phenyloxy group, an alkyl group, an alkyloxy group, or a pyrrole group, and R 3 is a methyl group, an ethyl group, a phenyl group, or an acetyl group.
The bisaryl compound of formula 1 may be a compound represented by formula 5 or 6 below:
wherein,
R 6 , R 7 , R 8 , and R 9 are each hydrogen, an alkyl group of 1-20 carbon atoms, an aryl group of 6-20 carbon atoms, a triarylsilyl group, a trialkylsilyl group, a carboalkoxy group represented by —CO 2 R where R is an alkyl group of 1-20 carbon atoms or an aryl group of 6-20 carbon atoms, a carboaryloxy group, an aryloxy group, an alkoxy group, an alkylcarbonyl group, an arylcarbonyl group, an amide, a halogen, or a nitrile group, and preferably, R 6 is a methyl group, a methoxy group, a tert-butyl group, R 7 is hydrogen, R 8 is a methyl group, a methoxy group, or a tert-butyl group, and R 9 is hydrogen or a methyl group,
wherein,
R 10 , R 11 , R 12 , R 13 , R 14 , and R 15 are each hydrogen, an alkyl group of 1-20 carbon atoms, an aryl group of 6-20 carbon atoms, a triarylsilyl group, a trialkylsilyl group, a carboalkoxy group represented by —CO 2 R where R is an alkyl group of 1-20 carbon atoms or an aryl group of 6-20 carbon atoms, a carboaryloxy group, an aryloxy group, an alkoxy group, an alkylcarbonyl group, an arylcarbonyl group, an amide, a halogen, or a nitrile group.
In the transition metal catalyst, the transition metal M may be cobalt (Co), rhodium (Rh), or iridium (Ir). More specifically, the transition metal catalyst may be acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ), acetylacetonatocarbonyltriphenylphosphinerhodium (Rh(AcAc)(CO)(TPP)), hydridocarbonyltri(triphenylphosphine)rhodium (HRh(CO)(TPP) 3 ), acetylacetonatodicarbonyliridium (Ir(AcAc)(CO) 2 ), or hydridocarbonyltri(triphenylphosphine)iridium (HIr(CO)(TPP) 3 ).
In the catalytic reaction of the present invention, the content of the transition metal may be in the range from 50 to 500 ppm based on a reactant solution. If the content of the transition metal is less than 50 ppm, hydroformylation reaction may be retarded, which restricts industrial application. On the other hand, if it exceeds 500 ppm, process costs increase due to the increased use of an expensive transition metal. Furthermore, a reaction rate is not increased in proportion to the increased amount of the transition metal.
The content of the bidentate ligand is in the range from 0.5 to 100 moles, preferably from 1 to 20 moles, based on 1 mole of the transition metal. If the content of the bidentate ligand is less than 0.5 moles, the stability of a catalyst system may be lowered. On the other hand, if it exceeds 100 moles, the increased use of the expensive ligand without additional benefits may increase process costs.
Particularly preferably, the transition metal catalyst is acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ), and the bidentate ligand is 2,2′-bis[N-(diphenylphosphino)methylamino]-1,1′-bipehnyl (BPNP-1).
The olefin compound may be a compound selected from the group consisting of ethene, propene, 1-butene, 1-pentene, 1-hexene, 1-octene, and styrene.
A solvent that can be used in the hydroformylation reaction of the present invention may be aldehydes such as propionaldehyde, butyraldehyde, and valeraldehyde; ketones such as acetone, methylethylketone, methylisobutylketone, acetophenone, and cyclohexanone; aromatics such as benzene, toluene, and xylene; halogenated aromatics such as orthodichlorobenzene; ethers such as tetrahydrofuran, dimethoxyethane, and dioxane; halogenated paraffins such as methylene chloride; paraffin hydrocarbons such as heptane; etc. Aldehydes and aromatics such as toluene are preferable.
The composition of the syngas (CO/H 2 ) used in the hydroformylation reaction of the present invention may be changed within a broad range. Generally, the molar ratio of CO/H 2 is in the range from about 5:95 to 70:30, preferably from about 40:60 to 60:40, particularly preferably about 1:1.
Generally, the hydroformylation reaction is performed at a temperature of about 20 to 180° C., preferably about 50 to 150° C., and at a pressure of about 1 to 700 bar, preferably 1 to 300 bar.
A process for preparing the compound of formula 1 will now be described in detail. First, a compound of formula 4 below is dissolved in a solvent, and a base such as n-butyl lithium is added to the reactant solution with cooling to 0° C. or less to obtain an amine salt. A compound represented by XPR 1 R 2 (where X is a halogen, and R 1 and R 2 are as defined above) is dropwise added to the amine salt solution, and the resultant precipitate is then filtered, purified, and dried, to obtain a bidentate compound with a direct phosphorus-nitrogen bond as represented by formula 1.
wherein,
R 3 and Ar 1 —Ar 2 are as defined above.
In the preparation of the compound of formula 1, the solvent may be tetrahydrofuran (THF), benzene, toluene, ether, dichloromethane, etc. THF is particularly preferable. The base may be selected from the group consisting of n-butyl lithium, tert-butyl lithium, sodium hydride (NaH), potassium hydride (KH), triethylamine, and pyridine.
In the compound represented by XPR 1 R 2 , X may be chlorine (Cl), bromine (Br), or iodine (I), R 1 and R 2 may each be a phenyl group, a phenyloxy group, an alkyl group, or an alkyloxy group.
A catalyst composition according to the present invention including a nitrogen-containing bidentate phosphorus compound ligand exhibits very high catalytic activity, and at the same time high selectivity to normal-aldehyde or iso-aldehyde according to the type of a substituent in the hydroformylation reaction of an olefin compound.
Hereinafter, the present invention will be described more specifically with reference to the following examples. The following examples are for illustrative purposes and are not intended to limit the scope of the invention.
SYNTHESIS EXAMPLE 1
Synthesis of 2,2′-bis[N-(diphenylphosphino)methylamino]-1,1′-biphenyl (BPNP-1)
1.5 g of 2,2′-bismethylamino-1,1′-bipheny was dissolved in an anhydrous tetrahydrofuran solvent. 6.5 mL of a n-butyl lithium (2.5 M) solution was added to the reactant solution with cooling with ice water and stirred for 30 minutes. Then, 15 mL of an anhydrous tetrahydrofuran solution containing 3.1 mL of chlorodiphenylphosphine was dropwise added to the reactant solution with stirring and the resulting solution was stirred at room temperature overnight. A precipitate was filtered, and a solvent was removed from the remaining solution under a reduced pressure. The resultant precipitate was washed with a small quantity of purified ethanol and dried in a vacuum to give 2.66 g (yield 65%) of the titled compound. The titled compound was dissolved in chloroform-D (CDCl 3 ) to perform the hydrogen and phosphorus nuclear magnetic resonance (NMR) spectrum analysis for the titled compound. The NMR analysis results were as follows: 1 H NMR (CDCl 3 ): δ 2.52 (s, 6H, —CH 3 ), 6.81-7.32 (m, 28H, Ar—H). 31 P NMR (CDCl 3 ): δ 54.39 (s).
SYNTHESIS EXAMPLE 2
Synthesis of 2,2′-bis[N-(dipyrrolylphosphino)methylamino]-1,1′-biphenyl (BPNP-2)
The titled compound was synthesized in the same manner as in Synthesis Example 1 except that chlorodipyrrolylphosphine was used instead of chlorodiphenylphosphine. The titled compound was dissolved in chloroform-D (CDCl 3 ) to perform the hydrogen NMR spectrum analysis for the titled compound. The NMR analysis result was as follows: 1 H NMR (CDCl 3 ): δ 2.58 (bs, 3H, —CH 3 ), 3.04 (bs, 3H, —CH 3 ), 6.24 (t, 2H, -py), 6.45 (t, 6H, -py), 6.82 (m, 2H, -py), 6.89 (m, 6H, -py), 7.32-7.40 (m, 8H, Ar—H).
EXAMPLES 1-4
Hydroformylation reaction of propene using acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ) and 2,2′-bis[N-(diphenylphosphino)methylamino]-1,1′-biphenyl (BPNP-1)
0.100 mg (0.390 mmol) of a Rh(AcAc)(CO) 2 catalyst, 0.2 mL of hexadecane which was an internal standard for GC analysis, and BPNP-1 as bidentate ligand, according to its molar ratio relative to rhodium presented in Table 1 below were dissolved in a toluene solvent until the total volume of the reactant solution reached 100 mL, and charged into a high throughput screen (HTS) unit manufactured by the Autoclave company. A reaction gas of propene, CO, and H 2 (1:1:1, molar ratio) was injected to the reactant solutiont to maintain a pressure at 6 bar, and then the reactant solution was stirred at a temperature of 85° C. for 2.5 hours.
The types of the catalyst and the ligand used, the molar ratio of the ligand to the catalyst, the N/I selectivity, and the catalytic activity are listed in Table 1 below.
In Table 1, the N/I selectivity value is the production ratio of normal-butyraldehyde to iso-butyraldehyde. The production amount of each aldehyde was calculated based on the amount of hexadecane used as the internal standard for the GC analysis.
The catalytic activity was obtained by dividing the total amount of normal-butyraldehyde and iso-butyraldehyde produced by the molecular weight of butyraldehyde, the concentration of the used catalyst, and the reaction time. The unit of the catalytic activity was mol (BAL) /mol (Rh) /h.
TABLE 1
Catalytic
activity
Ligand
L/Rh
(mol (BAL) /
Example
Catalyst
(L)
(mol/mol)
N/I
mol (Rh) /h)
Example 1
Rh(AcAc)(CO) 2
BPNP-1
1
1.8
169.5
Example 2
Rh(AcAc)(CO) 2
BPNP-1
3
23.2
145.6
Example 3
Rh(AcAc)(CO) 2
BPNP-1
5
23.6
139.9
Example 4
Rh(AcAc)(CO) 2
BPNP-1
10
23.0
136.0
EXAMPLES 5-9
Hydroformylation reaction of propene with respect to reaction temperature using acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ) and 2,2′-bis[N-(diphenylphosphino)methylamino]-1,1′-biphenyl (BPNP-1)
Catalytic activity experiments were performed in the same manner as in Example 1 except that the molar ratio of the ligand to rhodium was fixed to 3 and the reaction temperature was changed from 70 to 110° C. while increasing the temperature by 10° C. increments. The results are presented in Table 2 below.
TABLE 2
Ligand
L/Rh
Temp.
Catalytic activity
Example
Catalyst
(L)
(mol/mol)
(° C.)
N/I
(mol (BAL) /mol (Rh) /h)
Example 5
Rh(AcAc)(CO) 2
BPNP-1
3
70
23.1
50.4
Example 6
Rh(AcAc)(CO) 2
BPNP-1
3
80
24.8
102.7
Example 7
Rh(AcAc)(CO) 2
BPNP-1
3
90
27.1
168.4
Example 8
Rh(AcAc)(CO) 2
BPNP-1
3
100
31.1
253.8
Example 9
Rh(AcAc)(CO) 2
BPNP-1
3
110
27.8
275.1
EXAMPLES 10-13
Hydroformylation reaction of propene using acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ) and 2,2′-bis[N-(dipyrrolylphosphino)methylamino]-1,1′-biphenyl (BPNP-2)
Catalytic activity experiments were performed in the same manner as in Examples 1-4 except that BPNP-2 was used instead of BPNP-1, and the results are presented in Table 3 below.
TABLE 3
Catalytic
activity
Ligand
L/Rh
(mol (BAL) /
Example
Catalyst
(L)
(mol/mol)
N/I
mol (Rh) /h)
Example 10
Rh(AcAc)(CO) 2
BPNP-2
1
1.2
188.2
Example 11
Rh(AcAc)(CO) 2
BPNP-2
3
1.5
198.2
Example 12
Rh(AcAc)(CO) 2
BPNP-2
5
2.2
144.6
Example 13
Rh(AcAc)(CO) 2
BPNP-2
10
3.6
62.5
COMPARATIVE EXAMPLE 1
Hydroformylation reaction of propene using acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ) and triphenylphosphine (TPP)
A catalytic activity experiment was performed in the same manner as in Example 1 except that TPP was used as a ligand and the molar ratio of the ligand to rhodium was 100, and the results are presented in Table 4 below.
COMPARATIVE EXAMPLES 2-3
Hydroformylation reaction of propene with respect to temperature using acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 and triphenylphosphine (TPP)
Catalytic activity experiments were performed in the same manner as in Comparative Example 1 except that the reaction temperature was 70° C. (Comparative Example 2) and 100° C. (Comparative Example 3), and the results are presented in Table 4 below.
COMPARATIVE EXAMPLE 4
Hydroformylation reaction of propene using acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ) and ISO-44
A catalytic activity experiment was performed in the same manner as in Comparative Example 1 except that a bisphosphite ligand, 6,6′-[[3,3′-bis(1,1-dimethylehtyl)-5,5′-dimethoxy-[1,1′-biphenyl]-2,2′-diyl]bis(oxy)]bis-di benzo[d,f][1,3,2]dioxaphosphine (ISO-44, Dow) was used instead of TPP, and the molar ratio of the ligand to rhodium was 5, and the results are presented in Table 4.
COMPARATIVE EXAMPLES 5-6
Hydroformylation reaction of propene using acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ) and BISBI
Catalytic activity experiments were performed in the same manner as in Comparative Example 1 except that 2,2′-bis(diphenylphosphinomethyl)-1,1′-biphenyl (BISBI) was used instead of TPP, and the molar ratio of the ligand to rhodium was 3 (Comparative Example 5) and 10 (Comparative Example 6), and the results are presented in Table 4 below.
COMPARATIVE EXAMPLE 7
Hydroformylation reaction of propene using acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ) and 2,2′-bis[N-(diphenylphosphino)amino]-1,1′-biphenyl (BPNP-0)
A catalytic activity experiment was performed in the same manner as in Comparative Example 1 except that BPNP-0 was used instead of TPP, and the molar ratio of the ligand to rhodium was 1, and the results are presented in Table 4 below.
TABLE 4
Ligand
L/Rh
Temp.
Catalytic activity
Section
Catalyst
(L)
(mol/mol)
(° C.)
N/I
(mol (BAL) /mol (Rh) /h)
Comparative Example 1
Rh(AcAc)(CO) 2
TPP
100
85
3.9
85.4
Comparative Example 2
Rh(AcAc)(CO) 2
TPP
100
70
3.6
26.4
Comparative Example 3
Rh(AcAc)(CO) 2
TPP
100
100
8.0
177.2
Comparative Example 4
Rh(AcAc)(CO) 2
ISO-44
3
85
9.5
219.3
Comparative Example 5
Rh(AcAc)(CO) 2
BISBI
3
85
20.7
88.8
Comparative Example 6
Rh(AcAc)(CO) 2
BISBI
10
85
21.0
79.9
Comparative Example 7
Rh(AcAc)(CO) 2
BPNP-0
1
85
1.1
21.9
As shown in Table 4, in Comparative Example 1, in which hydroformylation reaction of propene was performed using a monodentate phosphorous compound, TPP, catalytic activity was 85.4 mol (BAL) /mol (Rh) /h, and N/I selectivity was 3.9. In Comparative Examples 2-3, in which hydroformylation reaction of propene was performed using the same catalyst system as in Comparative Example 1 at a temperature of 70° C. and 100° C., respectively, the catalytic activity (177.2 mol (BAL) /mol (Rh) /h) of Comparative Example 3 was remarkably greater than that (26.4 mol (BAL) /mol (Rh) /h) of Comparative Example 2. N/I selectivity was also remarkably increased with increasing reaction temperature (3.6 and 8.0).
Among currently available ligands, ISO-44 is known to be the most excellent for catalytic activity and N/I selectivity. It is also known that ISO-44 has been still applied in some processes under the trade name MARK-IV. In Comparative Example 4, in which hydroformylation reaction of propene was performed using a catalyst modified with ISO-44, catalytic activity was 219.3 mol (BAL) /mol (Rh) /h, and N/I selectivity was 9.5.
In Comparative Examples 5-6, in which hydroformylation reaction of propene was performed using BISBI, a very high N/I selectivity of 20 or more was observed, but catalytic activity was relatively low. In particular, as the molar ratio of the ligand to rhodium increased, the catalytic activity was gradually reduced.
In addition, in Comparative Example 7 using as a ligand 2,2′-bis[N-(diphenylphosphino)amino]-1,1′-biphenyl (BPNP-0), i.e., a compound in which a methyl group attached to a nitrogen of BPNP-1 was substituted by hydrogen, catalytic activity was very low. Furthermore, in experiments performed in the same manner as in Comparative Example 7 except that the molar ratio of the ligand to rhodium was 3 or more, no aldehydes were observed due to very low catalytic activity.
In Examples 2-4, in which 2,2′-bis[N-(diphenylphosphino)methylamino]-1,1′-biphenyl (BPNP-1) according to the present invention was used as a ligand, and the molar ratio of BPNP-1 to rhodium was 3 or more, the average catalytic activity was 165% higher than when Rh/TPP was used. N/I selectivity was about 23, which was 5.9 times higher selectivity to normal-aldehyde than when Rh/TPP was used. From these results, it can be seen that even the use of a small quantity of BPNP-1 ensures very high catalytic activity and high N/I selectivity. Even when the molar ratio of the ligand to rhodium was increased from 3 to 10, no reduction in catalytic activity was observed. This is in contrast to the Eastman Kodak report in which catalytic activity rapidly reduced as the amount of BISBI increased under the same conditions (U.S. Pat. No. 4,694,109).
In comparison between Comparative Example 4 using ISO-44 and Example 3 using BPNP-1 under the same conditions, the catalytic activity of Comparative Example 4 was about 30% higher than that of Example 3. However, the N/I selectivity of Comparative Example 4 was 9.5, whereas the N/I selectivity of Example 3 was 23.6 which was 2.5 times that of Comparative Example 4. That is, it can be seen that even though the catalytic activity of BPNP-1 is slightly lower than that of ISO-44, BPNP-1 exhibits very high selectivity to normal-aldehyde.
In Examples 5-9, in which hydroformylation reaction of propene was performed at a 3:1 molar ratio of BPNP-1 to rhodium and at different temperatures from 70 to 110° C., as the reaction temperature increased, catalytic activity almost linearly increased and N/I selectivity also slightly increased, i.e., from 23 to 31. Such an increase in catalytic activity with increasing reaction temperature was also observed in Comparative Examples 2-3. However, Rh/PBNP-1 exhibited better catalytic activity than Rh/TPP at the same temperature condition. In addition, no change in color of the reactant solution was observed at low reaction temperatures and high reaction temperatures in Examples 5-9. This shows that a BPNP-1-modified catalyst is very stable under the above conditions.
Table 3 shows the catalytic activity and N/I selectivity of Examples 10-13 using as a ligand 2,2′-bis[N-(dipyrrolylphosphino)methylamino]-1,1′-biphenyl (BPNP-2) in which phenyl groups of R 1 and R 2 of BPNP-1 were substituted by pyrroles. In Examples 10-11, in which a molar ratio of BPNP-2 to rhodium was relatively low, catalytic activity was higher than Examples 1-7 in which BPNP-1 was used. However, in Examples 12-13, as the molar ratio of BPNP-2 to rhodium increased, catalytic activity gradually reduced. This phenomenon was also observed in Comparative Examples 5-6 using BISBI. However, when BPNP-1 was used, the N/I selectivity value was about 23 due to very high selectivity to normal-aldehyde. When BPNP-2 was used, the N/I selectivity value was 3.6 or less due to high selectivity to iso-aldehyde.
From the above results, it can be seen that an acetylacetonatodicarbonylrhodium (Rh(AcAc)(CO) 2 ) catalyst modified with a bidentate ligand, 2,2′-bis[N-(diphenylphosphino)methylamino]-1,1′-bipehnyl (BPNP-1), exhibits high catalytic activity of 65% or more and high selectivity to normal-aldehyde compared to commercially widely available Rh/TPP. Furthermore, catalytic activity and N/I selectivity are stably retained even at a high reaction temperature. In addition, a catalyst modified with 2,2′-bis[N-(dipyrrolylphosphino)methylamino]-1,1′-biphenyl (BPNP-2) in which phenyl groups of R 1 and R 2 of BPNP-1 are substituted by pyrrole groups exhibits very high catalytic activity and high selectivity to iso-aldehyde. | Provided are a catalyst composition including a transition metal catalyst and a nitrogen-containing bidentate phosphorus compound and a process for hydroformylation reaction of olefins to prepare aldehydes which includes stirring the catalyst composition, an olefin compound, and a gas mixture of of carbon monoxide and hydrogen, under high temperature and pressure condition. Therefore, very high catalytic activity and high selectivity in normal-aldehyde or iso-aldehyde according to the type of a substiuent are ensured. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to Korean Patent Application No. 10-2011-0056497 filed in the Korean Intellectual Property Office on Jun. 10, 2011, the entire contents of which is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a disk rotor assembly for a vehicle. More particularly, the present invention relates to a disk rotor assembly for a vehicle that prevents heat crack of a disk rotor by braking heat.
[0004] 2. Description of Related Art
[0005] Generally, a braking apparatus of a vehicle converts kinetic energy into heat energy by friction so as to lower the vehicle's speed. The braking device is classified into a drum brake and a disk brake according to a shape of a rotating member rotating with a wheel and braking method.
[0006] Meanwhile, the disk brake includes an adaptor, a disk rotor, and a brake pad. The adaptor is mounted on a hub and receives torque of a wheel. The disk rotor rotates together with the adaptor and is made from cast iron. The disk brake brakes the vehicle by applying pressure to both side surfaces of the disk rotor by the brake pad.
[0007] Compared with the drum brake, the disk brake should generate a sufficient braking force by friction of a smaller area. Therefore, materials that can bear high load and high temperature are used for constituent elements of the disk brake.
[0008] However, a temperature of the disk rotor is raised higher than 400° C. by friction between the brake pad and the disk rotor, and heat deformation of the disk rotor may occur in this case.
[0009] Since a conventional disk brake where the adaptor and the disk rotor are integrally formed is thermally deformed in a state that the disk rotor is restricted by the adaptor, heat crack may occur at the disk rotor.
[0010] The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY
[0011] Various aspects of the present invention are directed to provide a disk rotor assembly for a vehicle having advantages of preventing heat crack by heat deformation of a disk rotor as a consequence of separating a disk rotor from a adaptor.
[0012] In addition, various aspects of the present invention are directed to provide a disk rotor assembly for a vehicle having further advantages of increasing marketability by improving durability of an adaptor and a disk rotor.
[0013] In an aspect of the present invention, a disk rotor assembly for a vehicle may include an adaptor adapted to be mounted on a hub and to receive torque of a wheel, a disk rotor generating a braking force, a transmitter engaging the adaptor with the disk rotor and adapted to transmit the torque received by the adaptor to the disk rotor or to transmit the braking force generated by the disk rotor to the adaptor, and engaging member for engaging the adaptor, the disk rotor, and the transmitter altogether.
[0014] The adaptor has a plurality of transmitter mounting surfaces contacting with a side surface of the transmitter, and a plurality of rotor contacting surfaces contacting with the disk rotor, and wherein the disk rotor has a plurality of transmitter mounting grooves at which the transmitter mounting surfaces of the adaptor are disposed therein to mount the transmitter, and a plurality of adaptor contacting surfaces contacting with the rotor contacting surfaces of the adaptor.
[0015] The transmitter penetrates the transmitter mounting groove and the side surface of the transmitter is engaged with the transmitter mounting surface, wherein a penetration hole through which the engaging member penetrates is formed at the transmitter, and an engaging hole for engaging with the engaging member is formed at the transmitter mounting surface.
[0016] The plurality of transmitter mounting surfaces is formed at an exterior circumference of the adaptor along a circumferential direction, and the rotor contacting surface is formed between the neighboring transmitter mounting surfaces.
[0017] The transmitter mounting surface may have a concave shape in an axial direction and open in the axial direction and a radial direction of the adaptor, wherein an exterior circumference of the transmitter mounting surface is shorter than an interior circumference thereof.
[0018] The transmitter mounting groove and the adaptor contacting surface are formed at an interior circumference of the disk rotor, wherein the plurality of transmitter mounting grooves is formed at the interior circumference of the disk rotor along a circumferential direction, and the adaptor contacting surface is formed between the neighboring transmitter mounting grooves.
[0019] The rotor contacting surface and the adaptor contacting surface contact with each other in a case that the adaptor and the disk rotor are engaged.
[0020] A bracket is formed at the transmitter so as to engage the adaptor with the adaptor contacting surface of the disk rotor and to prevent disengagement of the disk rotor.
[0021] The adaptor and the transmitter are directly engaged with each other by the engaging member, and the disk rotor is engaged to the adaptor by engagement of the adaptor and the transmitter, wherein a bracket is formed at the transmitter so as to engage the adaptor with the disk rotor and to prevent disengagement of the disk rotor.
[0022] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an exploded view of a disk rotor assembly for a vehicle according to an exemplary embodiment of the present invention.
[0024] FIG. 2 is a perspective view of a disk rotor assembly for a vehicle according to an exemplary embodiment of the present invention.
[0025] FIG. 3 is a perspective view of an adaptor according to an exemplary embodiment of the present invention.
[0026] FIG. 4 is a perspective view of a disk rotor according to an exemplary embodiment of the present invention.
[0027] FIG. 5 is a perspective view of a transmitter according to an exemplary embodiment of the present invention.
[0028] FIG. 6 is a cross-sectional view taken along the line A-A in FIG. 2 .
[0029] FIG. 7 is a cross-sectional view taken along the line B-B in FIG. 2 .
[0030] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
[0031] In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION
[0032] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that the present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0033] An exemplary embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings.
[0034] FIG. 1 is an exploded view of a disk rotor assembly for a vehicle according to an exemplary embodiment of the present invention.
[0035] As shown in FIG. 1 , a disk rotor assembly 10 for a vehicle according to an exemplary embodiment of the present invention includes an adaptor 20 , a disk rotor 30 , a transmitter 40 , and engaging member 50 .
[0036] The adaptor 20 is mounted on a hub of a wheel, transmits torque of the wheel to the disk rotor 30 , and transmits braking force of a disk brake from the disk rotor 30 to the wheel.
[0037] The disk rotor 30 rubs with a brake pad of the disk brake and brakes a vehicle. The disk rotor 30 has a disk shape. If the brake pad applies pressure to both side surfaces of the disk rotor 30 , kinetic energy of the vehicle is converted into heat energy by friction between the brake pad and the disk rotor 30 . Therefore, the kinetic energy of the vehicle is reduced and braking of the vehicle is performed. Herein, frictional force between the brake pad and the disk rotor 30 is braking force of the disk brake.
[0038] The transmitter 40 facilitates and assists assembling of the disk rotor assembly 10 according to an exemplary embodiment of the present invention.
[0039] The transmitter 40 connects the adaptor 20 with the disk rotor 30 . In addition, the transmitter 40 delivers torque of the adaptor 20 to the disk rotor 30 or delivers braking force of the disk rotor 30 to the adaptor 20 .
[0040] The engaging member 50 engages the adaptor 20 , the transmitter 40 , and the disk rotor 30 . Herein, the adaptor 20 and the transmitter 40 are directly engaged by the engaging member 50 , and the disk rotor 30 is indirectly engaged with the adapter through engagement of the adaptor 20 and the transmitter 40 . Thereby, the disk rotor assembly 10 is assembled.
[0041] FIG. 2 is a perspective view of a disk rotor assembly for a vehicle according to an exemplary embodiment of the present invention.
[0042] As shown in FIG. 2 , the disk rotor assembly 10 for a vehicle according to an exemplary embodiment of the present invention is assembled by engaging the adaptor 20 , the disk rotor 30 , and the transmitter 40 through the engaging member 50 .
[0043] Hereinafter, constituent elements of the disk rotor assembly 10 according to an exemplary embodiment of the present invention will be described in detail with reference to FIG. 3 to FIG. 5 .
[0044] FIG. 3 is a perspective view of an adaptor according to an exemplary embodiment of the present invention.
[0045] As shown in FIG. 3 , a transmitter mounting surface 22 , a rotor contacting surface 24 , and an engaging hole 26 are formed at the adaptor 20 .
[0046] The adaptor 20 has a hollow cylindrical shape. One circular side surface between two circular side surfaces of the adaptor 20 is connected to the disk rotor 30 . In addition, the transmitter mounting surface 22 , the rotor contacting surface 24 , and the engaging hole 26 are formed at the circular side surface of the adaptor 20 connected to the disk rotor 30 .
[0047] A plurality of rotor contacting surfaces 24 is formed radially at the circular side surface of the adaptor 20 connected to the disk rotor 30 along an external circumference thereof. The rotor contacting surface 24 is open to a radial outward direction.
[0048] A plurality of transmitter mounting surfaces 22 is formed radially at the circular side surface of the adaptor 20 connected to the disk rotor 30 along the external circumference thereof In addition, a plurality of transmitter mounting surfaces 22 are formed between the neighboring rotor contacting surfaces 24 . That is, the transmitter mounting surface 22 and the rotor contacting surface 24 are alternately arranged along the external circumference of the circular side surface of the adaptor 20 . In addition, the transmitter mounting surface 22 has a concave shape from the circular side surface of the adaptor 20 in an axial direction. The transmitter mounting surface 22 is open in the axial direction and the radial direction. An exterior circumference of the transmitter mounting surface 22 is shorter than an interior circumference thereof The transmitter mounting surface 22 contacts with a side surface of the transmitter.
[0049] The engaging hole 26 is formed at the transmitter mounting surface 22 . At least one of engaging holes 26 is formed at one transmitter mounting surface 22 . If the engaging member 50 is a bolt, a screw thread is formed at an interior circumference of the engaging hole 26 .
[0050] Since the adaptor 20 is hollow, the adapter 20 can be mounted on a hub of the wheel. Engagement of the adaptor 20 and the wheel is well known to a person skilled in the art, and thus detailed description thereof will be omitted.
[0051] FIG. 4 is a perspective view of a disk rotor according to an exemplary embodiment of the present invention.
[0052] As shown in FIG. 4 , a transmitter mounting groove 32 and an adaptor contacting surface 34 are formed at the disk rotor 30 .
[0053] The disk rotor 30 has a hollow disk shape. Therefore, the disk rotor 30 includes an exterior circumference and an interior circumference. In addition, the transmitter mounting groove 32 and the adaptor contacting surface 34 are formed at an interior circumference of the disk rotor 30 .
[0054] A plurality of transmitter mounting grooves 32 are formed at the interior circumference of the disk rotor 30 . The transmitter mounting groove 32 corresponds to the transmitter mounting surface 22 of the adaptor 20 . In addition, the transmitter mounting groove 32 is open in the axial direction such that the transmitter 40 penetrates through the transmitter mounting groove 32 and contacts with the transmitter mounting surface 22 .
[0055] A plurality of adaptor contacting surfaces 34 is formed at the interior circumference of the disk rotor 30 . The adaptor contacting surface 34 is protruded radially inwardly from the interior circumference of the disk rotor 30 . In addition, the adaptor contacting surface 34 is formed between the neighboring transmitter mounting grooves 32 . That is, the adaptor contacting surface 34 and the transmitter mounting groove 32 are alternately formed. Further, the adaptor contacting surface 34 corresponds to the rotor contacting surface 24 .
[0056] FIG. 5 is a perspective view of a transmitter according to an exemplary embodiment of the present invention.
[0057] As shown in FIG. 5 , the transmitter 40 includes a bracket 42 , a penetration hole 44 , and a column 46 . The transmitter 40 is engaged with the adaptor 20 by the engaging member 50 , and restricts a movement of the disk rotor 30 so as to form the disk rotor assembly 10 .
[0058] As shown in FIG. 5 , a cross-sectional shape of the column 46 is trapezoid, but is not limited to this. The cross-sectional shape of the column 46 corresponds to shapes of the transmitter mounting surface 22 and the transmitter mounting groove 32 . The column 46 extends from a side surface of the bracket 42 to the axial direction. Therefore, a side surface of the transmitter 40 penetrates through the transmitter mounting groove 32 and contacts with the transmitter mounting surface 22 , and the bracket 42 is formed at the other side surface of the transmitter 40 .
[0059] The bracket 42 contacts with the other side surface of the disk rotor 30 so as to apply pressure to the disk rotor 30 toward the adaptor 20 . Therefore, the disk rotor 30 and the adaptor 20 are engaged with each other by the transmitter 40 . In addition, the bracket 42 prevents the disk rotor 30 from being disengaged from the adaptor 20 .
[0060] The penetration hole 44 is formed axially at the transmitter 40 . If the engaging member 50 is a bolt, a screw thread is formed at an interior circumference of the penetration hole 44 such that the bolt is engaged thereto.
[0061] The engaging member 50 penetrates through the penetration hole 44 formed at the transmitter 40 and engages to the engaging hole 26 formed at the adaptor 20 so as to engage the adaptor 20 with the transmitter 40 . At this time, the column 46 of the transmitter 40 is mounted at the transmitter mounting groove 32 . Therefore, the adaptor 20 , disk rotor 30 , and the transmitter 40 are engaged by the engaging member 50 so as to form the disk rotor assembly 10 .
[0062] Referring to FIG. 6 to FIG. 7 , an engaging state of the disk rotor assembly for a vehicle according to an exemplary embodiment of the present invention will be described in detail.
[0063] FIG. 6 is a cross-sectional view taken along the line A-A in FIG. 2 .
[0064] In a state that the disk rotor assembly 10 is engaged as shown in FIG. 6 , the transmitter 40 is mounted at the transmitter mounting groove 32 of the disk rotor 30 . In addition, the side surface of the transmitter 40 contacts with the transmitter mounting surface 22 of the adaptor 20 , and the bracket 42 contacts with the other side surface of the disk rotor 30 so as to apply the pressure to the disk rotor 30 toward the adaptor 20 .
[0065] At this time, the engaging member 50 is engaged simultaneously to the engaging hole 26 and the penetration hole 44 . Therefore, the adaptor 20 and the disk rotor 30 are engaged by the transmitter 40 and the engaging member 50 .
[0066] FIG. 7 is a cross-sectional view taken along the line B-B in FIG. 2 .
[0067] In a state that the disk rotor assembly 10 is engaged as shown in FIG. 7 , the rotor contacting surface 24 of the adaptor 20 contacts with the adaptor contacting surface 34 of the disk rotor 30 . If the bracket 42 contacts with the other side surface of the disk rotor 30 and applies the pressure to the disk rotor 30 toward the adaptor 20 , the rotor contacting surface 24 supports the adaptor contacting surface 34 and the disk rotor 30 is fixed to the adaptor 20 .
[0068] In addition, since an entire contour of the rotor contacting surface 24 supports the adaptor contacting surface 34 , a contact area between the rotor contacting surface 24 and the adaptor contacting surface 34 becomes large. Therefore, the adaptor 20 and the disk rotor 30 can be engaged with each other even though large load is not applied to the engaging member 50 and the transmitter 40 .
[0069] Since the adaptor 20 and the disk rotor 30 are manufactured independently and are assembled by the transmitter 40 and the engaging member 50 instead of being integrally formed, the disk rotor 30 is not completely restricted by the adaptor 20 according to an exemplary embodiment of the present invention. Therefore, when heat deformation occurs at the disk rotor 30 , the heat deformation may be absorbed by the disk rotor 30 . Therefore, heat crack of the disk rotor 30 may be prevented and durability of the adaptor 20 and the disk rotor 30 may be improved.
[0070] For convenience in explanation and accurate definition in the appended claims, the terms “upper”, “lower”, “inner” and “outer” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0071] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise fauns disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A disk rotor assembly for a vehicle may include an adaptor adapted to be mounted on a hub and to receive torque of a wheel, a disk rotor generating a braking force, a transmitter engaging the adaptor with the disk rotor and adapted to transmit the torque received by the adaptor to the disk rotor or to transmit the braking force generated by the disk rotor to the adaptor, and engaging member for engaging the adaptor, the disk rotor, and the transmitter altogether. | 5 |
BACKGROUND OF THE INVENTION
Local anesthetics are pharmaceutical materials useful in the relief of many discomforts such as teething, sunburn, pruritus, various dental and surgical procedures, for temporary relief of minor burns, cuts, scratches, nonpoisonous insect bites, poison ivy and other minor skin irritations. They may also be used for postpartum care. In brief, local anesthetics may be employed for diminishing the pain in a restricted area as distinguished from general anesthetics used for eliminating the perception of all stimuli. Many of the known local anesthetics are derivatives of p-aminobenzoic acid; for example, procaine, tetracaine and butacaine. Lidocaine is another type of local anesthetic in wide use.
There is constant interest in developing compounds showing improvement in the therapeutic index over conventional anesthetics such as the above and others. In particular, there is a striving to discover local anesthetics which have a relatively short onset and longer duration of action than those presently employed.
SUMMARY OF THE INVENTION
In summary, we have discovered novel aminotetralin compounds which find particular utility as local anesthetics.
These compounds are selected from the group consisting of a member of the formula: ##STR2## where R 1 is a radical selected from the group consisting of higher branched or straight chain alkyl and cycloalkyl radicals wherein said R 1 radical contains at least six carbon atoms, R 2 is a radical selected from the group consisting of hydrogen, loweralkyl and loweralkanol radicals, wherein said R 2 radical contains 1-3 carbon atoms, and R 3 is methoxy; and nontoxic pharmaceutically acceptable acid addition salts thereof.
DETAILED DESCRIPTION OF THE INVENTION
In order to prepare the compounds of the invention, it is preferred to begin with various methoxy tetralines such as 6-methoxy-1-tetralone, and 5-methoxy-1-tetralone. These are well known materials whose preparation needs little elaboration.
In order to prepare the compounds here essentially two general methods were followed. In Method I the methoxy tetralones were reacted with long chain alkyl or cycloalkyl amines to produce the substituted ketamines which in turn were hydrogenated to the final amine products.
In Method II the methoxy tetralones were reacted with hydroxyl amine to form the corresponding oximes. The oximes were reacted with hydrogen to form the primary amino compound, which compound in turn was reacted with a long chain alkyl or cycloalkyl aldehyde to form a Schiff base. The Schiff base thus formed was then reduced to form the secondary amine compound containing the long chain alkyl or cycloalkyl radical.
The following examples illustrate preparation of typical compounds of the invention. It is understood, of course, that these examples are merely illustrative, and that the invention is not to be limited thereto.
EXAMPLE I
Here 0.1 mole (17.6 g.) of 5-hydroxy-1-tetralone was reacted with 0.1 mole (11 g.) of N-hexylamine in the presence of 200 ml. benzene solvent. Para-toluene sulfonic acid was employed as a catalyst. The benzene solution was refluxed for about 72 hours until the theoretical amount of 1.8 ml. of water was collected in a water separator. The benzene was then stripped to produce the corresponding N-hexyl ketamine compound.
0.1 Mole of the ketamine in 200 ml. ethanol was then hydrogenated with Raney nickel catalyst (6 g.). After no additional uptake of hydrogen was noted the reaction was stopped. The reaction mixture was filtered, the solvent removed and the product was distilled.
The product has a boiling point of 161° C./1.3 mm. and an index of refraction N D 25 1.5203. The product having a structure as follows: ##STR3## analyzed as follows:
______________________________________Element Theory Found______________________________________C 78.11 78.51H 10.41 10.75N 5.36 4.99______________________________________
EXAMPLE II
Here the procedure of Example I was followed with the exception that N-heptyl amine was employed as a reactant in place of the N-hexyl amine of Example I.
Specifically, 0.1 mole (17.6 g.) of 5-methoxy-1-tetralone was reacted with 0.1 mole (12 g.) of N-heptyl amine in presence of benzene solvent and para-toluene sulfonic acid catalyst. After the theoretical amount of water was split out by azeotropic distillation the corresponding N-heptyl compound was obtained.
The ketamine was then again hydrogenated in presence of Raney nickel catalyst and the reaction was run until hydrogen uptake ceased. The crude product was filtered, washed, solvent stripped and then distilled. The product which had a structure of ##STR4## had a boiling point of 171°-74° C./1.2-1.4 mm. and a refractive index of N D 25 1.5182. The product analysis was as follows:
______________________________________Element Theory Found______________________________________C 78.49 78.23H 10.61 10.93N 5.06 4.71______________________________________
Other products may be formed in the same manner as illustrated in the above examples. Table I shows typical additional products falling within the scope of the invention.
Table I______________________________________ ##STR5##______________________________________R.sub.1 R.sub.2 R.sub.3______________________________________(CH.sub.2).sub.7 CH.sub.3 H 6-OCH.sub.3(CH.sub.2).sub.8 CH.sub.3 H 6-OCH.sub.3 ##STR6## H 6-OCH.sub.3(CH.sub.2).sub.6 CH.sub.3 H 5-OCH.sub.3(CH.sub.2).sub.6 CH.sub.3 CH.sub.3 6-OCH.sub.3(CH.sub.2).sub.6 CH.sub.3 CH.sub.2 CH.sub.2 OH 6-OCH.sub.3 ##STR7## H 6-OCH.sub.3______________________________________
the N-substituted aminotetralins can be prepared in the form of their halide salts, for example, as shown above. The free base form of the compounds can then be prepared by reacting the salt with an alkaline reagent, for example, sodium carbonate, sodium hydroxide, aqueous ammonia and other such alkaline reagents commonly employed for converting salts to free bases. The free base can be converted, in turn, to the salt form of the compound by reaction with a pharmaceutically acceptable acid, for example, sulfuric, phosphoric, nitric, hydrochloric, hydriodic, hydrobromic, acetic, tartaric, lactic, malic, fumaric, succinic, ascorbic, pyruvic and the like inorganic and organic acids known to be pharmaceutically acceptable.
The substituted aminotetralins of the present invention can be used as local anesthetic agents in the free base form or in the form of pharmaceutically acceptable acid salts of the free bases. For convenience in administration in aqueous solution, it is preferable to use the salt form of the compounds. The free base form is preferable when it is desired to use the compounds in oleaginous pharmaceutical diluents. The compounds of the present invention can be conveniently administered topically or subcutaneously in the form of ointments, salves, aerosol sprays, solutions and the like. The effective amount of anesthetic agent to be administered will, of course, depend upon many factors such as, for example, the size of the local area to be anesthetized, the length of time anesthesia is desired, the nature of the treatment requiring local anesthesia, the physical condition of the subject undergoing treatment and other such factors. It will be understood that the method of the present invention includes any and all such variations in administering effective amounts of the local anesthetic agents of the present invention as would be apparent to those skilled in the art after reading this specification and is not limited to the illustrative embodiments of the invention specifically described herein.
When administered in the form of solution in a pharmaceutical carrier and used as local anesthetics in therapy, the compounds may be present in widely varying concentrations. Typical solutions may contain from 0.02% up to as high as about 10% by weight. The same type of concentrations may be used in suspension, jelly, ointment or base form.
When solutions of the local anesthetics are made, they may be made isotonic by the addition of i.e. sodium chloride. Further, as is known in the art of local anesthesia, the anesthesia effectiveness may be improved by addition of a vasoconstrictor, such as adrenalin, noradrenalin or octapressin.
If necessary repeated applications of the compounds here at therapeutically effective intervals may be made to obtain a prolonged anesthetic effect.
Typical ointment formulations which may be prepared are the following:
FORMULA A
Using the hydrochloride of the topical anesthetic agent of Example II:
For the preparation of 500 g. of ointment to be used as a topical anesthetic agent, containing 5.0% of the active ingredient: Stir, with heating to 70° C. (mixture A)--
______________________________________ G.______________________________________Stearic acid 100Glycerol monostearate 20Sorbitan monopalmitate 20Beeswax 10Methyl p-hydroxybenzoate 0.25Propyl p-hydroxybenzoate 0.15Stir, with heating to 70° C. (mixture B)--Example II Compound 25.0Sorbitol 70% 28.5Polyoxyethylene sorbitan monopalmitate 10.0Water 286.1______________________________________
Add mixture B to mixture A at 70° C. Stir and cool to room temperature. It is then packaged cold into tubes or jars.
FORMULA B
Using the free base of the topical anesthetic agent of Example II:
For the preparation of 500 g. of ointment to be used as a topical anesthetic agent, containing 5.0% of the active ingredient: Stir, with heating to 70° C. (mixture C)--
______________________________________ G.______________________________________Stearic acid 100Glycerol monostearate 20Sorbitan monopalmitate 20Beeswax 10Methyl p-hydroxybenzoate 0.25Propyl p-hydroxybenzoate 0.15Example II Compound 25.0Stir, with heating to 70° C. (mixture D)--Water 286.10Sobitol 70% 28.5Polyoxyethylene sorbitan monopalmitate 10.0______________________________________
Add mixture D to mixture C at 70° C. Stir and cool to room temperature. It is then packaged cold into tubes or jars.
In order to test the efficacy of the compounds of the invention, the compound of Example II in the form of the methanesulfonic acid salt was tested for its local anesthetic effect.
Specifically 1.3 g. of the salt was prepared in 113 ml. of water and buffered with NaH 2 PO 4 and Na 2 HPO 4 to a pH of 6.2-6.4. The concentration of the active ingredient was approximately 1%.
A group of six male albino rabbits weighing between 2.4 and 3.6 kg. was used to determine the activity of the above pharmaceutical composition as a local anesthetic. 0.1 cc of the sample was instilled into the right eye of each of the animals. The contralateral eye was instilled with an equal volume of 1% lidocaine HCl. The corneal reflexes were then tested at 5 minute intervals with a stiff hair. Results were as follows:
Table II__________________________________________________________________________Corneal Response Control 0 5 10 15 20 25 30-55 60 minutes__________________________________________________________________________Lidocaine HCl + + + - - + + + + + + - - + + + + + + + - - - + + + + + + ± - - + + + + + + + - - + + + + + + - - - + + + +Example IICompound + ± ± - - - - - + + + - - - - - - + + ± - - - - - - + + ± - - - - - - + + ± - - - - - - - + + ± - - - - - - +__________________________________________________________________________ + = No anesthesia - = Anesthesia ± = Questionable response
From the above it can be seen that the compound of the instant invention as described in Example II appears to have a shorter onset and a longer duration than the lidocaine HCl compound used as a standard.
Various minor additives can be employed in combination with the N-substituted aminotetralines of the present invention such as, for example, stabilizers, preservatives and the like substances for their desired effects. Thus, preservative agents such as benzyl alcohol and the parabens, for example, methyl p-hydroxybenzoate, which are useful for their preservative effects in prolonging the shelf life of the local anesthetics of this invention can be employed with said anesthetics during their administration.
Numerous adaptations and modifications of the foregoing examples and various other examples will be apparent to the person skilled in the art after reading the foregoing specification and the appended claims without departing from the spirit and scope of the invention. All such further examples, adaptations and modifications are included within the scope of this invention. | Covers a compound selected from the group consisting of a member of the formula: ##STR1## where R 1 is a radical selected from the group consisting of higher branched or straight chain alkyl and cycloalkyl radicals wherein said R 1 radical contains at least six carbon atoms, R 2 is a radical selected from the group consisting of hydrogen, loweralkyl and loweralkanol radicals, wherein said R 2 radical contains 1-3 carbon atoms, and R 3 is methoxy; and nontoxic pharmaceutically acceptable acid addition salts thereof. Also covers the use of said compound as a local anesthetic and pharmaceutical compositions comprising said above compounds as the active ingredient. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of orthopedic surgery and, particularly, to bone and joint prosthesis.
[0003] 2. Description of the Prior Art
[0004] The prior art is replete with artificial bone and joint devices for surgical implantation to structurally compensate for diseased, damaged or missing natural skeletal anatomical elements. Such prosthesis include bone pins, articulating joints, both total and partial, for the knee and hip, as well as, fingers, toes, elbows, shoulders and vertebra. In total replacement both bearing surfaces of an articulating joint are artificial, eg., the femur head and the acetabulum within which the ball rotates.
[0005] These prosthesis are made from a variety of biologically inert materials having the requisite strength and longevity to provide the recipient with approximately normal activity and life style. Another important consideration in selecting materials and design is to reduce or eliminate repeated surgeries during the recipient's life. For many years, the standard material has been stainless steel and other metal alloys, such as cobalt-chromium-molybdenum, for such prosthesis. For example, U.S. Pat. No. 5,263,988 to Huebner discloses a hip prosthesis made from the cobalt alloy.
[0006] Another steel is known as nitrogen alloyed class III super 12 chromium stainless steel, called Cronidur 30, as disclosed in German application, DE 19729450 C2, published Dec. 9, 1999, and produced in Germany by Vereinigte Schmiedewerke GmbH. This material is used as a hard bearing surface in space shuttle engine turbopumps. As a component of space shuttle main engines, this steel has undergone intense testing and review. Some of the operational requirements include reliability in sustaining high hertzian contact stresses at high speeds in liquid oxygen or hydrogen under marginal lubrication conditions. Between missions the steel must resist stress corrosion cracking at ambient conditions with periods of high humidity. These requirements necessitate a steel with high hardness (58 Rc), fracture toughness, corrosion resistance, and liquid oxygen comparability. The prior art benchmark has been AISI 440C martensitic stainless steel however this steel has a limited fracture toughness and modest stress corrosion resistance. Cronidur 30 was developed to overcome these weaknesses and is a martensitic stainless steel based on nitrogen alloying to a chromium stainless steel. The steel exhibits superior corrosion resistance with a surface hardness of 58-60 Rc and core fracture toughness in excess of 50 ksi/in. The microstructure consists of a fine dispersion of refractory metal carbides in a martensitic matrix that affords the alloy a good balance of strength and toughness. In contrast, AISI 440C comprises of coarse primary carbide stringers in a martensitic matrix. These same properties that make the Cronidur 30 desirable in the space program also make the steel preferable in the surgical implant field.
[0007] More recently, non-metals such as polymers and ceramics, have been gaining acceptance in the field. Some flexible hinge joints use silastic material or a hard bearing surface laminated to a ultrahigh molecular weight polyethylene. U.S. Pat. No. 6,524,342 to Muhlhauser discloses a shoulder joint that has components of metal and others of ceramic materials. Pope et al, U.S. Pat. No. 6,517,583, disclose hip joints and knee joints with hardened bearing surfaces which include ceramic material or diamond material.
[0008] There are certain areas of concern when using the prior art components for prosthesis. Osteolysis from particulate debris in the artificial joint can cause complications for the recipient of the prosthesis. Inflammation may result from the generation of large amounts of small wear particles and in acute cases the implant may fail due to lack of stability in the bone/prosthesis connection or undue wear in the bearing surface. The metal to metal prosthesis also generate particles within the joint, though to a lesser degree. In spinal arthroplasty, wear particles may cause a severe inflammatory response, with resultant nerve root adhesions.
[0009] Silicon nitride forms the basis for ceramic products of general utility, as taught by Ikeda et al, U.S. Pat. No. 5,635,431, Goto et al, U.S. Pat. No. 4,886,767, and Fukuhara et al, U.S. Pat. No. 4,609,633. This sintered material is extremely hard and highly resistant to abrasion. As disclosed by Goto et al, the material may be cast or molded. A preferred silicon nitride is disclosed in U.S. Pat. No. 4,986,972, U.S. Pat. No. 4,911,870, and U.S. Pat. No. 4,902,653 which has the desired characteristics of hardness, toughness, and resistance to abrasion.
[0010] What is needed in the art is a prosthesis with reduced friction and wear on the bearing surfaces and reduced incidence of osteolysis.
SUMMARY OF THE INVENTION
[0011] A prosthesis for total or partial replacement of an articulating skeletal joint having two opposed bearing surfaces. The opposed bearing surfaces are made of a ceramic and a metal, respectively. The ceramic material is a silicon nitride or carbide and the metal may be a nitrogen alloyed chromium stainless steel, know as Cronidur 30.
[0012] Thus, an objective of this invention is to teach the use of materials for the bearing surfaces in skeletal prosthesis with improved surface smoothness and wear resistence to reduce the causes of osteolysis.
[0013] Another objective of this invention is to teach the use of a silicon nitride or carbide sintered body as a bearing surface in a prosthesis.
[0014] A further objective of this invention is to teach the use of a ceramic bearing surface in contact with a metal bearing surface in a prosthesis.
[0015] Yet another objective of this invention is to teach the combination of a silicon nitride or silicon carbide bearing surface and a nitrogen alloyed chromium steel bearing surface in contact with each other in an articulating prosthesis.
[0016] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a side view, partially in section, of a prior art total hip prosthesis;
[0018] [0018]FIG. 2 is a side view, partially in section, of another prior art total hip prosthesis;
[0019] [0019]FIG. 2A is a side view, partially in section, of another prior art total hip prosthesis;
[0020] [0020]FIG. 3 is a side view of a artificial head of the femur of this invention;
[0021] [0021]FIG. 4 is a top view of the head of the femur of FIG. 3;
[0022] [0022]FIG. 5 is a cross section of the artificial acetabulum of this invention; and
[0023] [0023]FIG. 6 is a top view of the acetabulum of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0024] [0024]FIGS. 1, 2 and 2 A depict prior art hip prosthesis showing the pelvis P, a proximal acetabulum A and distal femur F components forming a total hip replacement. The head of the femur F has been replaced with a ball 11 mounted on a neck 12 which is supported by a rod 13 . The rod 13 is inserted in a prepared bore in the central canal of the femur. The orientation of the ball, neck and rod is adjusted to simulate the angular disposition of the natural head of the femur to assure proper rotation in the acetabulum A. The rod 13 may have a outer surface modified to make a better connection with the shaft of the femur.
[0025] In FIG. 2A, a coating 14 is shown to improve the surface area between the natural bone and the prosthesis. Also, the bore and rod may have an intermediate layer of bone cement, growth factors or combinations thereof (not shown).
[0026] The ball 11 may be a unitary construction with the neck, as shown in FIG. 1, or it may be integrally mounted on a pin 15 , as shown in FIG. 2. Also shown in FIG. 2A is an integrally mounted ball 11 with a coating or layer of a different material 16 on the outer surface.
[0027] The prosthetic acetabulum 17 , as shown in FIG. 1, is a cup shaped structure that is attached to the pelvis P by screws (not shown). The cup shaped structure 17 is illustrated with a smooth domed outer surface engaging a prepared surface in the natural bone. The interior surface 18 of the dome may be shaped to receive a liner 19 having an outer surface keyed to the inner surface of the cup shaped structure 17 . The interior surface of the liner 19 must complement the shape of the ball 11 for satisfactory performance. As shown in FIGS. 1 and 2, the exterior of the ball 11 and the interior of the liner may be of different materials or, as shown in FIG. 2A, the complementary surfaces may be the same.
[0028] The prosthetic ball 40 , shown in FIG. 3, is preferably made from a silicon nitride or silicon carbide material. The ball 40 may be formed entirely of the ceramic material with a bore 41 for mounting on the pin of a femoral rod. The silicon nitride or silicon carbide material can be hot isostatic pressed formed substantially in the final shape. The ball 40 is then polished to a mirror-like finish that will fit over the prosthetic pin, such as pin 15 . The ball and the pin are permanently affixed with each other. The ceramic ball is completely corrosion resistant and is non-abrasive. The solid matrix eliminates the wear particles, such as liberated from metal, coated metal and polyethylene implants. The ball 40 has excellent thermal conductivity thereby reducing patient discomfort associated with exposure to cold weather. Further, the silicon nitride implant will react well with x-ray and MRI (magnetic resonance imaging) diagnostic procedures. The rod, neck and pin of the prosthesis may be of any materials that have the requisite biological non-toxicity and strength, including metals and polymers.
[0029] The acetabulum 43 , shown in FIG. 5, is preferably constructed of Cronidur 30 steel, described above. The wear characteristics of this material are especially suited to use with the silicon nitride of the ball to reduce accumulation of wear particles in a prosthesis. This material is preferred because it possesses superior hardness, high wear resistance, good fracture toughness and excellent corrosion resistance. While other acceptable steels may have one or more of these properties, none have all of these properties plus the corrosion resistance of Cronidur 30. The acetabulum may be made entirely of Cronidur 30 or only the concave surface.
[0030] The outer or convex surface of the acetabulum 43 may have lands 44 and grooves 45 forming a fluted surface for increasing the resistance to turning in the pelvis. The acetabulum may be driven into the bone to seat the lands and grooves to the bone. Bone screws may also be used in addition to or in lieu of the fluting.
[0031] The highly polished concave surface 46 of the acetabulum 43 serves as a bearing surface for the rotation of the silicon nitride ball 40 . The strength and hardness of the steel matches the properties of the silicon nitride or silicon carbide to lessen the collection of wear particles in a joint. While the invention has been described in relation to a total hip replacement, the silicon nitride or silicon carbide material may be used in total or partial replacement of other articulating joints, such as the knee, shoulder, vertebrae or others. Alternative constructions would include fabrication of the entire prosthesis from either of the materials of this invention, coating different metallic or polymeric materials with the materials of this invention, to include coating the Cronidur 30 with the silicon nitride, and reversing the use of the materials on components. The invention has been described in relation to a total hip replacement however, the invention may be used in prosthesis for all other articulation joints of the body it should be considered a teaching for use with all skeletal joints.
[0032] A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiment but only by the scope of the appended claims. | A prosthesis for total or partial replacement of an articulating skeletal joint has two opposed bearing surfaces. The opposed bearing surfaces are made of a ceramic and a metal, respectively. The ceramic material is a silicon nitride or silicon carbide and the metal is preferably a nitrogen alloyed chromium stainless steel, know as Cronidur 30. | 0 |
BACKGROUND OF THE DISCLOSURE
1. Field of the Invention
The present invention is directed to a process for depositing thin films in nanometer structures. More specifically, the present invention is directed to a process for depositing thin films in nanometer structures by utilizing supercritical carbon dioxide.
2. Background of the Prior Art
The application of thin films onto surfaces of nanometer structures, such as silicon wafers, microelectrical machines or other semiconductor devices, represents an evolving area of technology. In the past, two methods were primarily utilized to provide this function, chemical vapor deposition and ion sputtering. Both of these methods are highly effective in depositing films on flat surfaces of nanometer structures. However, these methods are not reliable enough when it is desired to provide a thin film coating on the surface of holes, trenches, vias and the like or if the surface to be coated is interrupted by holes, trenches, vias and the like. This is so because the vapor employed in these applications react with the structure to compromise the geometry of the holes, trenches, vias and the like.
The absence of reliability suggests the advisability of a third method of applying a thin film onto surfaces of a nanometer structure characterized by the presence of holes, trenches, vias and the like. This third method, spin coating, involves disposing an aerogel on a surface. The aerogel thereupon solidifies as a thin film. The aerogel is usually dissolved in a solvent and is applied, in spin coating, as a solution. An example of the preparation of an inorganic is illustrated in U.S. Pat. No. 6,140,377. U.S. Pat. No. 6,087,729 exemplifies film forming from inorganic aerogels. Although the problem of changes in nanometer structure geometry resulting from structure reaction with an ionic atmosphere does not arise in spin coating, this method presents its own unique reliability problem when spin coating is utilized in the forming a thin film on a nanometer structure.
This reliability problem resides in the inability to prevent film coating of the sides of the holes, trenches, vias and the like which results in filling the sides of these opening so that the opening is closed. This not only prevents the complete filling of the hole, trench, via and the like but, in addition, prevents the coating of a film on the surface of the base of the hole, trench, via and the like.
The above phenomena is scientifically explained by the relatively high surface tension of the thin film coating. This high surface tension makes it very difficult or even impossible for the film material to penetrate to the bottom of the hole, trench, via or the like. As such, the film material, which cannot penetrate to the bottom of the hole, trench, via or the like, builds up on the top portion of the sides of the hole, trench, via or the like which ultimately results in complete blockage of the opening.
Another problem in the prior art resides in deposition of metals, provide electrical conductivity, in nanometer structures containing trenches, vias and the like. To accomplish this deposition, a metallic seed layer must first be deposited in these holes. Techniques for depositing metallic seed layers, prior to catalyzed electroless deposition of metal, are described in U.S. Pat. Nos. 5,989,787, 6,087,258; and 6,106,722.
The problem associated with filling trenches, vias and the like with a metallic seed layer is identical to the problems associated with filling such holes with an aerogel spin coating. The sidewall deposition of the metallic seed layer often causes the hole to close in on itself prior to the complete filling of the trench, via or the like. The greater the aspect ratio, the more apt it is for this result to occur.
It is therefore apparent that the art is in need of a new process for providing thin films on nanometer structures in those cases where nanometer structures include holes, trenches, vias and the like so that those openings, in the course of coating such structures, do not plug or fill those openings.
SUMMARY OF THE INVENTION
A new process has now been developed for depositing thin films on nanometer structures. In this process the thin film is coated onto nanometer structures provided with holes, trenches, vias and the like without the resultant filing of the holes, trenches, vias and the like with the coating material. Instead, this method permits coating of the sides of the hole openings such that the base of the hole is coated without plugging by the coating on the hole's sides.
Although the invention is not limited to any theory explaining its operation, it is believed that a requirement must be met in order to overcome the difficulties discussed above. That is, a film forming material must be utilized which has a low enough surface tension to permit the fluid to penetrate into very narrow openings. The present invention provides an aerogel composition whose surface tension is low enough to enable the composition to completely coat openings to their bottom without plugging.
In accordance with the present invention a process is provided for deposition of a thin film on a nanometer structure in which a supercritical aerogel material or metallic seed layer, which solidifies into a thin film, is prepared. In this process an aerogel material or a metallic seed layer, which solidifies into a film, is prepared. The aerogel material or metallic seed layer is combined with a supercritical composition to form a supercritical aerogel composition. Thereupon, thermodynamic conditions are adjusted to eliminate supercritical conditions whereupon the supercritical composition is removed and the aerogel material or metallic seed layer solidifies into a solid film.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be better understood by reference to the accompanying FIGURE which is a schematic diagram of the apparatus employed in the present invention for depositing a thin film on a nanometer structure.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention may be conducted in an apparatus 10 depicted in the FIGURE. Apparatus 10 includes a process chamber 12 having a sample zone 14 wherein a nanometer structure, noted by reference numeral 16 , is disposed. The nanometer structure may be a silicon wafer, a microelectric machine or other semiconductor device. The process chamber 12 is surrounded by heater jacket 18 and may include stirring mechanism 20 . Additionally, the process chamber contains inlet line 22 , outduct 24 and thermocouple 26 . The inlet line 22 contains a high pressure pump system 28 which is in communication with a gas cylinder 30 for supplying a supercritical fluid to the process chamber 12 . Thermocouple 26 is also connected to a heat control unit 32 which is utilized for controlling and monitoring the temperature in the process chamber 12 . Apparatus 10 may also include a reservoir 34 for collecting and/or purifying supercritical fluids that exit process chamber 12 through outduct 24 . This material may then be recycled into the process chamber via duct 35 .
Apparatus 10 is shown provided with a stirring mechanism. In this preferred embodiment, depicted generally at 20 , the speed of the stirring unit varies from about 100 rpm to about 1000 rpm. More preferably, stirring occurs at about 500 rpm.
The term “supercritical” fluid refers to a fluid which is above its critical point, i.e., critical temperature, T c , and critical pressure, P c , so that the two fluid phases of a substance, liquid and gas, are in equilibrium with each other such that they become identical single phase. The supercritical fluid of the present invention comprises supercritical carbon dioxide and a co-solvent. The supercritical fluid co-solvent may be an alcohol, a ketone, a cyclic ether, N-methyl pyrrolidine or an acetonitrile.
The supercritical fluid, which comprises supercritical carbon dioxide and the co-solvent, is preferably present such that the co-solvent represents less than about 20% of the total volume of the supercritical fluid. More preferably, the supercritical fluid comprises between about 1% and about 10% co-solvent and the remainder supercritical carbon dioxide. The aforementioned percentages are by volume, based on the total volume of the supercritical fluid.
The purity of the supercritical fluid is not critical to the practice of the present invention. If a low purity supercritical fluid is employed, the supercritical fluid can be first purified to remove the impurities using techniques well known to those skilled in the art. For instance, a low purity supercritical fluid could be purified by passing it through a purification column prior to entering the processing chamber.
It is also emphasized that it is a supercritical composition that is employed in the present invention. The supercritical composition comprises the aforementioned supercritical fluid and a surfactant. The surfactant forms a homogeneous mixture with the supercritical fluid under the thermodynamic conditions extant in the process chamber 12 . The surfactant may be introduced into the chamber 12 prior to the introduction of the supercritical fluid. In an alternate embodiment, a surfactant is maintained in a reservoir 36 . Reservoir 36 is in communication with a conduit 37 which is also in communication with conduit 22 . In this arrangement the surfactant is separately introduced into the process chamber 12 concurrent with the introduction of the supercritical fluid therein.
As shown in the FIGURE, the supercritical fluid may be pre-pressurized by a high pressure pump 28 . Typically, the supercritical fluid is pre-pressurized to a pressure in the range of between about 1000 psi to about 6000 psi. More preferably, the supercritical fluid is pre-pressurized to a pressure of about 3000 psi before entering the processing chamber. The pre-pressurized supercritical fluid is then transferred to the processing chamber 12 through inlet line 22 .
The nanometer structure 16 employed in the present invention is any semiconductor sample that may be subjected to spin coating. Illustrated examples of suitable nanometer structures that may be used in the present invention include, but are not limited to, semiconductor wafers, semiconductor chips, ceramic substrates, patterned film structures and the like. For example, the nanometer structure 16 may include one or more of the following materials: titanium silicide, tantalum nitride, tantalum silicide, silicon, polysilicon, silicon nitride, SiO 2 , diamond-like carbon, polyimide, polyamide, aluminum, aluminum with copper, copper, tungsten, titanium, palladium, platinum, iridium, chromium, ferroelectric materials and high dielectric materials such as BaSrTi or PbLaTi oxides.
In practice, a nanometer structure 16 is placed in sample zone 16 of processing chamber 12 wherein the structure 16 is exposed to a supercritical aerogel or metallic seed layer composition. The supercritical aerogel or metallic seed layer composition includes an aerogel or a metallic seed layer and the aforementioned supercritical composition. The conditions in processing chamber 12 are such that the supercritical fluid is maintained above its critical temperature and pressure. As such, the aerogel or metallic seed layer composition is maintained at supercritical conditions. Typically, the pressure within processing chamber 12 is in the range of from about 1000 psi to about 6000 psi. More preferably, the pressure within processing chamber 12 is about 3000 psi. The temperature within the process chamber 12 is in the range of between about 40° C. to about 100° C. More preferably, the temperature within the process chamber during aerogel composition application is about 70° C.
It is emphasized that temperature conditions in process chamber 12 are controlled by heat control unit 32 which has the capability to monitor the temperature in chamber 12 by means of thermocouple 26 . The measured temperature can be adjusted by heat jacket 18 , controlled by controller 32 , in accordance with temperature control means well known in the art.
To ensure effective penetration of the aerogel or metallic seed layer composition, the nanometer structure is exposed to the supercritical fluid under the above conditions for about 2 minutes to about 30 minutes. More preferably, the time period of exposure of the nanometer structure 16 to the supercritical fluid under the above-identified conditions is about 2 minutes.
Upon coating of the aerogel or metallic seed layer composition onto all the desired surfaces of the nanometer structure 16 , the thermodynamic conditions in the process chamber 12 are adjusted so that the CO 2 is no longer in the supercritical state. This is preferably accomplished by a reduction in pressure to below supercritical pressure. Upon pressure reduction, the CO 2 immediately gasifies, entraining the co-solvent and surfactant. As such, only the aerogel, which solidifies, remains on the nanometer structure.
It is emphasized that the aerogel, which solidifies as a thin film in the nanometer structure, is a low density dielectric material obtainable by the gelling of a solution followed by supercritical solvent extraction. The formation of aerogels is well understood by those skilled in the art and the specific aerogel, other than it being maintained under supercritical conditions, is not an inventive feature of the process of the present invention.
It is furthermore emphasized that the metallic seed layer, which solidifies as a thin film in the nanometer structure, is a metal precursor comprised of metal chelates. Particularly preferred metal chelates include platinum or palladium acetyl actonates. These compounds are described in U.S. Pat. Nos. 5,989,787 and 6,087,258 incorporated herein by reference. Most preferably, the metal chelate is platinum or palladium perfluoroacetyl acetonate.
After deposition of the metallic seed layer, electroless metal deposition, to fill the trench, via or the like, which is coated with the metallic seed layer, occurs. To accomplish this task the metallic seed layer deposition process is repeated albeit employing a supercritical metal-containing composition which comprises a solution of the aforementioned supercritical composition and a metal-containing composition employed in electroless metal deposition.
The subcritical fluid exiting the process chamber through outduct 24 may be cleaned, as described above, and recycled back into the apparatus under supercritical conditions. In this manner a closed reactor system may be utilized. Such a closed reactor system is illustrated in the FIGURE. Such an apparatus may or may not be provided in the process of the present invention. Obviously, a closed reactor system reduces processing costs at the price of increased capital expense. In the preferred embodiment illustrated in the FIGURE, where such a system is employed, the exhaust subcritical fluid enters a reservoir 34 through conduit 24 and is recycled back into chamber 12 through conduit 35 .
The above description of the present invention will make apparent, to those skilled in the art, other embodiments and examples. These other embodiments and examples are within the contemplation of the present invention. Therefore, the present invention should be limited only by the appended claims. | A process of depositing a thin film on a nanometer structure in which a coating, which may be an aerogel material or metallic seed layer, is prepared. The coating is combined with a supercritical composition to form a supercritical coating composition. The supercritical coating composition is deposited upon a nanometer structure under supercritical conditions. Supercritical conditions are removed whereby the supercritical composition is removed and the coating solidifies into a thin solid film. | 2 |
BACKGROUND
[0001] The present invention pertains to spectra and particularly infrared spectra of various substances. More particularly, the invention pertains to the generation of synthetic spectra and use of such spectra in testing and calibration of spectrometers.
[0002] The invention may be related to U.S. Pat. No. 5,905,571, by Butler et al. issued May 18, 1999, and entitled “Optical Apparatus for Forming Correlation Spectrometers and Optical Processors”; U.S. Pat. No. 5,757,536, by Ricco et al., issued May 26, 1998, and entitled “Electrical-Programmable Diffraction Grating; and U.S. Pat. No. 6,664,706, by Hung et al., issued Dec. 16, 2003, and entitled “Electrostatically-Controllable Diffraction Grating”; which are herein incorporated by reference. The invention may also be related to U.S. patent application Ser. No. 10/352,828, by Hocker, filed Jan. 28, 2003, and entitled “Programmable Diffraction Grating Sensor”; and U.S. patent application Ser. No. 09/877,323, by Hocker et al., filed Jun. 8, 2001, and entitled “Apparatus and Method for Processing Light”, which are herein incorporated by reference.
SUMMARY
[0003] The invention may be an apparatus and method for the testing and calibration of spectrometers using generated synthetic spectra. These generated synthetic spectra may be used for other purposes such as scene generation.
BRIEF DESCRIPTION OF THE DRAWING
[0004] FIG. 1 is a schematic of a spectra generator having an electrically programmable reflective diffraction grating;
[0005] FIG. 2 is an intensity versus wavelength graph of radiation from an example black body;
[0006] FIG. 3 is an example spectrum that may represent the absorption of infrared light by a particular substance;
[0007] FIG. 4 is a diagram of an actual spectrum of HF, a simulated spectrum of HF and a displaced simulated spectrum of HF;
[0008] FIG. 5 is a diagram of an actual spectrum of TCE, a simulated spectrum of TCE and a modified simulated spectrum of TCE; and
[0009] FIGS. 6 a and 6 b show end and top views, respectively, of an electrically adjustable grating.
DESCRIPTION
[0010] Spectrometers may be used to detect molecules in the atmosphere by observing the characteristic spectra of light absorbed by the molecules. Such spectrometers should be tested and calibrated with spectra that resemble the target molecules. Creating test spectra by using samples of the molecules, such particular species of them, may be inconvenient, time consuming and expensive. Additionally, using samples of the actual molecules may be hazardous if the species are toxic. Specifically, military systems used for standoff chemical agent detection need capabilities for test and calibration with actual spectral input representing the chemical agents to be detected, but without the need to use samples of actual toxic chemical agents.
[0011] In FIG. 1 , a generator 10 of spectra is shown. A light source 11 may output light 12 of a black body, that is, broadband infrared light. A lens 13 may collimate light 12 for impingement on a diffractive grating 14 . Electrically programmable diffractive grating 14 may reflect broadband light 12 as spectra light 15 . The design may instead incorporate a transmissive grating in lieu of the reflective grating. The reflective grating may be generally referred to here.
[0012] Spectra light 15 may be detected by a spectrometer 16 . Light 15 may be a synthesization of a light spectrum resulting from absorption by a specific substance. If spectrometer 16 is functioning properly, then it may identify that that spectrum light 15 to be that of the specific substance. The light 15 beam width may be adjusted with a beam expander or beam compressor so that light 15 is more effectively transmitted and detected by spectrometer 16 .
[0013] The electrically programmable diffraction grating 14 may transform broadband light 12 into spectra light 15 in accordance with a dimension, such as the height of diffraction elements 17 , relative to the base of diffractive gating 14 . These dimensions of electrically programmable diffraction grating 14 in the Figures are not drawn to scale but are illustrative. The actual number of elements 17 may be over 1000, e.g., 1024 . Also, angle 18 may be a factor affecting the synthesized spectra 15 . The spectra of light 15 generated may be a function of the heights of the elements 17 and of angle 18 of the direction of diffracted light 15 relative to the direction of incident light 12 impinging grating 14 . Each element 17 may have a unique height.
[0014] The heights of the elements 17 may be adjusted in order to generate various spectra in diffracted light 15 . The heights of the diffractive elements 17 may be set with electrical signals from a computer 19 via a connection 21 to an interconnection base 22 attached to grating 14 . Computer 19 may be programmed to provide ready-made settings for the elements 17 to generate specific spectra of respective substances. Background about an electrically programmable diffraction grating may be disclosed in U.S. Pat. Nos. 5,905,571 and 5,757,536, and U.S. patent application Ser. No. 09/877,323.
[0015] For instance, if a request is input to computer 19 for a spectrum of CO, than an element pattern may be sent to grating 14 which may result in an adjustment of elements 17 so as to result in a spectrum of CO being in diffracted light 15 sent to a receptor 16 such as a spectrometer. Elements 17 may be adjusted so as to reflect light 15 having spectra of more than one substance. Also, background may be added to the spectra of light 15 . Spectrometer 16 may be tested with the reception of light 15 to determine detection capability of various substances among various backgrounds. Device 16 may be tested for identifying a spectrum of a particular substance or several substances buried in noise at one level or another. Computer 19 may provide spectra settings to elements 17 in a sequential fashion over a given period of time. Spectra for calibration of spectrometer 16 or other instrumentation may be provided via light 15 . Further, a detection mechanism may be used added to device 16 to identify and verify the spectra being used for testing and calibrating spectrometers and the other instrumentation. Also, spectra may be generated for scene generation and the testing and/or calibration of microbolometers and other detection mechanisms.
[0016] FIG. 2 is a graph of intensity versus wavelength of infrared light. Curve 31 reveals a spectrum of black body source which may be light source 11 of generators 10 and 20 . However, source 11 may emit other wavelengths of the like, such in the ranges of visible or UV light. FIG. 3 is an example of a spectrum 32 of light 15 or 24 after the light 12 is transmitted through a region containing a specific molecule. Light may be absorbed in spectral wavelengths in a pattern characteristic of that molecule.
[0017] FIG. 4 shows a graph of three spectra of HF. The top spectrum may be regarded as an actual spectrum curve 51 of HF. Curve 52 may be a synthetic spectrum of HF as provided by spectra generator 10 or 20 . Curve 53 is the same as curve 52 except that it is shifted to the right about 50 wave numbers. If the spectrum 52 is compared with the actual HF spectrum 51 , and spectrum 52 is delayed periodically to the position of spectrum 53 , spectrum 51 may be easier to detect when a comparison is done for calibrating the generator. Generators 10 and 20 may generate both a spectrum 52 and a displaced spectrum 53 of HF. This spectra displacement shifting may accommodate AC detection of an actual spectrum.
[0018] FIG. 5 shows an actual spectrum 61 of TCE and a synthetic spectrum 62 of TCE. Spectrum 62 may be provided by generators 10 and 20 . Another provided spectrum 63 may effectively be spectrum 62 of TCE with the 850 cm −1 absorption line removed by generator 10 or 20 due to an adjustment of the elements 17 in diffractive grating 14 or 23 , respectively.
[0019] FIGS. 6 a and 6 b show aligned end and top views of the adjustable grating 14 that may be used in generator 10 . A basic structure of this adjustable grating 14 may be like that of grating 23 , except that grating 23 may have a transparent property rather than a reflective one. Elements 17 may be pulled down electrostatically by elements 71 . One polarity of a voltage source may be connected to all of the elements 17 at support 73 . The other polarity of the voltage source may be connected to an individual element 71 positioned relative to its corresponding element 17 . Elements 17 may be like flexible tongs that have a natural resting position close structure 72 and a fixed structural connection to structure 73 . A magnitude of a voltage applied across element 17 and 71 may determine the position of element 17 relative to element 71 . The greater the voltage magnitude, element 17 may be drawn closer to element 71 . Thus, all elements 17 may be individually adjusted to achieve a particular and unique diffractive grating 14 setting for providing a desired spectrum from generator 10 . The voltage inputs to elements 71 may be individual and different from one another. The base 74 is insulated so that elements 71 may be electrically isolated from one another and connected to an external signal source such as computer 19 . The various sets of voltage inputs with their respective combinations of magnitudes may be programmed in computer 19 . The positions of elements 17 and consequently grating 14 may be dynamically changed in a manner to get the effect of going from spectrum 52 to spectrum 53 of FIG. 5 or from spectrum 62 to spectrum 63 of FIG. 6 .
[0020] Although the invention has been described with respect to at least one illustrative embodiment, many variations and modifications will become apparent to those skilled in the art upon reading the present specification. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications. | A spectra generator having an electrically programmable diffraction grating. There may be a broad band light source that emits light which is diffracted by the grating. Diffracting elements in the grating may be individually adjustable so that generation of a specific spectrum or spectra may be achieved. The diffracting elements may be adjusted according to electrical signals of a program from a computer. The generated synthetic spectra may be used for testing and calibration of spectrometers or other devices. Synthetic spectra may also be used for scene generation and other purposes. | 6 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] U.S. Provisional Application for Patent No. 60/571,543, filed May 13, 2005, with title “Stretchable, Intra-Curing Halogenated Based Rubber Tape” which is hereby incorporated by reference. Applicant claims priority pursuant to 35 U.S.C. Par. 119(e)(i).
[0002] Statement as to rights to inventions made under federally sponsored research and development: Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates generally to the field of tapes which are substantially non-tacky in their relaxed state but whose overlapping layers self- bond when stretched and wrapped on a substrate.
[0005] 2. Brief Description of Prior Art
[0006] Many articles are coated for protection from the environment in a variety of ways including the application of a thin sheet or tape in a wrapping operation. The technology for the application of such coatings generally includes a separate adhesive layer used to achieve adhesion to the substrate and of the overlapping layers to each other. These tapes are usually made of a non-cured single layer of self-fusing elastomers. The fusing of the tape is due to each adjacent layer or double layer being composed of the same compound and therefore compatible and fusable. Upon exposure to temperature, these tapes lose their elastomeric memory and assumes the applications shape.
[0007] As will be seen from the subsequent description, the preferred embodiments of the present invention overcome shortcomings of the prior art.
SUMMARY OF THE INVENTION
[0008] The present invention relates generally to a rubber composition and a method of forming a curing composition blend. By inciting cross-linking between layers, the one layer is substantially non-tacky in the relaxed state while the adjacent layer is tacky. Both layers are composed of a semi-cross-linked elastomer that when forced into intimate contact, will further fuse with increase of time and temperature providing improved stability and strength. This results in a continued presence of an inward pressure on the wrapped area for the life of the splice.
[0009] The rubber composition blend is comprised of multiple components. One component is a halogenated rubber, or combination thereof, and a second component is a non-halogenated rubber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will be illustrated on the basis of the following description of the preferred embodiments thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] In accordance with the present invention, a stretchable, self-shrinking, intra-curing halogenated based rubber, and method of forming the composition blend is disclosed. The present invention discloses a rubber composition that is substantially non-tacky in the relaxed state but whose overlapping layers cross-link layer to layer when stretched and wrapped on a substrate. In the broadest context, the composition blend of the present invention consists of components configured and correlated with respect to each other so as to attain the desired objective.
[0012] The blend of the present invention comprises at least two components: a halogenated rubber component and a halogenated modified component.
[0013] Any cross-linkable polymer may be employed in the practice of this invention. The halogenated rubber component may include, but is not in any way limited to, the following polymers: butyl rubber, halogenated butyl rubber, isobutylene homopolymer, ethylene/propylene/diene terpolymers, ethylene/propylene copolymers, polybutadiene, polyisoprene, halogenated isoolefin/paralkylstyrene copolymer, natural rubber, and combination mixtures thereof.
[0014] The blended composition further includes a cure system to allow the resultant product to have cross-linkable properties at room temperature. The cure system as will be described is preferably blended with the halogenated rubber component.
[0015] The cure system is a combination of phenolic resins. The amount of the curing agent will generally vary depending upon the types utilized and especially the desired degree of cure, as is well recognized in the art. However, in general, the preferred amount of the cure system is about 0.5% to about 1.5% of the total mixture blend.
[0016] It has now been found that the incorporation in the halogenated rubber component of the described cure system, in the amounts described, produces a marked improvement in the resultant product's cross-linking properties and further causes the blend to be room temperature cross-linkable.
[0017] Various additives can be further used in suitable amounts. For example, various reinforcing agents or fillers known in the art may be combined with the blend at any point during production. Further, various colorants may be added such as carbon black and the like, and various resins known in the art can be utilized in the present blend. Moreover, the inclusion of a separate tackifier known in the art and known for its intended purpose is preferred.
[0018] The described mixture further incorporates a petroleum product, preferably polybutene. The preferred proportion of polybutene in the mixture is from about 20% to about 30% of the total mixture.
[0019] The first halogenated rubber component which includes the cure system, and the non-halogenated component are combined in amounts effective to produce the desired improvement in strength and stability. The relative amounts are as follows:
[0020] The relative proportions of the halogenated rubber component used in the practice of the present invention fall within a rather narrow range. The proportion of the halogenated rubber component is from about 10% to about 25% of the total blend. A wetting agent known in the art is further included with the halogenated rubber component. The wetting agent as is known, causes the mixture to blend easier. The preferred proportion of the wetting agent is from about 0.5% to about 1.5% of the total blend;
[0021] It is preferred to use from about 1% to about 1.5% of colorant in the total blend. To achieve the desired effect it is preferred to use carbon black in the composition;
as stated, the preferred proportion of petroleum product in the mixture is from about 20% to about 30% of the total mixture; the amount of a particular, filler or pigment which can be used without adversely affecting the fusion properties for example of the resultant product can be readily determined by those skilled in the art. However, such filler can be included in an amount equal to about 48% to about 55% of the blend; the amount of the tackifier in the mixture is from about 0.5% to about 1.5% of the total mixture; provided that the proportion of the halogenated rubber component (including the wetting agent and the cure system) in the mixture does not exceed about 30% of the total blend; and the proportion of the cure system in the mixture does not exceed about 1.5% of the total mixture.
[0026] The present invention further includes a removable liner known in the art that is temporarily adhered to a surface of the resulting sheet or tape product.
[0027] The resulting sheet or tape product are strong but can readily be stretched without breaking and are readily handleable over a wide temperature range.
[0028] In practicing the present invention, there is formed a blend which is capable of cross-linking. The application forms a continuous, solid rubber cover that applies inward pressure on the protected area for the life of the application.
[0029] The method used to combine the components is not critical and known in the art. Thus any mixing device may be used. Further, the mixing order is not critical. For convenience, the components may be blended at one time. Alternatively, the first halogenated rubber component (and components of the described cured system) may be blended first, followed by addition of the non-halogenated components and additives. The composition blend may include for example, initially blending the ingredients in solid form using standard blending equipment at elevated temperatures to improve blending. The resultant blend is then usually cooled, and preformed. Sheets may be prepared such as by passing the blend through a calendar or an extruder equipped with a sheet die. Tapes are produced by cutting or extruding the sheet to form tapes having the desired width.
[0030] Both layers of the rubber composition are post cured after forming into the final product. The application forms a stretchable tape with “built-in” memory to reform back to its shape before stretching.
[0031] The tape is applied to the substrate by subjecting it to a stretching elongation and in the elongated state applying it to the substrate, as for example in a wrapping action. Such stretching results in the tapes developing the ability to self-bond and the overlapping layers adhere strongly to each other. These layers have the appearance of a fused sheet on, or covering the substrate within a few hours of application. We have found that the layers will cross-link and continue to fuse with the increase of time and temperature following application until the layers of tacky and non-tacky elastomer have formed cross-linked adhesive bonding between layers. The rebounding properties of the cured non-tacky layer will, during the life of the application, exert an inward pressure that will prevent intrusion of extrusion of water, gases, air, dirt, or other elements.
[0032] It has been found that the blended composition demonstrates substantially improved thermal and aging stabilization. Thus, not only is the strength improved, the overall characteristics of the resultant product are improved.
[0033] The resulting tapes of the present invention may be used in a wide variety of applications such as splicing, encapsulation and connection.
[0034] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of the invention. It will be obvious that embodiments described may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the present invention.
[0035] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | A stretchable, intra-curing halogenated based rubber composition having increased strength and capable of being stretched without breaking. The composition comprises blends of a first halogenated rubber component and a second halogenated modified rubber component. The present invention further relates to methods for preparing these compositions. | 2 |
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