description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
1. Field of the Invention.
This invention relates in general to earth boring bits of the type used to drill oil and gas wells.
2. Description of the Prior Art.
Commercially available earth boring bits can be generally divided into the rolling cutter bits, having either steel teeth or tungsten carbide inserts, and diamond bits, which utilize either natural diamonds or artifical or man-made diamonds. The artificial diamonds are "polycrystalline," used either individually or as a component of a composite compact or insert on a cemented tungsten carbide substrate. Recently, a new artificial polycrystalline diamond has been developed which is stable at higher temperatures than the previously known polycrystalline diamond.
The diamond earth boring bits can be generally classified as either steel bodied bits or matrix bits. Steel body bits are machined from a steel block and typically have cutting elements which are press-fit into recesses provided in the bit face. The matrix bit is formed by coating a hollow tubular steel mandrel in a castin mold with metal bonded hard material, such as tungsten carbide. The casting mold is of a configuration which will give a bit of the desired form. The cutting elements are typically either polycrystalline diamond compact cutters brazed within a recess provided in the matrix backing or are thermally stable polycrystalline diamond or natural diamond cutters which are cast within recesses provided in the matrix backing.
The single piece bits, whether steel bodied or matrix, typically include a bit body with a tubular bore which communicates with the interior bore of the drill string for circulation of fluids. At least one fluid opening communicates the bit face with the tubular bore for circulating fluid to the bit face to carry off cuttings during drilling. A plurality of fluid courses, sometimes referred to as "void areas" or "junk slots" allow the flow of drilling fluid and formation cuttings from the bit face up the bore hole annulus.
In the past, these void areas or fluid courses have tended to be of uniform width and depth, particularly in the gage region of the bit body and have tended to become packed off by cuttings in certain formations. As a result, the bit penetration rate dropped.
SUMMARY OF THE INVENTION
A bit is shown for use in drilling earthen formations which includes a body having a bit face on one end and a shank on the opposite end with means for connection to a drill string for rotation about a longitudinal axis. The bit body has a tubular bore which communicates with an interior bore of the drill string for circulation of fluids. The bit face increases in external diameter between a nose and a gage region of the bit. At least one fluid opening communicates the bit face with the tubular bore for circulating fluid to the bit face. A plurality of fluid courses disposed on the bit face extend through the gage region of the bit. The fluid courses become ever wider and ever deeper along their entire disposition.
Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a bit of the invention showing the ever widening and deepening fluid courses on the bit body.
FIG. 2 is a simplified, schematic view of the bit of FIG. 1 showing the ever deepening nature of the fluid course.
FIG. 3 is a simplified, schematic view of the bit of FIG. 1 showing the ever widening nature of the fluid course.
FIG. 4 is a partial, sectional view taken along lines B--B' in FIG. 3.
FIG. 5 is a partial, sectional view taken along lines A--A' in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
The numeral 11 in the drawing designates an earth boring bit having a body 13 with a threaded shank 15 formed on one end for connection with a drill string member (not shown). The body 13 further includes a pair of wrench flats 17 used to apply the appropriate torque to properly "make-up" the threaded shank 15. The body 13 has a tubular bore 19 which communicates with the interior of the drill string member, and which communicates by internal fluid passageways (not shown) with one or more fluid openings 21 which are used to circulate fluids to the bit face.
On the opposite end of the bit body 13 from the threaded shank 15, there is formed a bit head or "matrix" 19 in a predetermined configuration to include cutting elements 23, longitudinally extending lands 25, and fluid courses or void areas 27. The matrix 19 is of a composition of the same type used in conventional diamond matrix bits, one example being that which is disclosed in U.S. Pat. No. 3,175,629 to David S. Rowley, issued Mar. 30, 1965. Such matrices can be, for example, formed of copper-nickel alloy containing powdered tungsten carbide.
Matrix head bits of the type under consideration are manufactured by casting the matrix material in a mold about a steel mandrel. The mold is first fabricated from graphite stock by turning on a lathe and machining a negative of the desired bit profile. Cutter pockets are then milled in the interior of the mold to the proper contours and dressed to define the position and angle of the cutters. The fluid channels 27 and internal fluid passageways are formed by positioning a temporary displacement material within the interior of the mold which will later be removed.
A steel mandrel is then inserted into the interior of the mold and the tungsten carbide powders, binders and flux are added to the mold. The steel mandrel acts as a ductile core to which the matrix material adheres during the casting and cooling state. After firing the bit in a furnace, the mold is removed and the cutters are mounted on the exterior bit face within recesses in or receiving pockets of the matrix.
The bit body 13 in FIG. 1 has a ballistic or "bullet-shaped" profile which increases in external diameter between a nose 29 and a gage region 31 of the bit. Referring to FIG. 2, the face region extends generally along the region "X," the gage region extends generally along the region "Y" and the shank extends generally along the region "Z." The bit is generally conical in cross-section and converges from the gage region "Y" to the noze 29. By "gage" is meant the point at which the bit begins to cut the full diameter. That is, for an 81/2 inch diameter bit, this would be the location on the bit face at which the bit would cut an 81/2 inch diameter hole.
As shown inFIG. 1, each fluid course 27 comprises a groove of lesser relative external diameter located between two lands (25, 33 in FIG. 1) on the bit face. The lands 25, 33 have polycrystalline diamond cutter elements 23 mounted therein within backings of the matrix for drilling the earthen formations. The backings 35 for the cutting elements 23 are portions of the matrix which protrude outwardly from the face of the bit and which are formed with cutter receiving pockets or recesses during the casting operation.
The cutting elements 23 are of a hard material, preferably polycrystalline diamond composite compacts. Such cutting elements are formed by sintering a polycrystalline diamond layer to a tungsten carbide substrate and are commercially available to the drilling industry from General Electric Company under the "STRATAPAX" trademark. The compact is mounted in the recess provided in the matrix by brazing the compact within the recess. The preferred cutting elements 23 are generally cylindrical.
As shown in FIG. 1, each land 25, 33 is formed as a convex ridge of the matrix material which extends from the nose 29 outwardly in an arcuate path, the path gradually transitioning to extend generally longitudinally along the bit axis 37 to terminate in a planar pad 39 at the gage region 31 of the bit. The planar pads 39 have small diamonds (polycrystalline and/or natural) imbedded in the surface thereof and have longitudinal troughs which extend generally parallel to the longitudinal axis 37 of the bit.
The fluid courses 27 become ever wider and deeper through the gage region "y" of the bit where prior art bits were of constant width and depth. In the preferred embodiment shown in FIG. 1, the fluid courses 27 become ever wider and deeper along the face of the bit from the nose 29 through the gage region 31 to the shank region "Z" (FIG. 2). As illustrated in FIGS. 4-5, D 2 -D 1 is always greater than 0, and W 2 -W 1 is always greater than 0. Thus a normal plane drawn through any selected fluid course 27 at one incremental location (such as that illustrated in FIG. 5) along the bit face increases in cross-sectional area in the direction of the gage region 31 (as indicated in FIG. 4). The cross-sectional area of the normal plane decreases in increments in the direction of the nose 29.
The constantly deepening feature of the void area is illustrated in FIG. 2. Imaginary line 43 drawn parallel to the bit axis 37 represents the constant depth of a prior art bit in the gage region "Y". Imaginary line 45 is an extension of the actual depth of the fluid course 27 in the bit of the invention. The angle alpha formed between lines 43 and 45 is preferably in the range from about 1/4 degree to about 7 degrees and most preferably is in the range from about 1 degree to 2.5 degrees.
The constantly widening feature of the void area is illustrated in FIG. 3. Imaginary line 47 in FIG. 3 is parallel to a plane drawn through the bit axis 37 and corresponds to an edge of a constant width void area of a prior art bit in the gage region "Y." Imaginary line 49 is an extension of the fluid course 27 in the bit of the invention. The angle beta is in the range from about 1/4 degree to 10 degrees, preferably in the range from about 2 degrees to 4 degrees, most preferably about 3 degrees on either side of the fluid course. That is, angle tau in FIG. 3 is equal to angle beta.
An invention has been provided with several advantages. The drilling bit of the invention features fluid courses which are ever widening and ever deepening from their lowermost and/or centermost disposition through the gage region of the bit. Because the void area is fully expanding, there is no choke point present which would tend to form a constriction for entrained cuttings in the drilling fluid. Any tendency of the fluid course to pack-off is eliminated because any differential movement of the obstruction moves the obstruction to a larger cross-sectional flow area to allow release. It is no longer necessary for the operator to run a special additive in the drilling fluid to strip off a packed formation or to back the drill string off the bottom of the hole in an attempt to blow the obstruction away with drilling fluid. In addition, the improved removal of cuttings allowed by a bit embodying the invention results in faster penetration rates and more economical drilling.
While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof. | A bit is shown for use in drilling earthen formations which includes a body having a bit face on one end and a shank on the opposite end which is connected in the drill string. The bit body has a tubular bore which communicates with an interior bore of the drill string for circulation of fluids. The bit face increases in external diameter between a nose and a gage region of the bit. A fluid opening communicates the bit face with the tubular bore for circulating fluid to the bit face. A plurality of fluid courses are disposed on the bit body, the fluid courses becoming ever wider and ever deeper along their entire disposition from their lowermost incorporation through the gage region thereof. | 4 |
REFERENCE TO PENDING PATENT APPLICATION
This application is a continuation-in-part of pending U.S. patent application Ser. No. 132,940, filed Dec. 15, 1987, U.S. Pat. No. 4,879,743, by James E. Nicholson et al.
FIELD OF THE INVENTION
This invention relates to surgical devices in general, and more particularly to suture anchors of the sort adapted to anchor one end of a piece of conventional suture in bone, and installation tools for deploying the same.
BACKGROUND OF THE INVENTION
In copending U.S. Patent Application Ser. No. 051,367, filed 5/18/87 by Roland F. Gatturna et al. for "Suture Anchor", there is disclosed a variety of suture anchors of the sort adapted to anchor one end of a piece of conventional suture in bone, and there is disclosed several suture anchor installation tools for deploying such suture anchors in bone.
The specification and drawings of the above-identified U.S. Pat. Application Ser. No. 051,367 is hereby incorporated by reference into the present patent application.
Looking now at FIG. 1, there is shown one of the suture anchors disclosed in the above-identified U.S. Pat. Application Ser. No. 051,367. This suture anchor, identified generally by the numeral 105, comprises a coupling member 110 and a barb 115.
Coupling member 110 comprises a piece of 6A14V titanium alloy having a first end surface 120 and a second end surface 125. First end surface 120 is disposed at an angle of approximately 30 degrees to the coupling member's longitudinal axis, and second end surface 125 is disposed at a right angle to the coupling member's longitudinal axis, as shown. Coupling member 110 has a blind hole 130 opening on second end surface 125, and a bore 135 extending at an angle between the coupling member's side wall and its bottom end surface 120, as shown. Bore 135 extends at a right angle to the coupling member's bottom end surface 120. In the case of a suture anchor adapted to anchor a No. 0 suture (i.e., a suture having a diameter of approximately 0.014 inch), coupling member 110 preferably has a length of approximately 0.160 inch and a diameter of approximately 0.053 inch, blind hole 130 has a depth of approximately 0.070 inch and a diameter of approximately 0.028 inch, and bore 135 has a diameter of approximately 0.028 inch.
Barb 115 comprises a curved length of nickel titanium alloy having a first end 140 and a second end 145. In the case of a suture anchor adapted to anchor a No. 0 suture, barb 115 preferably has a diameter of approximately 0.026 inch and, in its unrestrained state, comprises an arc of approximately 135 degrees of a loop approximately 0.250 inch in diameter (when measured to the inside of the loop). Barb 115 is attached to the coupling member by fitting the barb's first end 140 into the coupling member's blind hole 130, whereby the barb's second end 145 extends upward and outward from the coupling member. Coupling member 110 is then crimped inward at one or more points as shown at 150 to lock barb 115 to the coupling member. Barb 115 is made of such a nickel titanium alloy that it is capable of being elastically deformed to a substantially straight length when desired (i.e., so that the barb's second end 145 is aligned with its first end 140, as well as with the opposite ends of the coupling member). By way of example, barb 115 may be made out of binary nitinol such as that sold by Furukawa of Japan and Raychem Corporation of Menlo Park, California, or it might be made out of ternary nitinol such as that sold by Raychem Corporation and described in U.S. Pat. No. 4,505,767 (Quinn).
Looking next at FIG. 2, there is shown one of the suture anchor installation tools disclosed in the above-identified U.S. Pat. Application Ser. No. 051,367. This suture anchor installation tool, identified generally by the numeral 205, may be used to deploy the suture anchor shown in FIG. 1. Installation tool 205 comprises a hollow sheath or cannula 210, a hollow loader or inserter 215 and a solid (or hollow) plunger 220.
Hollow sheath 210 terminates in a flat annular surface 225 at its front end and a flat annular surface 230 at its rear end. Surfaces 225 and 230 are disposed at an angle substantially perpendicular to the longitudinal axis of sheath 210. Sheath 210 has an axial bore 235 extending between its front and rear surfaces 225 and 230. Sheath 210 includes a disk-like finger grip 240 which is affixed to the rear end of the outer sheath member and includes a flat surface 245 which is coplanar with the sheath member's rear surface 230. In the case of an installation tool adapted to deploy a suture anchor for anchoring a No. 0 suture, sheath 210 preferably has an outer diameter (i.e., forward of finger grip 240) of approximately 0.083 inch, an inner diameter of approximately 0.071 inch, and a length of approximately 4.0 inches.
Hollow loader 215 terminates in a flat annular surface 250 at its front end and a flat annular surface 255 at its rear end. Surfaces 250 and 255 are disposed at an angle substantially perpendicular to the longitudinal axis of loader 215. Loader 215 has an axial bore 260 extending between its front surface 250 and its rear surface 255. Loader 215 includes a disk-like finger grip 265 which is attached to the rear end of the loader member and includes a flat surface 270 that is coplanar with the loader's rear surface 255. Loader 215 is sized so that it will make a close sliding fit within bore 235 of sheath 210, as will hereinafter be described in further detail, and also so that its leading tip 250 will not protrude from the front end of sheath member 210 when the loader is inserted into the sheath's axial bore 235 and the loader's finger grip 265 is in engagement with the sheath's rear surface 230, as will hereinafter be described in further detail. In the case of an installation tool adapted to deploy a suture anchor for anchoring a No. 0 suture, loader 215 preferably has an outer diameter (i.e., forward of finger grip 265) of approximately 0.065 inch, an inner diameter of approximately 0.047 inch, and a length of approximately 4.13 inches.
Plunger 220 includes a solid (or hollow) body section 275 and a head section 280. Body section 275 has a round cross-section and terminates in a front surface 285. Plunger 220 is sized so that its body section 275 will make a close sliding fit within bore 260 of loader 215 and also so that its leading tip 285 will protrude from the front end of the loader member a short distance when the plunger's head section 280 is in engagement with the loader member's rear surface 270, as will hereinafter be described in further detail. In the case of an installation tool adapted to deploy a suture anchor for anchoring a No. 0 suture, plunger 220 preferably has a diameter of approximately 0 047 inch forward of head section 280, and a length of approximately 4.32 inches, as will hereinafter be described in further detail.
Installation tool 205 is intended to be utilized as follows. Looking next at FIG. 3, suture anchor 105 is loaded into the top end of sheath member 210 so that the suture anchor's coupling member 110 resides inside the sheath's axial bore 235 and the suture anchor's barb 115 extends above finger grip 240 of the sheath member. Looking next at FIG. 4, the front end 250 of loader 215 is then slipped over the free end of the suture anchor's barb 115 so that the free end of the barb extends into the loader member's axial bore 260. Then loader member 215 is (a) forced into coaxial alignment with outer sheath member 210, thereby straightening out barb 115 in the process, and (b) pushed into the interior of sheath member 210, carrying the suture anchor downward within the sheath member as it goes. In order to assure that barb 115 of suture anchor 105 is contained completely within loader 215 such that suture anchor loader surface 250 contacts suture anchor surface 125, the sheath's bottom surface 225 is rested against a stationary surface 305 (see FIG. 5) while suture anchor loader 215 is brought downward into direct contact with the suture anchor's rear surface 125. Sheath member 210 and loader member 215 are carefully sized relative to one another (and relative to suture anchor 105) so that when the loader member's finger grip 265 is thereafter brought into contact with the sheath member's top surface 245, the suture anchor will protrude slightly from the bottom end of the sheath member, as shown in FIG. 6. More specifically, as seen in FIGS. 7 and 8, sheath member 210 and loader member 215 are sized relative to one another (and relative to suture anchor 105) so that both ends of the suture anchor's diagonal bore 135 will be exposed to view when the loader member's finger grip 265 is brought into contact with the sheath member's top surface 245. With the suture anchor so held by the installation tool, a conventional suture 405 may then be easily attached to the suture anchor by passing the suture through the anchor's diagonal bore 135 and tying a knot 410 at the end of the suture which can then bear against the bottom end 120 of the suture anchor's coupling member, as shown in FIGS. 7 and 8.
Once the suture has been attached to the suture anchor in the foregoing manner, plunger member 220 may then be inserted into the loader member's internal bore 260 (see FIG. 9) and pressed downward until its bottom tip 285 contacts the suture anchor barb contained in the loader member's bore 260. By appropriately sizing the respective members involved, the head section 280 of the plunger member will remain slightly above finger grip 265 of loader member 215 when the plunger member's tip 285 engages barb 115 of suture anchor 105.
Thereafter, when the installation tool is actually to deploy the suture anchor (and its attached suture) into bone, the tip of the installation tool is inserted into a hole 505 formed in a bone 510 until the suture anchor rests on the bone surface 515 (see FIG. 10), and then head section 280 of plunger member 220 is held stationary while finger grip 240 of sheath member 210 is pulled upward so that the loader's flat surface 270 engages the underside of the plunger's head section 280, thereby ejecting the suture anchor 105 (and its attached suture 405) out of the installation tool and into the bone, as shown in FIGS. 10 and 11.
Complete details regarding the construction and use of suture anchor 105 and installation tool 205 are provided in the above-identified U.S. Pat. Application Ser. No. 051,367, which is incorporated herein by reference; the foregoing description is provided merely for convenient reference in understanding the present invention.
With the three-element installation tool 205 described above, a hole slightly larger in size than the combined diameters of the outer sheath member 210 and the suture 405 must be drilled in the bone. For example, with a suture anchor for anchoring a No. 0 suture, where the suture anchor's coupling member 110 has a diameter of approximately 0.053 inch, suture 405 has a diameter of approximately 0.014 inch, and outer sheath 210 has a diameter of approximately 0.083 inch, a hole approximately 0.098 inch in diameter must be drilled in the bone. In the case of a suture anchor for anchoring a No. 2 suture, where the suture anchor's coupling member 110 has a diameter of approximately 0.061 inch, suture 405 has a diameter of approximately 0.020 inch, and outer sheath 210 has a diameter of approximately 0.095 inch, a hole approximately 0.116 inch in diameter must be drilled in the bone.
A summary table of such sizing is given below:
TABLE 1______________________________________ Suture Size: No. 0 No. 2______________________________________Suture Anchor Dia. 0.053 0.061Sheath Diameter 0.083 0.095Suture Diameter 0.014 0.020Sheath + Suture Dia. 0.097 0.115Drill Diameter 0.098 0.116(Drill hole) - (Suture Anchor) 0.045 0.055______________________________________
Unfortunately, while the three-element installation tool 205 described above is known to work, it is also believed to suffer from a number of disadvantages.
For one thing, it will be seen from Table 1 above that the three-element installation tool 205 takes up a substantial amount of room in the bone hole relative to the diameter of the suture anchor. More specifically, as seen in Table 1 above, the suture anchor for anchoring a No. 0 suture has a coupling member diameter of approximately 0.053 inch, yet it requires a drilled hole of approximately 0.098 inch to accommodate the suture anchor when it is set by installation tool 205. Therefore, the suture anchor's barb must essentially take up the difference between the 0.053 inch coupling member and the 0.098 inch hole when the suture anchor is set in the hole. Thus, the barb must expand approximately 0.045 inch for the suture anchor used to anchor a No. 0 suture. Similarly, as seen in Table 1 above, the suture anchor for anchoring a No. 2 suture has a coupling member diameter of approximately 0.061 inch, yet it requires a drilled hole of approximately 0.116 inch to accommodate the suture anchor when it is set by installation tool 205. Therefore, the barb must essentially take up the difference between the 0.061 inch coupling member and the 0.116 inch hole when the suture anchor is set in the hole. Thus, the barb must expand approximately 0.055 inch for the suture anchor used to anchor a No. 2 suture. Inasmuch as the barb loses force as it returns closer and closer to its original curved shape from its constrained straight shape (e.g. much like a spring), the larger the difference existing between the bone hole diameter and the suture anchor body, the smaller the force applied to the side wall of the bone by the suture anchor's barb when the suture anchor is set in the bone, and hence the weaker the attachment of the suture anchor to the bone. Accordingly, a fit such as that mandated by the use of the three-element installation tool 205 could possibly lead to inconsistent anchoring of the suture in the bone.
Another disadvantage of the three-element installation tool 205 described above is that the outer sheath 210 and loader member 215 can be preloaded with the suture anchor (in the manner shown in FIGS. 5 and 6) but, if it is then left for a substantial amount of time between loading and use, the barb can lose its resiliency and relax over time, so that when the suture anchor is thereafter used, its barb may not contact the bone wall with the same force that it would have if the suture anchor had been used immediately after loading the suture anchor into sheath 210 and loader 215. Accordingly, preloading accompanied by delayed use can possibly lead to inconsistent and unsatisfactory anchoring of the bone anchor in the bone.
OBJECTS OF THE INVENTION
A principal object of the present invention is to provide a novel suture anchor configuration which facilitates insertion of the suture anchor.
Another object of the present invention is to provide a suture anchor and suture anchor installation tool which improve upon the suture anchor and the three-element installation tool of the above-identified U.S. Pat. Application Ser. No. 051,367.
Still another object of the present invention is to provide a novel method for deploying a suture anchor in bone.
SUMMARY OF THE INVENTION
These and other objects of the present invention are achieved through the use of a novel suture anchor which comprises (a) a coupling member having a first end portion and a reduced second end portion, and a shoulder formed at the junction of the first end portion and the reduced second end portion, (b) at least one barb, the barb having a first end and a second end and being curved in its normal unstressed state and being capable of being elastically deformed to a substantially straight configuration, the barb being attached to the coupling member so that the second end of the barb is substantially displaced from the coupling member when the barb is in its normal unstressed state but is capable of being aligned with the coupling member when the barb is deformed to a substantially straight length, and (c) attachment means for attaching one end of a suture to the suture anchor.
The foregoing suture anchor is used with a novel suture anchor installation tool which comprises an elongated hollow member having a first end and a second end and a slot extending from the first end towards the second end, the elongated hollow member being sized to accommodate the reduced second end portion of the suture anchor, and the slot being sized to accommodate the barb, whereby the suture anchor may be attached to the elongated hollow member by fitting the reduced second end portion of the suture anchor into the first end of the elongated hollow member and by fitting the barb into the slot so that the barb extends upward and outward from the first end of the elongated member, through the slot, with the shoulder of the suture anchor engaging the first end of the elongated hollow member.
BRIEF DESCRIPTION OF THE DRAWINGS
Still other objects and features of the present invention will be more fully described or rendered obvious in the following detailed description of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
FIG. 1 is a side view in elevation of a prior art suture anchor disclosed in the above-identified U.S. Pat. Application Ser. No. 051,367;
FIG. 2 is a side view in elevation, in section, showing a prior art suture anchor installation tool disclosed in U.S. Pat. Application Ser. No. 051,367;
FIGS. 3-11 are a series of views showing the suture anchor of FIG. 1 being deployed into a bone hole using the suture anchor installation tool of FIG. 2;
FIG. 12 is a side view in elevation, partly in section, showing the preferred embodiment of the suture anchor installation tool which constitutes the present invention;
FIG. 13 is an end view in elevation showing the distal end of the suture anchor installation tool of FIG. 12;
FIG. 14A is a side view in elevation showing the suture being attached to the suture anchor remote from the installation tool;
FIG. 14B is a perspective view showing the suture and suture anchor of FIG. 14A, the installation tool of FIGS. 12 and 13, and a target bone which is to receive the suture anchor, all in exploded relation to one another;
FIG. 15 is an enlarged partial perspective view showing the suture anchor of FIG. 1 being loaded onto the distal end of the suture anchor installation tool of FIGS. 12 and 13;
FIG. 16 is a perspective view showing the suture anchor of FIG. 1 being loaded onto the distal end of the suture anchor installation tool of FIGS. 12 and 13;
FIG. 17 is a side view in elevation showing the suture anchor of FIG. 1 and the suture anchor installation tool of FIGS. 12 and 13 as the suture anchor is being introduced into a hole formed in bone;
FIG. 18 is a side view in elevation showing the suture anchor of FIG. 1 remaining in the hole formed in the bone as the suture anchor installation tool is withdrawn;
FIG. 19 is a partial perspective view showing a second embodiment of the suture anchor installation tool;
FIG. 20 is a partial side elevation showing a third embodiment of the suture anchor installation tool receiving a suture anchor;
FIG. 21A is a partial perspective view showing a fourth embodiment of the suture anchor installation tool;
FIG. 21B is a partial side elevation showing a fifth embodiment of the suture anchor installation tool;
FIG. 22 is a partial perspective view showing a sixth embodiment of the suture anchor installation tool;
FIG. 23 is a side view in elevation showing a novel drill for forming the hole in the bone which is to receive the suture anchor;
FIG. 24 is a side view in elevation showing the novel drill of FIG. 19 in the process of forming a hole in bone;
FIG. 25 is a side view in elevation, partly in section, showing the suture anchor installation tool of FIG. 12 and a modified form of suture anchor, in exploded relation; and
FIG. 26 is a side view in elevation showing the modified suture anchor of FIG. 25 loaded onto the suture anchor installation tool of FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
Looking now at FIGS. 12 and 13, there is shown a suture anchor installation tool 605 which constitutes the preferred embodiment of the present invention. Installation tool 605 comprises a hollow cannula 610 having a distal end 615 terminating in a flat end surface 620 and a rear end 625 terminating in a flat disk or knob 630. A longitudinally-extending slot 635 is formed in the side wall of cannula 610. Slot 635 begins at the cannula's distal end surface 620 and terminates in a rear surface 640.
Installation tool 605 is adapted to be used to install a suture anchor such as the suture anchor 105 previously described, and to this end it is important that installation tool 605 be dimensioned in accordance with the dimensions of the actual suture anchor being deployed by the tool. Specifically, it is important that suture anchor installation tool 605 be sized so that (a) its cannula 610 has an outer diameter smaller than, equal to or just slightly larger than the outer diameter of the suture anchor's coupling member 110 so that the smallest possible hole may be formed in the bone which is to receive the bone anchor, (b) its cannula 610 has an internal diameter smaller than the outer diameter of the suture anchor's coupling member 110, so that the coupling member will not be able to slip inside the cannula, (c) its slot 635 has a width equal to or just slightly larger than the diameter of the suture anchor's barb 115, so that the barb will fit snugly between the walls of cannula 610 which define its slot 635, as will hereinafter be described in further detail, and (d) its slot 635 has a length sufficient to accommodate the suture anchor's barb 115 when the barb is bent backwards into the cannula during deployment of the suture anchor, as will hereinafter be described in further detail.
For example, in the case where suture anchor 105 is to be used to anchor a No. 0 suture, so that the suture anchor has the dimensions identified above, cannula 610 preferably has an inner diameter of approximately0.050 inch and an outer diameter of approximately 0.058 inch, slot 635 has a length (i.e., when measured from flat end surface 620 to slot rear surface 640) of approximately 0.370 inch and a width of approximately 0.031 inch. In the case where suture anchor 105 is to be used to anchor a No. 2 suture, the same installation tool may be used, since the suture anchor used in conjunction with a No. 2 suture will have the same size barb and an even wider diameter coupling member than the suture anchor used in conjunction with a No. 0 suture. Preferably, suture anchor installation tool 605 has an overall length, when measured from distal end 620 to the rear of disk 630, of approximately 4.0 inches.
In use, a suture is first attached to suture anchor 105, then the suture anchor is attached to the distal end of installation tool 605, and then the suture anchor is deployed into a hole formed in the bone using installation tool 605.
More specifically, and looking now at FIGS. 14A, 14B and 15, the suture is first attached to the suture anchor in the manner shown in FIG. 14A, i.e., by passing the suture through the suture anchor's bore 135 and then tying a knot 410 at the bottom end of the suture so that the knot seats against face 120 of suture anchor 105. Suture anchor 105 is then attached to the distal end of the installation tool by fitting the suture anchor's barb 115 into the installation tool's slot 635 and pressing the top surface 125 of the suture anchor flush against the installation tool's bottom surface 620. It will be appreciated that in view of the relative dimensioning of the suture anchor and the installation tool, coupling member 110 of the suture anchor is unable to enter the interior of cannula 610, and barb 115 will make a snug fit in cannula slot 635, the fit being snug enough to hold the suture anchor attached to the bottom end of the cannula.
The suture anchor is then ready to be deployed in a hole 505 formed in a bone 510 (see FIG. 16). It is to be appreciated that the hole formed in the bone is carefully sized according to the dimensions of the suture and suture anchor being deployed in the bone. For example, in the case of a No. 0 suture anchor, the hole formed in bone 510 is sized so as to have a diameter of approximately 0.072 inch and a depth of approximately 0.70 inches.
Looking next at FIGS. 17 and 18, the suture anchor is then deployed in the bone hole by pressing the distal end of the cannula down into the predrilled hole 505 in bone 510 until the assembly bottoms out on bone surface 515. As the distal end of the cannula forces the suture anchor down into the bone, the suture anchor's barb 115 engages the side wall of the bone, forcing the barb to retract inwards, into the cannula slot, so that the suture anchor installation tool (and the suture anchor and the suture carried by the suture anchor) can enter bone hole 505. When the bottom of the bone anchor bottoms out in bone hole 505 (see FIG. 18), and the cannula is thereafter withdrawn, the engagement of the suture anchor's barb with the bone wall causes the suture anchor to separate from the cannula, leaving the suture anchor (and its attached suture) securely anchored in the bone.
By using the installation tool 605 just described, a hole only slightly wider than the combined diameters of the cannula 610 and the suture 405 may be drilled in the bone. For example, where a No. 0 suture is to be attached to the bone using a bone anchor 105 and an installation tool 605 of the dimensions indicated above, a hole only approximately 0.072 inch in diameter must be drilled in the bone; where a No. 2 suture is to be attached to the bone using an appropriately sized bone anchor 105 and an appropriately sized installation tool 605, a hole only approximately 0.086 inch in diameter must be drilled in the bone.
A summary table of such sizing is given below:
TABLE 2______________________________________ Suture Size: No. 0 No. 2______________________________________Suture Anchor Dia. 0.053 0.061Cannula Diameter 0.058 0.058Suture Diameter 0.014 0.020Cannula + Suture Dia. 0.067 0.081Drill Diameter 0.072 0.086(Drill hole) - (Suture Anchor) 0.019 0.025______________________________________
A comparison of Table 2 with Table 1 shows that significantly smaller bone holes may be used when using the installation tool of FIGS. 12 and 13 in place of the three-element installation tool of FIG. 2; as a result, less expansion of barb 115 is required to fix the suture anchor in the bone and a tighter attachment of the suture anchor to the bone results.
It is to be appreciated that certain modifications may be made to the preferred embodiment described above without departing from the scope of the present invention.
Thus, for example, it is anticipated that installation tool 605 could be formed out of a substantially solid rod rather than a hollow cannula; in this case, installation tool 605A (see FIG. 19) would comprise a solid rod 610A having a slot 635A formed therein. Rod 610A would have the same outer diameter as the cannula 610 previously described. It will be appreciated that installation tool 605A functions in exactly the same manner, and provides substantially the same advantages, as the installation tool 605 previously described.
It is also anticipated that some or all of the suture anchor's coupling member 110 could be received within a portion of the installation tool to help hold the suture anchor aligned with the installation tool during insertion of the suture anchor into the bone. Thus, for example, a modified form of installation tool 705 is shown in FIG. 20. Installation tool 705 is identical to the installation tool 605 previously described, except that the cannula 710 is sized to accept a portion of the coupling member 110 of the suture anchor 105. More specifically, cannula 710 has a slightly larger outer diameter than the cannula 610 previously described, and it includes a counterbore 745 which opens on the cannula's distal surface 720 and which terminates in an internal shoulder 750. Shoulder 750 is positioned at a sufficient depth to allow a portion of the suture anchor's coupling member to be received within the cannula's counterbore 745, with the suture anchor's suture-receiving hole still being completely exposed. Preferably counterbore 745 and shoulder 750 are created by relieving a thick-walled hypodermic tubing to the desired depth.
In the case where suture anchor 105 is to be used to anchor a No. 0 suture, so that the suture anchor has the dimension identified above, cannula 710 preferably has an inner diameter of approximately 0.054 inch and an outer diameter of approximately 0.065 inch, slot 735 has a length (i.e., when measured from flat end surface 720 to the slot rear surface 740) of approximately 0.370 inch and a width of 0.031 inch. The cavity which accepts the suture anchor has a length (i.e., when measured from flat end surface 720 to stop 750) of approximately 0.060 inch.
In the case where suture anchor 105 is to be used to anchor a No. 2 suture, so that the suture anchor has the dimension identified above, cannula 710 preferably has an inner diameter of approximately 0.062 inches and an outer diameter of approximately 0.072 inches, slot 735 has a length (i.e., when measured from flat end surface 720 to the slot rear surface 740) of approximately 0.370 inch and a width of approximately 0.031 inch. The cavity which accepts the suture anchor has a length (i.e., when measured from flat end surface 710 to stop 750) of approximately 0.060 inch.
Preferably the suture anchor installation tool 705 has an overall length, when measured from distal end 720 to the rear of its top end, of approximately 4.0 inches.
Looking next at FIG. 21A, there is shown a substantially "solid" installation tool 705A which is adapted to receive a portion of the suture anchor's coupling member in the installation tool's distal end. To this end, installation tool 705A comprises a solid rod 710A having a slot 735A and a blind hole 745A formed therein. During use, the upper end of the suture anchor's coupling member is received in blind hole 745A. Blind hole 745A is sized to have a depth such that the suture anchor's suture-receiving hole will remain exposed when the coupling member is attached to the installation tool. Rod 710A is intended to have the same outer diameter as the cannula 710 previously described.
Looking next at FIG. 21B, there is shown yet another form of the invention. Installation tool 705B is identical to the installation tool 705 previously described, except that the hollow cannula 710B has an internal diameter as large as the diameter of the previously described counterbore 745, in order that the entire suture anchor will be received inside cannula 710A. No counterbore 745 or shoulder 750 is provided; instead, the cannula is crimped inward at 755B at one or more locations to form a stop for engaging the upper surface of the coupling member. Preferably crimps 755B are placed sufficiently far up along cannula 710B so that the entire length of the suture anchor's coupling member may be received within the cannula; in this case, a slot 736B is formed in the cannula, diametrically opposed from the barb-receiving slot 735B, to allow suture 405B to pass through the cannula's side wall. Cannula 710B is intended to have the same outer diameter as the cannula 710 previously described.
The installation tools shown in FIGS. 20, 21A and 21B all have an outer diameter which is greater than the outer diameter of the installation tools shown in FIGS. 12 and 19; nonetheless, smaller bone holes can still be used when using the installation tools of FIGS. 20, 21A and 21B than when using the three-element installation tool of FIG. 2. More specifically, a summary table of the sizing for the tools of FIGS. 20, 21A and 21B is given below:
TABLE 3______________________________________ Suture Sizes No. 0 No. 2______________________________________Suture Anchor (SA) OD .053 .061Inserter OD .065 .072Inserter ID .054 .062Suture Diameter .014 .020(Inserter OD) + (Suture Diameter) .079 .092Drill Diameter .079 .094(Drill Hole) - (SA Diameter) .026 .033______________________________________
A comparison of Table 3 and Table 2 with Table 1 shows that significantly smaller bone holes can be used when using the installation tools of FIGS. 12 and 19, or FIGS. 20, 21A and 21B, in place of the three-element installation tool of FIG. 2. In both designs, less expansion of barb 115 is required to fix the suture anchor in the bone.
Furthermore, it is anticipated that installation tools 605, 605A, 705, 705A and/or 705B could be provided with a plurality of slots 635, 635A, 735, 735A and 735B, respectively, for situations where the installation tool is to be used to deploy a suture anchor 105B of the sort having two or more barbs 115B. FIG. 22 illustrates a suture anchor installation tool 605B which may be used to install a suture anchor 105B (having three barbs 115B) in bone.
Yet another modification relates to the method of utilizing the present invention. More specifically, while in all of the foregoing embodiments it was described that the suture is attached to the suture anchor prior to attaching the suture anchor to the installation tool, it is also anticipated that the suture could be attached to the suture anchor after the suture anchor is attached to the installation tool.
Looking next at FIGS. 23 and 24, there is also shown a novel drill 805 for forming the hole 505 in bone 510 which is to receive the suture anchor. Drill 805 comprises a conventional helical drill thread 810 at its distal end. Thread 810 terminates in an inclined frustoconical shoulder 815 which serves as a stop to prevent the drill from penetrating too far into the bone. Shoulder 815 also serves to chamfer bone 510 at 515 as shown so as to minimize chafing of the suture about the top of hole 505.
It is also to be appreciated that the suture anchor's coupling member 110 could be formed out of a material other than 6AL4V titanium alloy, and barb 115 could be formed out of a material other than nickel titanium alloy. For example, coupling member 110 could be formed out of titanium and its alloys, ceramics, plastics, stainless steel and other suitable bio-compatible materials, and barb 115 could be formed out of titanium and its alloys, and stainless steel.
Looking next at FIGS. 25 and 26, a modified suture anchor 105A is shown with the suture anchor installation tool 605 previously described.
Suture anchor 105A is identical to the suture anchor 105 previously described, except as will hereinafter be noted. More particularly, the coupling member 110A of suture anchor 105A is slightly longer than the coupling member 110 of suture anchor 105, and comprises a lower portion 111A and an upper portion 112A. Lower portion 111A has a diameter similar to the diameter of coupling member 110, and includes first end surface 120A and suture bore 135A. Upper portion 112A has a reduced diameter that is somewhat less than that of lower portion 111A, and includes second end surface 125A and the blind hole 130A for receiving the first end 140A of barb 115A. A shoulder 113A is formed at the junction of the coupling member's lower portion 111A and its upper portion 112A.
Suture anchor 105A is sized, relative to suture anchor installation tool 605, so that the suture anchor's upper portion 112A can be received in the interior of the tool's cannula 610 (FIG. 26) while the suture anchor's lower portion 111A is positioned in front of the cannula, with the cannula's flat end surface 620 engaging the coupling member's shoulder 113A, and with the suture anchor's barb 115A being accommodated in the tool's slot 635.
In operation, suture anchor 105A and installation tool 605 operate in the manner previously described with respect to suture anchor 105 and tool 605, except that receipt of the suture anchor's upper portion 112A within tool cannula 610, and engagement of the cannula's flat end surface 620 with suture anchor shoulder 113A, yields a more stable engagement between the suture anchor and the suture anchor installation tool during deployment of the suture anchor in bone.
It should also be appreciated that a further advantage obtained by the foregoing construction is that the suture anchor's upper portion can be sized so as to facilitate proper crimping of the coupling member about the barb (i.e., the upper portion 112A can be formed with a diameter more closely corresponding to the diameter of barb 115A, so that there is no excess material to interfere with crimping), while the suture anchor's lower portion 111A (and its associated suture bore 135A) can be sized so as to accommodate the desired suture width. For example, where it is desired to pass a relatively thick suture through suture bore 135A, or even to pass two or more suture strands 405A through suture bore 135A (as shown in FIG. 26), the lower portion 111A of suture anchor 105A can be formed with a greater diameter than it might otherwise be, without interfering with the proper crimping of the coupling member about the barb.
ADVANTAGES OF THE INVENTION
Numerous advantages are achieved by utilizing the present invention.
First, a novel suture anchor configuration is disclosed which facilitates insertion of the suture anchor.
Second, a suture anchor and suture anchor installation tool are provided which improve upon the suture anchor and the three-element installation tool of the above-identified U.S. Patent Application Serial No. 051,367.
Third, a novel method for deploying a suture anchor in bone is disclosed. | A novel suture anchor comprising (a) a coupling member having a first end portion and a reduced second end portion, and a shoulder formed at the junction of the first end portion and the reduced second end portion, (b) at least one barb, the barb having a first end and a second end and being curved in its normal unstressed state and being capable of being elastically deformed to a substantially straight configuration, the barb being attached to the coupling member so that the second end of the barb is substantially displaced from the coupling member when the barb is in its normal unstressed state but is capable of being aligned with the coupling member when the barb is deformed to a substantially straight length, and (c) attachment means for attaching one end of a suture to the suture anchor. The suture anchor is installed in a hole in bone using a suitable installation tool by aligning the second end of the barb with the coupling member, inserting the anchor in the hole, and then permitting the second end of the barb to assume a displaced position whereby the barb and coupling member are driven into engagement with the sidewall of the hole. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of Italian patent application number TO2006A000435, filed Jun. 15, 2006, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to door and window frames.
2. Description of the Related Art
The invention was developed for the application to door or window frames constituted by extruded section bars made of aluminium or similar metallic alloys, constituted by a quadrangular frame formed by four section bars defining a pair of uprights and a pair of cross members. The section bars forming the frames are constituted by bars with complex section, produced by extrusion, drawing or profiling. Each of said section bars is provided on an outer side of the frame with a longitudinal groove to be used for mounting the articulation hinges and the drive assembly of the door or window frame. In the remainder of the description and in the claims, “drive assembly” means the set of devices and components that allow to transmit the opening/closing motion from the handle to the various closure elements.
Door and window frames are classified as door and window frames with wing opening, with swivel opening and with wing and swivel opening. Wing opening is defined as an opening movement that takes place by rotation around a vertical axis. Swivel opening means an opening movement that takes place by rotation around a horizontal axis. Door and window frames with wing and swivel opening can be opened selectively by means of rotation around a vertical axis or by means of rotation around a horizontal axis.
In the case of door window frames within wing opening only or with swivel opening only, the drive assembly enables to select the closed or open position of the door or window frame. In the case of door or window frames with wing and swivel opening, the drive assembly enables selectively to activate closed positions, wing opening positions or swivel opening positions, under the command of a cremone bolt device.
The standard conformation of the metal section bars for doors or windows comprises on the outer side of the frame a longitudinal groove with undercut profile formed by a base, two parallel lateral walls and two edges oriented against each other and defining an undercut engagement area at each of the lateral walls of the longitudinal groove. Mounting the components of the drive assembly in the longitudinal slots of the section bars of the frame is an operation that has a considerable impact on the time required to assemble the door or window frames. In the most traditional solutions, the members comprising the drive assembly are provided with two longitudinal tenons that engage the two undercut engagement areas of the respective longitudinal grooves. This solution is not very attractive to the manufacturers of window and door frames because it entails the need to obtain notches at the end of each groove to allow the insertion of the actuating members in the longitudinal direction.
To overcome this drawback, the document FR-A-2722527 proposed a solution in which each actuating member is provided with a single tenon that engages only one undercut area of the longitudinal groove. According to the solution described in FR-A-2722527, the actuating members are arranged contiguous in alternated fashion, so that the first actuating member has its tenon engaging a first undercut engagement area of the groove and the actuating member adjacent to it has its own tenon engaging a second undercut engagement area opposite the first one. Arranging the actuating members in alternating fashion aims to solve the problem of the stability of the engagement between the actuating members and the groove of the frame. When two or more adjacent actuating members are fastened to each other, the set constituted by the series of mutually fastened actuating members comprises at least one tenon that engages the first undercut engagement area and at least one tenon that engages the second undercut engagement area of the groove.
The drawback of this solution is that the alternated mounting of the actuating members is inconvenient and it may require repeatedly upsetting the frame.
European patent application no. 05425179 by the same Applicant (not yet published as of the filing date of the present application) describes a drive assembly for door and window frames provided with actuating members with a single tenon which are inserted in transverse direction into the respective longitudinal slots of the frame. Said document does not describe that the actuating members all engage a same undercut engagement area of the respective groove.
The document DE-A-3225049 describes a door or window frame in which the longitudinal groove comprises a single undercut engagement area and with a lateral wall of the groove with a T shape engaged at opposite sides by two opposite tenons of the actuating members.
SUMMARY OF THE INVENTION
The object of the present invention is to provide actuating members for door and window frames that can be mounted with greater simplicity relative to prior art solutions.
According to the present invention, said object is achieved by a door or window. that includes a movable quadrangular frame formed by four section bars each having a longitudinal groove. Each of the longitudinal grooves comprising a base, two parallel lateral walls and two edges oriented towards each other, wherein the edges and the lateral walls define a first undercut engagement area adjacent to a first face of the frame and a second undercut engagement area adjacent to a second face of the frame. The door or window further includes a drive assembly for opening/closing the movable quadrangular frame. The drive assembly comprising a plurality of actuating members and a plurality of transmission rods that operatively connect adjacent actuating members to each other, wherein each of the actuating members and each of the transmission rods has a single integral tenon, and wherein the tenons of all the actuating members and the tenons of all the transmission rods engage the first undercut engagement area.
In the solution according to the present invention, the actuating members have a single tenon and they all engage the undercut engagement area situated on the same side of the respective groove.
Thanks to this solution idea, during the assembly of the actuating members in the grooves of the section bars, it is not necessary repeatedly to upset the frame to mount the actuating members in alternated fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention shall now be described in detail with reference to the accompanying drawings, provided purely by way of non limiting example, in which:
FIG. 1 is a perspective view of a window or door frame according to the present invention,
FIG. 2 is a partially sectioned perspective view showing the mounting sequence of an actuating member indicated by the arrow II in FIG. 1 ,
FIG. 3 is also a partially sectioned perspective view showing the mounting sequence of an actuating member indicated by the arrow II in FIG. 1 ,
FIGS. 4 and 5 are sections respectively according to the lines IV-IV and V-V of FIGS. 2 and 3 ,
FIG. 6 is a partially sectioned perspective view showing the mounting sequence of the actuating member indicated by the arrow VI in FIG. 1 ,
FIG. 7 is also a partially sectioned perspective view showing the mounting sequence of the actuating member indicated by the arrow VI in FIG. 1 ,
FIGS. 8 and 9 are sections respectively according to the lines VIII-VIII and IX-IX of FIGS. 6 and 7 ,
FIG. 10 is a partially sectioned perspective view showing the actuating member indicated by the arrow X in FIG. 1 in the mounted position, and
FIG. 11 is a section according to line XI-XI of FIG. 10 .
DETAILED DESCRIPTION
With reference to FIG. 1 , the number 10 designates a door or window frame according to the present invention. The door or window frame 10 comprises a quadrangular frame 12 formed by four section bars 14 preferably constituted of aluminium or alloys thereof. Each of the section bars 14 has an outer side provided with a longitudinal groove 16 .
With reference to FIGS. 2 and 3 , the frame 12 has two front faces designated respectively by the numbers 18 and 20 . The section bars 14 have respective front bearing edges 22 aligned to the first face 18 of the frame 12 and projecting outwards beyond the respective groove 16 . The front bearing edges 22 have respective grooves 24 able to receive a front sealing gasket (not shown) which in the closed position of the window or door frame is pressed against a front surface of the fixed frame of the door or window.
With reference for example to FIGS. 2 and 4 , the longitudinal groove 16 of each section bar 14 comprises a base 26 , two lateral walls 28 and two longitudinal edges 30 oriented towards each other. The two longitudinal ends of the edges 30 facing each other define the outer opening of the longitudinal groove 16 . The longitudinal edges 30 define an undercut engagement area at each lateral wall 28 of the groove 16 . A first undercut engagement area 32 is adjacent to the first face 18 of the frame 12 and a second undercut engagement area 34 is adjacent to the second face 20 of the frame 12 .
Each undercut engagement area 32 , 34 has substantially “C” shape and is defined between the inner surfaces of the edge 30 , of the lateral wall 28 and by the lateral portion of the base 26 . The shape of the longitudinal groove 16 is standardised and it is used by most metallic section bars for door or window frames.
With reference to FIG. 1 , the window or door frame 10 is provided with a drive assembly globally designated by the number 36 . The drive assembly 36 comprises a plurality of actuating members 38 , 40 , 42 , 46 49 and a plurality of transmission rods 48 , 50 that operatively connect adjacent actuating members to each other. The drive assembly 36 shown in FIG. 1 is that of a door or window frame with wing and swivel opening and it comprises a vertical fulcrum 38 , an angled transmission 40 , a scissors arm 42 a cremone bolt coupling and a cursor 49 .
According to the present invention, each actuating member and each transmission rod is provided with a single integral tenon for engagement with the respective groove 16 , so that all the components of the drive assembly 36 can be mounted frontally in the respective grooves. The tenons of the actuating members and of the transmission rods all engage the undercut engagement area 32 of the respective groove 16 adjacent to the first wall 18 of the frame 12 , i.e. the wall provided with front bearing edge 22 .
FIGS. 2 to 11 schematically show some details and the manners of mounting of some actuating members 40 , 42 , 49 comprising the drive assembly 36 .
With reference to FIGS. 2 through 5 , the actuating member 49 (cursor) has a single tenon 52 obtained in integral form with the body of the actuating member 49 and engaging the first undercut engagement area 32 of the groove 16 . The actuating member 49 is mounted by positioning the tenon 52 into the first undercut engagement area 32 as shown in FIGS. 2 and 4 and then making the engagement member 49 oscillate towards the interior of the groove 16 obtaining the frontal insertion of the actuating member 49 into the groove 16 as shown in FIGS. 3 and 5 . On the opposite side of the tenon 52 , the actuating member 49 is provided with a bearing longitudinal edge 54 that bears on the outer side of the edge 30 situated at the second undercut engagement area 34 .
The actuating member 49 is fastened to the transmission rod 50 by means of a screw 56 . The manner in which each actuating member 38 , 40 , 42 , 46 and 49 is fastened to the respective transmission rods 48 , 50 is described in detail in a contemporaneous patent application by the same Applicant.
FIGS. 6 through 9 show the way in which the frontal mounting of the angled transmission 40 is carried out. In this case, too, the angled transmission 40 is provided with a single integral tenon 52 that engages the first undercut engagement area 32 of the longitudinal groove 16 . The mounting operation is carried out by frontally inserting the angled transmission 40 into the groove 16 as indicated in FIGS. 6 and 8 and then making the angled transmission 40 oscillate towards the interior of the groove 16 until it reaches the position shown in FIGS. 7 and 9 . On the opposite side of the tenon 52 there is a bearing edge 54 that bears on the outer side of the edge 30 situated at the second undercut engagement area 34 . The angled transmission 40 can also be provided with a recessing tooth 58 that engages in snap-in fashion the edge 30 during the frontal insertion into the groove 16 . The recessing tooth 58 is thrust elastically outwards and it has the purpose of holding the angled transmission 40 inside the groove 16 during the assembly. Similar retaining teeth can also be provided on other actuating members of the assembly 36 .
With reference to FIGS. 10 and 11 , the scissors arm 42 is also mounted in the manner described previously. FIGS. 10 and 11 show the scissors arm 42 at the end of the mounting in the groove 16 . The insertion takes place frontally, positioning the single integral tenon 52 in engagement with the first undercut engagement portion 32 and then making the scissors arm 42 oscillate towards the interior of the groove 16 .
The fact that all the actuating members and all the transmission rods are provided with a single tenon for connection to the section bars 14 could cause instability problems due to pressures on the door or window frame. However, said problems are solved thanks to the fact that all the actuating members engage the undercut engagement area 32 of the groove 16 that is oriented towards the face 18 of the frame 12 provided with the front bearing edge 22 . In the case of inward opening door and window frames, the face 18 is the inner face of the door or window frame whilst in the case of outward opening door and window frames, the face 18 is the outer face of the door or window frame.
The fact that all the tenons of the drive assembly 36 engage the inner portion of the groove 16 in the case of inward opening door and window frames and the outer portion of the groove 16 in the case of outward opening door and window frames determines a complete stability, even without a tenon with structural function on the opposite side of the groove 16 . It can be demonstrated that the connection between the actuating members and the section bars 14 is perfectly stable in the case of thrusts directed from the outside inwards, in the case of inwardly opening door and window frames, or under the action of thrusts directed from the inside outwards, in the case of outwardly opening door and window frames.
The fact that all the tenons of the drive assembly 36 engage the same side of the groove 16 enables to carry out the frontal mounting of the actuating members and of the transmission rods without upsetting the frame 12 , i.e. keeping the frame 12 with the face 18 bearing on a horizontal plane during the entire assembly operation.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. | A closure includes a frame that is selectively pivotable about a vertical axis and a horizontal axis. A drive assembly is disposed in a groove of the frame to selectively determine which axis the frame pivots about as the frame pivots between an open position and a closed position. The drive assembly includes a plurality of actuating members and a plurality of transmission rods that operatively connect adjacent actuating members to each other. Each of the actuating members and each of the transmission rods has a single tenon which is disposed in only one side of the groove. | 4 |
FIELD OF THE INVENTION
[0001] Anti bacterial and teeth whitening mouth rinse compositions.
BACKGROUND OF THE INVENTION
[0002] Oral mouth rinse compositions have been used for the prevention of bad breath, elimination of oral microorganisms that are responsible for bad breath, tooth decay, plaque, gum diseases such as gingivitis, and for whitening of the teeth. Oral mouth rinses containing hydrogen peroxide are well known for their ability to whiten teeth and reduce the bacterial flora in the oral cavity. Hydrogen peroxide is utilized due to its ability to decompose into water and oxygen, with the oxygen then acting as both an antimicrobial agent, and a bleaching agent to whiten teeth.
[0003] In the oral cavity, the decomposition of hydrogen peroxide into water and oxygen is aided by the enzyme peroxidase (also known as catalase). One factor affecting the rate of decomposition is the amount of peroxidase present in the oral cavity, with greater concentration resulting in greater decomposition. Thus, a mouth rinse that can cause an increase in the amount of peroxidase will have greater whitening and antimicrobial effectiveness.
[0004] Day U.S. Pat. No. 6,692,757 discloses a system for cleaning water lines, particularly in dental offices in which the peroxide decomposition is accelerated by the presence of an acidic sulfate. The presence of a disinfectant is also required. There is no disclosure or suggestion of oral use.
[0005] A second factor that will increase the rate of hydrogen peroxide decomposition is temperature. Higher temperature will increase the reaction rate between the peroxidase and peroxide, thus causing a faster onset of whitening and microbial kill. A heated mouth rinse will whiten teeth and kill microbes to a greater extent than an unheated mouth rinse of the same composition.
[0006] The generation of heat in solutions for hair bleaching and dying using a combination of hydrogen peroxide and sulfites is well known, but there has been no disclosure of suggestion of such combinations in the oral cavity.
SUMMARY OF THE INVENTION
[0007] The present invention provides a novel group of mouth rinses which enhance the activity of peroxide mouth rinses. This is achieved in two ways. The presence of orally acceptable inorganic cationic salts of sulfates, bisulfates or pyrosulfates in these rinses enhances the generation of saliva in the oral cavity and thus the level of peroxidase therein. This in turn causes a more rapid and efficient generation of active oxygen from the peroxide which in turn brings about greater whitening and microbial kill.
[0008] A particularly preferred embodiment utilizes an in-situ formation of sulfate, bisulfate pyrosulfate or mixture thereof from the reaction between sulfites, bisulfites or metabisulfites and peroxide to form sulfates. This embodiment suitably utilizes a 2-phase system that is mixed just prior to use in the oral cavity. Part 1 of the system contains an orally acceptable inorganic cation salt of sulfite, bisulfite, metabisulfite or mixture thereof. Part 2 contains an orally acceptable peroxide in an amount that exceeds the stoichiometric amount required to convert the sulfite, bisulfite, metabisulfite or mixture thereof, by at least 0.5%. Other ingredients such as flavor, ethanol etc. may optionally be included when desired, as described below.
[0009] During the reaction, not only is a sulfate and or a bisulfate formed but also the reaction is exothermic, which results in a temperature increase of about 3 to about 30 degrees centigrade depending on the concentrations employed. The resulting solution forms the mouth rinse, which if used substantially at once after formation, will provide not only increased salivary flow, but also increased temperature, both of which will increase the rate of peroxide decomposition, and result in greater antimicrobial efficacy and/or tooth whitening efficacy.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] In order for the peroxidase acceleration of peroxide decomposition to be effective, the saliva stimulation must be effective but taste acceptable. Clearly this is an individual matter. While operative, concentrations above 10 wt % in the rinse have a salty taste, it is thus preferred to provide somewhat less salt, suitably between about 1.5 and about 6 wt % of the solution in the oral cavity.
[0011] For the reaction creating the oxidized salt to be sufficiently exothermic, sulfite, bisulfite or metabisulfite initial levels at the higher end of this range are preferred. Clearly there also needs to be not only the stoichiometric equivalent of peroxide to generate the exothermic reaction, but also sufficient excess peroxide to generate the active oxygen provided by the acceleration of decomposition caused by the rise in temperature. This excess should be at least 0.5 wt % of the solution used, but suitably may rise to about 5 wt %, though this should not be considered a limiting amount.
[0012] Thus the oral mouth rinse composition which is utilized suitably consists essentially of: a) 1-20 wt % of an orally acceptable peroxide, b) 0.5-15 wt % of an orally acceptable sulfate, bisulfate, or pyrosulfate salt of an inorganic cation or mixtures thereof, and c) water to 100 wt %. For example this may be prepared by mixing equal amounts of i) an aqueous solution consisting essentially of 2-40 wt % of the peroxide, and ii) an aqueous solution consisting essentially of 1-30 wt % of the said inorganic cation salt of a sulfite, bisulfite, metabisulfite or mixture thereof, provided that the amount of peroxide in (i) exceeds the stoichiometric amount required to completely oxidize the salt of the sulfite, bisulfite, metabisulfite or mixture thereof, by at least 0.5 wt %. Similarly, the final mouthrinse can be prepared by mixing unequal amounts of i) and ii) in such quantities as needed to achieve a final solution within the ranges specified above. Desirably, the components i) and ii) are contained in a kit of containers each containing one of these components.
[0013] Suitably, the peroxide is any orally acceptable peroxide, suitably hydrogen peroxide, urea peroxide or mixtures thereof and the cation is selected from the group consisting of sodium, potassium, ammonium, magnesium, calcium, aluminum, zinc, iron or mixture thereof.
[0014] The rinse may contain other ingredients conventionally used in mouth rinses. These include but are not limited to ethanol, flavor oils, sweeteners, and surfactant in an amount to enable solubilization of flavor oils,
[0015] While in no way to be considered as limiting favorable ranges in the present invention provide peroxide/bisulfate mouth rinses consisting essentially of from about 1.5 to about 6 wt %, preferably about 3 wt % peroxide and from about 3 to about 10 wt %, preferably about 5 wt % bisulfate. Additionally the rinses may contain ethanol, flavor oils, sweeteners and surfactant in an amount to enable solubilization of flavor oils, and water.
EXAMPLES
Example 1
Pre-Brushing Mouth Rinse
[0016] Ingredient % by Weight Ethanol 5.00 Flavor Oil 0.10 Benzoic Acid 0.25 Poloxamer 407(10% Aq. Sol'n) 0.25 Sucralose (1% Aq. Sol'n) 15.00 Water 74.90 Sodium Bisulfate 3.00 Disodium Pyrophosphate 1.50 Total 100.00
Combine Ethanol, Flavor and Benzoic Acid. Mix until clear. While mixing, slowly add the Poloxamer, Sucralose, and water. Continue mixing and add the Sodium Bisulfate and Disodium Pyrophosphate. Mix until a clear solution is obtained.
Example 2
Breath Freshening Mouth Rinse
[0017] Ingredient % by Weight Ethanol 20.00 Flavor Oil 0.20 Benzoic Acid 0.25 Magnesium Lauryl Sulfate 0.20 Sorbitol 15.00 Water 61.85 Sodium Bisulfate 2.50 Total 100.00
Combine Ethanol, Flavor and Benzoic Acid. Mix until clear. While mixing, slowly add the Magnesium Lauryl Sulfate, Sorbitol, water and Sodium Bisulfate. Mix until a clear solution is obtained
Example 3
Two Phase Tooth Whitening Mouth Rinse
[0018]
Ingredient
% by Weight
Phase A:
Ethanol
10.00
Flavor Oil
0.20
Magnesium Lauryl Sulfate
0.27
Sucralose (1% Aq. Sol'n)
15.00
Water
61.53
Sodium Bisulfate
8.00
Tromethamine
5.00
Phase A Total
100.00
Phase B:
Hydrogen Peroxide(50% Aq. Sol'n)
6.00
Water
94.00
Phase B Total
100.00
Phase A: Combine Ethanol, Flavor Oil and Magnesium Lauryl Sulfate. Mix until clear. While mixing, add the Sucralose, Water, Sodium Bisulfate, and Tromethamine. Mix until a clear solution is obtained.
Phase B: Combine the Hydrogen Peroxide and water. Mix until uniform
Combine equal amounts of Phase A and Phase B, just prior to use, to form the final mouthrinse
Example 4
Two Phase Whitening Mouth Rinse (In-Situ Formation of Sodium Bisulfate)
[0019]
Ingredient
% by Weight
Phase A:
Ethanol
10.00
Flavor Oil
0.20
Magnesium Lauryl Sulfate
0.27
Sucralose (1% Aq. Sol'n)
15.00
Water
61.53
Sodium Metabisulfite
4.00
Sodium Sulfite
4.00
Tromethamine
5.00
Phase A Total
100.00
Phase B:
Hydrogen Peroxide(50% Aq. Sol'n)
12.00
Water
88.00
Phase B Total
100.00
Phase A: Combine Ethanol Flavor Oil and Magnesium Lauryl Sulfate. Mix until clear. While mixing, add the Sucralose, water, Sodium Metabisulfite, Sodium Sulfite and Tromethamine. Mix until a clear solution is obtained.
Phase B: Combine the Hydrogen Peroxide and water. Mix until uniform
Combine equal amounts of Phase A and Phase B, just prior to use, to form the final mouthrinse
[0020] In accordance with the above formulation, but where in place of sulfite and/or the metabisulfite there is utilized only the metabisulfite, sulfite, or bisulfite, a similar solution is obtained.
[0021] In accordance with the above formulation, but where in place of sodium the cation utilized is potassium, ammonium, magnesium, calcium, aluminum, zinc, iron or mixture thereof a similar formulation is obtained.
[0022] Similarly in place of hydrogen peroxide, there may be utilized urea peroxide or mixtures thereof with hydrogen peroxide.
[0023] The formulation is utilized by introducing a comfortable amount, suitably about 10 ml, into the mouth agitating it, and ejecting it. | There are provided oral mouth rinse compositions, consisting essentially of: a) 1-20 wt % of an orally acceptable peroxide, b) 0.5-15 wt % of an orally acceptable sulfate, bisulfate, pyrosulfate salt of an inorganic cation or mixtures thereof, and c) water to 100 wt %. There are further provided methods of preparing and using said compositions as well as kits for maintaining the components to prepare said compositions. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hand-held power tool, in particular electrical power tool, including a housing and an identification element which, e.g., can be formed separately from the housing, is provided with an appropriate identification mark, and is mountable on the housing so that it becomes visible on the outer side of the housing from outside. The present invention also relates to a method of manufacturing such a tool, in particular, the identification element.
2. Description of the Prior Art
In the hand-held power tools of the type discussed above, certain data such as, e.g., mark, indication of the type of the power tool, or serial number of the power tool are clearly visible on the apparatus housing. In particular, with a separate manufacturing of the indication element from the remaining of the housing and a subsequent at least partial handling of the indication element, a particularly elegant execution of the indication is possible.
German Utility model DE 20 2004 020 518 U1 discloses a hand-held power tool with lettering being provided on a separate part of the power tool housing. During the manufacturing of the power tool housing, this separate part is placed in the housing mold and becomes surrounded with the plastic material the housing is made of when the remaining portion of the housing is injection-molded. The lettering is formed of another material than the housing of the power tool.
With the known approach, the lettering can be produced from a particularly scratch-resistant material in order to retain a clear impression over the service life of the power tool.
The drawback of the known power tool consists in that the power tool housing already includes the lettering upon being produced and, therefore, is suitable only for a corresponding type of power tools. However, in particular, during manufacturing of a series of power tools with different types of power tools which, however, have the same housing, it makes sense when the housing is suitable, after its production, for all of the power tool types of the series. In this case, the housings can be produced and stored for all of the power tool types and only later be distributed between separate types of the power too, as needed.
Accordingly, an object of the present invention is to provide a power tool in which the drawbacks of the known power tool are eliminated, and a simple lettering or label is provided that can be used firstly, after the housing has been produced.
SUMMARY OF THE INVENTION
This and other objects of the present invention, which will become apparent hereinafter, are achieved by forming the identification element as a tag that is pushed into a correspondingly dimensioned receptacle formed in the housing.
According to the present invention, the housing has, after being produced, a predetermined position for the indication element. The proper indication mark of the housing and its mounting can be effected later, e.g., during the end assembly of the power tool. In addition, the subsequently insertable, in the receptacle, indication element provides for its separate handling and an easy affixing of the indication mark.
According to a particularly advantageous embodiment of the present invention, the indication element can be secured in the receptacle by a third element of the power tool. This enables a simple, cost-effective and long-lasting fixation of the indication element in the power tool housing.
Advantageously, the securing element has a locking region, and the identification element has a formlocking element that abuttingly engages the locking region of the securing element in a direction opposite the direction in which the identification element is pushed into the receptacle, when the indication element is positioned in the receptacle. Thereby, in a simple way, a stable and precisely positioned fixation of the indication element relative to the power tool housing is insured.
Advantageously, the third tool element is formed by an air guide which is produced separately from the housing and then inserted in the housing. At that, e.g., an elastic locking region can be formed on the air guide in a particularly simple manner and which the formlocking element of the identification element can engage. Alternatively, it can be provided that the air guide is inserted into the housing only after the positioning of the indication element therein, with the locking region being so formed that upon insertion of the air guide, it engages the formlocking element from behind, blocking the displacement of the indication element relative to the receptacle.
Advantageously, the indication mark is arranged in a recess formed in the indication element. Thereby, the indication mark is protected from scratches, in particular when the power tool is laid down.
Advantageously, the receptacle is provided in a recess formed in the housing. Thereby, double-walling, which requires additional constructional space and a greater material consumption is prevented.
It is particularly advantageous when both the identification element and the receptacle taper in the direction in which the identification element is pushed into the receptacle. This insures an exact positioning of the indication element when it is pushed in the receptacle.
Advantageously, the hand-held power tool includes two identification elements of the type discussed above which are provided on two sides of the power tool housing.
The method of manufacturing such a hand-held power tool includes forming a power tool housing provided on two of its sides thereof with two receptacles, respectively, forming two identification elements dimensioned in accordance with respective dimensions of the two receptacles, as parts of a single cast element, providing the two identification elements with respective identification marks in a single printing process, separating the two identification elements and inserting the two identification elements in the respective receptacles. The foregoing method provides for a particular cost-effective manufacturing of the indication elements and of applying indication marking thereon.
The novel features of the present invention, which are considered as characteristic for the invention, are set forth in the appended claims. The invention itself, however, both as to its construction and its mode of operation, together with additional advantages and objects thereof, will be best understood from the following detailed description of preferred embodiment, when read with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show:
FIG. 1 a side view of a hand-held power tool according to the present invention;
FIG. 2 a side view of motor housing part of the hand-held power tool shown in FIG. 1 , with the identification element being pulled out;
FIG. 3 a cross-sectional view along line III-III in FIG. 2 ; and
FIG. 4 a side view of a cast element with two identification elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An electrical hand-held power tool 2 according to the present invention, which is shown in FIG. 1 and is formed as a hammer drill, includes a multi-part housing 4 and a motor 6 for driving the power tool 2 and located in a motor housing part 8 . The motor 6 is cooled by an aeration device 10 which is located at the upper end of the motor housing part 8 .
As shown in FIG. 1 , a tag-shaped first identification element 14 . 1 is secured on a first side S 1 of the motor housing part 8 . On the first identification element 14 . 1 , a first identification mark 16 . 1 is provided. The first identification mark 16 . 1 can contain letters or figures, marking, a pictogram, here, e.g., indicated with XXX, or a mixed form. The first identification mark 16 . 1 is formed on the first identification element as a print or embossing, or by other means bonded to the first identification element 14 . 1 .
FIGS. 2-3 show the motor housing part 8 separately and before installation of the first identification element 14 . 1 . As can be seen in FIG. 3 , a second, likewise tag-shaped, identification element 14 . 2 is provided on a second side S 2 of the housing 4 opposite the first side S 1 . The second identification element carries a second identification 16 . 2 that corresponds to the first identification mark 16 . 1 . Both identifications 16 . 1 , 16 . 2 are located in respective recesses 18 . 1 , 18 . 2 formed in the corresponding identifications 14 . 1 , 14 . 2 , and are visible from outside of the housing 4 .
As further shown in FIGS. 2-3 , a receptacle 20 . 1 , 20 . 2 is provided on each side S 1 , S 2 . The receptacle 20 . 1 , 20 . 2 is formed by a respective recess 22 . 1 , 22 . 2 in the housing 4 , which is limited by opposite guides 24 . The guides 24 serve for receiving complementary counter-guides 26 provided on the identification elements 14 . 1 , 14 . 2 . The guides 24 and counter-guides 26 can form, as shown, groove and spring connections.
As particularly shown in FIG. 3 , a rib-shaped formlocking element 28 is provided on each of the identification elements 14 . 1 , 14 . 2 . When the identification elements 14 . 1 , 14 . 2 are pushed in a displacement direction E, the formlocking elements 28 are pressed against respective locking regions 30 of respective third housing elements 32 ( FIG. 2 ). In the embodiment shown in the drawings, the locking regions are formed by an elastic bar lock 34 , and the housing element 32 is formed by an air guide that is inserted in the motor housing 8 at its upper end 12 , with the bar lock 34 extending therefrom (see FIG. 2 ).
As soon as the end position of the first identification element 14 . 1 , which is shown in FIG. 1 , or, correspondingly, the end position of the second identification element 14 . 2 is reached, the bar lock 34 snaps behind the formlocking element 28 which, thus, abuts the bar lock 34 in a direction opposite the displacement direction E. Thereby, the identification elements 14 . 1 , 14 . 2 are secured in the housing 4 in their inserted position.
Alternatively, it is possible to form the locking region 30 by a rigid region of the third housing element 32 . For securing the identification elements 14 . 1 , 14 . 2 in the housing 4 , they are pushed into the receptacles 20 . 1 , 20 . 2 , and only then the third housing element is placed in the housing 4 in order to provide a formlocking connection between the locking region 30 and the formlocking element 28 and which would act in a direction opposite the displacement direction E of the identification elements 14 . 1 and 14 . 2 .
In each case, both the identification elements 14 . 1 , 14 . 2 and the receptacle 20 . 1 , 20 . 2 taper in the displacement direction in order to achieve a precise positioning during insertion of the identification elements 14 . 1 , 14 . 2 .
As shown in FIG. 4 , both identification elements 14 . 1 , 14 . 2 , which are received in the receptacle 20 . 1 , 20 . 2 of the power tool 2 , are formed by parts of a single cast element 36 that is produced separately from a conventional housing 4 . After the identification elements 14 . 1 , 14 . 2 have been formed, the identification marks 16 . 1 , 16 . 2 are placed on the single-piece cast piece 36 . Only a single common printing process is necessary for placing the identification marks on the identification elements 14 . 1 , 14 . 2 . Only then, the two identification elements 14 . 1 , 14 . 2 are separated from each other for securing them in the housing 4 during the final assembly in accordance with the above-described procedure.
Though the present invention was shown and described with references to the preferred embodiment, such is merely illustrative of the present invention and is not to be construed as a limitation thereof and various modifications of the present invention will be apparent to those skilled in the art. It is, therefore, not intended that the present invention be limited to the disclosed embodiment or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims. | A hand-held power tool includes a housing ( 4 ), and a tag-shaped identification element ( 14.1; 14.2 ) mountable on the housing ( 4 ) so that it becomes visible on an outer side of the housing ( 4 ), provided with an identification mark ( 16.1; 16.2 ), insertable in a receptacle ( 20.1; 20.2 ) provided on the housing. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part and claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 13/398,615 filed on Feb. 16, 2012, which claims the benefit of priority from German patent application DE 10 2011012 678.3 filed on Mar. 1, 2011. Each of these applications is hereby incorporated by reference in its entirety as if set forth herein in full. This is a substitute specification which includes no new matter.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a corner protector member for finishing and protecting interior or inside corners in a room and creating a visually pleasing and mechanically strong transition between a first and a second surface forming an inside corner.
BRIEF SUMMARY OF THE INVENTION
[0003] In the course of completing interior architectural finishes, such as tiled wall surfaces, it is desirable to achieve seamless finishing of corners. A particular goal of a seamless transition between convergent walls and floors is to render both outside and inside corners protected from physical damage caused by prolonged or repeated contact with moisture, as well as from damage caused by impacts or other causes that could lead to water damage, fungal growth, soiling, embrittlement, peeling or spalling of the wall or floor finish and the respective substrates upon which the interior-facing finish surfaces are applied. Careful finishing of corners can help to minimize costly repairs and repeated cleaning that will follow where corners are not well protected or smoothly finished and properly sealed, in the case of tile or similar wall and floor finishes. The seamless finishing of corners or, insofar as practicable, the creation of smooth or integral transition zones, as in corners created by the convergence of walls and floors covered intile, wood, or a range of other materials, is also desirable to provide a pleasing visual transition from one surface to the next. Within various industries engaged in the manufacture of wall and floor coverings and finishes, within the cabinetry industry, and in a variety of building trades as well as within other service sectors such as the hospitality industry, it is well recognized that various surfaces, and in particular tiled surfaces, especially as found in bathrooms, spas, and swimming pool areas are susceptible to soiling and often costly damage by various physical forces and by repeated contact with moisture in the form of steam, condensate and liquid water, and other fluids. The application of harsh chemicals, such as chlorine and other sanitizers and oxidizers employed in cleaning bathrooms and maintaining pools and spas, commonly lead to failure of surface treatments such as tile and tile grouts and other sealants and fills used in interstices and voids between surface elements and substrates. Integral curves in surfacing materials such as cove base tiles present one solution to creating a smooth transitional zone, but especially in corners, and particularly in inside corner, the installation of such tiles and the associated labor involved in cutting these tiles to fit properly add cost to the finishing of a room and provide no guarantee that moisture and grime will not accumulate. In view of the often inevitable soiling, wear or actual damage to wall and floor surfaces and surface finishes, junctions or convergence points of horizontal and vertical surfaces such as bath countertops, tile joints and floor and ceiling junctions are routinely sealed with grout or similar materials in a manner that permits maintenance of these interstices and joints both for esthetic purposes and to protect the underlying substrate. In many cases, such interstices, voids or joints that would be otherwise filled with standard grouting materials are often instead filled with special permanently elastic grouts or grouts which maintain a substantial degree of plasticity, or similar caulks or other materials which in many cases are more effective at repelling water, and for purposes of maintenance are relatively easily removed and replaced, thus leading to the industry term “maintenance joint” for such areas. Especially in wet or sanitary applications, such as in baths and spas, tile joints and seams filled with highly elastic caulks or sealing agents that have a high degree of elasticity and plasticity are integral parts of any tile installation. Such joints or points of surface convergences with such fill or sealant treatments are commonly found in, but not restricted to the area between a row of tile or tiles, and the hard surface it abuts, for example in an angular relationship, such as surfaces including counters or bathtubs surfaces and the transitional zone between walls and floors and the aforementioned fittings and fixtures. Maintenance and often also expansion-type joints can also be found in inside corners between walls of glass tiles, the grouted joints in interior corners of a shower stall, and in similar settings.
[0004] As mentioned, such joints, as well as many other surface finishes and points of surface convergence, are highly prone to soiling, wear, and mildewing among other problems. Even in the case of a readily maintainable joint or juncture where it is not overly difficult to replace stained or deteriorating fill or grout material, especially if this fill has an elastic component or is of sufficient plasticity to be easily removed and replaced, it is generally accepted fills, caulks, sealants and the like must be replaced at significant cost in terms of labor from time to time to address the aforementioned problems. If left untreated, heaving surfaces, peeling surfaces, and chipped or spalled surfaces, not to mention surfaces exposed to mold and other fungal attack could potentially cause deterioration of the underlying substrates, diminished holding capacity of underlay adhesives, and other problems that only become more costly to address later.
[0005] The present invention assumes for illustrative purposes an inside or interior corner consisting of a first, a second and a third convergent surface in three planes (e.g., two walls and a countertop, floor, or ceiling). In none of the embodiments set forth below is there any intent to limit the embodiments to a particular first, second and/or third surface. The present invention does not require that this inside or interior corner be equipped with elastic or elastomeric seams, interstices or joints. Similarly, the various embodiments of the present invention are not limited to particular surfaces that at their point of junction meet relative to each other at fixed 90-degree angles; any possible combination of angles or inside corner configuration is contemplated. However, for illustrative purposes, the following description in relevant part assumes such a situation. Moreover, it should be noted that the term “inside” or “interior” in relation to a corner or abutment of horizontal and vertical surfaces is used interchangeably. In connection with the forgoing, it is also understood that the interstices referred to as joints may extend to cover the sharp inside edge formed by the intersection of two surfaces, such as the corner of a masonry unit or the junction between two planes of plaster or any intersection of divergent architectural details.
[0006] As set forth above, when tile or any other desired finish for horizontal and vertical surfaces is installed in areas exposed to cleaning agents, high levels of moisture, or repeated physical contact, there exists a significant risk that the surfaces may be marred, be subjected to moisture-related damage, and the like. The present invention seeks to significantly reduce the initial installation cost of protective members for such surfaces, as well as to reduce maintenance costs enabling a simplified, ideally one-time installation of a corner protection or protective member which creates an integrated, seamless transition from wall and counter or wall and floor surfaces or wall and ceiling using a simple, easily installed component. Further, by using a generally design that can be reduced to a member formed from one workpiece blank or molded or otherwise formed as a simple, one-piece member, the invention provides a very adaptable and concurrently visually appealing sealing member in addition to the protective properties possessed, at minimum expense.
[0007] Various measures for providing protective sealing and transitional surface to corners s to prevent damage, to restrict water incursion, and to shield adjoining surfaces from the combined effects of moisture, corrosive substances, dirt and mechanical wear or impact have been disclosed. Examples are noted below.
[0008] German Patent Application No. DE 20 2005 015 386 U I describes a wedge-like sealing component for application to the interior corners of rooms where walls and ceilings abut each other. A fundamental requirement for the proper application of this device is the insertion or keying of a wedge-shaped component into a receiving component consisting of three interlocking components. A further precondition to the successful installation of this sealing or protective component or set of components is that the assembly must be installed with suitable adhesives or other fixative materials. Take as a whole, this interior corner sealing system is suitable only for applications where a substantial surface area is presented by the abutting horizontal and vertical surfaces. The above-referenced invention's complex assembly requirements, arising out of the fact that four discrete constituent parts must be assembled, necessarily lead to high production and installation costs.
[0009] Disclosed in German Patent Application No. DE 10 2008 007 478 A I is a shaped component constructed of plastic material suitable for enclosing edges of convergent horizontal and vertical surfaces such as tiled surfaces. The invention involves a bracket or brackets with integrated projecting lugs arranged so as to be relationally opposed at ninety-degree angles, which are to be anchored behind a surface tile or tiles, such that a rounded frontal portion of the component engages with the visible surface of the tile, forming a border or edge. This invention is suitable only for enclosing or finishing exterior or outside corners.
[0010] German Patent Application DE 299 05 821 U I discloses a transitional surface which is integrated into a tile assembly so as to provide corner protection. This invention teaches that the corner protection to be achieved depends upon the component being installed in such a way as to engage behind the tiled surface which it is intended to shield from damage or soiling.
[0011] In German Patent Application No. DE 298 20 687 U I, a rail or track is disclosed which is affixed between and to surface tiles and the masonry substrate upon which those tiles are installed. The rail or track features a plurality of opposed brackets, lugs, or similar projections which present a surface with which a mating endplate or similar protective edge engages. A key condition for the successful installation of the invention is, similar to the preceding example, complete embedment of the rail or track behind the finished surface, and in this case also between the masonry substrate and the surface finishing material.
[0012] In view of the limitations presented by the aforementioned examples, it is the object of the present invention to offer a protective, transitional finishing architectural feature with inside corner protective properties that creates an easily installable, protective and transitional inside corner finish securable to inside corners that requires no complex anchoring involving additional components associated with the wall substrate or masonry surface.
[0013] Another goal achieved by the present invention is simplicity of manufacture and installation, which relates to and derives from the fact that the corner protector member is of very simple construction, presenting a visible face or surface which is oriented to the interior of a room or space, and which features on the rear face, which is oriented towards a confluence of horizontal and vertical surfaces, as in a corner, a surface which seamlessly and in a visually pleasing and mechanically strong and physically durable manner fixably attaches to an inside corner and can be even more firmly anchored to same by means of a pin or barb and where so desired with adhesive or sealing materials.
[0014] The present technical disclosure also reveals a further significant advantage in that what is disclosed is a single, in the case of one embodiment, button-shaped and unobtrusive device that easily permits itself to be affixed and positively engaged and firmly locked into an inside corner from the front or visible face or side, seamlessly meeting and mating with the existing wall surfaces and horizontal surfaces, as the case may be.
[0015] In the preferred embodiment, the diameter of the corner protector member may range from a diameter of approximately 16.25 millimeters to 24.25 millimeters. It is to be understood that the present invention may be constructed or formed, whether by casting, machining, injection molding, rotational molding, or other method of manufacture, as one piece, or as a single body with a pin or barn which upon assembly may become an integral component, as best seen in the figures which are part of this disclosure, and not as an elongate track or rail or in such a manner as to extend to any significant degree into the interior surfaces of a room or space. Rather, the size of the corner protector member is limited to the space required for finishing the inside corner. Any obtrusive extension into adjacent wall surfaces or significant overlap with abutting wall surfaces is not required to effect a seamless transition and to achieve the desirable results sought in such an installation.
[0016] In a preferred embodiment, the corner protector member has a generally triangular pyramidal shape or form, such that it could be compared to the frustum of a cone or a truncated cone, of which the base surface or basal face forms the visible surface or outwardly-oriented surface in relation to the walls of a room, and from which the associated frusta attach to the respective corners of an inside corner, thereby creating a seamless or smoothly-fitting corner which establishes a fluid transition in terms of linear surfaces of, for example, a tiled corner where two walls meet.
[0017] In a further embodiment of the present invention, rather than the aforementioned tetragonal shape, a semicircular, lenticular, fillister or ball or spherical form or shape may define at least the front face or base or basal face the corner protector member, which may have emanating from the visible frontal face a preferably conically shaped pin or barb-like component, which similar to the preferred embodiment serves to attached the corner protector member to the inside corner and permits for a seamless and uniform connection to the respective surfaces forming the corner.
[0018] Rather than such the completely symmetrical body (which may also be constructed in such a way as to be axially symmetric) form previously described, it is also possible to employ spherical or ball-shaped designs such that the inside corner is not delineated by a lenticular shape or a semicircular or hemispherical shape, but rather by a ball-like shape or curvature, from which extends the aforementioned barb-like portion which affixes to the wall and thus creates a seamless and form-fitting inside corner.
[0019] It should of course be understood that the present invention contemplates and extends to a broad range of alternatives in form or shape, or modifications to the triangular pyramidal, truncated conical or frustal design or form.
[0020] In a further preferred embodiment of the present invention, the mounting and anchoring of the previously described corner protector member in all of the previously described designs or shapes is facilitated by means of a maintenance joint or fillable interstice or caulk or grout joint or line composed of a durable, elastic, plastic material situated in or along the inside corner. The aforementioned maintenance joint or caulked or grouted joint or interstice may further be composed of a durable, elastic plastic material such as silicone caulk or sealing compound, acrylic caulk or sealing compound, a polymer-based caulk or sealing compound, or a caulk or sealing compound based on an expandable foam-like substance such as polyurethane foam.
[0021] In the case of the aforementioned embodiment, where a maintenance joint or the like using any of the aforementioned caulking or sealing materials is contemplated, the installation and positive locking or anchoring of the corner protector member is particularly uncomplicated and easily achieved, as it is possible to simply press-fit the inventive corner protective member into caulking or sealing material which is intended to seal the inside corner before this material cures and solidifies, whereupon the inventive device is anchored firmly in place once the sealing or caulking materials has fully “set up” and sufficiently cured.
[0022] It is thus obvious that the present invention teaches a corner protector member which creates and achieves a seamless, form-fitting connection to permanently elastic surface joints by way of being installed into of affixed onto such a joint before the joint solidifies. This results in an inside corner which is protected against becoming dirtied, and furthermore achieves the goal of creating a solid corner and corner protector member assembly which cannot be damaged nor fail structurally, and which above all leads to an inside corner which is considerably less labor intensive to clean. It should be understood, however, that the present invention is not restricted to applications where it must be employed in combination with a sealant- or caulk-filled maintenance joint in an inside corner or edge at the confluence of vertical and horizontal surfaces.
[0023] In yet another embodiment, the maintenance joints are not required, and the corner protective element may be installed or fitted by, for example, the simple application of slight pressure in an existing inside corner wall surfaces composed of wood, synthetic materials such as thermoplastics, natural stone, metal or the like meet. In such an application, featuring these relatively solid materials, the preferred method of anchoring the corner protector member involves a corner protector member formed or otherwise designed and constructed so as to feature at least one center bore, or roughened surfaces, or specifically designed depressions of similar anchoring surfaces into which a curable adhesive or caulking materials may be introduced or onto which such a material may be applied. In this embodiment, the corner protector member is pressed or press-fitted—prior to the curing of the adhesive or caulking or sealant material—into the inside corner, and the adhesive, caulk, or sealant is allowed to cure in place, such that the corner protector member seamlessly integrates into the inside corner, thereby providing the corner against staining, dirt, and damage. It should be obvious to those skilled in the art that the adhesive, caulk or sealant need not necessarily be introduced into the aforementioned center bore on the rear face of the corner protector member.
[0024] In still another embodiment, the rear surfaces of the corner protector member, which attach to the inside corner created by the convergence of walls and potentially also horizontal surfaces, may be furnished with roughened surfaces, grooves, lugs or other projections commonly deemed “male” surfaces, or recesses or “female surfaces” or the like, even possibly including barbed hooks or recurved spikes or the like such that the corner protector member can be driven into an inside corner without the need for a an adhesive, caulk or sealing material for purposes of anchoring the corner protector member.
[0025] The visible face of the corner protector member disclosed herein may have any of a variety of forms, all of which are considered crucial and are claimed in the present application.
[0026] In a first embodiment, the pyramidal base of a tetrahedral body forms the visible face of the corner protector member, and this visible face is smooth and thoroughly level.
[0027] In another embodiment of the present invention, the visible face of the corner protector member may take on other designs or forms, such as a cambered or arched, or convex or concave, or any other desired form, shape or design. Not only the visible face of the tetrahedral body may be formed and manufactured according to a variety of designed shapes, but also all other integral sections of the herein claimed corner protector member may take on such other configurations as previously stated, such as a lenticular or fillister head, a semicircular or hemispherical head, or ball head.
[0028] As such, it is evident that it is possible that a tetragonal body, along its base face, which in turn is the visible face upon installation, may also be manufactured so as to have a lenticular, button, fillister or ball-shaped head.
[0029] In a preferred embodiment of the invention, the corner protector member is manufactured of a suitable metallic material, particularly, a stainless steel. However, this is in no way to be understood to limit the scope of the present invention. The corner protector member may be composed of any suitable material fit for providing a functional and decorative finish and lining for an inside corner, such as any of various light alloys, plastics, wood, plastic and wood combinations, plastic and metal combinations, and the like.
[0030] The determinative factor is that the end result is a fitted, seamless finish achieved in an inside corner which provides the further benefits of a corner protector member permitting easy cleaning of inside corners and protector of the inside corner against damage and soiling.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0031] The following drawings are attached in explanation of the invention, the features of which are referenced within the detailed description of the invention. Note that, although the example sectional shape of the corner protective member for inside corner protector is tetragonal or tetrahedral as illustrated throughout the majority of the following drawings, the shape may be of any practicable multi-sided geometry. In order to better understand the drawings, the following legend is provided:
1 Corner protector member 2 Wall 3 Floor 4 Vertical maintable interstice or joint 5 Horizontal maintable interstice or joint 6 Horizontal maintable interstice or joint 7 Inside corner of room or other space 8 Transition zone 9 Face, basal or visible surface portion 10 Lateral or side face 11 Connecting or mating face 12 Tetrahedron/tetragonal or triangular pyramidal body 13 Center bore 14 Face, basal or visible surface portion 15 Barb or pin 16 Groove or rill 17 Rounded edge 18 Sharp corner 19 Lateral edge 20 Lateral edge 21 Corner protector member 22 Ball head shape 23 Corner or edge indent 24 Beveled corner 31 Corner protector member
[0057] FIG. 1 : This figure presents a top, cross-sectional view of the corner protector member showing its particular features as installed relative to common wall and floor angles in a typical installation in a first embodiment.
[0058] FIG. 2 : This figure presents a view of the corner protector member as emplaced in an interior or inside corner with the view oriented towards the convergence of two vertical wall surfaces and an adjoining horizontal surface and for reference further depicts horizontal and vertical joints relative to the corner protector member.
[0059] FIG. 3 : This figure presents a rear view of the corner protector member showing the central bore and side surfaces.
[0060] FIG. 4 : This figure presents a frontal view of the corner protector member.
[0061] FIG. 5 : This figure presents a side view of the corner protector member in accordance with FIGS. 3 and 4 .
[0062] FIG. 6 : This figure presents a further side view of the corner protector member in accordance with FIGS. 3, 4, and 5 .
[0063] FIG. 7 : This figure presents a further side view of the corner protector member according to FIGS. 3, 4, 5, and 6 .
[0064] FIG. 8 : This figure presents a plan view of the visible face of the corner protector member in a modified embodiment with pointed corners.
[0065] FIG. 9 : This figure represents a plan view of the visible face of the corner protector element with rounded corners.
[0066] FIG. 10 : This figure presents a plan view of the visible face of the corner protector member configured as a scalene triangle.
[0067] FIG. 11 : This figure presents a perspective view of modified corner protective member configured in a hemispherical or lenticular form or shape.
[0068] FIG. 12 : This figure presents another perspective view of another embodiment of a corner protector member in a spherical shape configuration.
[0069] FIG. 13 : This figure presents a modification of a tetrahedral-shaped corner protector member according to FIGS. 8, 9, and 10 with recessed corners.
DETAILED DESCRIPTION OF THE INVENTION
[0070] FIGS. 1 and 2 depict a first embodiment of the inventive corner protector member, which is depicted as completing and finishing an inside corner 7 of a room. As depicted, a vertical wall surface 2 meets a horizontal floor surface 3 at an angle of approximately ninety degrees, thus establishing the corner of a room as depicted in FIG. 2 .
[0071] Depicted for purposes of illustration is the wall of a sanitary architectural installation, for example a bathroom, which features a vertical interstice, seam or joint 4 and two horizontal, angularly intersecting vertical walls, each of which feature a similar interstice, seam or joint 5 , 6 and all of which converge at an inside corner 7 , where the inventive corner protective member device is mounted or otherwise affixed to the interstices, seams or joints 4 - 6 , and where the inventive corner protective member has been fitted by the application of pressure into as-yet uncured adhesive, caulk or sealant emplaced in or filling interstices, seams or joints 4 - 6 , such that fully seamless, flush, and integral transition regions or transition zones 8 result between the visible face of the corner protector member 1 and the adjacent or adjoining surfaces of the interstices, seams or joints 4 - 6 .
[0072] The scope of the present invention is not limited to the above-referenced method of anchoring the corner protector member. For example, rather than a permanently elastic interstice, seam or joint which is maintainable and of which the sealing or caulking material may be readily replaced, other types of interstices, seams or joints may be employed, such as flexible or expansion joint-type interstices, seams or joints, which interrupt otherwise seamless or otherwise uniform surface finishes or assemblies such as tiled surfaces so as to prevent stress fractures from forming. All such interstices, seams or joints are suited to receive the corner protector member to result in a finished inside corner.
[0073] It is important to note that the transition regions or transition zones 8 as depicted in FIG. 2 should ideally be achieved by careful placement of the corner protector member in relation to all interstices, seams or joints 4 - 6 in order to result in a smooth, impervious, and seamless confluence, with due attention given to the proper alignment of all sides of the corner protector member 1 with the interstices, seams or joints 4 - 6 converging at inside corner 7 . It should be noted that in an alternative embodiment, as previously set forth, it is not necessary to anchor the corner protector member in the interstices, seams or joints 4 - 6 .
[0074] In view of the above, it follows from FIGS. 1 and 2 that the interstices, seams or joints 4 - 6 may be dispensed with such that the corner protector member 1 may be driven into or otherwise forcibly inserted into an inside corner resulting from the convergence of walls 2 , and floor 3 thus leading to the creation of a seamless, integrated finishing fixture or component.
[0075] It is to be appreciated that as an alternative to the use of physical force to install or fit the corner protector element to an inside corner 7 , an adhesive may also be used to achieve the same results. In such applications, it is desirable to manufacture the corner protector member, which is this embodiment has faces 12 generally tetrahedral 12 in terms of shape, as can be seen in FIGS. 3 and 5 , with a central bore 13 , which can be filled with a curable adhesive, a putty, or a caulk or sealant for purposes of anchoring and affixing the corner protector element to an inside corner 7 which features no interstices, seams or joints.
[0076] In a further embodiment of the invention, it is possible that the central bore 13 , optimally manufactured as a threaded recess, depicted in FIGS. 3, 5, and 6 and located on the rear of or, as oriented towards the interior of a room, inside corner facing surface of the corner protector member, may receive a suitably threaded barb or pin which is in turn oriented towards the inside corner. Given that the tip of this barb is oriented towards the inside corner 7 , the corner protector member may accordingly be pressed, hammered, or otherwise inserted into the inside corner and firmly anchored.
[0077] FIGS. 3 through 7 present additional detail regarding the first mentioned embodiment of a corner protector member 1 . As can be determined from the referenced drawings, the first embodiment referenced possesses a generally tetragonal shape 12 with a flat visible face 9 which is the base or basal face of a generally truncated cone, where
[0000] the visible face 9 features adjoining equilateral or symmetrical side surfaces 10 which are beveled or slanted towards the center of the corner protector member and which in turn feature diminishing edges or vanishing edges which via mating faces or connecting faces 11 are effectively bridged.
[0078] Those skilled in the art will appreciate that the generally tetragonal and symmetrical body 12 may in terms of design and intended purpose as a corner protector element 1 also be manufactured with asymmetrical or unlike surfaces 10 . This would result in an asymmetrical tetragonal body, among the other shapes, designs and forms contemplated by the present invention.
[0079] It is important to note that the rear-facing apex of the corner protector member, were it to be represented as a full tetragonal structure complete with fully terminal angles or corners or apexes, is essentially lacking, and that where essentially a frustum would result, the aforementioned central bore 13 is found, with the central bore, which may be unthreaded, descending to a suitable given depth in the core of the body of the corner protector member. The central bore in this case may be viewed as a production aid in that a material blank used in the course of the production of the corner protector member may be simply affixed to a jig, receiving clamp or the like or pin received by the bore, and the workpiece blank thereby safely and easily machined or otherwise processed and formed to achieve the desired shape and configuration.
[0080] A second advantage of the central bore is that when the central bore 13 is provided with a thread by, for example, manually or otherwise tapping the central bore, it becomes possible to insert a threaded bolt, the thread of which may be made to project from the main body or from the apex. This makes it possible to fit a corner protector member so equipped with a threadably inserted or adhesively-secured tip into an otherwise empty inside corner 7 and anchor it firmly.
[0081] FIGS. 11 and 12 depict further embodiments in the form of an axially symmetrical corner protector member 21 , 31 that in the embodiment depicted in FIG. 11 possesses a hemispherical, lenticular or ball-like face, basal or visible surface portion 14 to which is attached a barb-like element 15 , the exterior periphery of which bears rills 16 , grooves or which may be threaded. As can be seen in the figures, it is thus entirely possible that a largely lenticular or hemispherical corner protector element 21 may be formed and may be desirable and useful.
[0082] The above also applies in the case of a spherically-shaped or spheroidal member according to FIG. 12 , which depicts a spheroid head 22 from which in integral barb 15 formed from the workpiece blank as one piece or body leads, with the barb featuring the aforementioned rills 16 or grooves or threads. In the case of this embodiment of the invention, it is also entirely possible to install and anchor such a corner protector member 31 either in curable interstices or joints or the like. Alternatively, it is possible to drive the barb 15 into bare or otherwise unfitted, in terms of interstices or joints, into the transitional zones between a wall 3 and floor 3 and in such a way anchor—in the absence of interstices or joints—the corner protector member in the inside corner 7 .
[0083] FIGS. 9 through 13 depict various modifications of the tetrahedral or tetragonal form according to FIGS. 3 through 7 .
[0084] Initially it should be obvious from the figures thus presented that the corners or edges of the tetrahedron or tetragonal form are flattened to form beveled corners 24 to result in and achieve a more positive and more flowing and seamless integration with the adjoining surfaces of the interstices of joints 4 - 6 or the wall or other room surfaces 2 , 3 .
[0085] In a modification of this form, FIG. 8 depicts that possibility of employing not the level or smooth face, basal or visible surface portion 14 but also sharp edges 18 , thus leading to the omission of the flat or vanishing edges 24 .
[0086] As can be seen in FIG. 9 , the beveled edges 24 may also be formed as a radius or with a radius to create rounded edges 17 .
[0087] FIG. 10 depicts that instead of a tetragonal shape 12 with uniform sides or surfaces. It is also entirely possible to employ unequal surfaces or sides where for example the lateral edge 19 may be longer than the angularly convergent lateral edges 20 . It is to be understood that in the case of such an irregular tetragonal form, all of the previously described edges or forms may also be made part of the design of the corner protector member.
[0088] A further embodiment is depicted in FIG. 13 , which shows that the edges may also be punched or similarly formed and shaped to create so-called edge depressions 23 which in turn form sharply angled anchorage points, which adhere very well into elastic, as-yet uncured caulks or sealants filled into interstices or joints 4 - 6 of various surface treatments and finishes such as ceramic tile.
[0089] It is obvious and will be appreciated by those skilled in the art that the various designs depicted do not necessarily show that the visible face 9 of the tetragonal body 12 may also be hemispherical, ball-like, cambered or curved, or formed in any number of other configurations or forms. The present invention is also not intended to be limited to the various designs or forms presented and disclosed herein.
[0090] While specific embodiments have been set forth and described herein, those of ordinary skill in the art will appreciate that various adaptations are possible, and that this disclosure is intended to cover adaptations or variations of various embodiments of the present disclosure. The aforementioned embodiments should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Combination of the above elements, and other embodiments not specifically described herein will be apparent to those skilled the art upon a review of foregoing description. The scope of the various embodiments of the present disclosure includes other applications in which the above structures and methods are used. Thus, the scope of the invention should be determined with reference to the appended claims and the full range of their legal equivalents.
[0091] In the foregoing detailed description, various features are grouped together in a single embodiment for purposes of presenting the disclosure in a compact manner. This method of disclosure is not to be interpreted as reflecting an intention that the disclosed embodiments of the present disclosure must necessarily employ more features than expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the detailed description, with each claim standing on its own as a separate embodiment. | A corner protector member for establishing and finishing a transition between a first surface, a second surface and a third surface, the first, second and third surfaces forming an inside corner. One corner protector embodiment includes a read face portion oriented inwardly in relation to the inside corner, which is securable to the inside corner, and from which integrally extends an external frontal or basal face portion, the lateral edges of which are securable alone or with the addition of an integral pin or barb to the inside corner, positively locking and engaging with the interior corner surfaces so as to firmly anchor therein and thereto. | 4 |
BACKGROUND OF THE INVENTION
It has been known for some time in the prior art to provide can ends which can be opened without use of a can opener or other tool. For some years, the most popular can ends of this type were those in which a ring was provided for finger insertion, which when pulled removed a section of the can end along score lines. The ring tab and the removed section of the end were then discarded. This was undersirable for a variety of reasons perhaps chiefly those of unsightly litter; and so a new type of can end was developed which could be opened without the use of tools, but which did not result in any of the components of the can end becoming detached from the can.
Typically in the prior art, such can ends and tabs were both made of aluminum. However, with the well known recent rise in cost of electrical power, aluminum has become a disfavored material for applications where steel can be used, inasmuch as aluminum is, in general, made by electric refining processes which consume enormous quantities of electricity. Therefore, wherever possible, it is desired to substitute steel for aluminum.
In the can end making art, however, steel has been a disfavored material for a number of reasons, chief among those being corrosion. Although steel is preferred for reasons of economy and for certain reasons of ease of manufacture which will be discussed in more detail below, steel has not been a preferred material for tab ends. The present invention involves a steel for tabs coated with a metal chosen to reduce corrosion by means of sacrificial oxidation. It has been found by the applicant that if a steel tab is coated with a material having a higher electronegative potential, that material will be attacked in preference to the steel and if the material is so chosen that a certain amount of oxidation only is permitted, then the tab end will rapidly form its own protective corroded layer which will prevent any further corrosive attacks upon a tab end.
OBJECTS OF THE INVENTION
It is therefore an object of the invention to provide a method whereby a can end can be provided with a tab which is less expensive than those found in the prior art.
A further object of the invention to provide such a tab end which can be made readily and economically without suffering any functional disadvantages compared to those in the prior art.
Still a further object of the invention is to provide a tab end of steel which is not attacked by corrosion.
SUMMARY OF THE INVENTION
In accordance with the above needs of the art and the objects of the invention, a can end is provided with a steel tab as an integral part of the can end. The tab is coated with a metal chosen so as to be preferentially corroded over the steel, and which is only corroded to a certain depth below its surface, thus providing a limitation on the total amount of corrosion suffered by the tab end. In the preferred embodiment the coating material is zinc; another possibility would be aluminum.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of the top of a can with a can end according to the invention attached.
FIG. 2 shows a top view of such a can end.
FIG. 3 shows a cross-section at an enlarged scale of such can end.
FIG. 4 shows a detail of the anti-corrosive coating applied to the tab.
FIGS. 5A to 5F and 6A to 6F show a sequence of stages in the formation of the tab of the invention.
FIG. 7 shows a partial sequence of operations according to another embodiment of a process for making the tab of the invention.
FIGS. 8,9,10 and 11 show other embodiments of can ends which can be made according to the invention.
FIGS. 12 through 15 are photomicrographs showing the details of the coating.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Understanding of the can end of the invention and the method of making it will be better understood by reference to the figures appended hereto. Referring now to FIG. 1, a can 10 is shown provided with an end 11 having attached thereto a tab 12 and having marked thereon a segment 13 of the end 11 which, upon elevation of the end of tab 12 by a consumer of the contents of the can 11, is adapted to pivot into the interior of the can 11, thus opening the can 11. Referring now to FIGS. 2 and 3, the method of operation of the can end of the invention will be described in detail. In these figures, the can end 11 is shown in FIG. 2 in an elevation, and FIG. 3 in a partial cross-section. It will be observed that the tab 12 is attached to the can end 11 by means of a rivet 14 integrally formed from the material of the can end 11. Upon the insertion of the user's finger under rounded end 15 of the tab 12, the tab 12 tends to pivot about the shortest part of its junction with a hinge member 17. As will be discussed in further detail hereinafter, the hinge member 17 is formed integrally with the tab 12, but is cut therefrom nearly entirely around its circumference, so as to provide a hinging section about which the tab 12 can pivot. When the tab 12 pivots about this hinge member 17, as shown in phantom in FIG. 3, extension portion 16 exerts a downward force on the openable section 13 of the can end 11, thus forcing this section 13 into the interior of the can 10, thus providing an opening through which the contents of the can 10 may be withdrawn. In order that the openable section 13 is not detached from the can end 11 during this operation, it is provided with a score line which runs most of the way around its circumference, but not entirely. Thus, when a force is applied to it by the extension 16 by the application of pressure by the user at 15, the openable portion 13 is detached along the scoreline 18 and pivots about the unscored section of its circumference by which it remains attached to the can end 11.
Up to this point, the description in this preferred embodiments of the invention section of this specification has been of material which is all in the prior art. However, no mention has yet been made of materials used to make can ends and tabs, which applicant has discovered to be of cardinal importance. In particular, the prior art cans and tabs have all been made of aluminum material which, while reasonably well suited to the purpose, is expensive due to the large quantities of electricity required for its refinement. Therefore, and as suggested above, it is desirable to replace as much of the aluminum as possible with some less expensive material such as steel.
It would be desirable, of course, to make the entire can end 11 of steel; however, it turns out that it is not possible to score steel, for example, around the periphery of operable portion 13 along line 18, due to the high tensile strength and ductility of the low cost steel which is sought to be used in this sort of application. The applicant has found, however, that the tab can possibly be made of steel if and only if it is coated with a material which will prevent it from being corroded. It is found that steel is corroded particularly readily when in intimate contact with aluminum, as is the case here. Therefore, good corrosion prevention is particularly important. Moreover, steel has other than economic advantages over aluminum in this application because the portion of the tab which connects the protrusion 16 and the handle 15 with hinge member 17 about which the tab pivots is far tougher when made of steel than it would be when made of aluminum. This increased toughness eliminates breakage of this hinge section which can, when the tab is of aluminum, be a problem; that is, the tab can break off without opening portion 13 of the can, which is clearly undesirable. The constraint on one seeking to make a steel tab for a beverage can is that it must be of a steel which will withstand exposure to a variety of contaminants and which, under such circumstances, will not be corroded. The applicant has found that this objective can be satisfied by manufacturing the tab of a steel which is coated with a material which will be corroded in preference to the steel, and which has only surface corrosion properties so that once the surface is corroded by exposure to various reactant materials, corrosion will stop. By comparison, it is well known that steel corrodes from the inside of a mass thereof rather than simply on the surface so that, for example, a piece of solid steel can rust through. On the contrary, a mass of, for example, aluminum is corroded only on the surface and only in a very thin layer, so that once the layer has formed, no further corrosion is possible.
It will be clear to those skilled in the art that manufacturing the tab out of steel coated with a corrosion preventive material will be effective as to those surfaces of the steel which are exposed when the coating is applied to the steel. However, if tabs are sheared or stamped from a sheet of steel after having been coated, it would appear that the edges of the stamped tab would not be covered with the coating, and therefore would be liable to corrosion. Applicant has found, however, that if the stamping operation is properly designed and operated, the coating can be made to cover a considerable fraction of the edge of the tab, thus preventing corrosion from attacking the tab at any point.
Referring now to FIG. 4, a section corresponding to that identified by the box labeled "4" in FIG. 3 is shown in greater detail. There, a section of tab 12 is shown abutting against can top 13. Can top 13 is of aluminum and tab 12 is formed from sheet of steel 21, which is coated all around with a layer of corrosion-reducing metal 20. In this way, it can be assured that the tab will not be attacked by corrosion and will not contaminate any beverage or any other material contained within the can.
FIGS. 5A through 5F and 6A through 6F show corresponding stages in the manufacture of such tabs. FIGS. 5A through 5F show elevations, and 6A through 6F show cross-sections of the tab as it is formed and as marked in FIGS. 5A through 5F. Thus, FIGS. 5A and 6A show a steel strip 30 prior to any processing leading to the manufacture of such a can tab. FIG. 6B shows a cross-section of the strip after such coating where this strip 30 has now been covered with a layer of zinc 40. FIG. 5C shows the first stamping stage which may profitably be used to form the tab. There, the tab outline 32 is shown having been formed in the strip 30 resulting in a general outline of tab 12 having a hinged section 33. In FIG. 6C, it is shown how the tab 12 coated with a layer of zinc 40 is separated from the strip 30, also coated with a layer of zinc 40, by a gap 32 which defines the periphery of the tab. It will be observed that the coating 40 is shown as having been drawn into the gap 32. It has been found by applicant that this drawing operation is effected when the dies defining the gap 32 are not too tightly fitted; that is, if, for example, the strip is stamped into tabs by a vertical process where the strip is advanced horizontally through a press and a die descends vertically upon the strip, the zinc will not be drawn into the gap thus formed as well when the die fits tightly into the die cavity as it will when the die has a certain amount of clearance with the die cavity. In FIG. 5D, the next stage in the process of manufacture of the tab is shown. There, the gap 32 has become wider and better defined, due to the curvature of the section of the periphery of the tab as shown in FIG. 6D. Furthermore, the hinged section 33 has been better defined, and a rim 34 has been formed around the inner portion of the curved section of the periphery, again referring to FIG. 6D. In FIGS. 5E and 6E, the tab 12 is shown still further defined, the edge of the tab 35 has been tucked under, and the gap 32 has been widened considably. Throughout these stages, the tab 12 remains attached to the strip 30 by a tag at its left for ease of processing. Thus, the strip 30 with its coating 40 is shown along with tabs in FIGS. 5O. In FIG. 5F, the tab is shown in a finished form. There, the rim of the tab 12 has been tucked under so as to provide a smooth surface for the user's finger; consequently, the gap 32 has widened still further. The rim around the hinge section of the tab 34 has been raised, and the tab has been finally detached from strip 30 by punching at strip 36. The tab thus made can be attached to a can lid by processes well known in the art where a rivet is integrally formed out of the can top 11 through a hole 39 punched in the hinged section of the tab as shown in FIG. 3.
FIG. 7 shows another process for making such a coated steel tab. There, a strip 30, FIG. 7A, is formed into a tab, FIG. 7B, as discussed above. However, in this case, strip 30 was not coated prior to formation of tab 12. Instead, after formation the tab is dipped into a bath of molten metal 13, FIG. 7C, thus coating all surfaces, edges as well as flat surface, with essentially a uniform layer of anti-corrosive coating.
FIGS. 8,9,10 and 11 show alternative embodiments of can ends wherein the invention is also useful. In the can end of FIG. 8, a tab 201 is provided with a ring 204 and attached to a can top 200 by means of a rivet 203. Around rivet 203 is a cut line 202 which extends entirely through the tab, but which is left with an uncut area 206. When the ring 204 is picked up by the consumer of the contents of the can, the tab pivots about this area 206, thus cutting loose the can top 200 from its rim 199 along score line 207 which extends all the way around the top of the can. Again, the entire tab 201 may be made of steel coated with a protective metal in accordance with the invention while the top 200 and rim 199 may be made of aluminum.
In FIG. 9, another embodiment of a can top and tab is shown. There can 199 is provided with a top 300 to which is riveted, by means of rivet 304, a tab 301. A score line 302 is indented into can top 300, but provided with a blank space 306. Upon picking up of the ring portion of tab 301 by a consumer, the tab pivots about rivet 304, thus pressing down on the opening area, which is defined by score line 302, which pivots about area 306 into the center of the can, thus allowing access to its contents. A finger depression 303 may be provided in case the tab 301 does not push the openable section of the top far enough into the can for complete access.
In FIG. 10, yet another can top which can be improved by the use of the present invention is shown. The can 199 is provided with tab 501 and a completely circumferential score line 503. Tab 501 is attached by means of rivet 502 to the top of the can 500. Upon picking up of the rightmost end, as shown in the drawing, of tab 501, it pivots about uncut area 505, thus exerting a localized force on the section of the scoreline 503 nearest to tab 501, thus initiating a break around the scoreline which can be completed by application of pressure directly by the use of the consumer's finger.
Finally, FIG. 11 shows yet another embodiment of the invention which is somewhat similar to that described above in connection with FIGS. 1,2 and 3. Here, can 199 is provided with a top 400 which is attached tab 401 by means of rivet 403. A scoreline 402 is provided which is almost completely circular in outline, but in which is left an unscored region 405. Tab 401 is divided into a handle portion and a hinge portion 406 by a cut line 407 which is not a complete cut. By virtue of the uncut area 408, when a consumer picks up the right end of a tab, it tends to pivot about area 408, thus exerting a downward force on the removable section of the can which in turn pivots about area 405 into the interior of the can 199 thus allowing access to the contents of the can 199.
It will be appreciated that all the embodiments of FIGS. 8, 9, 10 and 11, as well as that shown in FIGS. 1, 2, and 3 can be improved by the use of a tab formed with steel coated with a corrosion-preventive material according to the invention. In each case money can be saved by using such a tab of coated steel rather than the aluminum which is found in the prior art; for example, in U.S. Pat. Nos. 3,322,296, 4,051,976 and 3,967,753 in which embodiments are shown very much like FIGS. 8, 9, and 10 respectively. Furthermore, in each of these designs considerable stress is put upon the tab when operated, which can be much better handled without failure if the tab is steel than if it is aluminum.
It was discussed earlier in this specification that it is of importance that the edges of the coated steel tab be also coated with a corrosion preventive material if corrosion of these edges is to be avoided, and it was shown in FIGS, 4, 5, and 6 and the discussion thereof how, through careful die design, this could be achieved even if the tab is formed after the strip which it is formed is coated. FIGS. 12 through 15 are photomicrographs of tabs made in accordance with this invention which show that the zinc coating from the planar surface of the tab is "washed over" onto the edge of the tab during the forming process. This effect can be observed from a comparative study of FIGS. 12 and 13. FIGS. 12 and 13 are photographs of the same tab in the same position, but FIG. 12 is a scanning electron micrograph at 120 power magnification, while FIG. 13 is a so-called X-ray map view of the same tab at the same magnification. This is done so that corresponding zones of the scanning electron photograph can be compared with the X-ray may for precise identification of the various areas of the X-ray map. Thus, in both FIGS. 12 and 13, the edge of a coated steel tab is shown identified as areas H and I. Area G is the planar surface of the tab, which is curved, as can be seen from FIG. 12, during the forming process. Area J is the interior surface of the curved tab. Thus, the edge is one which might correspond to that shown, for example, in FIG. 4. It will be observed from a comparison of FIGS. 13 and 12 that the zinc, which is identified in FIG. 13 by white dots, the density of the dots indicating the thickness of the zinc coating, that while coverage of the zinc on the cut edge of the tab in Areas A and I is not as thick as it is in the surface which was exposed when the tab was dipped prior to forming, that is, area G, a considerable amount of zinc is nonetheless present on the cut edge, areas H and I, due to it being washed over by the forming process, by the action of a comparatively loosely fitting punch in a die.
Referring now to FIGS. 14 and 15, a second form of modern metallurgical equipment has been used to make essentially the same point. In FIG. 14 we see once again a scanning electron micrograph of the edge of a tab; the magnification is now 300-fold, so that the tab is presented in considerably more detail. In both FIGS. 14 and 15, area A represents the top or planar surface of the tab. Area B is the corner, so to speak, between the planar surface and the cut edge, and area C and D are the edge itself. Area C shows a comparatively smooth cut, while area D is a portion of the edge which has been comparatively roughly torn away from the strip by the stamping process. FIG. 15 shows a backscattered electron image of the same tab edge section shown in FIG. 14 and at the same magnification. It will be observed that the edge C and D is in two shades, a lighter, whitish shade and a darker, grayer shade marked respectively 100 and 101. The areas are so colored because of differences in material. In essence, the area marked "100," the lighter area, is so colored due to a coating of zinc thereon, whereas the gray area 101 is essentially iron based (i.e., steel). While the zinc area 100 clearly does not extend uniformly over the entire area of the edge C and D, it is equally clear that the zinc does provide a substantial amount of coating to the iron. In any case, it has been found by the inventor that the edges of the tabs do not tend to corrode, which is, of course, the end to be sought. It appears from study of FIGS. 13 and 15 that the coating covers some 10-20% of the edge, and that this would appear to be sufficient.
It will be appreciated that due to the electrochemical nature of the protective mechanism, a full coating of protective metal may not be necessary in order to give adequate protection to the steel. That is, the protection is in the nature of a preferential chemical reaction between the zinc and the corrosive agents in the environment to which the can end is subjected, rather than the iron. Thus, full coating may not be required for full protection. From this it will be apparent that any metal having a more preferential reaction with such agents than iron will be a suitable coating; that is, any element having a higher electronegativity than iron will be suitable in place of the zinc. Zinc is used in the preferred embodiment simply because it is cheap and can readily be applied by, e.g., dipping.
Those skilled in the art will recognize that a number of modifications can be made to the invention as disclosed in the above without departing from its essential concept; that is, the can end can be made entirely from such steel coated from aluminum, but as discussed above, it is believed that in most applications the can end itself will be made of aluminum and the tab will be made of steel coated with a metal with a higher electronegativity, and the invention has been described in terms of these materials. Moreover, it will be clear that the zinc or other metal coating can be applied by any suitable process at any suitable step in the formation of the tab. Moreover, it will be apparent that a further coating can be also be added in order to prevent, for example, the zinc from being scraped off during later processing. Preferably a lacquer is used to protect the zinc during further handling.
Therefore, this description of the invention should not be construed to limit it, inasmuch as it is exemplary only; rather, the invention's scope should be determined only by the limitations expressed in the following claims. | This application is concerned with a can end comprising an end plate and a tab, the tab and end plate being so adapted to one another that by bending of the tab up by one desiring to open the can, the tab forces a section of the can to pivot inward, thus allowing access to the contents of the can without detaching any piece of the end or tab. The can end is made of aluminum, and the tab is made of steel coated with a material so chosen as to minimize or eliminate corrosion of the steel. In a preferred embodiment, the steel tab is coated with zinc. | 1 |
BACKGROUND OF THE PRESENT INVENTION
The present invention is directed to the manufacture of a bent portion of a pipeline and, in particular to a pipeline having a large cross-sectional measurement. Pipelines of this type are used in civil engineering or public works, for example, for the construction of thermal or nuclear power stations.
The manufacture of curved pipes or bends, that is, the manufacture of hollow toroidal segments of circular cross-section and of various thicknesses which are used together with cylindrical pipelines presents difficulties, especially if the constituent material is a metal and if the environmental stresses to which they are subjected, such as pressure, fatigue, and corrosion are high.
Several techniques are currently used for manufacturing these curved pipes. For example, these curved pipes may be formed using traditional molding processes, namely sand molding or chill casting, with a core. Alternatively, these curved pipes may be formed by mechanical bending of tube elements under the action of heat or in the cold, by bending using electrical induction, by hot deformation by the forging of tubular pieces, or by welding of stamped shells.
The continuity of the toroidal wall is sometimes sacrificed by welding together sections of welded or seamless tube elements, to the detriment of the quality of the flow of the fluid to be conveyed therethrough.
Apart from traditional molding, whose technical limits result from the severity of the specifications, the other methods consist of deforming the constituent material of a tube. This leads, in the majority of cases, to a lack of homogeneity in the thickness of the walls and also to damage to the original structure of the material. Alternatively, this introduces numerous welds into a portion of piping which is already particularly sensitive to erosion, pitting, corrosion and so on, because of the deflection of the stream of fluid running through it.
The present invention provides a method which overcomes the above recited disadvantages by combining the techniques of centrifugation of materials in the liquid phase and the techniques of machining these same materials in the solid phase.
Furthermore, the present invention makes it possible to produce very thick curved pipes capable of withstanding high stresses without damage to the structure obtained during the initial shaping, except the stresses resulting from the heat treatments frequently applied to materials and, in particular, to metal materials, after solidification.
It is known that centrifugation under high acceleration provides the materials produced in this way with good characteristics and an exceptional internal constitution.
In fact, the density differences between these materials in the liquid state and the impurities which could be present therein in the form of inclusions are considerably increased by the centrifugal force. The impurities are thus thrown out, either towards the bore in the centrifuged hollow body, under the influence of the Archimedean thrust, or towards the periphery, under the influence of the centrifugal force, depending on whether they are more or less dense than the material in question.
The dissolved gases are also excluded from the liquid mass under the influence of the pressure difference between the ambient environment, generally the atmosphere and the body of the liquid subjected to the centrifugal force before and during its solidification.
For the same reasons, the centrifuged materials also possess no pores.
If the processing and the centrifugation of these materials are carried out correctly, they are capable of withstanding high pressures because of their noteworthy water tightness.
A centrifuged body can be given any desired external shape, provided that this shape enables it to be released from the mold, which is virtually always made of metal, either directly or by splitting the mold.
However, the bore in this body will theoretically be either a cylinder or revolution, if the centrifugation axis is horizontal, or a portion of a paraboloid of revolution, if the centrifugation axis is vertical. The axis of symmetry of both these surfaces is identical to the axis of rotation of the mold. The paraboloid of revolution is closer to a cylinder of revolution, as the centrifugal force increases relative to the earth's gravity.
The internal and external surfaces of a circular cross-section are two curved pipe toroids with the same center and the same mean radius. The thickness to be obtained is equal to the difference in radius of the concentric circular sections of the external surface and the internal surface.
The novel method and apparatus according to the present invention makes it possible to obtain the external surface of the toroid by centrifugation, while the internal surface will be obtained by machining the crude surface, of virtually cylindrical shape, resulting from the centrifugal force.
As the principle is the same for both horizontal and vertical centrifugations, the application of the invention to the vertical centrifugation of a curved pipe bend will be described below. To simplify the account, it will be assumed that the centrifugation mold is made of metal, although it is understood that it could consist of any other appropriate material.
SUMMARY OF THE PRESENT INVENTION
The process according to the present invention for manufacturing a pipeline bend by centrifugal casting is characterized in that it includes the following stages in succession:
(a) a centrifugation mold which can be taken to pieces is used, in which the internal impression has the shape of the external surface of the bend to be produced;
(b) this mold is rotated about a geometrical axis which substantially coincides with the mean internal longitudinal axis of the bend to be produced;
(c) the molten material is cast into the rotating mold and then left to solidify;
(d) the mold is opened in order to release the blank of bend, the external surface of which is bent; and
(e) this blank is mounted on a machining device in order to machine the internal surface to give the final bent shape.
It is pointed out that, if appropriate, the external surface of the bend can be preserved as such, rough-cast, that is to say without any external machining.
The process is further simplified if the bend to be produced has the shape of a hollow toroidal segement. In this case, each meridian section is circular, while the mean longitudinal internal axis of the bend is also an arc of a circle. The blank can then be demolded by sliding it in an arc of a circle within the solid hollow body of the mold, only the two end faces of which can be removed like simple covers.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are given by way of non-limiting example, will provide a better understanding of the characteristics of the invention.
FIG. 1 is a partial axial sectional view showing a centrifugal mold for a pipe having a bend, according to the present invention;
FIG. 2 is a diagrammatic view showing the method of machining the blank produced by the mold of FIG. 1 after it has been demolded, according to the method of the present invention;
FIG. 3 is a graph illustrating the process for correcting the imbalance on the centrifugation mold, according to the method of the present invention;
FIG. 4 is a sectional view through the blank and illustrates the step of machining the internal surface of a 60° bend in the blank according to the method of the present invention;
FIG. 5 is a view similar to FIG. 4 and shows an analogous operation for a 90° bend;
FIG. 6 is a view similar to FIG. 4 and illustrates an alternate step for machining the internal surface of the blank according to the method of the present invention;
FIG. 7 is a schematic view illustrating still another alternate step for machining the internal surface as well as the external surface of the blank according to the method of the present invention;
FIG. 8 is an equatorial sectional view of the blank, illustrating the progress of the solidification and the structure of the material within the finished curved pipe produced by the method of the present invention;
FIG. 9 is a longitudinal sectional view of a curved pipe of constant thickness, obtained according to the method of the present invention; and
FIG. 10 is a longitudinal sectional view of a curved pipe of variable thickness, obtained according to the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a mold 1 having a cavity 1c in the shape of a portion of a circular toroid of circular section, affixed to the horizontal plate 2 of a vertical centrifuging machine. Two end members or covers 8 and 9 bear against the ends 1a and 1b of the mold 1.
The plane of symmetry 40 of this portion of a circular toroid passing through its longitudinal axis is parallel to the plate of the machine.
It will be apparent to one skilled in the art that it is possible to pour into the cavity 1c a sufficient amount of liquid material to insure that the internal limit of the centrifuged molding or blank 4 is capable, after suitable machining of the inside of the solidified molding or blank, of having the desired toroidal internal surface (FIG. 2).
For this purpose, it is sufficient for the length of the segments 5 and 6 to be slightly greater than the final wall thickness of the curved pipe to be obtained.
It will also be readily apparent that the angle 7, defined between the two planes in which the end members or covers 8 and 9 bear against the ends of the mold 1, must be less than the value for which the generatrices 10 and 11 of the internal cylinder are theoretically identical. Of course, it is necessary to remain within these limiting values so that a considerable centrifugal force will be exerted on the material during its solidification.
FIG. 3 shows a graph in which the value of the imbalance of the rotating mass is plotted on the ordinate and the time is plotted on the abscissa.
It is seen that, before the material to be centrifuged is introduced into the mold 1, there is an imbalance 12 due to the fact that the center of gravity of the mold is offset from the axis of rotation 3 (FIGS. 1 and 2).
A new imbalance 13, in the same direction but of a smaller value, exists after the material has been introduced into the mold.
These imbalances can be partially corrected by reducing the mass of the mold 1 on the side opposite the convexity of the bend, so as to produce a pre-casting imbalance 14 and a post-casting imbalance 15 equal in value but opposite in direction, and each smaller in terms of absolute value than the initial imbalance 12 and the final imbalance 13 observed without this modification.
This static balancing operation can also be accompanied by dynamic balancing.
In any case, the centrifuging machine used must withstand, without suffering fatigue, the variable imbalances imposed by this process.
After solidification and after the end members or covers 8 and 9 have been opened, the centrifuged blank 4 can be released from the cavity 1c, without breaking the mold 1, by means of a circular sliding movement coinciding with the mean circle of the toroid as shown by arrow 35 in FIG. 1. After demolding, the blank 4, which has the shape illustrated in FIGS. 1 and 2, is machined. This operation consists firstly in converting the cylindrical internal surface 16b of the blank 4 to a toroidal surface parallel to the external surface 16a thereof and located at a distance from the external wall 16 which is equal to the desired thickness 17 assuming, of course, that the external surface 16a remains substantially as it is formed by centrifugation.
It should be noted that reference number 33 in FIG. 2 denotes the mean longitudinal internal axis of the toroid of which the bend or curved pipe to be produced constitutes a segment. FIG. 2 also shows a mean longitudinal axis 43 tangential to the curved longitudinal axis 33 at the midpoint.
As a circular toroid is the envelope of a circle rotating about an axis located in the plane of this circle, there are two possible ways in which the cylindrical internal surface 16b of the toroid can be machined. One example is illustrated in FIG. 4 and is described immediately below. Another example is illustrated in FIG. 6 and will be described later herein.
Referring now to FIG. 4, according to the method of the present invention, the blank 4 is locked parallel to the circular plane of the toroid on a machine tool 41. The horizontal plate of the machine tool 41 can rotate about the theoretical tordidal axis 18 of the toroid.
A cutting tool 19 is rotatably driven about the longitudinal geometrical axis of the machine tool 41 to machine the surface in the toroid by means of successive passes, the advancing movement then being caused by rotation of the plate about the toroidal axis 18 of the toroid. The tool 19 rotates about the longitudinal geometrical axis 34 of a tool carrier 22, the axis 34 being tangential to the mean longitudinal internal axis 33 of the toroidal bend.
This type of machining can be carried out on a boring machine or a milling machine fitted with a conventional plate or a cast-iron plate with controlled rotation.
The shape of the bend and the different relative values of the angle 7 of the bend, of the radius 20 of the bend and of the internal diameter 21 of the bend define the limits of the boring process described above. The tool carrier 22 abuts against the projecting edge formed by the face of the bend and its toroidal internal surface at the point 23 furthest from the center.
The operation can be continued by repeating the machining operation through the opposite orifice in the blank.
For example, the process can be used to machine the bore in a curved pipe 25 in which the angle 7 is equal to 90°, and of which the radius of curvature is equal to the internal diameter 24 (FIG. 5).
On the other hand, less sharp curves or bends, such as those having an angle 7 of 60° and having a radius of curvature in excess of three times the internal diameter, for example, cannot be machined internally by the above described process, even by gaining access to the bore successively through the two ends.
The present invention, therefore, includes an additional method and device which can be used either when the ends accessible by the above method have already been machined, or directly in order to carry out the entire operation. This device is illustrated in FIG. 6 and is described below.
FIG. 6 illustrates a curved pipe 25' in the shape of a toroid, the generating radius of which is the same as that of the bend and the diameter of which is less than the diameter 27 of the machined bore to be produced. The curved pipe blank is held at one of its ends by a frame, which is not shown in the drawing. At the other end of the blank, there is a drive head 26 equipped with a cutting tool 28, the cutting part of which describes the generating circle of the internal toroidal surface of the curved pipe. This curved arm 29 can be introduced by means of a circular movement, the advancing axis of which is identical to the toroidal axis 18, the guiding axis of which is identical to the mean longitudinal internal axis 33 of the toroid, into the bore to be machined, the tool thus generating the internal surface to be obtained. Conversely, with the curved arm 29 remaining fixed, the blank 4 of the bend can be locked on a rotating table as previously described.
In certain cases, it may be desired to also machine the exterior toroidal surface of the blank according to the method of the invention. For example, extra external thicknesses may have been created during centrifugation. It is possible to use a method similar to that described above, as depicted in FIG. 7, to machine the external surface of the blank using a cutting tool generating the external toroidal surface of the curved pipe by rotation around the latter, while rotating the blank in the direction of the arrow 31 about the toroidal axis 18 which causes the tool to advance along the toroidal surface.
It is, thus, possible to obtain a curved pipe of constant thickness 38, as illustrated in FIG. 9.
Still another variation of the method and apparatus of the present invention is contemplated for machining one or both of the toroidal surfaces of the blank to be used as a curved pipe.
The purpose of this variation is to obtain a curved pipe of variable wall thickness 36, as shown in FIG. 10, or alternatively of variable wall thickness and variable internal section 37.
To achieve this result, it is sufficient to combine the advancing of the tool or of the blank, as described earlier, with an apparatus for varying the bore diameter. This is possible, for example, to provide a surface with plateaus.
This variation provides curve restrictions with or without variation in wall thickness as depicted in FIG. 10. Of course, the centrifugation molds will have a shape corresponding to the external shape to be obtained on these blanks.
However, it is simpler in that case to consider the toroid as a surface of revolution and to produce the external surface by turning on a lathe, the circular shape being obtained, for example, with the aid of a reproducing device following a circular template, while the blank 30 is fixed to the face-plate 32 of a lathe as shown in FIG. 7.
It will be understood by one skilled in the art that the present invention has numerous advantages.
Apart from the fact that the material of the tube is centrifuged, which gives it an excellent internal constitution in all cases, it will be appreciated that there is an advantage peculiar to metal alloys centrifuged in a metal mold. The solidification of metal alloys obeys an imperative law. The solidification is unidirectional and, furthermore, involves the entire surface of the tube in a uniform and simultaneous manner. The arrows 44 and 42 in FIG. 8, in fact, show the progress of the solidification starting from the wall of the mold 1 demonstrating the fact that, despite the non-uniformity of the thicknesses of liquid metal after the metal has been introduced into the rotating mold or after the rotation of the metal already introduced in the static state into the mold has been started (according to the process chosen), all the points on the internal surface of the bend which are shown in broken lines are reached simultaneously by the solidification front progressing inwardly from the outside of the blank. As this internal surface is close to the external surface, the solidification takes place rapidly, and this gives the solidified alloy a particular fine-grained structure, which is always desirable for the high mechanical characteristics which result therefrom.
It is also known that centrifuged metal alloys possess isotropic, mechanical characteristics, that is, the properties are identical irrespective of the direction of the stresses.
The process described above, therefore, has considerable advantages over the conventional processes. For example, the prior art process involving hot deformation of forged or rolled tubes produces a fibrous structure with heterogeneous mechanical characteristics by the bulk machining of blanks, the solidification of which has not been directed logically from the external wall of the bend to be produced. Traditional molding also fails to produce the high mechanical characteristics expected of centrifuged products, and does not insure the homogeneity or isotropy of these same characteristics.
The above constitutes a detailed description of the present invention and is offered by way of example and not by way of limitation. Many variations and modifications will be apparent to those skilled in the art upon reviewing the present application. Such variations and modifications are intended to be within the scope of the claims appended hereto.
What is claimed as novel is as follows: | A method and an apparatus for manufacturing a hollow curved member, especially a curved pipe as well as the curved member or pipe produced by the method and apparatus. A blank is formed by rotating fluid material in a mold having a toroidal cavity about an axis displaced a predetermined distance from the mean longitudinal axis of the cavity and solidifying the fluid material. The blank is removed from the mold and a toroidal inner surface is machined into the blank so as to provide a passageway therethrough. In the preferred embodiment, the toroidal cavity is circular in cross-section and has a circular arcuate axis and the inner surface is machined into the blank coaxial with the outer surface of the blank. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of U.S. patent application Ser. No. 13/795,056, filed Mar. 12, 2013, now abandoned, which is a division of U.S. patent application Ser. No. 13/065,454, filed Mar. 23, 2011, now U.S. Pat. No. 8,397,436, issued Mar. 19, 2013, which is a continuation of U.S. patent application Ser. No. 11/698,879, filed Jan. 29, 2007, now U.S. Pat. No. 7,913,458, issued Mar. 29, 2011, which is a continuation in part of U.S. patent application Ser. No. 10/849,913, filed May 21, 2004, now U.S. Pat. No. 7,191,564, issued Mar. 20, 2007; the entirety of which is hereby incorporated by reference.
BACKGROUND
1. Field of the Invention
Gutter covering systems are known to prevent debris from entering into the open top end of a rain gutter. When debris accumulates within the body of a rain gutter in an amount great enough to cover the opening of a downspout-draining hole, the draining of water from the rain gutter is impeded or completely stopped. This occurrence will cause the water to rise within the rain gutter and spill over its uppermost front and rear portions.
The purpose of a rain gutter, to divert water away from the structure and foundation of a home, is thereby circumvented.
2. Related Art
The invention relates to the field of Gutter Anti-clogging Devices and particularly relates to screens with affixed fine filter membranes, and to devices that employ recessed wells or channels in which filter material may be inserted, affixed to gutters to prevent debris from impeding the desired drainage of water.
Various gutter anti-clogging devices are known in the art and some are described in issued patents.
In my U.S. Pat. No. 6,598,352, I teach a gutter protection system for preventing entrance of debris into a rain gutter. I teach a gutter protection system to include a recessed perforated angled well within a rigid main body that receives an insertable flexible polymer support skeleton that supports overlying micro mesh filtering membrane that is attached to the underlying support skeleton. This insertable flexible filtration configuration is manufactured separately from the rigid four or five foot length body in fifty foot rolls and allows for a seamless filter protecting an underlying gutter, over long gutter lengths. The insertable support skeleton includes a perforated plane with integral downward extending planes and integral upward extending support planes, separated by unbroken air space, that contact an overlying micro mesh filtering membrane on it's undermost surface. I further teach that the contacting of the undermost surface of a micromesh filtering membrane by optimally spaced support planes encourages the downward flow of rain water through said micro mesh filtering membrane and into an underlying rain gutter. This gutter protection system has been shown, in the field to be extremely effective at preventing rain gutter clogs without a single known instance of clogging. However, the insertable flexible polymer support skeleton with attached filtering membrane is somewhat heavy and has been found to be cumbersome, even impossible, to install in the recessed angled well of the rigid main body of the gutter protection system during cold weather as the flexible polymer skeleton has been found to stiffen and becomes inflexible. The insertable flexible skeleton also has been known to expand and contract at a different coefficient that rigid main body of the gutter protection system. This can cause areas of the main body of the gutter protection to become exposed to potential debris entrance due to relative shrinkage of the insertable polymer support skeleton or, in other instances, the insertable filtration configuration may expand and extend past the main body of the gutter protection system and further expand past end caps of an underlying gutter which home owners view as undesirable from a cosmetic perspective.
U.S. Pat. No. 5,557,891 to Albracht teaches a gutter protection system for preventing entrance of debris into a rain gutter. Albracht teaches a gutter protection system to include a single continuous two sided well with angled sides and perforated bottom shelf 9 into which rainwater will flow and empty into the rain gutter below. The well is of a depth, which is capable of receiving a filter mesh material. However, attempts to insert or cover such open channels of “reverse-curve” devices with filter meshes or cloths is known to prevent rainwater from entering the water receiving channels. This occurrence exists because of the tendency of such membranes, (unsupported by a proper skeletal structure), to channel water, by means of water adhesion along the interconnected paths existing in the filter membranes (and in the enclosures they may be contained by or in), past the intended water-receiving channel and to the ground. This occurrence also exists because of the tendency of filter mediums of any present known design or structure to quickly waterproof or clog when inserted into such channels creating even greater channeling of rainwater forward into a spill past an underlying rain gutter. Filtering of such open, recessed, channels existing in Albracht's invention as well as in U.S. Pat. No. 5,010,696, to Knittel, U.S. Pat. No. 2,672,832 to Goetz, U.S. Pat. No. 5,459,350, & U.S. Pat. No. 5,181,350 to Meckstroth, U.S. Pat. No. 5,491,998 to Hansen, U.S. Pat. No. 4,757,649 to Vahldieck and in similar “reverse-curved” inventions that rely on “reverse-curved” surfaces channeling water into an open channel have been known to disallow entrance of rainwater into the water-receiving channels. Albracht's as well as previous and succeeding similar inventions have therefore notably avoided the utilization of filter insertions. What may appear as a logical anticipation by such inventions at first glance, (inserting of a filter mesh or material into the channel), has been shown to be undesirable and ineffective across a broad spectrum of filtering materials: Employing insertable filters into such inventions has not been found to be a simple matter of anticipation, or design choice of filter medium by those skilled in the arts. Rather, it has proved to be an ineffective option, with any known filter medium, when attempted in the field. Such attempts, in the field, have demonstrated that the filter mediums will eventually require manual cleaning.
U.S. Pat. No. 5,595,027 to Vail teaches a continuous opening 24A between the two top shelves. Vail teaches a gutter protection system having a single continuous well 25, the well having a depth allowing insertion and retention of filter mesh material 26 (a top portion of the filler mesh material capable of being fully exposed at the holes). Vail does teach a gutter protection system designed to incorporate an insertable filter material into a recessed well. However, Vail notably names and intends the filter medium to be a tangled mesh fiberglass five times the thickness of the invention body. This type of filtration medium, also claimed in U.S. Pat. No. 4,841,686 to Rees, and in prior art currently marketed as FLOW-FREE™ is known to trap and hold debris within itself which, by design, most filter mediums are intended to do, i.e.: trap and hold debris. Vail's invention does initially prevent some debris from entering an underlying rain gutter but gradually becomes ineffective at channeling water into a rain gutter due to the propensity of their claimed filter mediums to clog with debris. Though Vail's invention embodies an insertable filter, such filter is not readily accessible for cleaning when such cleaning is necessitated. The gutter cover must be removed and uplifted for cleaning and, the filter medium is not easily and readily inserted replaced into its longitudinal containing channel extending three or more feet. It is often noted, in the field, that these and similar inventions hold fast pine needles in great numbers which presents an unsightly appearance as well as create debris dams behind the upwardly extended and trapped pine needles. Such filter meshes and non-woven lofty fiber mesh materials, even when composed of finer micro-porous materials, additionally tend to clog and fill with oak tassels and other smaller organic debris because they are not resting, by design, on a skeletal structure that encourages greater water flow through its overlying filter membrane than exists when such filter meshes or membranes contact planar continuously-connected surfaces. Known filter mediums of larger openings tend to trap and hold debris. Known filter mediums smaller openings clog or “heal over” with pollen and dirt that becomes embedded and remains in the finer micro-porous filter mediums. At present, there has not been found, as a matter of common knowledge or anticipation, an effective water-permeable, non-clogging “medium-of-choice” that can be chosen, in lieu of claimed or illustrated filter mediums in prior art, that is able to overcome the inherent tendencies of any known filter mediums to clog when applied to or inserted within the types of water receiving wells and channels noted in prior art. Vail also discloses that filter mesh material 26 is recessed beneath a planar surface that utilizes perforations in the plane to direct water to the filter medium beneath. Such perforated planar surfaces as utilized by Vail, by Sweers U.S. Pat. No. 5,555,680, by Morin U.S. Pat. No. 5,842,311 and by similar prior art are known to only be partially effective at channeling water downward through the open apertures rather than forward across the body of the invention and to the ground. This occurs because of the principal of water adhesion: rainwater tends to flow around perforations as much as downward through them, and miss the rain gutter entirely. Also, in observing perforated planes such as utilized by Vail and similar inventions (where rainwater experiences its first contact with a perforated plane) it is apparent that they present much surface area impervious to downward water flow disallowing such inventions from receiving much of the rainwater contacting them. A simple design choice or anticipation of multiplying the perforations can result in a weakened body subject to deformity when exposed to the weight of snow and/or debris or when, in the case of polymer bodies, exposed to summer temperatures and sunlight.
U.S. Pat. No. 4,841,686 to Rees teaches an improvement for rain gutters comprising a filter attachment, which is constructed to fit over the open end of a gutter. The filter attachment comprised an elongated screen to the underside of which is clamped a fibrous material such as fiberglass. Rees teaches in the Background of The Invention that many devices, such as slotted or perforated metal sheets, or screens of wire or other material, or plastic foam, have been used in prior art to cover the open tops of gutters to filter out foreign material. He states that success with such devices has been limited because small debris and pine needles still may enter through them into a rain gutter and clog its downspout opening and or lodge in and clog the devices themselves. Rees teaches that his use of a finer opening tangled fiberglass filter sandwiched between two lateral screens will eliminate such clogging of the device by smaller debris. However, in practice it is known that such devices as is disclosed by Rees are only partially effective at shedding debris while channeling rainwater into an underlying gutter. Shingle oil leaching off of certain roof coverings, pollen, dust, dirt, and other fine debris are known to “heal over” such devices clogging and/or effectively “water-proofing” them and necessitate the manual cleaning they seek to eliminate. (If not because of the larger debris, because of the fine debris and pollutants). Additionally, again as with other prior art that seeks to employ filter medium screening of debris; the filter medium utilized by Rees rests on an inter-connected planar surface which provides non-broken continuous paths over and under which water will flow, by means of water adhesion, to the front of a gutter and spill to the ground rather than drop downward into an underlying rain gutter. Whether filter medium is “sandwiched” between perforated planes or screens as in Rees' invention, or such filter medium exists below perforated planes or screens and is contained in a well or channel, water will tend to flow forward along continuous paths through cur as well as downward into an underlying rain gutter achieving less than desirable water-channeling into a rain gutter.
U.S. Pat. No. 5,956,904 to Gentry teaches a first fine screen having mesh openings affixed to an underlying screen of larger openings. Both screens are elastically deformable to permit a user to compress the invention for insertion into a rain gutter. Gentry, as Rees, recognizes the inability of prior art to prevent entrance of finer debris into a rain gutter, and Gentry, as Rees, relies on a much finer screen mesh than is employed by prior art to achieve prevention of finer debris entrance into a rain gutter. In both the Gentry and Rees prior art, and their improvements over less effective filter mediums of previous prior art, it becomes apparent that anticipation of improved filter medium or configurations is not viewed as a matter of simple anticipation of prior art which has, or could, employ filter medium. It becomes apparent that improved filtering methods may be viewed as patentable unique inventions in and of themselves and not necessarily an anticipation or matter of design choice of a better filter medium or method being applied to or substituted within prior art that does or could employ filter medium. However, though Rees and Gentry did achieve finer filtration over filter medium utilized in prior art, their inventions also exhibit a tendency to channel water past an underlying gutter and/or to heal over with finer dirt, pollen, and other pollutants and clog thereby requiring manual cleaning. Additionally, when filter medium is applied to or rested upon planar perforated or screen meshed surfaces, there is a notable tendency for the underlying perforated plane or screen to channel water past the gutter where it will then spill to the ground. It has also been noted that prior art listed herein exhibits a tendency to allow filter cloth mediums to sag into the opening of their underlying supporting structures. To compensate for forward channeling of water, prior art embodies open apertures spaced too distantly, or allows the apertures themselves to encompass too large an area, thereby allowing the sagging of overlying filter membranes and cloths. Such sagging creates pockets wherein debris tends to settle and enmesh.
U.S. Pat. No. 3,855,132 to Dugan teaches a porous solid material which is installed in the gutter to form an upper barrier surface (against debris entrance into a rain gutter). Though Dugan anticipates that any debris gathered on the upper barrier surface will dry and blow away, that is not always the case with this or similar devices. In practice, such devices are known to “heal over” with pollen, oil, and other pollutants and effectively waterproof or clog the device rendering it ineffective in that they prevent both debris and water from entering a rain gutter. Pollen may actually cement debris to the top surface of such devices and fail to allow wash-off even after repeated rains. U.S. Pat. No. 4,949,514 to Weller sought to present more water receiving top surface of a similar solid porous device by undulating the top surface but, in fact, effectively created debris “traps” with the peak and valley undulation. As with other prior art, such devices may work effectively for a period of time but tend to eventually channel water past a rain gutter, due to eventual clogging of the device itself.
There are several commercial filtering products designed to prevent foreign matter buildup in gutters. For example the FLOW-FREE™ gutter protection system sold by DCI of Clifton Heights, Pa. comprises a 0.75-inch thick nylon mesh material designed to fit within 5-inch K type gutters to seal the gutters and downspout systems from debris and snow buildup. The FLOW-FREE™ device fits over the hanging brackets of the gutters and one side extends to the bottom of the gutter to prevent the collapse into the gutter. However, as in other filtering attempts, shingle material and pine needles can become trapped in the coarse nylon mesh and must be periodically cleaned.
U.S. Pat. No. 6,134,843 to Tregear teaches a gutter device that has an elongated matting having a plurality of open cones arranged in transverse and longitudinal rows, the base of the cones defining a lower first plane and the apexes of the cones defining an upper second plane. Although the Tregear device overcomes the eventual trapping of larger debris within a filtering mesh composed of fabric sufficiently smooth to prevent the trapping of debris he notes in prior art, the Tregear device tends to eventually allow pollen, oil which may leach from asphalt shingles, oak tassels, and finer seeds and debris to coat and heal over a top-most matting screen it employs to disallow larger debris from becoming entangled in the larger aperatured filtering medium it covers. Tregear indicates that filtered configurations such as a commercially available attic ventilation system known as Roll Vent™ manufactured by Benjamin Obdyke, Inc. Warminster, Pa. is suitable, with modifications that accommodate its fitting into a rain gutter. However, such a device has been noted, even in its original intended application, to require cleaning (as do most attic screens and filters) to remove dust, dirt, and pollen that combine with moisture to form adhesive coatings that can scum or heal over such attic filters.
Filtering mediums (exhibiting tightly woven, knitted, or tangled mesh threads to achieve density or “smoothness”) employed by Tregear and other prior art have been unable to achieve imperviousness to waterproofing and clogging effects caused by a healing or pasting over of such surfaces by pollen, fine dirt, scum, oils, and air and water pollutants. Additionally, referring again to Tregear's device, a lower first plane tends to channel water toward the front lip of a rain gutter, rather than allowing it's free passage downward, and allow the feeding and spilling of water up and over the front lip of a rain gutter by means of water-adhesion channels created in the lower first plane.
Prior art has employed filter cloths over underlying mesh, screens, cones, longitudinal rods, however such prior art has eventually been realized as unable to prevent an eventual clogging of their finer filtering membranes by pollen, dirt, oak tassels, and finer debris. Such prior art has been noted to succumb to eventual clogging by the healing over of debris which adheres itself to surfaces when intermingled with organic oils, oily pollen, and shingle oil that act as an adhesive. The hoped for cleaning of leaves, pine needles, seed pods and other debris by water flow or wind, envisioned by Tregear and other prior art, is often not realized due to their adherence to surfaces by pollen, oils, pollutants, and silica dusts and water mists. The cleaning of adhesive oils, fine dirt, and particularly of the scum and paste formed by pollen and silica dust (common in many soil types) by flowing water or wind is almost never realized in prior art.
Prior art that has relied on reverse curved surfaces channeling water inside a rain gutter due to surface tension, of varied configurations and pluralities, arranged longitudinally, have been noted to lose their surface tension feature as pollen, oil, scum, eventually adhere to them. Additionally, multi-channeled embodiments of longitudinal reverse curve prior art have been noted to allow their water receiving channels to become packed with pine needles, oak tassels, other debris, and eventually clog disallowing the free passage of water into a rain gutter. Examples of such prior art are seen in the commercial product GUTTER HELMET™ manufactured by American metal products and sold by Mr. Fix It of Richmond, Va. In this and similar Commercial products, dirt and mildew build up on the bull-nose of the curve preventing water from entering the gutter. Also, ENGLERT'S LEAFGUARD®, manufactured and distributed by Englert Inc. of Perthamboy N.J., and K-GUARD®, manufactured and distributed by KNUDSON INC. of Colorado, are similarly noted to lose their water-channeling properties due to dirt buildup. These commercial products state such, in literature to homeowners that advises them on the proper method of cleaning and maintaining their products.
With the exception of U.S. Pat. No. 6,598,352, none of these above-described systems keep all debris out of a gutter system allowing water alone to enter, for an extended length of time. Some allow lodging and embedding of pine needles and other debris to occur within their open water receiving areas causing them to channel water past a rain gutter. Others allow such debris to enter and clog a rain gutter's downspout opening. Still others, particularly those employing filter membranes, succumb to a paste and or scum-like healing over and clogging of their filtration membranes over time rendering them unable to channel water into a rain gutter. Pollen and silica dirt, particularly, are noted to cement even larger debris to the filter, screen, mesh, perforated opening, and/or reverse curved surfaces of prior art, adhering debris to prior art in a manner that was not envisioned. My earlier patent has proven effective but may exhibit undesirable cosmetic features and may prove difficult, even impossible, to install under certain cold weather conditions.
Accordingly, it is an object of the embodiments of the present invention to provide a gutter shield that employs the effective properties of my U.S. Pat. No. 6,598,352: a gutter shield device that employs a fine filtration combination that is not subject to gumming or healing over by pollen, silica dust, oils, and other very fine debris, a gutter shield device that provides a filtration configuration and encompassing body that eliminates any forward channeling of rain water, a gutter shield that will accept more water run-off into a five inch K-style rain gutter than such a gutter's downspout opening is able to drain before allowing the rain gutter to overflow (in instances where a single three-inch by five-inch downspout is installed to service 600 square feet of roofing surface).
Another object of the embodiments of the present invention is to provide a gutter shield with the above noted properties that incorporates and makes integral within it's main rigid body the features and structure of the insertable flexible polymer support skeleton disclosed in my U.S. Pat. No. 6,598,352 thereby eliminating the most prominent expansion and contraction coefficients found to exist between a rigid main body utilizing an insertable flexible polymer filtration configuration.
Another object of the embodiments of the present invention is to provide a gutter shield with the above noted properties that utilizes a stainless steel or aluminum micromesh filter cloth that may be inserted into a main body with integral recessed and perforated wells that incorporate integral upward extending planes allowing for a lower cost of manufacture by eliminating a separately manufactured flexible polymer support skeleton and allowing for a lighter, more stable under varying temperatures, and more easily installed insertable filtering component.
Another object of the embodiments of the present invention, is to provide a gutter shield that employs a filtration membrane that is readily accessible and easily replaceable if such membrane is damaged by nature or accident.
Other objects will appear hereinafter.
SUMMARY
In one example embodiment, a gutter shield device for mounting to a rain gutter is provided. The gutter shield device comprises an elongated body comprising a first body portion; a second body portion; and an intermediate body portion disposed between the first and second body portions and connected to the first and second body portions. The intermediate body portion defines a surface and includes a plurality of extending portions extending in a direction away from the surface to define a plurality of openings in the surface. The gutter shield device further comprises a filter element secured to the intermediate body portion such that surface of the filter element is arranged adjacent to the openings.
In another example embodiment, the intermediate body portion is connected to the first and second body portions by a first u-shaped receiving channel and a second u-shaped receiving channel, respectively. The filter element includes a first lateral edge received in the first u-shaped receiving channel of the intermediate body portion and a second lateral edge received in the second receiving channel of the intermediate body portion.
In another example embodiment, the surface of the filter element arranged adjacent to the openings contacts the surface defined by the intermediate portion, whereby, when water is passed over the filter element, the water is directed away from the filter element, through the openings, and along the plurality of extending portions.
In yet another example embodiment, the filter element comprises a plurality of interwoven threads defining a mesh screen. The mesh screen may define a mesh of between approximately 80 and 280 and the plurality of interwoven threads defining the mesh screen may comprise a plurality of stainless steel or aluminum threads.
In still another example embodiment, a diameter of each of the plurality of interwoven threads is between approximately 0.04 mm (0.0015 in) and approximately 0.14 mm (0.0055 in).
In still another example embodiment, the mesh screen comprises a plurality of intersecting threads having a diameter, each intersection of threads being crimped or pressed so that a maximum thickness of the mesh screen is less than two times the thread diameter.
In another alternative example embodiment, a body of a gutter shield device for mounting to a rain gutter is provided. The body of the gutter shield device comprises a first body portion; a second body portion; and an intermediate body portion disposed between and connected to the first and second body portions. The intermediate body portion defines a surface adapted to receive a filter element thereon and includes a plurality of extending portions extending in a direction away from the surface to define a plurality of openings in the surface. When the filter element is secured to the surface of defined by the intermediate body portion, a surface of the filter element is positioned adjacent to the plurality of openings.
In another example embodiment, the intermediate body portion is connected to the first and second body portions via a first u-shaped receiving channel and a second u-shaped receiving channel, respectively. The first and second u-shaped receiving channels are adapted to hold lateral edges of the filter element therein.
In one embodiment, the gutter guard is a simple filter element comprising a plurality of threads defining a mesh screen having corrugated portions that are perpendicular and/or not completely parallel to the longitudinal (lengthwise) edge of the filter element. The corrugated portions may be continuous or segmented. The gutter guard may be dropped onto underlying gutter hangars for support, lying flat, or may be angled upward from it's edge closest to the front lip of a rain gutter.
In another embodiment the filter element may be attached to a front securing member that attaches to the front lip of a rain gutter and/or be attached to a rear securing member that attaches to or rests against or upon an element of a rain gutter, or rain gutter securing member, or fascia board or roof structure or roof covering elements.
In another embodiment the filter element may have its forward longitudinal edge and/or it's rearward longitudinal edge shaped into a form that enables the filter element to attach to or rest upon the rain gutter or rain gutter securing members or any rearward element intrinsically a part of or attached to a building structure.
In another alternative example embodiment, a filtration element adapted to be mounted to a rain gutter is provided. The filtration element comprises a plurality of interwoven threads defining a first substantially planar surface and at least one substantially planar extending portion extending at an angle to the first substantially planar surface. The at least one substantially planar extending portion may be a folded portion. The at least one extending portion may be a plurality of spaced extending portions defining a plurality of substantially planar surfaces extending at angles to the first substantially planar surface. Each of the plurality of extending portions may be a folded portion.
In yet another example embodiment, the plurality of interwoven threads may be metallic threads, for example, stainless steel or aluminum threads. The plurality of interwoven threads may define a mesh screen having a mesh of for example, between approximately 80 and 280.
In still another example embodiment, a diameter of each of the plurality of interwoven threads is between approximately 0.0015 inches and 0.0055 inches.
In still another example embodiment, the mesh screen may comprise a plurality of intersecting threads having a diameter, each intersection of threads being crimped or pressed so that a maximum thickness of the mesh screen is less than two times the thread diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . is a sectional edge view displaying the profile of the main body of an example embodiment of the present invention as it would appear extruding from a roll forming machine or plastic extrusion die.
FIG. 2 . is a detailed sectional edge view displaying the profile of the main body of FIG. 1 .
FIG. 3 . is an isolated view of the profile of the main body of FIGS. 1 and 2 .
FIG. 3 a . is an isolated view of the profile of the main body of FIGS. 1-3 .
FIG. 4 . is a partial top perspective view of the main body of FIG. 1 .
FIG. 5 . is an isolated view of an example filter medium which may be affixed to the main body of FIGS. 1-4 or which is inserted into filter medium receiving channels of the main body of FIGS. 1-4 .
FIG. 5 a . is an isolated and exploded view of the example embodiment of the filter medium of FIG. 5 . is an isolated view of an example filter medium which may be affixed to the main body of FIGS. 1-4 or which is inserted into filter medium receiving channels of the main body of FIGS. 1-4 .
FIG. 6 . is a partial top perspective view of an example embodiment of the present invention displaying the main body of the gutter cover assembled with inserted filter medium.
FIG. 7 . is a partial top perspective view of an example embodiment of the present invention, displaying a roofline portion of a building structure, roof shingles, K-style gutter, and attached gutter cover.
FIG. 8 . is a sectional edge view displaying an alternate example embodiment of the profile of the main body of the present invention as it would appear extruding from a roll forming machine or plastic extrusion die.
FIG. 9 . is a partial top perspective view of an optional joining member that may be inserted into an alternate example embodiment of the main body of the present invention.
FIG. 10 . is a partial top perspective view of an alternate example embodiment of the main body of the present invention.
FIG. 11 . is a partial top perspective view displaying a joining member inserted into an alternate example embodiment of the main body of the present invention prior to being joined to a second section of gutter cover.
FIG. 12 . is a partial top perspective view of an example alternative embodiment of the body of the present invention.
FIG. 13 . is a detailed view of an opening in the intermediate body portion of the body according to the example embodiment of FIG. 12 .
FIG. 14 . is a partial top perspective view of a filtration element assembled with the body of FIG. 12 according to an alternative example embodiment of the invention.
FIG. 15 . is a detailed view of an opening covered by the filtration element according to the example embodiment of FIG. 14 .
FIG. 16 . is a partial top perspective view of a filtration element according to an alternative example embodiment.
FIG. 17 . is a detailed view of the filtration element according to the example embodiment of FIG. 16 .
DETAILED DESCRIPTION
Referring now specifically to the drawings, FIG. 6 shows a gutter cover (protector) body 69 with an insertable metallic micro mesh filtering membrane 71 attached thereto.
In one embodiment, body 69 may be composed of poly vinyl chloride (PVC) that is reduced to liquid form through screw compression of PVC “tags”. This liquid plastic mixture is then extruded through a profile forming die, then through a cooling tray and cut to 5 foot lengths. The extruded body material is rigid and has a thickness of approximately 0.06 inch. The extruded body 69 has intrinsic channels 22 and 65 arranged to receive, for example, an insertable stainless steel wire cloth 71 of 120 “thread count” with hemmed lateral edges and having a width of 3 and ⅝ inches. In another embodiment, body 69 may be a metallic body roll-formed from 0.019 to 0.027 aluminum coil and slit to widths of 113/4 inches and greater; depending on the width of gutter to be covered.
Referring to FIG. 1 , a profile of the main body 69 of an example embodiment of the present invention is illustrated having five major interconnected planes, M1( 3 ), M2( 5 ), M3( 11 ), M4( 23 ev ), M5( 66 ) with a width that may vary between 5.4 and 7 inches (illustrated at 5.4 inches wide) and a height 69 a , measured from the lowest point of channel 55 c to the uppermost point of angle 4 , of approximately 0.67 inch.
Referring to the example embodiment depicted in FIG. 2 , plane 1 is extruded or roll formed to a length of approximately 0.11 inch. Adjoining plane 1 is circumference 2 which is extruded or roll formed to an outside diameter of approximately 0.06 inch. Adjoining circumference 2 is plane 3 having a length of approximately 0.53 inch. Plane 3 adjoins and angles 4 approximately 60 degrees downward from horizontal plane 5 . Plane 5 has an approximate length of 0.5 inch and extrudes or roll forms downward at an approximate 96 degree angle 4 a to form downward extending plane or channel 9 which is formed by plane 6 , circumference 7 , and plane 8 .
In its roll formed metallic state, portions 6 , 7 , and 8 , form a downward extending u-shaped channel 9 with an open air space existing between planes 6 and 8 of approximately 0.022 inch. In its roll formed metallic state, plane 6 has a length of approximately 0.49 inch, plane 8 has a length of approximately 0.42 inch and circumference 7 has an outside diameter of approximately 0.06 inch. When the body 69 is formed as an extruded polymer product, channel 9 is non-existent and planes 6 and 8 are combined integrally and may be thought of as singular plane 6 / 8 with 7 existing as a termination of the downward extension of 9.
The combination of body portions 1, 2, 3, 4, 5, 6, 7, 8, 9 of the present invention in its roll formed metallic state, or the combination of body portions 1, 2, 3, 4, 5, 6/8, 7 of the present invention in its extruded polymer state, forms a front fastening member arranged to secure the body 69 to the top front lip of a k-style gutter, for example.
Referring to FIG. 3 , which is an exploded view of the embodiment depicted in FIG. 2 : 22 ev , plane 11 adjoins and angles rearward (toward the rear of the present invention) and upward from plane 8 approximately 30 degrees forming an angle 10 between planes 8 and 11 of approximately 60 degrees. Plane 11 has an approximate length of 0.44 inch. Plane 11 , in a roll formed metallic embodiment of the body 69 of the present invention, adjoins circumference 12 which curves downward into plane 13 that lies directly beneath and parallel to plane 11 . In this roll formed metallic state, plane circumference 12 has an approximate outside diameter of 0.06 inch. and plane 13 has an approximate length of 0.44 inch. Alternatively, when the body 69 is formed as an extruded polymer product plane 11 and plane 13 combine integrally and may be thought of as singular plane 11 / 13 with 11 being the topmost surface and 13 the undersurface of 11 / 13 and circumference 12 exists as a termination point rather than as a circumference. Plane 13 is a separate plane in the metallic roll formed state of the present invention and adjoins downward curving circumference 14 . Similarly, plane 11 / 13 is a singular plane in the extruded polymer state of the present invention and adjoins downward curving circumference 14 .
Circumference 14 may have an outside diameter of approximately 0.075 and adjoins plane 15 which is parallel to plane 13 (or plane 11 / 13 ). Plane 15 has an approximate length of 0.17 inch. Plane 15 adjoins plane 16 which has an approximate length of 0.045 inch and angles downward approximately 90 degrees from plane 15 . Plane 16 angles rightward and upward at an approximate 90 degree angle and adjoins plane 17 . Plane 17 has an approximate length of 0.157 inch and adjoins upward angling plane 18 at an approximate 90 degrees. Plane 18 has an approximate length of 0.045 inch and adjoins plane 20 at an approximate 90 degree angle.
Plane 20 has an approximate length of 0.10 inch. Planes 16 , 17 , and 18 form a recessed well 19 shown to serve as a perforated water receiving well (see FIGS. 3 and 4 ).
Plane 11 , circumference 12 , plane 13 (or plane 11 / 13 ), circumference 14 , planes 15 , 16 , 17 , 18 , and 20 form a u-shaped receiving channel 22 with an approximate width 22 w of 0.48 inch and an approximate height 22 h of 0.056 measured from planes 13 to 20 . This receiving channel is illustrated and referred to, collectively, as 22 as illustrated in FIG. 6 . FIG. 6 further illustrates that an example embodiment of the present invention may employs a second receiving channel 65 that serves, with channel 22 , to receive and secure filtering membrane 71 . The structure and dimensions of receiving channel 65 are discussed further below.
FIG. 2 illustrates a multilevel water receiving area of an example embodiment of the present invention. Referring to FIG. 3 a , which is an exploded view of portion 23 ev of FIG. 2 , plane 20 is formed or extruded at an approximate 90 degree downward angle into plane 21 . Plane 21 may have an approximate length of 0.045 inch and is extruded or roll formed rearward into plane 23 . Plane 23 is perforated, as is illustrated in FIG. 4 , with elliptical perforations 70 which may be, for example, approximately 0.09 in wide, 0.38 inches long, and spaced longitudinally at approximately 0.15 inch intervals. As a profiled illustration, plane 23 may have an approximate length of 0.154 inch and is extruded or roll formed upward at an approximate 90 degree angle into plane 24 . Plane 24 may be roll formed or extruded upward approximately 0.045 inch then further roll formed or extruded into partial ellipse 24 e . Planes 21 , 23 , 24 jointly form a water receiving perforated well or channel 25 (further illustrated in FIG. 4 ) that may have an approximate height 25 h of 0.06 inch and an approximate interior width 25 w of 0.15 inch. measured from the inner wall of plane 21 to the inner wall of plane 24 .
Partial ellipse 24 e may have an approximate partial circumference of 0.03 inch. Partial ellipse 24 e is roll formed or extruded into plane 26 which, if extended, parallels plane 23 . Plane 26 may have an approximate length of 0.076 inch. and is roll formed or extruded downward into partial ellipse 27 e . Partial ellipse 24 e , plane 26 , and plane 27 e jointly form an ellipsed cap 28 that contacts the underside of an overlying filtration membrane 71 (as illustrated in FIG. 6 ). Ellipsed cap 28 may have an approximate length of 0.16 inch measured from the initial point of partial ellipse 24 e , through plane 26 , to the termination point of partial ellipse 27 e . Partial ellipse 27 e is roll formed or extruded downward into plane 27 which parallels plane 24 . Plane 27 may have an approximate length of 0.045 inch.
Referring again to FIG. 3 a , plane 24 , partial ellipse 24 e , plane 26 , partial ellipse 27 e , and plane 27 jointly form a “bump” 29 that extends upward and supports and contacts the underside of an overlying filtration membrane 71 (as illustrated in FIG. 6 ) that rests on the ellipsed cap 28 integral to bump 29 . Bump 29 may have an approximate height 29 h of 0.068 inch and an approximate width 29 w of 0.13 inch.
Referring again to FIG. 2 and FIG. 3 a , “Bumps” 36 , 43 , 48 , 51 , and 59 and their respective integral caps 35 , 42 , 47 , 50 , and 58 existent in the multi-level water receiving well of the present invention may have measurements identical to bump 29 and its respective integral cap 28 as illustrated in FIG. 3 a.
Referring again to both FIG. 2 and FIG. 3 a , “Bumps” 43 and 54 with their respective integral caps 42 and 53 also have measurements identical to bump 29 and its respective integral cap 28 with the exception of their rear most downward extending legs 41 and 55 respectively. These legs may each have an approximate length of 0.25 inch and serve to form a wall of downward extending channels 44 and 56 respectively as well as act as a supporting plane for the respective bumps they exist in.
Referring again to FIG. 3 a , as previously described, partial ellipse 27 e extends downward into plane 27 which further extends at a 90 degree angle into plane 30 . As a profiled illustration, plane 30 may have an approximate length of 0.154 inch. Plane 30 is perforated, as is illustrated in FIG. 4 with elliptical perforations 70 that may be, for example, approximately 0.09 in wide, 0.38 inches long, and spaced longitudinally at approximately 0.15 inch intervals. Plane 30 extends upward at an approximate 90 degree right angle into plane 31 . Plane 31 parallels plane 27 and may have an approximate length of 0.045 inch. Plane 31 extends upward into partially ellipsed plane 31 e . Partially ellipsed plane 31 e may have an approximate partial circumference of 0.03 inch. Partial ellipse 27 e , plane 27 , plane 30 , plane 31 , and partial ellipse 31 e jointly form perforated well 32 .
Wells 39 , 49 , and 52 existent in the multi-level water receiving well of the present invention have measurements identical to well 32 of the present invention. The dimensions of wells 22 and 24 have been previously described in this disclosure.
Referring again to FIG. 2 : 23 ev , wells 46 and 57 incorporate two downward extending planes or channels 44 and 56 respectively which differentiates them from other perforated wells existent in the present invention. Wells 46 and 57 and their respective channels 44 and 56 may have identical measurements.
Well 46 is jointly formed by partial ellipse 43 e , plane 41 , circumference 41 c , plane 41 d , plane 45 , plane 45 a and partial ellipse 45 e . Partial Ellipse 43 e may have an approximate partial circumference of 0.03 inch and extends downward into plane 41 which parallels plane 38 . Plane 41 may have an approximate length of 0.28 inch and extends into circumference 41 c.
Circumference 41 c may have an approximate outside diameter of 0.06 inch. Circumference 41 c extends upward into plane 41 d . Plane 41 d may have an approximate length of 0.23 inch. Plane 41 d extends into or joins plane 45 at an approximate 90 degree angle. Plane 45 may have an approximate length of 0.13 inch. Plane 45 extends upward into partial ellipse 45 e which may have an approximate partial circumference of 0.03 inch. As mentioned earlier, well 57 may have measurements identical to those of well 4 .
Plane 41 , circumference 41 c , and plane 41 d within well 46 additionally jointly form channel 44 which may have an approximate height 43 h of 0.24 inch and an approximate width 44 w of 0.03 inch. As mentioned earlier, channel 56 within well 57 may have measurements identical to those of channel 44 .
Referring again to FIG. 2 : 23 ev , plane 59 d may have an approximate length of 0.45 inch and extends into plane 60 a . Plane 60 a may have an approximate length of 0.154 inch and extends upward at an approximate 90 degree angle into plane 61 . Plane 61 may have an approximate length of 0.045 inch. Plane 59 d , plane 60 a and plane 61 jointly form perforated well 60 .
Referring again to FIG. 2 , plane 61 extends at an approximate 90 degree angle into plane 62 which serves as the bottom shelf of receiving channel 65 and may have an approximate length of 0.44 inch. Plane 62 extends upward into partial circumference 63 which may have an approximate outside diameter of 0.05 inch. Partial circumference 63 extends into plane 64 which serves as the top shelf of receiving channel 65 and may have an approximate length of 0.4 inch. Plane 62 , partial circumference 63 , and plane 64 jointly form the second receiving channel 65 according to one embodiment of the present invention which is arranged to receive and secure a lateral edge of the filtration membrane 71 as illustrated in FIG. 6 .
Plane 64 extends upward into partial circumference 66 . Partial circumference 66 may have an approximate outside diameter of 0.05 inch and extends rearward into plane 66 . Plane 66 may have an approximate length of 1.55 inch. Partial circumference 66 extends downward into partial circumference 67 which may have an approximate outside diameter of 0.06 inch. Partial circumference 67 extends into plane 68 which may have an approximate length of 0.11 inch.
Referring to FIGS. 5 and 5 a , there is illustrated in 71 a metallic filtering membrane composed of stainless steel threads. This filtering membrane is commonly referred to as “wire cloth” and is presently employed as a screening debris filter in the manufacture of plastics and as a filtering component of industrial mufflers. The diameter of the metallic threads may range from approximately 0.04 mm (0.0015 in) to approximately 0.14 mm (0.0055 in) and may be crimp woven in meshes from 280 to 80 mesh (thread counts or openings per inch), respectively.
Referring to FIG. 5 it is illustrated that the filtering cloth 71 has its lateral edges folded over or hemmed 71 a to eliminate sharp cutting edges often noted in wire cloth.
Referring to FIG. 6 it is illustrated that filtering cloth 71 is inserted into the body 69 of the present invention and held in place by channels 22 and 65 . In the field it has been noted that filtering cloth 71 will not be dislodged by wind due to the natural stiffness present in wire cloths of 120 mesh or less.
Referring to FIG. 6 , there is illustrated an example embodiment of the present invention. A gutter protection system includes a main body 69 with integral filtration membrane receiving channels 22 and 65 enveloping the lateral edges of an insertable filtration membrane 71 that overlies a multi-level supporting skeleton of perforated planes, non perforated planes, upward extending nodes and downward extending planes collectively noted as 23 ev.
The main body, 69 , may be an extruded polymer (e.g., Leaffilter®) or a roll formed aluminum product (Flow Screen®). Where body 69 is an extruded polymer, it may be, for example, composed of poly vinyl chloride (PVC) that is reduced to liquid form through screw compression of PVC “tags”. This liquid plastic mixture is then extruded through a profile forming die, then through a cooling tray and cut to 5 foot lengths. This length has proven ideal for installation by one individual in that its length is short enough to be readily handled and accessed while allowing for as few joints or seams as possible to exist between adjoining body members of the present invention when it is installed over the length of a rain gutter. The extruded material is rigid and may have a thickness of approximately 0.06 inch. The extruded material has proven, in the field, to be suitably thick to maintain its shape and not deform or dip under load bearing weight of snow and ice or deform when exposed to high ambient temperatures which have caused prior art of lesser thickness to deform vertically upwards and downwards allowing open-air gaps to form from one piece op prior art to the next when the rest abutted side by side. These gaps may allow debris entrance into a gutter.
Referring to FIG. 7 , an example embodiment of the body 69 of the present invention is illustrated as inserted into the top water receiving opening of a k-style rain gutter 72 and resting on the front top lip 73 of the k-style rain gutter and resting on a sub-roof 75 of a building structure. The body 69 is secured to the underlying rain gutter 72 by the encompassing of the front top lip 73 of the rain gutter by planes 3 , 5 , and 6 and further secured by the insertion of plane 66 beneath roof shingles 74 .
Once this is accomplished, main body 69 offers improvement over prior art as follows: As noted in U.S. Pat. No. 6,598,352: “Perforated surfaces existing in a single plane, such as are employed in U.S. Pat. No. 5,595,027 to Vail, or as exists in the Commercial Product SHEERFLOW® manufactured by L.B. Plastics of N.C., and similar prior art tend to channel water past perforations rather than down through them and into an underlying rain gutter. Prior art sought to correct this undesirable property by either tapering the rim of the open perforation and/or creating downward extensions of the perforation (creating a water channeling path down through open air space) as exhibited in prior art U.S. Pat. No. 6,151,837 to Ealer, or by creating dams on the plane the perforations exist on, as exhibited in prior art U.S. Pat. No. 4,727,689 to Bosler. Such prior art has been unable to ensure all water would channel into the underlying rain gutter because the water, that did indeed, travel through the open apertures on the top surfaces of these types of perforated planes or screens, would also travel along the underside of the screen wires or perforated planes, as it had on top of these surfaces, and still continue it's undesirable flow to the front of the invention and front lip of the underlying rain gutter, due to water adhesion. Additionally, this “underflow” of water on the underside of the perforated planes and screens illustrated in prior art exhibits a tendency to “backflow” or attempt to flow upwards through the perforations inhibiting downward flow of water. This phenomenon has been noted in practice, in the field when it has been observed that open air apertures appear filled with water while accomplishing no downward flow of water into the underlying rain gutter.
Other inventors sought to eliminate this undesirable property by employing linear rods with complete open air space existing between each rod, this method of channeling more of the water into the rain gutter exhibits greater success on the top surface of such inventions, but it fails to eliminate the “under channeling” of rainwater toward the front of the invention due to the propensity of water to follow the unbroken interconnected supporting rods or structure beneath the top layer of rods.”
I was able to accomplish significant improvement over prior art by employing a filter skeleton, illustrated in FIG. 3 of my U.S. Pat. No. 6,598,352, which incorporates ellipsed top members resting on upward extending planes adjoined to an underlying perforated planes. The upward extending planes of this filter skeleton contact the underside of a micromesh cloth composed of threads that are separated by no more than 120 microns of open airspace between threads and, at the point of plane and cloth contact, water has been noted to cease forward flow and redirect into significant downward flow of water into an underlying rain gutter. FIG. 8 of my U.S. Pat. No. 6,598,352 illustrates the filter skeleton and adjoined fine filtration cloth join and form separate member from the main body of the invention that is inserted into the main body of the invention. This unique configuration of fine filtration cloth and filter skeleton inserted into a recessed perforated well has been observed in practice, in the field over a two year period, to completely disallow the clogging of a rain gutter and to allow known clogging or moss overgrowth of the fine filtration cloth and skeleton combination in fewer than 10 product installations out of thousands of known installations. U.S. Pat. No. 6,598,352 has been marketed as “Leaffilter®”.
During this period of practice in the field several improvements were made to U.S. Pat. No. 6,598,352 to ease its installation and lower its cost of manufacture and shipping. Most notably, in June of 2003, I redesigned the main body of the embodiment described in U.S. Pat. No. 6,598,352 to incorporate the upward extending planes found in it's insertable filter skeleton directly into the perforated recessed well of the main body. This has been accomplished in both an extruded polymer main body and in a roll formed aluminum body of the present invention: This significantly improves ease of installation in that the present embodiment of “Leaffilter®” no longer employs an insertable polymer filter skeleton that was extruded in 50 foot lengths rolled into rolls approximately two feet in diameter and weighing approximately 9 lbs. These were discovered to be difficult to install due to the size and weight of the insertable filtration member and noted to significantly stiffen as field temperatures cool below approximately 40 degrees. Additionally, the insertable polymer filter skeleton illustrated in FIG. 6 of my U.S. Pat. No. 6,598,352 required transportation to a sewing converter which accomplished unrolling and re-rolling of the polymer filtration skeleton as polymer filtration cloth was sewn to the base of the skeleton. This action required additional shipping costs as well.
Referring to FIG. 3 , there is illustrated a multi level supporting skeleton comprised of perforated plane 17 (existing beneath plane 11 ), non perforated planes 18 , 20 , 21 , and, referring to FIG. 4 , comprised of perforated planes 25 , 32 , 39 , 49 , 52 , 60 , and comprised of non perforated planes 46 and 57 , and comprised of upward extending “bumps” 29 , 36 , 43 , 48 , 51 , 54 , 59 , and comprised of non perforated planes 39 and 49 which are adjoined by downward extending channels 38 and 48 collectively. This multi-level support skeleton is referred to, collectively, as 23 ev . Incorporating the upward extending planes and perforated wells found in the flexible insertable filter skeleton of my prior art into the main body of the present invention, in the above described manner, achieves the same water directing properties by means of water adhesion and water pressure (due to water volume existent in said wells) found in my prior art and does so utilizing less material resulting in a lower cost of manufacture while additionally eliminating a separate insertable member subject to stiffening during cold weather installations.
It was also discovered during this period of practice (installing the Leaffilter® gutter cover in the field over a period of two years) that the warp-knit polymer fabric employed as a filtration membrane sewn to an underlying insertable filtration skeleton, illustrated in FIGS. 5 and 6 of my U.S. Pat. No. 6,598,352, succumbed to UV exposure deterioration over a period of time regardless of the amount of UV inhibitors employed. This may have been due to the small denier of polymer threads that constituted the polymer fabric. Significant improvement is accomplished in the present invention in substituting a woven stainless steel micro mesh cloth as is illustrated in FIG. 6 of the present invention. In the prior art of U.S. Pat. No. 6,598,352 it is disclosed that threads that adjoin or intersect one another are less subject to debris lodging between threads and tend to present less resistance to downward water flow than does woven or knitted micromesh cloths: both intersecting threads of dissimilar deniers and adjoining threads of similar deniers have been noted to exhibit desirable debris repellant and water permeability features to a greater degree than is found in typical woven or knitted micromesh fabric. However, there is presently no known technology able to mass produce warp-knit cloth utilizing metallic threads. It has been noted in field installations of example embodiments of the present invention that woven stainless steel threads exhibit water permeability that approaches that found in polymer warp-knit micro mesh fabric, provided that the wire diameter of the woven stainless steel threads is between approximately 0.04 mm (0.0015 in) and approximately 0.14 mm (0.0055 in) and the micro mesh fabric has a mesh of between approximately 280.times.280 and approximately 80.times.80, respectively. For example, micro mesh fabric having a mesh of 100.times.100 may have a thread diameter of approximately 0.114 mm (0.0045 in). The wires (threads) may be crimped or pressed at their point of weave or contact so that the combined height of two threads is lessened at the point that one thread weaves over or under another. In testing, it has been further discovered that the same debris shedding properties are present in configurations of wire cloth that employ “crimped weaves” whereby pressure is applied at the point of weave contact between threads. This crimping of metallic threads at their point of contact places threads in more of a linear plane in relation to one another which allows the cloth to shed rather than trap debris. As disclosed in U.S. Pat. No. 6,598,352, the greater the vertical height between threads at their point of contact, the more likely it is that debris will be trapped and held rather than shed.
In one example embodiment of the present invention, woven wire cloth is utilized exclusively as it has been discovered that such cloth, even as a woven cloth, exhibits less shifting of threads and less height differential between threads as well as providing a filtering membrane less susceptible to decay in comparison to polymer or natural “warp-knit” fabrics.
FIGS. 5 and 5 a illustrate an example stainless steel wire cloth 71 of not less than 100.times.100 mesh, crimp woven.
Referring now to FIG. 6 , the illustrated micro mesh stainless steel wire cloth serves as an insertable filtration membrane 71 not subject to stiffening as field temperatures cool and has been noted, in the field, to be more easily handled in any temperature as it is much lighter and far less bulky than the filtration skeleton covered with attached polymer micromesh cloth that served as the insertable filtration member found in my prior art illustrated in FIGS. 5 and 6 of my U.S. Pat. No. 6,598,352.
In FIG. 5 , reference numeral 71 illustrates that the lateral edges 71 a of the stainless steel filtration membrane are hemmed. This is presently accomplished by passing 120 foot lengths of stainless steel cloth, slit to 4 inches width, through a roll former that hems the lateral edges of the stainless steel cloth and re-rolls its entire length into an easily handled roll approximately 4 inches in diameter and weighing less than 1.5 lbs. The manufacture and packaging of the stainless steel filtration member eliminates a shipping step necessary in manufacturing and packaging the polymer filtration skeleton used in other prior embodiments and allows the filtration member of example embodiments of the present invention to be packaged in the same box that holds 5 foot lengths of the main body. In contrast, the polymer filtration skeleton disclosed in prior embodiments, for example, the Leaffilter® product, was boxed separately from the main body of the Leaffilter® product. Hemming the stainless steel filtration membrane 71 provides a dull edge unlikely to cause cuts as filtration member 71 is handled in the field prior to and during installation.
The main body 69 is installed into the top open area of a k-style rain gutter 72 as illustrated in FIG. 7 . Referring now to FIG. 6 , installation of the stainless steel filtration member 71 is accomplished by grasping the leading edge of a roll of the filtration member and puffing it through channels 22 and 65 of the main body 69 of the present invention. Alternatively, filtration member 71 may be attached by any other known means such as, for example, welding, adhesive, or any other known fastener devices, to body 69 . Referring again to FIG. 7 , once this final step of installation is accomplished, rain water will flow off roof member 74 through stainless steel micro mesh filtration member 71 contacting upraised “bumps”, such as 48 and 51 , and being diverted downward by these planes down through perforations 70 into an underlying rain gutter 72 . The present invention thereby provides a more economical and more readily installed gutter protection method than Leaffilter® offers while proving equally capable of preventing debris as small as 100 microns from entering a rain gutter while ensuring nearly 100% of rain water run off from roof members enters underlying gutters as has been noted in the field.
The dimensions listed in the foregoing Description are descriptive of the example embodiment of the present invention as it currently has been manufactured for 11 months in a polymer embodiment that is different in several respects (disclosed in this application) from its original manufactured embodiment that closely resembled the preferred embodiment illustrated in my U.S. Pat. No. 6,598,352. Additionally, a roll-formed metallic prototype of the present invention employing smaller thinner “bumps” and shallower perforated “wells” has demonstrated that the operation of the present invention; specifically its ability to break the forward flow of water that occurs over flat perforated planes and direct it downward, varies little providing that the height of “bumps” does not fall below 0.06 inch. and provided the dimensions of perforations 70 have a minimum length of 0.25 inch and a minimum width of 0.15 inch and are spaced longitudinally at a distance no greater than 0.18 inch. Smaller perforations spaced further apart proved insufficient at draining large amounts of water into an underlying rain gutter.
In summary, a critical element described in claim one of technology described in my U.S. Pat. No. 6,598,352 (under which the Leaffilter® is manufactured) is the utilization of upraised planes rising from and forming the sides of perforated wells. These underlying planes contact the underside of a filtration cloth and break the forward flow of water and direct it downward into an underlying rain gutter. This technology of “upraised planes” breaking the forward flow of water and directing it downward, described in my U.S. Pat. No. 6,598,352, has been demonstrated to remain effective through subsequent alternate embodiments described in this present invention that have unified separate elements and varied the height and the width and positioning of the upraised planes resulting in a more easily installed and economically manufactured product. The process of roll-forming metal disallows exact duplication of shapes and dimensions possible in extrusion of polymers. Extensive testing and redesign of an alternate metallic roll formed embodiment of the Leaffilter® product has disclosed that some further alterations of the dimension and position of water directing planes can be accomplished resulting in a more easily installed and economically manufactured product.
DESCRIPTION OF ALTERNATE EMBODIMENTS
Referring to FIG. 8 there is illustrated an alternate embodiment of the present invention. A triangular shaped channel 44 tc is arranged to receive a triangular shaped joining member FIG. 76 (see FIG. 9 ). Sides 44 x and 44 z may have approximate lengths of 0.23 inch. and side 44 y may have an approximate length of 0.28 inch. Triangular shaped joining member 76 may have equilateral sides with approximate lengths 76 a , 76 b , 76 b , of 0.21 inch.
It has been noted in the field that after installation of the body 69 into a rain gutter, a variance in height between adjoining main bodies 69 of the present invention may occur. This alternate embodiment serves to lock main bodies 69 into the same horizontal plane preventing any debris entrance into a rain gutter occurring through open air spaces that may occur if adjoining main bodies 69 rise or fall above or beneath one another. FIG. 11 further illustrates that joining member 76 inserts partially into the triangular shaped channel 44 tc of a main body 69 a allowing an adjoining main body 69 b to be slid into place allowing its triangular shaped channel to encompass a remaining portion of joining member 76 .
Referring again to FIG. 8 , a triangular channel 77 tc may also be employed at the front most portion of the main body 69 of the present invention to serve as a means of receiving joining members.
Referring to FIG. 8 , downward extending triangular shaped channel 44 tc is defined by walls 44 x , 44 y , 44 z . This alteration of the downward extending channel illustrated in FIG. 2 allows for the insertion of an extruded polymer or roll formed metallic triangular shaped joining member 76 (see FIG. 9 ) to be inserted into two adjoining main bodies 69 a and 69 b of the present invention, as illustrated in FIG. 11 , allowing the main bodies 69 a , 69 b to abutted against each other and held at a consistent level prohibiting one main body 69 a , 69 b from rising above or falling beneath the profile of previous or subsequent main body members 69 a , 69 b it may be abutted against.
FIG. 12 . is a partial top perspective view of an example alternative embodiment of the body of the present invention. The main body 69 includes an intermediate body portion (water receiving plane) 23 evae having two channels 22 and 65 arranged to receive lateral edges of filtering screens or membranes 71 (see FIG. 14 ). Intermediate body portion 23 evae defines a substantially planar surface and includes a plurality of downwardly extending portions 77 b extending at an angle to the surface to define a plurality of openings 77 therein that serve to channel water downward and away from the surface. Referring to FIG. 13 , there is illustrated a path of forward flowing water 78 that approaches an opening 77 a and breaks downward at a topmost lateral edge 77 c of downwardly extending planar portion 77 b that extends between parallel edges 77 d and 77 e of opening 77 a.
FIG. 14 . is a partial top perspective view of a filtration element 71 assembled with the body of FIG. 12 according to an alternative example embodiment of the invention. In the example embodiment depicted in FIG. 14 , the filtration element 71 is shown as being inserted into receiving channels 22 and 65 and overlying the substantially planar surface defined by intermediate body portion 23 evae and the plurality of openings 77 formed therein. Alternatively, filtration element 71 may be secured to the main body 69 by other known fastening techniques, for example, by welding, adhesive, and/or other known fastening devices.
FIG. 15 . is a detailed view of an opening 77 a covered by the filtration element 71 . Referring to FIG. 15 , there is illustrated a path of forward flowing water 78 that flows, by water adhesion, along and around the threads of filtration element 71 toward opening 77 a . Referring again to FIG. 14 , filtration element 71 is contacted continuously on an underside thereof by the solid (e.g., non-punched) portions of the substantially planar surface defined by intermediate body portion 23 evae . When and where such contact occurs, water will continue to flow forward. Referring again to FIG. 15 , filtration element 71 is contacted on the underside thereof by the topmost lateral edge 77 c of downward extending portion 77 b . At these specific points of contact, water is channeled downward from filtration element 71 , i.e., away from the substantially planar surface defined by the intermediate body portion 23 evae , thereby breaking the forward flow of the water.
FIG. 16 . is a partial top perspective view of a filtration element 71 p according to an alternative example embodiment. Referring to FIG. 16 , there is illustrated a filtration element 71 p which defines a first substantially planar surface and which includes at least one substantially planar downward extending portion 79 extending at an angle to the first substantially planar surface. In the example embodiment, the downward extending portions 79 are folded portions of a continuous filtration element 71 p . Referring to FIG. 17 , the downward extending portion 79 a is shown to have a predetermined length 79 b . Where the downward extending portion 79 a is a folded portion, such folded portion may be created by sewing, by compression, or by any effective means of holding sides 79 c and 79 d in close proximity to each other and at an angle with respect to the first substantially planar surface defined by filtration element 71 p . Water 78 that adheres to and flows on and through element 71 p is redirected into a downward flowing path at the downwardly portion 79 a.
REFERENCE NUMERALS IN DRAWING
1 . plane 1 , length: approximately 0.11 inch
2 . circumference 2 , outside diameter approximately 0.06 inch
3 . plane 3 , length approximately 0.53 inch.
4 . angle 4 , approximately 60 degrees.
5 . plane 5 , length approximately 0.5 inch.
6 . plane 6 , length approximately 0.35 inch
7 . circumference 7 , when the present invention is in a metallic roll formed state, outside diameter approximately 0.06 inch termination point 7 , when the present invention is in a polymer extruded state
8 . plane 8 , length approximately 0.42 inch
9 . channel 9 , when the present invention is in a metallic roll formed state, with an open air space of approximately 0.022 inch
10 . angle 10 , approximately 60 degrees
11 . plane 11 , length approximately 0.44 inch
12 . circumference 12 , when the present invention is in a metallic roll formed state, outside diameter approximately 0.06 inch termination point 12 , when the present invention is in a polymer state
13 . Plane 13 , has an approximate length of 0.44 inch
14 . circumference 14 , has an approximate outside diameter of 0.075 inch
15 . plane 15 , length approximately 0.17 inch
16 . plane 16 , length approximately 0.045 inch
17 . plane 17 , length approximately 0.157 inch
18 . plane 18 , length approximately 0.045 inch
19 . perforated well
20 . plane 20 , length approximately 0.10 inch
21 . plane 21 , length approximately 0.045 inch
22 . receiving channel 22 22 w . width: 0.48 inch of channel 22 22 h . height: 0.056 inch of channel 22
23 . plane 23 , length of approximately 0.154 inch 23 ev . multi-level water receiving area of the present invention
24 . plane 24 , length of approximately 0.045 inch 24 e . partial ellipse, with a partial circumference of approximately 0.03 inch
25 . perforated well 25 w interior width: of perforated well 25 : 0.15 inch measured from plane 21 to plane 24 25 h . interior height: 0.06 of perforated well 25
26 . plane 26 , length approximately 0.070 inch measured from partial ellipse 24 e to partial ellipse
27 . plane 27 , length approximately 0.045 inch
28 . ellipsed cap 28 , length approximately 0.16 inch
29 . bump, a supportive and water directing plane 29 w . interior width: 0.13 inch of bump 29 measured from plane 24 to plane 27 29 h . height: 0.068 inch of bump 29
30 . plane 30 , length approximately 0.154 inch
31 . plane 31 , length approximately 0.045 inch 31 e partial ellipse, with a partial circumference of approximately 0.03 inch
32 . perforated well 32 w . interior width: of perforated well 32 : 0.15 inch measured from plane 27 to plane 31 32 h . interior height: 0.06 inch of perforated well 32
33 . plane 33 , length approximately 0.070 measured from partial ellipse 31 e to partial ellipse 34 e
34 . plane 34 , length approximately 0.045 inch 34 e . partial ellipse, with a partial circumference of approximately 0.03 inch
35 . ellipsed cap 35 , length approximately 0.16 inch
36 . bump, a supportive and water directing plane 36 h height: 0.068 inch of bump 36
37 . plane 37 , length approximately 0.154 inch
38 . plane 38 , length approximately 0.045 inch
39 . perforated well 39 h . interior height: 0.06 inch of perforated well 39 39 w . interior width: of perforated well 39 : 0.15 inch measured from plane 34 to plane 38
40 . plane 40 , length approximately 0.070 measured from partial ellipse 38 e to partial ellipse 41 e
41 . plane 41 , length approximately 0.28 inch 41 c . circumference 41 c , approximate outside diameter 0.06 inch 41 d . plane 41 d , length approximately 0.23 inch
42 . ellipsed cap 42 , length approximately 0.16 inch
43 . bump, a supportive and water directing plane 43 h . height: 0.33 inch of channel 44
44 . channel 44 44 w width: 0.03 inch of channel 44 44 tc . alternate triangular shaped embodiment of channel 44 44 x . side 44 x approximate length 0.23 inch 44 y . side 44 y approximate length 0.28 inch 44 z . side 44 z approximate length 0.23 inch
45 . plane 45 , length approximately 0.13 inch
46 . non-perforated well 46 h . interior height: 0.06 inch of non-perforated well 46
46 w . interior width: of on-perforated well 46 : 0.15 inch measured from plane 41 to bump
47 . ellipsed cap 47 , length approximately 0.16 inch
48 . bump, a supportive and water directing plane
49 . perforated well
50 . ellipsed cap 50 , length approximately 0.16 inch
51 . bump, a supportive and water directing plane
52 . perforated well
53 . ellipsed cap 53 , length approximately 0.16 inch
54 . bump, a supportive and water directing plane
55 . plane 55 , length approximately 0.28 inch 55 c . circumference 55 , approximate outside diameter 0.06 inch 55 . plane 55 d , length approximately 0.23 inch
56 . channel 56
57 . non-perforated well
58 . ellipsed cap 58 , length approximately 0.16 inch
59 . bump, a supportive and water directing plane
60 . perforated well
61 . plane 61 , length approximately 0.045 inch
62 . plane 62 , length approximately 0.44 inch
63 . circumference 63 , approximate outside diameter 0.06 inch
64 . plane 64 , length approximately 0.4 inch
65 . channel 65
66 . plane 66 , length approximately 1.5 inch
67 . circumference 63 , approximate outside diameter 0.06 inch
68 . plane 68 , length approximately 1.5 inch
69 . main body
70 . perforations
71 . metallic cloth filtration membrane
71 p . Corrugated filtration screen
72 . k-style rain gutter
73 . top lip of k-style rain gutter
74 . roof membrane
75 . sub roof
76 . joining member
76 a . side 76 a approximate length 0.21 inch
76 b . side 76 b approximate length 0.21 inch
76 c . side 76 c approximate length 0.21 inch
78 . denoting that any water will flow downward into the space present between the left segment and right segment of the first surface and that is present between the downward extending planes 79 c and 79 d that form downward extending element 79 .
79 . downward extending walls, inseams, or planes that define corrugation present in the corrugated filtration screen 71 p.
79 a . lowermost point, portion, or plane of corrugated filtration screen 71 p.
79 b . length of 79 .
79 c . left downward extending plane.
79 d . right downward extending plane. | A gutter guard device is provided for preventing material from entering a gutter to which the gutter guard device is mounted. The device includes a stand alone filtration element configured to be mounted to the gutter. The filtration element has a substantially planar surface formed from a plurality of threads, the substantially planar surface having a longitudinal edge configured to be positioned substantially parallel to a longitudinal direction of the gutter; and a downward extending channel having a longitudinal direction that is obliquely oriented relative to the longitudinal edge of the substantially planar surface. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of application Ser. No. 11/609,165 filed Dec. 11, 2006 now U.S. Pat. No. 7,263,761, which is a divisional application of application Ser. No. 11/409,651 filed Apr. 24, 2006 now U.S. Pat. No. 7,221,249; which is a divisional application of application Ser. No. 10/244,777, filed Sep. 16, 2002, now U.S. Pat. No. 6,946,944; which is a continuation of Ser. No. 09/546,859 filed Apr. 10, 2000, now U.S. Pat. No. 6,449,829; which is a divisional of application Ser. No. 09/271,748, filed on Mar. 18, 1999, now U.S. Pat. No. 6,135,375
This application is also a divisional application of application Ser. No. 11/609,165 filed Dec. 11, 2006 now U.S. Pat. No. 7,263,761, which is a divisional application of application Ser. No. 11/409,651 filed Apr. 24, 2006 now U.S. Pat. No. 7,221,249; which is a divisional of application Ser. No. 10/244,777 filed Sep. 16, 2002, now U.S. Pat. No. 6,946,944; which is a continuation of application Ser. No. 09/547,155, filed Apr. 11, 2000, now U.S. Pat. No. 6,460,244; which is a divisional of application Ser. No. 08/963,224 filed Nov. 3, 1997, now U.S. Pat. No. 6,204,744; which is a continuation of application Ser. No. 08/503,655 filed Jul. 18, 1995, now abandoned.
The Specification and Drawings of application Ser. No. 09/547,155, now U.S. Pat. No. 6,460,244, are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to an inductor coil structure and method for making same. The coil structure of the present invention is preferably for use in a high current low profile inductor commonly referred to by the designation IHLP. However, the particular coil structure may be used in other types of inductors.
Inductor coils have in the prior art been constructed from various shapes of materials formed into various helical shapes. However, there is a need for an improved inductor coil structure which is simple to manufacture and which provides an efficient and reliable inductance coil.
Therefore, a primary object of the present invention is the provision of an improved inductor coil structure and method for making same.
A further object of the present invention is the provision of an inductor coil structure which can be used in a high current low profile inductor having no air spaces in the inductor, and which includes a magnetic material completely surrounding the coil.
A further object of the present invention is the provision of an inductor coil structure which includes a closed magnetic system which has self-shielding capability.
A further object of the present invention is the provision of an inductor coil structure which maximizes the utilization of space needed for a given inductance performance so that the inductor can be of a minimum size.
A further object of the present invention is the provision of an improved inductor coil structure which is smaller, less expensive to manufacture, and is capable of accepting more current without saturation than previous inductor coil structures.
A further object of the present invention is the provision of an inductor coil structure which lowers the series resistance of the inductor.
SUMMARY OF THE INVENTION
The foregoing objects may be achieved by a high current low profile inductor comprising a conductor coil having first and second coil ends. A magnetic material surrounds the conductor coil to form an inductor body. The inductor coil comprises a plurality of coil turns extending around a longitudinal coil axis in an approximately helical path which progresses axially along the coil axis. The coil turns are formed from a flat plate having first and second opposite flat surfaces, at least a portion of each of the flat surfaces of the coil turns facing in a axial direction with respect to the coil axis.
The method for making the inductor includes taking an elongated plate conductor having a first end, a second end, opposite side edges, opposite flat surfaces, and a longitudinal plate axis. A plurality of slots are cut in each of the opposite side edges of the plate conductor so as to form the plate conductor into a plurality of cross segments extending transversely with respect to the plate axis and a plurality of connecting segments extending approximately axially with respect to the plate axis. The connecting segments connect the cross segments together into a continuous conductor which extends in a sine shaped path. As used herein the term “sine shaped” refers to any shape which generally conforms to a sine curve, but which is not limited to a continuous curve and may include apexes, squared off corners or other various shapes.
After cutting the slots in the opposite side edges of the plate conductor the connecting segments are bent along one or more bend axes extending transversely with respect to the plate axis so as to form the plate conductor into a plurality of accordion folds, each of which comprise one of the cross segments and a portion of one of the connecting segments. In the resulting structure, the cross segments and the connecting segments form a continuous conductor coil of approximate helical shape having first and second opposite ends.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIG. 1 is a perspective view of the inductor constructed in accordance with the present invention and mounted upon a circuit board.
FIG. 2 is a pictorial view of the coil of the inductor before the molding process.
FIG. 3 is a pictorial view of the inductor of the present invention after the molding process is complete, but before the leads have been formed.
FIG. 4 is an end elevational view taken along line 4 - 4 of FIG. 2 .
FIG. 5 is an elevational view taken along lines 5 - 5 of FIG. 4 .
FIG. 6 is a perspective view of an elongated conductor blank from which the inductor coil is formed.
FIG. 7 shows the blank of FIG. 6 after the formation of slots extending inwardly from the opposite edges thereof.
FIG. 8 is a view similar to FIG. 7 , showing the first folding step in the formation of the inductor coil of the present invention.
FIG. 9 is a side elevational view showing the same folding step shown in FIG. 8 .
FIG. 10 is a view similar to 8 and showing a second folding step in the process for making the inductor coil of the present invention.
FIG. 11 is an inverted pictorial view of the inductor after it has been pressed, but before the leads have been formed.
FIG. 12 is a view similar to FIG. 11 showing the inductor after partial forming of the leads.
FIG. 13 is a view similar to FIGS. 11 and 12 showing the final forming of the leads.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings the numeral 10 generally designates an inductor of the present invention mounted upon a circuit board 12 . Inductor 10 includes an inductor body 14 having a first lead 16 and a second lead 18 extending therefrom and being folded over the opposite ends of body 14 . Leads 16 , 18 are soldered or otherwise electrically connected on the circuit board 12 .
Referring to FIG. 2 , the inductor coil of the present invention is generally designated by the numeral 20 . Leads 16 , 18 form the ends of coil 22 . Between leads 16 , 18 are a plurality of L-shaped coil segments 26 each comprising a horizontal leg 28 and a vertical leg 30 . Vertical leg 30 terminates at a connecting segment 32 which is folded over at approximately 180° so as to create an accordion like configuration for inductor coil 20 . The L-shaped coil segments are connected together to form a helical coil having an open coil center 34 extending along a longitudinal coil axis 36 .
FIGS. 6-10 show the process for making the coil 20 . Initially as shown in FIG. 6 a blank flat conductor plate 50 formed of copper or other electrically conductive material includes: first and second ends 52 , 54 ; a pair of opposite flat surfaces 56 ; and a pair of opposite side edges 58 , 60 .
FIG. 7 shows the first step in forming the coil 20 . In this step a plurality of slots 62 , 64 are cut in the opposite edges 58 , 60 respectively of the blank flat plate 50 . Various cutting methods may be used such as stamping or actual cutting by laser or other cutting tools known in the art.
Upon completion of the cutting operation, the blank 50 is transformed into an elongated sine shaped body formed from a plurality of cross segments 66 extending transversely to the longitudinal axis of plate 50 and a plurality of connecting segments 67 extending axially with respect to the longitudinal axis of plate 50 . The segments 66 , 67 form a continuous sine shaped configuration as shown in FIG. 7 .
FIG. 8 shows the next step in forming the coil 20 . The end 52 is folded over at an angle of 180° to form the 180° angle bend 63 in the first connecting segment 67 . FIG. 10 shows a second bend 65 which is in the next connecting segment 67 . Bends 63 , 65 are in opposite directions, and are repeated until an accordion like structure is provided similar to that shown in FIG. 5 .
In FIG. 5 the coil 20 includes opposite ends 16 , 18 which are formed from the opposite ends 52 , 54 of blank 50 . The cross segments 66 of blank 50 form the first horizontal legs 28 of coil 20 , and the connecting segments 67 of blank 50 form the second vertical legs 30 and the connecting segments 32 of coil 20 .
An example of a preferred material for coil 20 is a copper flat plate made from OFHC copper 102, 99.95% pure.
The magnetic molding material of body 14 is comprised of a powdered iron, a filler, a resin, and a lubricant. The preferred powdered material is manufactured by BASF Corporation, 100 Cherryhill Road, Parsippany, N.J. under the trade designation Carbonyl Iron, Grade SQ. This SQ material is insulated with 0.875% mass fraction with 75% H 3 P04.
An epoxy resin is also added to the mixture, and the preferred resin for this purpose is manufactured by Morton International, Post Office Box 15240, Reading, Pa. under the trade designation Corvel Black, Number 10-7086.
In addition a lubricant is added to the mixture. The lubricant is a zinc stearate manufactured by Witco Corporation, Box 45296, Huston, Tex. under the product designation Lubrazinc W.
Various combinations of the above ingredients may be mixed together, but the preferred mixture is as follows:
1,000 grams of the powdered iron. 3.3% by weight of the resin. 0.3% by weight of the lubricant.
The above materials (other than the lubricant) are mixed together and then acetone is added to wet the material to a mud-like consistency. The material is then permitted to dry and is screened to a particle size of −50 mesh. The lubricant is then added to complete the material 82 . The material 82 is then ready for pressure molding.
The next step in the process involves compressing the material completely around the coil 20 so that it has a density produced by exposure to pressure of from 15 to 25 tons per square inch. This causes the powdered material 82 to be compressed and molded tightly completely around the coil so as to form the inductor body 14 shown in FIG. 1 and in FIGS. 11-13 .
At this stage of the production the molded assembly is in the form which is shown in FIG. 11 . After baking, the leads 16 , 18 are formed or bent as shown in FIGS. 12 and 13 . The molded assemblies are then baked at 325° F. for one hour and forty-five minutes to set the resin.
When compared to other inductive components the IHLP inductor of the present invention has several unique attributes. The conductive coil, lead frame, magnetic core material, and protective enclosure are molded as a single integral low profile unitized body that has termination leads suitable for surface mounting. The construction allows for maximum utilization of available space for magnetic performance and is magnetically self-shielding.
The unitary construction eliminates the need for two core halves as was the case with prior art E cores or other core shapes, and also eliminates the associated assembly labor.
The unique conductor winding of the present invention allows for high current operation and also optimizes magnetic parameters within the inductor's footprint.
The manufacturing process of the present invention provides a low cost, high performance package without the dependence on expensive, tight tolerance core materials and special winding techniques.
The magnetic core material has high resistivity (exceeding 3 mega ohms) that enables the inductor as it is manufactured to perform without a conductive path between the surface mount leads. The magnetic material also allows efficient operation up to 1 MHz. The inductor package performance yields a low DC resistance to inductance ratio of two milliOhms per microHenry. A ratio of 5 or below is considered very good.
The unique configuration of the coil 20 reduces its cost of manufacture. Coil 20 may be used in various inductor configurations other than IHLP inductors.
In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and the proportion of parts as well as in the substitution of equivalents are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims. | A high current, low profile inductor includes a conductor coil surrounded by magnetic material to form an inductor body. An inductor body is formed around the inductor coil and includes a resin and a magnetic material compressed while it is dry and surrounding the inside and the outside of the coil. | 8 |
FIELD OF THE INVENTION
The present invention relates to chemical processes involved in the manufacture of fiber materials and, more particularly, to methods for treating cotton yarn to be used in the manufacture of a variety of fabrics.
BACKGROUND OF THE INVENTION
In the textile industry, the most advanced technique today is the pneumatic spinning of fiber materials from natural and synthetic fibers and their combinations. The pneumatic spinning has a number of important advantages over the classical spinning techniques, except that in the former case the tensile strength of yarn of the same count is 18 to 20 percent lower than in the latter case. On the other hand, the warp yarn is sized so as to provide for a maximum intensification of the spinning process; as a result, the tensile strength of the yarn is improved because an elastic film adheres to it and individual fibers are glued together. The existing sizing techniques have practically exhausted the possibilities of further increasing the tensile strength and cannot make up for the reduction in the tensile strength of the yarn produced by pneumatic spinning.
As a result, yarn produced by pneumatic spinning is used as weft thread; when it is used as warp thread the operating speed of the looms is reduced.
There is known a method for treating twisted cotton yarn with liquid ammonia (cf. UK Pat. No. 1,141,016; Cl. D1P). According to this method, the mechanical strength of yarn is improved by stretching the thread as ammonia is removed therefrom in hot water. However, this method is inapplicable to the treatment of non-twisted yarn; although the mechanical strength of non-twisted yarn is improved, the method does not adjust all the yarn's parameters to the normal spinning process.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for treating cotton yarn, which would improve the mechanical strength of the yarn.
It is another object of the invention to provide a method for treating cotton yarn so that it should possess the properties of mercerized yarn.
The foregoing and other objects of the invention are attained by providing a method for treating cotton yarn, comprising the operations of impregnating the yarn with liquid ammonia and stretching it in an aqueous bath, which method is characterized in that the stretching takes place in an aqueous bath containing a sizing agent in an amount sufficient to increase the strength of the impregnated yarn 18 to 25 percent.
The proposed method is advantageous in that it is the swollen yarn that is put in the sizing agent solution. The immersion in that solution leads to an instantaneous evaporation of the liquid ammonia contained in the yarn, whereby voids are produced in the yarn, into which the sizing medium penetrates much faster than in the case of the conventional sizing process.
In addition, the sized yarn acquires the properties of mercerized yarn, which is due to the impregnation of the yarn with liquid ammonia; the overall effect is a marked improvement in the yarn properties which are indispensable for normal weaving conditions.
According to the invention, the sizing agent is starch taken in an amount of 30 to 70 g/l, or carboxymethyl cellulose taken in an amount of 30 to 50 g/l, or polyvinyl alcohol taken in an amount of 20 to 30 g/l; all these sizes are equally fit suitable treating cotton yarn used to manufacture calico, satin, shirting, linen, denim and other fabrics.
DETAILED DESCRIPTION OF THE INVENTION
A fuller understanding of the invention will be had from the following examples.
EXAMPLE 1
Unbleached single cotton yarn (tex 29.4), produced from low-count card web cotton, is impregnated during 3 seconds with liquid ammonia at a temperature of -35° C., whereupon the yarn is squeezed to 100% pick-up and treated during 2 seconds in an aqueous solution containing 30 g/l of carboxymethyl cellulose at a temperature of 60° to 65° C.; simultaneously with the treatment, the yarn is stretched 13% lengthwise. The yarn is then dried on the surface of a heated drum and spooled. The basic physico-chemical properties of the yarn thus treated are as follows:
1. Mean breaking load: 427.6 g wt
2. Mean elongation at break: 12.5 mm
3. Size regain: 3.2%
4. Barium number: 132.1%
EXAMPLE 2
Unbleached cotton yarn of tex 29.4 is treated as in Example 1, but the concentration of carbomethyl cellulose is 50 g/l. The physico-chemical properties of the treated yarn are as follows:
1. Mean breaking load: 440.1 g wt
2. Mean elongation at break: 12.2 mm
3. Size regain: 5.3%
4. Barium number: 133.4%
EXAMPLE 3
Unbleached single cotton yarn of tex 25, produced from low-count card web cotton, is impregnated during 3 seconds with liquid ammonia at a temperature of -35° C., whereupon the yarn is squeezed to 100% pick-up and treated during 2 seconds in an aqueous solution containing 30 g/l of starch at a temperature of 90° to 95° C.; simultaneously with the treatment, the yarn is stretched 13% lengthwise. The basic physico-chemical properties of the yarn thus treated are as follows:
1. Mean breaking load: 406.4 g wt
2. Mean elongation at break: 8.5 mm
3. Size regain: 3.9%
4. Barium number: 131.0%
EXAMPLE 4
Unbleached cotton yarn of tex 25 is treated as in Example 3, but the starch concentration in this case is 70 g/l. The physico-chemical properties of the treated yarn are as follows:
1. Mean breaking load: 405.0 g wt
2. Mean elongation at break: 9.1 mm
3. Size regain: 7.6%
4. Barium number: 139.4%
EXAMPLE 5
Unbleached twisted cotton yarn (tex 25×2) is impregnated during 3 seconds in liquid ammonia at a temperature of -35° C., whereupon the yarn is squeezed to 100% pick-up and treated during 2 seconds in an aqueous solution containing 20 g/l of polyvinyl alcohol at a temperature of 80° to 90° C.; in the course of the treatment, the yarn is stretched 15% lengthwise.
The physico-chemical properties of the yarn thus treated are as follows:
1. Mean breaking load: 888.5 g wt
2. Mean elongation at break: 14.1 mm
3. Size regain: 2.2%
4. Barium number: 132.1%
EXAMPLE 6
Twisted cotton yarn (tex 25×2) is treated as in Example 5, but in this case the concentration of polyvinyl alcohol is 30 g/l. The physico-chemical properties of the yarn after treatment are as follows:
1. Mean breaking load: 901.8 g wt
2. Mean elongation at break: 14.0 mm
3. Size regain: 3.1%
4. Barium number: 131.9%
The basic physico-chemical properties of cotton yarn treated as in Examples 1 through 6 illustrated the relationship between the quality of the yarn, on the one hand, and the type and concentration of the sizing medium and the type of yarn, on the other. These properties are tabulated in the following table.
Table__________________________________________________________________________Results of Cotton Yarn Testing Types of Treatment No 1 No 2 No 3 No 4 No 5 No 6 No No 8 Mercerized with Treated with liquid ammonia and sized Initial yarn liquid ammonia with carboxymethyl starch polyvinyl cellulose alcohol Cotton yarn, tex 29.4 25 25 × 2 29.4 25 25 × 2 29.4 25 25 × 2Serial No Parameter 1 2 3 4 5 6 7 8 9__________________________________________________________________________1. Mean breaking load, g wt 314.4 289.8 643.8 371.2 342.5 773 427.6 440.1 406.4 405.0 888.5 901.82. Mean elongation at break, 34.0 24.9 34.8 12.7 10.6 14.2 12.5 12.2 8.5 9.1 14.1 14.0 mm3. Size regain -- -- -- -- -- -- 3.2 5.3 3.9 7.6 2.2 3.14. Barium number -- -- -- 131.5 130.5 132.0 132.1 133.4 131.0 139.4 132.1 131.95. Increase in breaking load, as compared to breaking load of initial yarn, % -- -- -- 18.1 18.2 20.1 36 40 40.2 39.8 38.0 40.16. Reduction in elongation at break, as compared to elongation at break of initial yarn, % -- -- -- 62.7 57.4 59.2 63.2 64.1 65.9 63.5 59.5 59.8__________________________________________________________________________
Note: the types of treatment listed in the Table are designated as follows:
1--initial untreated yarn (tex 29.4, 25, 25×2);
2--yarn treated with liquid ammonia in the known manner (tex 29.4, 25, 25×2);
3, 4--yarn of tex 29.4 impregnated during 3 seconds with liquid ammonia at a temperature of -35° C., whereupon the yarn is stretched 13% lengthwise and simultaneously treated during 2 seconds with a solution of carboxymethyl cellulose with a concentration of 30 to 50 g/l at a temperature of 60° to 65° C. so as to raise the strength of the mercerized yarn 18 to 20 percent;
5, 6--yarn of tex 25, impregnated during 3 seconds with liquid ammonia at a temperature of -35° C., whereupon the yarn is stretched 13% lengthwise and simultaneously treated during 2 seconds with an aqueous starch solution having a concentration of 30 to 70 g/l at a temperature of 90° to 95° C. so as to raise the strength of the mercerized yarn 20 to 22 percent;
7, 8--yarn of tex 25×2, impregnated during 3 seconds with liquid ammonia at a temperature of -35° C., whereupon the yarn is stretched 15% lengthwise and simultaneously treated during 2 seconds with an aqueous solution of polyvinyl alcohol having a concentration of 20 to 30 g/l at a temperature of 80° to 90° C. so as to raise the strength of the mercerized yarn 20 to 25 percent.
Thus the proposed method, whereby the mercerization and sizing are carried out simultaneously, makes up for the 18% to 20% loss in the breaking strength of cotton yarn, which loss is due to the pneumatic spinning of that yarn. In addition, when treated in accordance with the method of this invention, the yarn acquires the properties of mercerized yarn. All these factors help to reduce the warp thread breakage and simplify the subsequent processes of dying and finishing unbleached fabrics. | The invention relates to methods for treating cotton yarn and can be used to the best advantage in the treatment of yarn produced by pneumatic spinning. According to the proposed method, the yarn is impregnated with liquid ammonia and then stretched in an aqueous bath containing a sizing agent in an amount sufficient to increase the yarn strength 18 to 25 percent. | 3 |
TECHNICAL FIELD
[0001] The present invention relates generally to quilting and embroidering and more specifically to a method for reducing the number of steps required in quilting and speeding up production time.
BACKGROUND OF THE INVENTION
[0002] Quilting is a sewing method done either by hand, by sewing machine, or by a longarm quilting system. The process uses a needle and thread to join two or more layers of material together to make a quilt. Typical quilting is done with three layers: the top fabric or quilt top, batting (filler sandwiched between two layers of fabric to give the quilt loft) and backing material. The quilter's hand or sewing machine passes the needle and thread through all layers and then brings the needle back up. The process is repeated across the entire piece where quilting is desired. A straight or running stitch is commonly used, and these stitches can be purely functional or decorative and elaborate.
[0003] Quilting is done on bed spreads, art quilt wail hangings, clothing, and a variety of textile products. Quilting can make a project thick or use dense quilting to raise one area so that another stands out.
[0004] Traditional, quilting is a six-step process that includes: 1) selecting a pattern, fabrics and batting: 2) measuring and cutting fabrics to the correct, size to make blocks from the pattern; 3) piecing blocks together (sewing cut pieces of fabric together using a sewing machine or by hand to make blocks) to make a finished “top”; 4) layering the quilt top with batting and backing to make a “quilt sandwich”; 5) quilting by hand or machine through all layers of the quilt sandwich; and 6) squaring up and trimming excess batting from the edges, machine sewing the binding to the front edges of the quilt and then hand-stitching the binding to the quilt backing. It should be noted, that if the quilt will, be hung on the wall, there is an additional step: making and attaching the hanging sleeve. For high volume operations, this multitude of steps is very labor and time intensive.
[0005] Therefore, it would be desirable to have a method of quilting that reduces the number of steps involved and speeds up production time.
SUMMARY OF THE INVENTION
[0006] The present invention provides an improved method and computer program product for quilting and embroidering fabric. The method comprises securing a quilt sandwich of top layer fabric, batting and backing fabric in an embroidery hoop and attaching said embroidery hoop to an embroidery machine. The user retrieves a digitized embroidery file that is fed into the embroidery machine. The digitized file instructs the embroidery machine to first stitch the quilt layers together according to a predetermined stippling pattern. The digitized file then instructs the embroidery machine to stitch an outline for an appliqué. Alternatively, the appliqué outline may be stitched before the stippling. After an appliqué fabric is placed over the outline, the digitized file sews a tackdown stitch, after which appliqué enhancements or additional layers of appliqué may also be stitched. The quilt is then removed from the embroidery hoop and the appliqué and quilt are trimmed. The invention allows all stitching and quilting to be completed before removing the quilt from the embroidery hoop and trimming the appliqué.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0008] FIG. 1 is a flowchart illustrating a method of quilting using embroidered blocks in accordance with the prior art;
[0009] FIG. 2 is a flowchart showing a method for quilting using foundation piecing in accordance with the prior art;
[0010] FIG. 3 is a flowchart showing yet another prior art method of quilting involving the use of machine embroidery appliqué;
[0011] FIG. 4 is a flowchart showing a quilting method in accordance with a preferred embodiment of the present invention;
[0012] FIGS. 5A and 5B show examples stippling in straight lines or a meandering style, respectively;
[0013] FIG. 6A shows an example of an appliqué outline within the stippling pattern;
[0014] FIG. 6B shows a tackdown stitch sewn into an appliqué layer; and
[0015] FIG. 6C shows an example of appliqué enhancements.
DETAILED DESCRIPTION
[0016] Referring now to FIG. 1 , a flowchart illustrates a method of quilting using embroidered blocks in accordance with the prior art. The process begins by cutting the quilt block larger than the required finished size (step 101 ). Next, the block is secured in an embroidery hoop with a stabilizer (step 102 ).
[0017] The user then retrieves a digital embroidery file on a computerized embroidery machine (step 103 ). The digitized file instructs the embroidery machine to embroider the decorative elements (e.g., embroidery designs, appliqué designs or foundation-piecing) (step 104 ).
[0018] After the block is embroidered, it is removed from the hoop (step 105 ) and trimmed to the finished size plus seam allowance (step 106 ). The blocks are then pieced together to create the quilt top (step 107 ).
[0019] The pieced quilt top, batting and backing are layered (step 108 ) and the layers are quilted together with running stitches (stippling) using a standard sewing machine or by hand (step 109 ).
[0020] FIG. 2 is a flowchart showing a method for quilting using foundation piecing in accordance with the prior art. This method begins by cutting the quilt block foundation larger than the finished block size (step 201 ) and securing the foundation in an embroidery hoop with stabilizer (step 202 ).
[0021] The user then retrieves a digital embroidery file, which is an outline designating where fabric pieces: are to be placed on by one (step 203 ). The digitized file instructs the embroidery machine to stitch the first color (outline) (step 204 ). The user places the first fabric piece right side down on the designated sewn line (step 205 ) and stitches the next color according to the digitized file (step 206 ). The fabric is then flipped down over the sewn line, and the seam is finger pressed (step 207 ).
[0022] If there are additional fabric pieces to be added to the block (step 208 ), steps 205 - 207 are repeated until the block is finished.
[0023] After the block is created, backing and batting can be added to the wrong side of the hoop and secured with temporary spray adhesive or a water soluble thread (step 209 ). The final colors of the digital embroidery file stipple the three layers (step 210 ). The finished block is removed from the machine (step 211 ) and trimmed to the desired size (step 212 ).
[0024] The blocks are then pieced together with a narrow seam allowance (step 213 ). A ribbon or narrow strip of fabric is fused to the back of the quilt, covering the seams, and secured with a topstitch (step 214 ).
[0025] FIG. 3 is a flowchart showing yet another prior art method of quilting involving the use of machine embroidery appliqué. This method is a variation of the method shown in FIG. 2 . The process begins by cutting the quilt block larger than the required finished size (step 301 ) and securing it in an embroidery hoop with a stabilizer (step 302 ).
[0026] The user retrieves a digital embroidery file that provides the outline of where to place the appliqué fabric (step 303 ) and stitches the first color according to the digitized file (step 304 ). The fabric is placed right side up, covering the sewn outline (step 305 ), and the tackdown is stitched (step 306 ).
[0027] At this point, the hoop is removed from the embroidery machine, while leaving the fabric in the hoop (step 307 ), and the excess appliqué fabric is trimmed (step 308 ). The user then reattaches the hoop to the embroidery machine (step 309 ). The next color is then stitched, typically a satin stitch that covers the raw edge of the appliqué fabric (step 310 ).
[0028] After the block is created, backing and batting can be added to the wrong side of the hoop and secured with temporary spray adhesive or a water soluble thread (step 311 ). The final colors of the digital embroidery file stipple the three layers (step 312 ). The user removes the finished block from the machine (step 313 ) and trims it to the desired size (step 314 ).
[0029] The blocks are pieced together with a narrow seam allowance (step 315 ), and a ribbon or narrow strip of fabric is fused to the back of the quilt, covering the seams and secured with a topstitch (step 316 ).
[0030] As is obvious from the above descriptions., the prior art methods of quilting can be rather labor and time intensive. In addition, the user has to remove the hoop from the machine to trim the appliqué fabric and then reattach the hoop to the machine and complete the design. Removing and reattaching the hoop in this manner can cause misalignment within the embroidery machine and is time consuming. The present invention overcomes these disadvantages by changing the sequencing of the steps during the embroidery process and reducing the number of steps and time involved in quilting as well as eliminating the potential misalignment issues noted above.
[0031] FIG. 4 is a flowchart showing a quilting method in accordance with a preferred embodiment of the present invention. The process begins by cutting the block, batting and backing larger than the desired finished size (step 401 ) and seeming all of the layers of the quilt sandwich in an embroidery hoop (step 402 ). The user then retrieves and executes a digital embroidery file (step 403 ).
[0032] The digitized file first instructs the embroidery machine to embroider the stippling stitches to quilt the layers together (step 404 ). FIGS. 5A and 5B show examples of stippling in straight lines or a meandering style, respectively.
[0033] The next stitch embroidered from the digitized file is the outline of the appliqué area sewn on the top layer of the quilt (step 405 ). FIG. 6 A shows an example of an appliqué outline 601 within the stippling pattern. This is a placement guide to show where to place the appliqué fabric. It should be noted that this step is optional, as the user could place the fabric over the entire hoop without the outline.
[0034] Alternatively, steps 405 and 404 can be reversed. The appliqué outline can be sewn first and the stippling sewn after. The key element is that both the stippling and appliqué outline are sewn before the tackdown.
[0035] The user places the appliqué fabric over the designated area (step 406 ). The digitized file then sews a tackdown stitch to secure the appliqué fabric to the base fabric (step 407 ). FIG. 6B shows a tackdown stitch 602 sewn into an appliqué layer 610 . Optionally, the digitized file may stitch other colors, which are aesthetic options such as, e.g., appliqué enhancements or additional layers of appliqué (step 408 ). FIG. 6C shows an example of appliqué enhancements.
[0036] The block is removed from the hoop (step 409 ), and the block is trimmed to the desired finished size plus a seam allowance, and the appliqué fabric is trimmed as well (step 410 ). The blocks are then sewn together using a reversible seaming method (step 411 ).
[0037] The advantage of the present invention over the prior art is that quilt blocks can be created faster and quilted all in one step (50% faster or more). In the prior art, one would normally have to create the quilt block first (decorate with appliqué), piece the blocks together and then quilt (stipple) the entire quilt. With the present invention, the blocks are already appliquéd and quilted when they are taken out of the hoop. The only thing left to do is sew the blocks together.
[0038] In the present invention all steps (appliquéing and quilting) are performed in one hooping. The appliqué fabric is applied after the quilting and outline stitches are sewn. The sequence of stitches enables the trimming to be completed after the quilt is removed from the hoop, thereby eliminates the risk of misalignment since there is no need to remove the hoop from the machine during the embroidery and quilting process.
[0039] The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. It will be understood by one of ordinary skill in the art that numerous variations will be possible to the disclosed embodiments without going outside the scope of the invention as disclosed in the claims. | The present invention provides an improved method and computer program product for quilting and embroidering fabric. The method comprises securing a quilt sandwich of top layer fabric, batting and backing fabric in an embroidery hoop and attaching said embroidery hoop to an embroidery machine. The user retrieves a digitized embroidery file that is fed into the embroidery machine. The digitized file instructs the embroidery machine to stitch the quilt layers together according to a predetermined stippling pattern and to stitch an outline for an appliqué. After an appliqué fabric is placed over the outline, the digitized file sews a tackdown stitch, after which appliqué enhancements or additional layers of appliqué may also be stitched. The quilt is then removed from the embroidery hoop and the appliqué and quilt are trimmed. | 3 |
[0001] This application is based on Provisional Patent Application 62/179,452, filed May 6, 2015, priority of which is claimed and which is incorporated herein by reference.
[0002] 0.5 This invention relates to a technique for hydrating ginned cotton in a cotton gin.
BACKGROUND OF THE INVENTION
[0003] In order to improve operation of gin stands in the ginning of cotton, seed cotton is dried to reduce the water content to low single digits at a location upstream of gin stands where seeds are removed from lint.
[0004] Low water content also helps lint cleaners upstream and downstream of the gin stands to separate seed cotton or cotton from dust and plant parts. Before the lint passes into a bale press, it is desirable to rehumidify the cotton lint so the bale press works efficiently—very dry cotton lint tends to rebound when the bale press retracts.
[0005] A typical gin includes a conduit or duct delivering cotton and propelling air from the gin stands through a downstream cleaner into a battery condenser where a screen allows air to escape thereby forming a cotton batt which slides by gravity down a lint slide into the bale press. The standard technique for rehumidifying cotton is to deliver high humidity air through the bottom of the lint slide so it passes upwardly through the batt whereby some or all of the water condenses on the cotton fibers.
[0006] Large modern commercial gins run about 60 bales/hour while small gins deliver at least 15 bales/hour. A bale is about 500 pounds of lint so the amount of cotton sliding down the lint slide may be in the range of 7500-30,000 pounds per hour or 2-8 pounds per second. One can imagine that getting a substantially uniform dispersion of condensed water on the batt with current equipment is unlikely.
[0007] It has been attempted in the prior art to spray a water taggant solution on a cotton batt as it slides down the lint slide. The results were not satisfactory because the taggant was not found on a disappointingly large fraction of cotton fibers.
[0008] Disclosures of some interest relative to this invention are found in U.S. Pat. Nos. 2,178,539; 2,764,013; 3,717,904; 3,834,869; 4,019,225; 4,074,546; 6,237,195; 6,240,601; 6,314,618; 6,389,647; 6,807,750; 7,591,048; 7,912,653 and 8,091,181 and U.S. Printed Patent Application 2014/0106357.
SUMMARY OF THE INVENTION
[0009] As disclosed herein, water is sprayed into an air duct downstream of the gin stands and upstream of the battery condenser while the cotton fibers are being pneumatically transported toward the battery condenser, i.e. while the cotton fibers are suspended in propulsion air. A mind's eye picture of the cotton/air mixture flowing through the duct is analogous to the worst imaginable blizzard. Flow through the duct may be relatively fast, e.g. 1500-2000′/minute or 25-34′ per second. The amount of cotton flowing through the duct varies, of course, with the capacity of the gin but for common gins is in the range of 2-8 pounds per second. A nozzle assembly is designed to produce water droplets that are of a diameter that is the same order of magnitude than the diameter of ginned cotton fibers.
[0010] It is an object of this invention to provide an improved technique for rehumidifying cotton lint upstream of a bale press.
[0011] A more specific object of this invention is to provide a technique for rehumidifying cotton lint upstream of a bale press in a manner that produces uncommonly consistent dispersion of liquid water onto cotton fibers.
[0012] A further object of this invention is to provide an improved technique for tagging cotton fibers with a material that can later be detected.
[0013] Another object of this invention is to spray water and a solution onto cotton fibers upstream of a bale press.
[0014] These and other objects of this invention will become more fully apparent as this description proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic view of a cotton gin;
[0016] FIG. 2 is a schematic view of a cleaner downstream of gin stands, a battery condenser, a lint slide and a bale press;
[0017] FIG. 3 is an isometric view of the cleaner of FIG. 2 and conduit connecting the cleaner with the battery condenser;
[0018] FIG. 4 is a cross-sectional view of FIG. 3 , taken along line 4 - 4 thereof as viewed in the direction indicated by the arrows to illustrate a nozzle assembly used to rehumidify cotton lint;
[0019] FIG. 5 is a schematic view of part of a modern gin showing another arrangement of duct work downstream of a cleaner that is, in turn, downstream of gin stands;
[0020] FIG. 6 is a broken view of another embodiment of a duct and nozzle array;
[0021] FIG. 7 is a broken view of another embodiment of a duct and nozzle array;
[0022] FIG. 8 is a broken view of another embodiment of a duct and nozzle assembly;
[0023] FIG. 9 is a broken view of another embodiment of a duct and nozzle assembly, and
[0024] FIG. 10 is a cross-sectional view of a nozzle assembly illustrating its connection with a duct.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to FIGS. 1-4 , a cotton gin 10 may comprise, as major components, a module feeder 12 for disintegrating a cotton module 14 , a transport system 16 for delivering cotton clumps from the module feeder 12 through the various components of the gin 30 . Cotton gins 10 typically include a feed controller 18 , a series of separators or cleaners 20 , 22 for separating seed cotton or cotton lint from plant debris upstream from one or more gin stands 24 which separate cotton seed from lint. A cleaner 26 downstream of the gin stands 24 may remove any residual dust or plant parts.
[0026] Conveying air introduced in a conventional manner downstream of the gin stands 24 delivers cotton fibers through the cleaner 26 and through a duct 28 leading to a battery condenser 32 . The duct 28 may be a wide rectangular duct which necks down through a transition 30 to a round duct 34 . Inside the battery condenser 32 is a screen 36 or other suitable means for separating conveying air flow cotton lint and producing a cotton batt 38 . The cotton batt 38 slides by gravity along a lint slide 40 into to a bale press 42 where the ginned cotton is compressed into a gin bale.
[0027] Conveying air from the battery condenser 32 passes through a conduit 44 to one or more cyclones 46 for removing dust from the conveying air before exhausting it to the atmosphere. Those skilled in the art will recognize the gin 10 as heretofore described as being typical of modern commercial gins. The disclosures of U.S. Pat. Nos. 8,046,877 and 8,356,389 are incorporated herein by reference for a more complete description of a cotton gin.
[0028] As will be explained more fully hereinafter, a series of nozzle assemblies 48 delivers a water spray into the duct 28 at one or more locations downstream of the gin stands 24 , such as between the gin stands 24 and the lint cleaner 26 or between the lint cleaner 26 and the battery condenser 32 . Downstream of the lint cleaner 26 may be preferred because many lint cleaners are more efficient with drier cotton lint. The water spray may preferably be into the duct 28 upstream of the battery condenser 32 or into the battery condenser 32 upstream of the screen 36 or other device to separate propulsion air from ginned cotton fibers. It may be preferred to have the nozzle assemblies 48 spraying water into the wide rectangular duct 28 because the cotton fibers are traveling at a lower speed than in the smaller round duct 34 where velocities are higher thereby promoting more consistent dispersion of water droplets onto the cotton lint.
[0029] Another advantage of spraying into the wide rectangular duct 28 is there is considerably more room for a large number of nozzle assemblies 48 as compared to the smaller round duct 34 as may be visualized in FIG. 3 . A further advantage of spraying into the wide rectangular duct 28 is the cotton fibers are more widely separated than in the round duct 34 . For example, saws (not shown) in the cleaner 24 act to separate cotton fibers to allow trash and dust to separate from the fibers and the cotton fibers have not had the opportunity to conglomerate as may occur in the smaller round duct 34 . The direction of water spray may be transverse to the direction of cotton flow to minimize cotton fibers aimed directly at the nozzle assemblies 48 . It may be preferred that water spray is generally perpendicular or obtuse to the direction of cotton flow. FIG. 3 is a schematic view of a prototype installation in a working gin and suggests that the rectangular duct 28 is upwardly inclined but this was done to provide adequate room for the spray equipment in an existing gin configuration. As explained more fully hereinafter, many different duct work configurations are feasible.
[0030] Referring to FIG. 4 , each nozzle assembly 48 may comprise a a fitting 50 securing the assembly 48 in any conventional manner in a threaded opening 52 in the duct 28 . The fitting 50 may accordingly comprise an externally and internally threaded bushing receiving an externally threaded nozzle 54 to which is attached a manifold 56 . The nozzle opening 52 may preferably be recessed inside the fitting 30 out of the flow diameter of the duct 28 , i.e. outward of the internal dimension of the duct 28 , to avoid collecting cotton lint on the nozzle 54 and thereby avoiding wet masses of cotton collecting on or clinging to the nozzle 54 . Another technique which may be effective to avoid the accumulation of wet cotton fibers on the nozzle 54 is to provide one or more air leakage passages 58 through the fitting 50 to allow air to be drawn into the recessed cavity adjacent the nozzle end 60 . This acts to dislodge any wet cotton fibers from the nozzle 54 or prevent their accumulation.
[0031] The nozzle 54 is connected to a water supply line 62 and an air supply line 64 . An oddity of the nozzle 54 is that it is capable of delivering very small droplets in the range of 5-25 micron diameter microns which is about the same size as the width or diameter of many cotton fibers. Preferably, the water droplets may be in the range of 5-25 microns and which may preferably be about 8-12 microns in diameter and which may practically be about microns in diameter. Cotton fibers may vary somewhat in diameter but this variation will likely be in the range of 7-22 microns. As pointed out more fully hereinafter, it is believed the size of the water droplets being about the same diameter as the width of the cotton fibers promotes the efficiency of contacting fibers with water droplets.
[0032] The nozzle assemblies 48 can be purchased commercially from such companies as Spray.com of Wheaton, Ill. By controlling the water pressure to the assembly 48 with a regulator 66 and controlling the air pressure at the assembly 48 with a regulator 68 , the size of droplets emitting from the nozzle 54 and the rate of water delivery can be controlled in a conventional manner, i.e. a table may be provided by the manufacturer so that if water pressure is selected and air pressure is selected, the droplet size and water quantity can be dictated.
[0033] To test how consistent water is applied to cotton fibers with the device of FIGS. 2-4 , a large batch of Pima cotton of fiber lengths in the range of 1.26-1.47 inches was run through a conventional gin 10 and a taggant was delivered through the conduit 62 along with water. The taggant was from a container 70 and the flow rate of the taggant was controlled by an electrically operated valve or flow meter 72 . It will be evident that the pressure regulators 66 , 68 , valves (not shown) on the water and air lines 62 , 64 , and the valve 72 may be controlled by a computer (not shown). This allows the taggant to be shut off when cotton flow ceases and matches the amount of taggant delivered through the conduit 62 to the amount of cotton fibers flowing through the duct 28 . A computer controller also allows control over the total amount of water in a gin bale by determining the amount of moisture in cotton upstream of the spray nuzzles, the amount of cotton flowing through the duct and the amount of water being sprayed. The amount of water in the gin bale may accordingly be controlled to be less than limits imposed by customers, industry standards or the like, which limit is currently around 7% by weight.
[0034] Such a taggant may be of any suitable type but, in the test, artificial DNA was used. The DNA taggant was from Applied DNA Science of Stony Brook, N.Y. Thirty two milliliters of DNA in a total of one liter of DNA/water solution was injected per minute into the water conduit 62 and sprayed into the duct 28 in a gin delivering 20 bales/hour of Pima cotton. Thus, 1920 milliliters/hour of the DNA solution was sprayed onto 20 bales/hour or approximately 10,000 pounds/hour of Pima cotton. The DNA solution was diluted by a substantial amount of water, as explained more fully hereinafter, meaning that the concentration of DNA in the DNA solution is susceptible of wide variation because it will be diluted significantly in the spraying operation.
[0035] At a rate of about 350 bales/day, a total of about 10,000 bales of cotton were sprayed with the DNA solution. A total of twelve fiber samples per day were delivered to a laboratory to determine whether the DNA taggant was present on the fiber or a total of about 350 fiber samples. 100% of the fiber samples submitted to the laboratory tested positive for the DNA taggant, Meaning that every tooted fiber had contacted a water droplet. This is difficult for knowledgeable cotton gin people to believe because the number of individual fibers in 10,000 bales of cotton is immense, almost beyond imagination. This is not proof that every fiber in the 10,000 bales had been contacted with water but sophisticated statistical calculations will show, to a very high degree of confidence, that a very large proportion of fibers were contacted with DNA laced water. The exact mechanism that distributes taggant so efficiently is not known and the invention is not bound by any theory. One may surmise that some of the fibers were contacted directly by sprayed taggant but it is not known that all of the tested fibers were contacted directly by sprayed taggant. It is possible that taggant was transferred indirectly to some fibers by a tagged fiber rubbing against an untagged fiber. Given the turmoil of fibers jostling along in a propulsion air stream, this seems possible and perhaps likely.
[0036] It is apparent this technique is a viable approach to mark fibers, including cotton fibers, in a quality control effort. Tagging a select type of cotton fibers with DNA taggants can readily assure that the select type of fibers is present in processed threads or textiles. In addition, it is clearly feasible to spray water onto ginned cotton upstream of a battery condenser with a penetrant, other than a taggant or marker, that has beneficial effects on cotton fibers. The penetrant may be of any suitable type such as a surfactant, wetting agent or the like.
[0037] Another advantage of this invention is that it is much, much cheaper than conventional rehumidifying equipment. The only cost are some commercially available nozzles, a water source, a source of low pressure air, conventional low pressure regulators, valves, a computer controller and the labor to install the equipment. The required water pressure in most applications is well below the pressure of conventional city water systems, meaning that no additional water pumping equipment is necessary.
[0038] Referring to FIG. 5 , there is illustrated a cotton gin 80 having a differently configured ducting arrangement downstream from a first plurality of cleaners 82 each of which includes an inlet 84 and an outlet 86 which may typically be a rectangular duct similar to the duct 28 . A second plurality of cleaners 88 may be provided which includes an inlet 90 and an outlet 92 which typically may be a rectangular duct similar to the duct 28 . Outlets 86 of the first cleaners 82 may be connected to a valve 94 which may connect one or both of the outlets 86 to an intermediate duct 96 which connects to a second valve 98 which typically may be connected to the outlets 92 of the second cleaners 88 . An outlet conduit 100 , which may be rectangular similar to the duct 28 , from the valve 98 may deliver cotton pneumatically conveyed through the valves 94 , 98 through a transition 102 to a round duct 104 leading to a battery condenser (not shown) in a manner similar to the gin 10 in FIGS. 1 and 2 . The gin 80 as heretofore described will be understood by those skilled in the art to be representative of modern high capacity gins where one or a plurality of the cleaners 82 , 88 may be operating, depending on the volume throughput of the gin 80 and as controlled by the position of the valves 94 , 98 .
[0039] A series of nozzle assemblies 106 delivers a water spray into the duct 100 at one or more locations downstream of the cleaners 82 , 88 . It may be preferred to have the nozzle assemblies 108 spraying water into the wide rectangular duct 100 rather than into the round duct 104 for the same reasons it may be desirable to spray water into the rectangular duct 28 rather than the round duct 32 .
[0040] Referring to FIG. 6 , another embodiment of this invention is illustrated comprising a duct 110 at some location in a cotton gin, such as shown in FIG. 1 , between the gin stands (not shown) and a lint cleaner (not shown), between the lint cleaner (not shown) and a battery condenser 112 or between the gin stands (not shown) and the battery condenser 112 if no lint cleaner is present. The duct 110 may be rectangular or round and includes an inlet 114 , one or more elbows or bends 116 and an outlet 118 leading to a bale press (not shown). The duct 110 can be horizontal or vertical, meaning that the elbow 116 may change the direction of the duct 110 in a horizontal plane, in a vertical plane or in an inclined plane. The elbow 116 changes the direction of lint flow and an includes an intersecting pipe section or access hatch 120 . The access hatch 120 comprises a curved inlet wall 122 of a thickness similar to the wall 124 of the duct 110 and a straight outlet wall 126 and normally include a hatch cover (not shown) which has been replaced by a nozzle array 128 having thereon a series of nozzle assemblies 130 . One effect of the access hatch 120 is to create a dead air space 132 .
[0041] It may be advantageous to spray water into the dead air space 132 for a variety of reasons. Pressure in the dead air space 132 is lower than atmospheric pressure because of the change of direction of lint flow. This allows outside air to flow, without a fan or pump, past the nozzle assemblies 130 to dislodge cotton or water collecting, or tending to collect, on the nozzle assemblies 130 as will be pointed out more fully hereinafter. Another aspect of the dead air space 132 is that lint flow detaches from the wall 122 along a line or zone 134 leaving the space 132 mostly free of cotton. This allows spray from the nozzle assemblies 130 to spread out before contacting any cotton thereby increasing the ability of the spray to reach most or all of the cotton fibers. Another advantage of the dead air space 132 is to allow ambient air to enter the duct 110 and thereby flow past the nozzle assemblies 130 in order to dislodge or prevent the accumulation of debris on the assemblies 130 .
[0042] Referring to Figure /, there is illustrated another approach to create a dead air space into which water spray may be directed. A round or pipe shaped duct 136 is located between the gin stands and the battery condenser and includes an inlet 138 , an enlarged section 140 and an outlet 142 . Because of the increase in diameter of the pipe wall 144 at a location 146 , a dead air space 148 is created where the lint detaches from the wall 144 along a line 150 downstream of the location 146 . The dead air space 148 is roughly annular because the duct 136 is round.
[0043] It will be apparent that many different approaches may be devised to create a dead air space in a duct of a pneumatic conveyor, as by the provision of a compartment 152 opening into a duct 154 as shown in FIG. 8 , particularly when an axis 156 of the opening 158 is inclined in the direction 160 of flow thereby producing a venturi like affect to reduce the pressure adjacent the end of the nozzle assembly 160 . It will be seen that lint flow in the duct 154 detaches from the wall 162 along a line or zone 164 creating a dead air space 166 inside the duct 154 . It will be apparent there are many other ways to create a dead air space adjacent a nozzle. For example, vanes or other obstructions upstream of a nozzle may be used to divert the air/lint stream away from the wall of a straight duct and thereby create a dead air space into which the nozzle sprays.
[0044] Some of the effects of a dead air space can be created by forcibly blowing air into a duct 168 as shown in FIG. 9 . A conduit 170 opens into the duct 168 and houses a nozzle assembly 172 and a fan 174 driven by a motor (not shown). Air blowing into the duct 168 depresses lint flowing through the duct 168 along a line or zone 176 to create a zone or area 178 which allows spray from the nozzle assembly 172 to spread out in much the same manner that a dead air zone allows spray to spread out and increase the fraction of cotton fibers contacted by water. Because of the direction of flow in the duct 168 , the zone 178 may typically be skewed in the downstream direction.
[0045] Referring to FIG. 10 , there is illustrated an exemplary nozzle assembly 180 mounted on or adjacent an opening 182 in a duct 184 by a bracket 186 affixed to the duct 184 in any convenient manner. A nozzle 188 may preferably be removably attached to the bracket 186 as by mating threads 190 . A manifold 192 attaches to the bracket 186 and/or nozzle 188 in any suitable manner and includes an air connection 194 and a water connection 196 separately connected to the nozzle 188 through fittings 198 , 200 . The end 202 of the nozzle 188 will be seen to be outboard, or spaced from, the interior wall 204 of the duct 184 to reduce the accumulation of cotton lint or debris on the nozzle 188 . The opening 182 allows outside ambient air to flow into the duct 184 around the nozzle end 202 thereby cleaning the nozzle end 202 and dislodging any cotton lint or debris attempting to collect on the nozzle 188 .
[0046] It may be desirable to employ filters to remove particles in the same range or larger than the water droplets emitting from the spray nozzles. To this end, referring to FIG. 4 , a filter 202 may be employed in the air line 64 to remove particles from the air stream. Similarly, a filter 204 may be employed in the water line 62 to remove particles from the water source. The filters 202 , 204 may preferably remove particles of any desired size, such as 1-20 micron, thereby eliminating two sources of dust in the baled cotton. Commercially available filters down to one micron are available and may be used. Five micron filters have proved successful.
[0047] It may be desirable to employ a heater in the water supply to minimize the effects of operating in abnormally cold climates or during an abnormally cold time of the year. To this end, a heater 206 may be incorporated in the water supply line 62 .
[0048] Although this invention has been disclosed and described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred forms is only by way of example and that numerous changes in the details of operation and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereafter claimed. | In a cotton gin, water is sprayed into a duct transporting pneumatically conveyed cotton fibers from a gin stand toward a battery condenser to improve the operation of a bale press where the ginned fibers are compacted into a bale. In some embodiments, a taggant is incorporated into the water to mark cotton fibers so threads or fabrics made from the cotton can be identified for quality control purposes. Spray nozzles may deliver water droplets of roughly the same size as the diameter of the cotton fibers. The nozzles may be located on a duct in a location adjacent dead air in the duct to promote coverage of the spray onto the cotton stream. Air may be delivered around the nozzles into the duct to prevent buildup of cotton and debris around the nozzles. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image scanning apparatus in which a linear image sensor performs mechanical scanning in a direction perpendicular to the longitudinal direction of said sensor, and more particularly to such scanning apparatus adapted for use in the image signal generation in a telephoto or facsimile transmitter.
2. Description of the Prior Art
In a conventional telephoto or facsimile transmitter, a photoelectric converting element is linearly moved parallel to the axis of a rotary drum on which a photograph is wound, thereby achieving a scanning with the photoelectric converting element in combination with the drum rotation (hereinafter called horizontal scanning) and a scanning with said element in combination with the axial movement thereof (hereinafter called vertical scanning).
In such system it is difficult to exactly measure the density information of the object photograph in a short time by preliminary scanning of the entire photograph, since the horizontal scanning is conducted by mechanical rotation of the drum, which revolution cannot be made very high.
Also such rotary drum system is associated with a drawback of requiring a complicated structure for a transmissive object such as a photographic film, since an illuminating optical system and a photodetector have to be positioned across the drum made of a transparent material, namely inside and outside thereof, and have to be linearly moved in synchronism along the rotary axis thereof to achieve vertical scanning. In addition, for a small film such as of 35 mm format, there are required a high precision for the movement in the vertical scanning direction and a high resolving power in the horizontal scanning direction.
Furthermore, the image scanning apparatus for the telephoto transmitter employing a photograph wound on a rotary drum requires a long time for the preparation for transmission because of darkroom operations such as enlarging, trimming, printing and developing for printing a photograph from a photographic film, and the place of transmission is therefore inevitably limited. Besides the presence of a printing step onto the photographic paper from the film inevitably gives rise to a loss of the image information contained in the original film, such as a deterioration of the resolving power and of delicate tonal rendition.
SUMMARY OF THE INVENTION
In consideration of the foregoing, an object of the present invention is to prevent the aforementioned drawbacks, and is to provide a photoelectric converting apparatus for converting light transmitted by a film into electrical signals, and for providing electrical signals of a determined range from films of various exposure conditions.
The apparatus of the present invention is featured by detecting the minimum image density (area closest to transparent) and the maximum image density (darkest area) recorded on a negative or positive film from the maximum and minimum values of light transmission through the film, setting the level of the electrical signal obtained by photoelectric conversion of the transmitted light of said minimum density area within a predetermined range by controlling the diaphragm aperture of an optical system or the gain of an amplifying circuit, and by normalizing the level of electrical signal obtained by photoelectric conversion of the transmitted light of said maximum density area into a predetermined range through a DC level shifting in a clamp circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a telephoto transmission system employing a photographic film;
FIG. 2 is a block diagram showing an embodiment of the present invention;
FIGS. 3 and 8 are wave form charts showing image signals of a horizontal scanning line obtained from the linear sensor in preliminary scanning;
FIG. 4 is a wave form chart showing image signals of a horizontal scanning line obtained according to the present invention;
FIG. 5 is a chart showing gamma characteristic of a negative film;
FIG. 6 is a chart showing gamma characteristic of a positive film;
FIG. 7 is a block diagram showing another embodiment; and
FIG. 9 is a chart showing gamma characteristic.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic view of a telephoto transmitter employing a photographic film, in which the image scanning apparatus of the present invention is applicable.
The optical system of the present invention is constructed in such a manner that the light of a determined intensity continuously emitted from a light source 1 illuminates a developed photographic film 7 through a concave mirror 2, a planar mirror 3, an infrared absorbing filter 4, a diffusing plate 5 and condenser lenses 6, and the image of said film 7 is focused on a focal plane 9 through an imaging optical system 8. A CCD linear image sensor 10 is so positioned as to scan said focal plane 9. A diaphragm driving motor 11 controls a diaphragm 8a of the imaging optical system 8, and a scanning drive motor 12 moves the image sensor 10 in the direction of the arrow on the focal plane 9. The longitudinal scanning of the CCD linear image sensor 10 corresponds to the horizontal scanning, while the scanning motion in the direction X of the image sensor 10 caused by the motor 12 corresponds to the vertical scanning.
The light beam from the light source 1 is reflected by the concave mirror 2 and the planar mirror 3, then transmitted by the infrared absorbing filter 4 and the diffusing plate 5, and concentrated by the condenser lens 6 to uniformly illuminate the entire frame area of the film 7. The light transmitted by the film 7 is focused by the imaging optical system 8 onto the focal plane 9 and is converted into electrical signals by means of the image sensor 10 scanning said focal plane. The film 7 is rendered movable horizontally and vertically, and the imaging optical system 8 is capable of zooming.
FIG. 2 is a block diagram of an embodiment of a telephoto transmitter employing a photograph as shown in FIG. 1 in which the present invention is applied. In FIG. 2, the same components as those in FIG. 1 are represented by the same numbers and will not be explained further. A sequence controller 18 controls the operation sequence of the transmitter, and controls the rotation of the motor 12 through a motor control circuit 13 in response to the positional information of the image sensor 10 in the direction X detected by a position detector 14. A pre-amplifier 19 amplifies the analog electrical signals from the image sensor. A clamp circuit 20 is provided to shift the DC level of the signals from the pre-amplifier 19. A negative film gamma correcting circuit 21, an inverting circuit 22 and a positive film gamma correcting circuit 23 are controlled by a selector switch 28. A filter 24 modifies the signals transmitted through the switch 28 to match with the frequency band of a telephone line. A digital image signal processing circuit 25 is provided for example for image processing with a computer. A modulator 26 performs AM or FM modulation of a carrier generated from a carrier signal generator 27 with the image signals obtained through the line filter 24 for image transmission through the telephone line. There are further provided a clock generator 29 for generating clock signals for sequence control of the apparatus; a sample hold circuit 30 for detecting optical black level; a maximum density detecting circuit 31 for detecting the maximum density value in the film image in a high-speed scanning (hereinafter called pre-scanning) preceding the scanning for photoelectric conversion for signal transmission through the telephone line or for digital image processing (hereinafter called main scanning); a minimum density detecting circuit 34 for detecting the minimum density value of the most transparent area in the film image in the pre-scanning; a diaphragm aperture calculating circuit 35 for calculating the optimum diaphragm aperture from the outputs of the maximum density detecting circuit 31 and the minimum density detecting circuit 34; a motor control circuit 36 for controlling the rotation of the diaphragm drive motor 11 in response to the output of the diaphragm aperture calculating circuit 35; and a potentiometer 37 for moving a brush to regulate resistance according to the diaphragm aperture of the diaphragm 8a. The output of the potentiometer 37 is fed to said motor control circuit 36 to form a feedback control loop for the diaphragm 8a. A clamp voltage calculating circuit 32 calculates a clamp voltage from the outputs of the sample hold circuit 30, maximum density detecting circuit 31 and diaphragm aperture calculating circuit 35 to regulate the output level of the minimum density in the main scanning to a standard level. A voltage hold circuit 33 holds the output voltage of said clamp voltage calculating circuit during the pre-scanning and main scanning and supplies said voltage to the clamp circuit 20.
FIG. 3 is a wave form chart of the image signals of a horizontal scanning line obtained from the linear sensor in the pre-scanning for detecting the maximum and minimum densities of the film employed, and FIG. 4 is a wave form chart of the image signals of a horizontal scanning line obtained in the main scanning according to the present invention.
FIG. 5 is a chart showing an example of the gamma characteristic of the negative gamma correcting circuit 21 in case a negative film is loaded, and FIG. 6 is a chart showing an example of the gamma characteristic of the positive gamma correcting circuit 23 in case a positive film is loaded.
In the following there will be given an explanation on the function of the telephoto transmitter for film shown in FIG. 2, while making reference to FIGS. 3 and 4.
Prior to the pre-scanning, the sequence controller 18 supplies a signal to the motor control circuit 36 in such a manner as to preset the aperture of the diaphragm 8a to a determined value. In this manner the saturation of the output of the linear sensor 10 can be prevented for a film of any density distribution. Then, again prior to the pre-scanning, the sequence controller 18 causes the clock pulse generator 29 to supply clock pulses to the sample hold circuit 30, thereby causing said circuit to detect the output level of a light-shielded photodiode (hereinafter called optical black photodiode) of the linear sensor 10. The clamp voltage calculating circuit 32 determines a voltage, taking the output level from the optical black photodiode as the reference level (level C=0(v) in FIG. 3), and the voltage hold circuit 33 holds the voltage determined by said calculating circuit 32 and continues to supply said voltage to the clamp circuit 20 during the pre-scanning. The pre-scanning allows detection, by the maximum density detecting circuit 31 and the minimum density detecting circuit 34, of the maximum and minimum densities respectively of the loaded film. FIG. 3 shows the minimum density level a and the maximum density level b. Then the position detector 14 determines the completion of the pre-scanning of the image sensor 10. Upon completion of the pre-scanning, in response to the minimum and maximum density levels a, b determined by the maximum density detecting circuit 31 and by the minimum density detecting circuit 34, the clamp voltage calculating circuit 32 and the diaphragm aperture calculating circuit 35 calculate an aperture and a clamp voltage in such a manner that the minimum and maximum levels in the main scanning become respectively equal to the predetermined minimum and maximum density levels a', b' shown in FIG. 4. The minimum density detecting circuit 34 may be composed of a peak-hold circuit.
The correction for the diaphragm aperture is determined by (a'-b')/(a-b) wherein b'=0, namely by a'/(a-b), and the positional information is fed back by the potentiometer 37 linked with the diaphragm 8a to control the diaphragm through the control circuit 36, whereby the minimum density level (level a in FIG. 3) of the loaded film is set as the reference level (level a' in FIG. 4). Also the clamp voltage calculating circuit 32 generates the clamp voltage according to a formula -(b-c)×(a'-b')/(a-b) wherein c=0, b'=0, namely by a formula -b×a'/(a-b), and the voltage hold circuit 33 continues to supply said clamp voltage to the clamp circuit 20 during the main scanning.
In response to the clamp pulse from the clock generator 29, the clamp circuit 20 receives the clamp voltage from the voltage hold circuit 33 and sets the maximum density level (level b in FIG. 3) of the loaded film as the reference level (level b' in FIG. 4) during the main scanning. In this manner the electrical image signals can be normalized within a determined level range for the film of any exposure status. Upon completion of the calculation of the clamp voltage and the diaphragm aperture, the sequence controller 18 effects the main scanning, and the image signals obtained in said main scanning are supplied through the pre-amplifier 19 and the clamp circuit 20 and subjected to correction of gamma or contrast characteristics, either in the negative gamma correction circuit 21 of the gamma characteristic shown in FIG. 5 in case of a negative film followed by inversion of polarity in the inverting circuit 22, or in the positive gamma correcting circuit 23 of the gamma characteristic shown in FIG. 6 in case of a positive film, according to the selection by the switch 28. The output signals of the inverting circuit 22 or the positive gamma correcting circuit 23 supplied through the switch 28 are supplied to the digital image processing circuit 25 for generating digital image signals suitable for computer processing etc. and to the telephone line filter 24. The output signals of said filter 24 effect AM or FM modulation of the carrier from the carrier signal generator 27 by means of a telephone line modulator 26, and the obtained signals are released from an output terminal OUT2 for the telephone line. Also the output signals of the image processing circuit 25 are released from an output terminal OUT1.
Each of the gamma correcting circuits 21, 23 has plural gamma correcting characteristics, but the number of such correcting characteristics can be reduced since the input electrical signals are contained within a determined level range. The minimum density detecting circuit 34 holds the maximum peak in the output signals of the linear sensor 10 in each horizontal scanning line in the pre-scanning. On the other hand, the maximum density detecting circuit 31 holds the minimum peak in the output signals of the linear sensor 10 during a predetermined period not affected by the optical black photodiode in each horizontal scanning line.
FIG. 7 is a block diagram showing the principal part of another embodiment, FIG. 8 is a wave form chart similar to FIG. 3, showing the image signals of a line obtained from the linear sensor in the pre-scanning, and FIG. 9 is a chart showing the gamma characteristic for gamma correction.
The circuit shown in the block diagram of FIG. 7 is to replace a part of the circuit shown in FIG. 2 representing the present invention, and is to be inserted between the pre-amplifier 19 and the digital image processing circuit and filter 24 shown in FIG. 2.
The circuit shown in FIG. 7 comprises an AD converter 40; buffer amplifiers BUF1, BUF2; a random access memory 41; data selectors DS1, DS2; a positive/negative film selector switch 42; and a micro computer 43 including a central processing unit. There are further shown a read/write port R/W; a contact R to be selected at data read-out; a contact W to be selected at data write-in; an address port A; and a data port D. The D-A converter 44 converts the digital output signals of the buffer amplifier BUF2 into analog signals. In the present embodiment the gamma correction curve is regulated to obtain a constant amplitude in the image signals. The function of the present embodiment is as follows.
At the pre-scanning, the output signals from the pre-amplifier 19 are converted into digital signals by means of the A-D converter 40. At said pre-scanning, the data selectors DS1, DS2 are both positioned at the contacts R by the CPU 43. Consequently the digitally converted image signals are supplied to the data port D of the CPU 43. In this state the port R/W of the CPU 43 assumes the high-level state to deactivate the buffer amplifier BUF2. Through the pre-scanning the CPU 43 detects the maximum and minimum densities of the entered image signals, namely the levels b1, a1 in FIG. 8, and determines a gamma correction curve for obtaining data b1, a1' shown in FIG. 9. The address and data of the thus determined gamma correction curve are supplied to the random access memory 41. At this state the data selectors DS1, DS2 are shifted to the contacts W, whereby the port R/W of the CPU assumes the low-level state to deactivate the buffer BUF1. The address and data are supplied from the address port A and data port D of the CPU to the random access memory to store the gamma correction curve therein.
In the succeeding main scanning, the CPU turns on the buffers BUF1, BUF2, whereby the output signals of the A-D converter 40 are supplied to the address port A of the random access memory, and the data port D releases the data processed according to thus determined gamma correction.
Instead of the linear sensor in the foregoing embodiment there can naturally be employed a two-dimensional sensor, in which case the scanning drive motor 12 can be dispensed with. | An image signal generating apparatus includes an optical system for focusing the image of a photographic film onto a predetermined plane and a scanning device for scanning the image with a photoreceptor positioned at the predetermined plane and generating output signals representing the light intensity distribution of the film. The scanning device performs a first scan of the image and a second scan of the image upon completion of the first scan. During the first scan the levels of the output signals indicative of the maximum density and the minimum density of the film are detected, and during the second scan the exposure of the photoreceptor is controlled in accordance with the detected levels. Also, during the second scan, the output signals are clamped to a clamp level calculated in accordance with the detected maximum density level and the minimum level of the output signals during the first scan. | 7 |
FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OR PROGRAM
Not Applicable
BACKGROUND
1. Field
This invention generally relates to container handling gantry cranes including ship to shore, rubber tire gantry, and rail mounted gantry.
2. Prior Art
Every year the ships and cranes get bigger and faster, but the means for loading stay the same. The driver of a tractor pulling a chassis with a container on it pulls under a crane, two or more workers on the ground uncouple the container from the chassis, and the load is lifted onto the ship. The container is coupled to the chassis by strong elliptical toggles in each corner which are rotated in elliptical sockets in the container. Sometimes the chassis is not fully uncoupled and the container, chassis, tractor, and operator are lifted into the air. This usually results in the tractor breaking free and falling to the ground causing injuries to the operator and damage to the equipment. Because the tractors have no rear springs, a drop from as little as 200 mm can jostle the operator and cause neck and back injuries, for this reason an improved system is needed.
Several attempts have been made to resolve this problem. U.S. Pat. No. 5,260,688 issued Nov. 9, 1993 used a user selectable radio transmitter to deactivate the crane if the tractor was rotated around the front wheel and a wand contacted the ground. This system had several drawbacks. The wand could be easily damaged by hitting debris in the container yard. Also by the time the wand contacted the ground the rear of the tractor could be up to 800 mm off of the ground. While it would protect the tractor from being lifted entirely off of the ground, the driver could still be injured. A careless operator could improperly select the radio channel, or forget to altogether. This could leave the tractor unprotected. It could also shut down an adjacent crane while it is in motion causing the crane operator to lose control of the load endangering workers on the ship and dock.
U.S. Pat. No. 5,455,567 describes a system using a photo sensor on the rear of the tractor to trigger a 28 Hz strobe light. The strobe is picked up by a pulse discriminator mounted on the cranes trolley that inhibits the crane hoist. The system is active any time the tractor is running. This system worked fairly well when it was developed but is not adequate for the newer, faster cranes unless slowdowns are added. Photo sensors are unreliable on asphalt. Paint stripes and other color changes can change their set points and result in a delayed hoist deactivation. The reaction time between the strobe and the pulse discriminator can be as high as 500 ms. Modern cranes have hoist speeds of 190 m per minute and accelerate to full speed in 2.0 seconds. If you take into account the strobe does not signal until the tractors rear wheels have lifted to about 150 mm and the crane continues to accelerate, the tractors rear wheels can be 800 to 1500 mm off of the ground before the hoist is stopped. For this reason the later versions of this system added a 2 second slowdown to the crane that limited the hoist speed to 20% of the base speed when hoisting a container from the dock. The later systems also abandoned the photo sensor and used a single axis tilt sensor to trigger the strobe. The single axis tilt sensor still did not detect the lift until the tractor had been lifted about 200 mm off of the ground. Even with the added slow down a perfectly operating system did not stop the hoist until the tractors rear wheels were about 300 mm off of the ground. The single axis tilt sensor was also ineffective at detecting roll that can happen if only one corner is coupled.
ADVANTAGES
The present embodiment solves these problems and has many advantages over prior art. The tractor can pull under any crane and the controller will automatically select the proper radio channel. Another advantage is the improved lift detection. This embodiment can detect lift before the tractor comes off of the ground. This coupled with a microprocessor based controller, and radio output. The signal for hoist deactivation is almost instantaneous. It can stop the hoist before the tractors rear wheels come off of the ground without adding a timed slow down to the crane and affecting production. Another added benefit is a reduction in jostling injuries that are common when the rear of the tractor is dropped from 200 mm or more.
SUMMARY
A system to prevent a tractor-trailer from being accidently lifted by a gantry crane including multiple tilt, height, and pressure sensors on the tractor to trigger a multichannel radio transmitter that will be received by the appropriate crane and stop the hoist from raising while still allowing lowering. The radio channel is automatically determined by communication between the crane and the tractor.
DRAWINGS FIGURES
FIG. 1 is an elevational view of a gantry crane that shows a chassis, and container that use the invention.
FIG. 2 is a side view of FIG. 1 showing more detail with the tractor visible; and
FIG. 3 is an enlarged view of FIG. 2 with the crane structure removed; and
FIG. 4 is an enlarged view of the tractor in FIG. 3 ; and
FIG. 5 is an enlarged view of the circled area in FIG. 4
FIG. 6 is a block diagram of the circuitry employed in the crane spreader; and
FIG. 7 is a block diagram of the circuitry employed in the tractor; and
FIG. 8 is a flow chart of the software used in the tractor; and
REFERENCE NUMERALS
10.
Container
12.
Chassis
14.
Tractor
16.
Trolley
18.
Head Block
20.
Spreader
22.
Crane Boom
24.
Ship
26.
Tractor Controller
28.
Inductive Proximity Sensor
30.
Hydraulic Cylinder
32.
Landing Leg
34.
Fifth Wheel Plate
36.
Ultrasonic Sensor
38.
Dual Axis Tilt Sensor
40.
Multi-Channel Radio Transmitter
42.
Radio Receiver
44.
Infrared Emitter
46.
Infrared Decoder
48.
Junction Box
50.
Messenger Cable
52.
Spreader Controller
54.
Off Delay Timer
56.
Shaft
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a ship to shore gantry crane for loading and offloading cargo containers from ships. When loading, a container 10 on a chassis 12 is pulled under the crane by a tractor 14 FIG. 2 . Tractors are spring-less vehicles that are never used on the highway. Dock workers unlock the container 10 from the chassis 12 . A trolley 16 is positioned over the container 10 a head block, 18 and spreader, 20 are lowered into position and lock on to the container 10 which is then hoisted out on to the cranes boom 22 FIG. 1 and loaded onto a ship 24 . Sometimes the container 10 is not completely uncoupled and the chassis 12 and tractor 14 are hoisted in to the air. This has resulted in many serious injuries and equipment damage. This invention will prevent the tractor 14 from being hoisted making ship loading a much safer operation as well as reduce equipment damage.
The invention uses a microprocessor based controller 26 ( FIG. 3 ) installed in the tractor. The controller 26 constantly monitors the status of several sensors to determine if the tractor 14 has been lifted. The primary sensor is an inductive proximity switch 28 FIG. 4 mounted on a fifth-wheel lift cylinder 30 . The tractors 14 are equipped with a hydraulic lift system to raise and lower the front of the chassis so that the operator does not have exit the cab and climb down to the ground to raise and lower a set of landing legs 32 FIG. 3 when coupling or de-coupling from the chassis. This system powers a fifth-wheel plate 34 up and down using double acting hydraulic cylinders 30 FIG. 4 . When the tractors fifth wheel plate 34 is pulled upward by the chassis 12 it also pulls up the lift cylinders 30 . The lower end of the cylinder is clamped around a shaft 56 FIG. 5 that is connected to the tractors frame. The shaft 56 is 2 mm smaller than the cylinder clamp leaving a gap at the bottom. By drilling and installing a shielded inductive proximity switch 28 any upward movement of the fifth wheel assembly can be detected. Using this as the primary sensor the crane hoist can be stopped before the tractors 14 rear wheels have been lifted off of the ground. This is also before any lift is visually detected by the crane operator. Many injuries are caused when the rear of the tractor is lifted 200 mm or more and dropped jostling the operator. As backups the embodiment uses an ultrasonic sensor 36 mounted on the rear frame of the tractor 14 . It will send a digital signal to the tractor controller if the frame of the tractor 14 is lifted a predetermined distance off of the ground. The system also utilizes a dual axis tilt sensor 38 with digital outputs mounted on the tractor frame to sense tilt and roll that will trigger at predetermined angles.
An off delay timer 54 FIG. 7 is used to keep the system active for several minutes after the tractor has been shut down. The tractors engines are loud and the operators occasionally shut them off to talk to workers on the ground. This could leave them unprotected if the crane lifted them while the engine is off.
When a lift is detected, the crane is signaled via a multi-channel radio transmitter 40 FIG. 3 and received by a radio receiver 42 FIG. 2 with a discrete or relay output mounted on the crane. The receiver 42 is shown mounted under the trolley cab 16 but can be mounted anywhere on the crane where the cranes controller inputs are accessible. When the signal is received the receiver 42 will send a discrete output signal to one of the cranes programmable logic controller inputs. The cranes controller will stop the hoist and trolley motion and prevent further hoisting but will allow lowering until the fault is corrected. The multi channel radios are widely available through many manufactures, one is Abacom Technologies, Etobicoke, Ontario Canada.
The radio channel the tractor transmits on is determined by multi channel infrared emitters 44 FIG. 3 mounted on the ends of the spreader 20 that are received by an infrared decoder 46 with relay outputs. It functions similar to the remote controls in use for televisions, radios, and other devices. The emitters 44 are controlled by the spreader controller 52 that acts the same as pushbuttons on a remote control transmitter. There are several manufactures of these products including Infrared Remote Solutions Inc. Syosset, N.Y. When an infrared signal is received by the tractors decoder 46 it is decoded and the appropriate relay is energized sending a signal to a discrete input on the tractor controller 26 this tells the controller which crane to signal in the event of a lift. The spreader 20 can often be damaged during operations and can be detached quickly from the head block 18 and replaced with a spare to reduce the amount of time the crane is out of service. The spreaders 20 will also fit on multiple cranes, for that reason the emitters 44 cannot transmit a fixed identification code. The cranes identification is set by jumper wires in the head block 18 junction box 48 . The head block is permanently attached to the crane by the hoist cables. The identification signal travels through a messenger cable 50 FIG. 3 and to a spreader controller 52 mounted on the spreader. The spreader controller 52 determines the timing, duration, and identification output of the emitters 44 . Emitters are required on both ends of the spreader 20 because the tractor can approach from either direction.
To help eliminate the possibility of false triggers the cranes built-in controller will only accept the hoist deactivation for the first several meters of hoisting after locking onto a container on the dock. Also the tractor controller 26 will not be permitted to transmit a signal unless the infrared crane identification signal transmitted from the spreader 20 is present. The only exception to this is if two or more lift sensors are triggered, the tractor controller 26 will signal the last crane it received an infrared identification signal from. A display or mode lights on the dashboard of the tractor will keep the operator updated on crane identification numbers, system faults, and sensor status.
FIG. 6 shows a block diagram of wiring connections in the cranes spreader 20 FIG. 3 and head-block 18 . The spreader controller 52 FIG. 6 is a Programmable Logic Controller with digital inputs and outputs. It receives its crane identification signal through permanent jumpers in the cranes head-block junction box 48 transmitted through the messenger cable 50 . The controller sends an output to the infrared emitters 44 located on both ends of the spreader. The output controls the channel output, timing, and duration of the infrared emitters that acts as a key press would on a remote control.
FIG. 7 shows a block diagram detailing wiring connections between the tractors components. The tractor controller 26 is a Programmable Logic Controller with digital inputs and outputs and either a small display screen or status lights to keep the operator informed of the system status. Although there are many controllers that are acceptable I have chosen a Horner APG model XLT with a 3 inch touch screen, 2 gigabytes of data logging memory, and 1.2 ms scan time. Connected to the controller are several input and output devices. The first is an infrared decoder 46 that receives the crane identification number when a crane spreader is in range. The decoder 46 has relay outputs that energize when a signal is received, relay one equals crane one and so on. Next is a multi-channel radio transmitter 40 for transmitting a lifted signal to the crane. Multiple sensors inductive proximity 28 , ultrasonic 36 , and dual axis tilt 38 are connected to inputs on the controller. This embodiment uses extra sensors for added safety but one or more can be eliminated and still achieve the desired results. An off delay timer 54 will control power to the system.
FIG. 8 shows a software flowchart for the tractor controller. To start 57 the controller determines if a crane identification signal is being received. If it is, the controller will save the crane identification number into a buffer 58 for later use. It will also update the operator display 60 to show a crane present. It will then check to see if any lift sensors are triggered 62 . If no sensors are triggered it will return to block 57 and start the scan over. If one or more sensors are triggered it will get the crane identification from the buffer and transmit a lifted signal 64 on the proper channel. It will then log the date, time, and the sensor status into memory 66 for later retrieval. It will also update the display to show current status 68 . Moving back to 57 if no crane identification is received it will update the display to show no crane present 70 . It will continue to check the sensor status and if two or more sensors are triggered 72 it will get the crane identification number of the last crane from the buffer and transmit lifted signal 74 . It will then log the date, time, and the sensors tripped into memory 66 for later retrieval. It will also update the display to show current status 68 .
CONCLUSION, RAMIFICATIONS, AND SCOPE
Thus the reader will see the embodiment provides a faster and safer system that eliminates human error and can stop the cranes hoist before the tractor is lifted. Furthermore it provides additional advantages in that:
it can react before the crane operator can see any lift, preventing the tractor operator from being jostled in the cab; it provides a visual display for the operator that shows system status, crane identification number, system faults, and sensor status; it provides logged data for later retrieval; it is fully automatic and does not require any operator inputs; it does not require any production robbing slowdowns;
Although the description above contains much specificity, this should not be construed as limiting the scope of the embodiments but merely providing illustrations of the presently preferred embodiment. For example the crane identification could be accomplished using large bar codes or long range RFID. The primary lift detection sensors could be pressure sensors in the tractors hydraulic system or mounted under the fifth wheel plate to sense a chassis is present.
Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given. | An automatic signaling system to prevent a tractor from being accidently lifted with the cargo by a ship to shore gantry crane. The embodiment includes multiple sensors to detect a lifted condition and radio output upon a lifted condition. The radio output channel is determined by an automatic identification system that identifies the crane the tractor is under. Upon receiving a lifted signal the cranes hoist will be stopped and disabled but will still allow lowering until the lifted signal stops. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims benefit of U.S. Provisional Patent Application No. 61/427,729, filed Dec. 28, 2010, entitled SYSTEM AND METHOD FOR DEPOSITING MATERIAL IN A SUBSTRATE, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to material deposition, and more particularly, to depositing material in a substrate.
BACKGROUND
Methods and systems that effectively deposit material, such as particles, into a substrate, remain an area of interest. Some existing systems have various shortcomings, drawbacks, and disadvantages relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.
SUMMARY
One embodiment of the present invention is a unique method for depositing materials within a substrate. Another embodiment is a unique system for depositing materials within a substrate. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for depositing materials within a substrate. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 schematically illustrates some aspects of a non-limiting example of a system for adding particles to a substrate for forming a matrix material in accordance with an embodiment of the present invention.
FIG. 2 schematically illustrates some aspects of a non-limiting example of particles disposed within a substrate, forming a matrix material, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nonetheless be understood that no limitation of the scope of the invention is intended by the illustration and description of certain embodiments of the invention. In addition, any alterations and/or modifications of the illustrated and/or described embodiment(s) are contemplated as being within the scope of the present invention. Further, any other applications of the principles of the invention, as illustrated and/or described herein, as would normally occur to one skilled in the art to which the invention pertains, are contemplated as being within the scope of the present invention.
Referring to the drawings, and in particular FIG. 1 , some aspects of a non-limiting example of a system 10 for adding particles to a substrate 12 for forming a matrix material in accordance with an embodiment of the present invention is schematically depicted. For example, in the case of a metallic substrate 12 and particles in the form of oxides or other composite material, system 10 forms a matrix material in the form of a metal matrix composite. In other embodiments, other matrix materials may be formed by system 10 , including metal/metal matrix materials, and metal/metal/composite matrix materials, e.g., where one of the metals is substrate 12 , and the other of the metals and the composite is from particles added to substrate 12 . In one form, system 10 is configured to achieve a desired level of porosity on the surface of substrate 12 .
In one form, substrate 12 is an abradable blade track for a gas turbine engine. In other embodiments, substrate 12 may be any component, including, for example, a gas turbine engine blade; vane or series of vanes; an abradable blade track for a compressor, fan or turbine; another gas turbine engine flowpath component or any other gas turbine engine component; or any mechanical component for any machine, device, system or structure. In one form, substrate 12 is a metallic component. In other embodiments, substrate 12 may be formed of one or more metallic and/or non-metallic materials.
System 10 includes an energy emitter means 14 for directing an energy beam 16 at substrate 12 . System 10 also includes a particle sprayer means 18 for directing one or more flow of particles 20 at substrate 12 , e.g., at and in the vicinity of the location of impact 22 of energy beam 16 upon substrate 12 . In one form, particles 20 are not the same material as substrate 12 . In other embodiments, some or all of particles 20 may be the same material as substrate 12 . In one form, means 14 and means 18 are housed in a single unit in the form of a combined discharge nozzle 24 that discharges both energy beam 16 and a flow of particles 20 . In other embodiments, means 14 and means 18 may take other forms, including discrete discharge devices, and may also include a plurality of discharge devices for discharging energy beam 16 and/or flow of particles 20 .
In one form, means 14 is configured and operative to form and direct energy beam 16 in the form of a laser beam. In other embodiments, means 14 may be configured to form other types of energy beams, e.g., including but not limited to one or more electron beams and/or one or more electric arcs. Means 14 is configured and positioned to direct energy beam 16 from below a portion of substrate 12 upward toward the portion of substrate 12 . Energy beam 16 is configured form a melt pool 26 in that portion of substrate 12 from the underside of substrate 12 . Energy beam 16 forms melt pool 26 by locally melting substrate 12 , whereby melt pool 26 faces in a vertically downward-facing direction, i.e., is upside-down.
Means 18 is configured and operative to direct flow of particles 20 from below the portion of substrate 12 upward toward the portion so that at least some of the particles 20 engage and enter melt pool 26 . In one form, some of the particles 20 have a property different than the other particles. For example, in one form, particles 20 are an aggregation of different kinds of particles, wherein some of the particles may have a lower density than others, and/or some particles may have a higher buoyancy in melt pool 26 relative to other particles. The particles having the different property are configured to rise in melt pool 26 toward substrate 12 (un-melted portions of substrate 12 ). Particles 20 may be formed of the same or different material, and may have the same or different size and shape, depending upon the needs of the particular embodiment. In one form, the particles are composite particles, e.g., ceramic composite. In other embodiments, the particles may be formed of metallic particles in addition to or in place of nonmetallic particles. Some particles may be hollow, e.g., hollow metallic and/or nonmetallic spheres or other shapes, whereas other particles may be solid, depending upon the particular embodiment. In still other embodiments, particles 20 may include reactive pore formers in addition to or in place of other types of particles. In yet other embodiments, all particles 20 may be the same or substantially the same, e.g., in composition, size and shape, and may all be configured to rise in melt pool 26 toward substrate 12 (un-melted portions of substrate 12 ).
System 10 is configured to allow the particles having the desired property to rise in melt pool 26 upward toward proximity with un-melted portions of substrate 12 . For example, in one form, system 10 supplies sufficient energy to maintain melt pool 26 laden with particles 20 for a sufficient period of time to allow the particles with the different property to rise upward in melt pool 26 . By forming melt pool 26 in a downward facing direction, the particles having the different property may rise upward toward substrate 12 , for example, forming a desired degree of porosity in substrate 12 adjacent to un-melted portions of substrate 12 . This is contrary to other systems that form a melt pool on an upper or side surface of the substrate, wherein the desired particles may not migrate toward un-melted portions of the substrates.
System 10 also includes a positioning system 28 and a positioning system 30 . In one form, system 10 also includes an enclosure 32 configured to enclose substrate 12 , means 14 , means 18 , positioning system 28 and positioning system 30 . Positioning system 28 is coupled to combined discharge nozzle 24 and operative to translate and/or rotate combined discharge nozzle 24 to form melt pool 26 using energy beam 16 . In one form, positioning system 28 is also configured to progressively or intermittently transition melt pool 26 to other portions of substrate 12 , e.g., portions adjacent to the initial or subsequent instances of melt pool 26 that are also disposed in a vertically downward-facing direction. In embodiments wherein energy emitter means 14 and particle sprayer means 18 are not combined into a single head, or where multiple means 14 and means 18 are employed, additional positioning systems may be coupled to each of means 14 and means 18 . In one form, positioning system 28 is a multi-axis positioning system. In other embodiments, positioning system 28 may be a single axis positioning system.
Positioning system 30 is coupled to and supports substrate 12 , and is operative to translate and/or rotate substrate 12 to form melt pool 26 in desired locations on substrate 12 using energy beam 16 . In one form, positioning system 30 is also configured to progressively or intermittently dispose second and subsequent portions of substrate 12 to energy beam 16 and flow of particles 20 , e.g., portions adjacent to the initial or subsequent instances of melt pool 26 that are also disposed in a vertically downward-facing direction. In one form, positioning system 30 is configured to rotate substrate 12 so that the desired melt pool 26 is facing downward. In one form, positioning system 30 is a multi-axis positioning system. In other embodiments, positioning system 30 may be a single axis positioning system.
In various embodiments, one or both of positioning systems 28 and 30 may be employed to position substrate 12 at the desired location to form melt pool 26 in a downward-facing direction. Other embodiments may not employ a positioning system to position substrate 12 , e.g., depending upon the geometry of substrate 12 . For example, if substrate 12 has a relatively flat surface that may be fixed in place, positioning system 30 may be replaced by a simple support system to maintain substrate 12 in the desired orientation. Still other embodiments may not employ a positioning system(s) to position means 14 and/or means 18 , but rather may employ a simple support system to support means 14 and/or means 18 , relying upon positioning system 30 to orient substrate 12 in the desired position.
Enclosure 32 is configured to allow control of the atmosphere inside system 10 during the forming of melt pool 26 and spraying of particles 20 . In one form, the atmosphere maintained inside enclosure 32 is ambient air. In other embodiments, an inert gas or a vacuum may be contained within enclosure 32 .
During the operation of system 10 , a desired portion of substrate 12 is disposed in a vertically downward-facing direction, e.g. by positioning system 30 . Energy beam 16 is directed from below the portion of substrate 12 where melt pool 26 is desired, and is directed upward toward the portion. In one form, energy beam 16 is directed at the portion of substrate 12 an angle φ less than 45 degrees from a vertical line 34 . In a particular form, energy beam 16 is directed at the portion of substrate 12 an angle φ less than approximately 15 degrees from vertical line 34 . In other embodiments, greater or lesser angles may be employed. Melt pool 26 is then formed by energy beam 16 , facing vertically downward from the portion of substrate 12 . Once melt pool 26 is formed, a flow of particles 20 is directed from below the portion on substrate 12 upward toward the portion in which melt pool 26 is formed. At least some of the particles are configured to rise in melt pool 26 toward substrate 12 . Weld pool 26 is maintained in the liquid state, e.g., by energy beam 16 , while the particles rise in the melt pool toward the substrate.
Referring to FIG. 2 , in embodiments wherein the particles are not homogeneous, those particles 20 A having the property of greater buoyancy in the melt pool and/or less density relative to the other particles 20 B are the particles that rise in melt pool 26 toward substrate 12 . In embodiments wherein the particles are homogeneous, e.g., having a density and/or buoyancy at desired levels to promote floating toward the top of the upside-down melt pool, similar results in the vicinity of substrate 12 at the top of the upside-down melt pool would be achieved, Various embodiments may include translating and/or rotating substrate 12 to dispose another portion of substrate 12 in a vertically downward-facing direction to form a new melt pool 26 or to transition melt pool 26 to a new location on substrate 12 . This may be performed while maintaining melt pool 26 in the vertically downward-facing direction, wherein melt pool 26 is progressively transitioned into the next or other portion of the substrate. Similarly, means 14 and means 18 may be continually or intermittently repositioned in order to transition melt pool 26 from one portion of substrate 12 to another portion of substrate 12 .
Once the desired amount of particles 20 has been dispersed into melt pool 26 and the desired particles have risen in the melt pool toward substrate 12 , melt pool 26 is solidified, e.g., providing a coating on substrate 12 . Such a coating may be, for example, a metal matrix composite coating having a desired level of porosity adjacent to the un-melted portions of substrate 12 . The amount of porosity is based on the selection of particles 20 . In one form, the amount of porosity is configured for abradability of substrate 12 , e.g., in a gas turbine engine blade track component. In other embodiments, the amount of porosity is configured for holding lubrication, e.g., forming a self-lubricating material on substrate 12 . In still other embodiments, the amount of porosity is configured to achieve a desired thermal conductivity, e.g., in a turbine section component of a gas turbine engine. In yet other embodiments, the amount of porosity may be configured to achieve other desired properties.
Embodiments of the present invention include a method for depositing materials in a substrate, comprising: disposing a first portion of a substrate in a vertically downward-facing direction; directing an energy beam from below the first portion upward toward the first portion, forming a melt pool in the substrate using the directed energy beam, wherein the melt pool is formed facing in the vertically downward direction in the first portion; and directing a flow of particles from below the first portion upward toward the first portion, wherein at least some of the particles are configured to rise in the melt pool toward the substrate.
In a refinement, at least some of the particles have a property different than the other particles; and the particles having the different property are the at least some particles that rise in the melt pool toward the substrate.
In another refinement, the property is a lower density than the other particles.
In yet another refinement, the property is a higher buoyancy in the melt pool than the other particles.
In still another refinement, the substrate is metallic, and the particles in the melt pool in conjunction with the melted substrate form a metal matrix composite.
In yet still another refinement, the particles include non-metallic particles.
In a further refinement, all the particles are non-metallic particles.
In a yet further refinement, the particles include hollow particles.
In a still further refinement, the particles include reactive pore formers.
In a yet still further refinement, the method further comprises translating and/or rotating the substrate to dispose a second portion of the substrate in a vertically downward-facing direction while maintaining the melt pool in the vertically downward-facing direction, wherein the melt pool is progressively transitioned into the second portion of the substrate.
In another further refinement, the energy beam is a laser.
In yet another further refinement, the method further comprises solidifying the melt pool to form a coating on the substrate.
In still another further refinement, the energy beam is directed at the first portion an angle of less than approximately 15 degrees from vertical.
In yet still another further refinement, the substrate is formed of a material; and wherein the melt pool is formed of the substrate material.
Embodiments of the present invention include a system, comprising: an energy beam emitter positioned to direct an energy beam from below a first portion of a substrate upward toward the first portion, wherein the energy beam is configured to form a melt pool facing in the vertically downward-facing direction in the first portion; and a particle sprayer operative to direct a flow of particles from below the melt pool upward toward the melt pool, wherein the system is configured to allow at least some of the particles to rise in the melt pool toward the substrate.
In a refinement, the system further comprises a positioning system coupled to the substrate and operative to translate and/or rotate the substrate to dispose a second portion of the substrate in a vertically downward-facing direction while maintaining the melt pool in the vertically downward-facing direction.
In another refinement, the positioning system is configured to progressively transition the melt pool from the first portion into the second portion of the substrate.
In yet another refinement, the system further comprises a positioning system coupled to the energy beam emitter and operative to translate and/or rotate the energy beam emitter to form the melt pool in a second portion of the substrate disposed in a vertically downward-facing direction.
In still another refinement, the energy beam emitter is configured to progressively transition the melt pool from the first portion into the second portion of the substrate.
Embodiments of the present invention include a system, comprising: means for disposing a portion of a substrate in a vertically downward-facing direction; means for forming a melt pool in the portion of the substrate using a directed energy beam, wherein the melt pool is formed facing in the vertically downward direction in the portion of the substrate; and means for directing a flow of particles upward and into the melt pool, wherein at least some of the particles have a property different than the other particles, and wherein the particles and the melt pool, once solidified, form a matrix material.
In a refinement, the means for forming the melt pool is configured to direct the energy beam upward to the portion of the substrate at an angle of less than approximately 15 degrees from vertical.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary. | One embodiment of the present invention is a unique method for depositing materials in a substrate. Another embodiment is a unique system for depositing materials in a substrate. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for depositing materials within a substrate. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith. | 2 |
BACKGROUND OF THE INVENTION
Small electric coils, such as may be used on electromagnets, solenoids, transformers, motors, relays and the like, are frequently wound with small diameter magnet wire, which is relatively fragile. The magnet wire is usually insulated by a thin coat of varnish or a synthetic resin, which is adequate for insulation between adjacent turns on the coil. Neither the small solid wire nor its insulation is satisfactory for use in making external connections. The end of the magnet wire is therefore joined to a larger diameter flexible lead wire, having a thicker flexible insulation, that is better adapted for making external connections. In the past the junction between the magnet and lead wires has been insulated from the coil as by a layer of fish paper and held in place by a layer of adhesive electrical tape. This did not provide a satisfactory anchor for the lead wire, which, upon being pulled, could break the magnet wire or pull it off of the coil. The lead wire was passed through one or more holes in the flange of the bobbin on which the coil was wound. Knots in the lead wires and various clamping devices were used to prevent pulling the lead wires from the holes. These solutions proved time consuming and unsatisfactory. Terminals were mounted on the bobbin flange and the magnet and lead wires were soldered to the terminals. This was time consuming and left an uninsulated terminal. None of these provided a satisfactory solution to the problem.
SUMMARY OF THE INVENTION
According to this invention the magnet and lead wires of an electrical coil are joined together by a connector having a transverse dimension larger than the diameter of the lead wire, after which the wires are retained by a wire holder mounted upon the coil. The wire holder positions the wires, relieves strain on the magnet wire and insulates the wire junction from the magnet wire wound on the coil. Barriers are provided to insulate a plurality of wire junctions from each other. Means are provided for positioning the holder on the coil. The coil and holder are covered with insulating material, which also retains the holder in fixed position on the coil and provides mechanical protection.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the wire holder.
FIG. 2 is a view of a coil partially cut-away substantially along the line 2--2 in FIG. 4, with a wire holder mounted thereon and showing how the wires are retained by the wire holder.
FIG. 3 is an end view of a solderless connection suitable for use with the wire holder.
FIG. 4 is an end view of the coil in FIG. 2
FIg. 5 is a plan view of another embodiment of the wire holder.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As seen in FIG. 1 the wire holder 10 comprises a rigid plane base 11 of insulating material from the surface of which a pair of spaced projections 12, 13 extend in a perpendicular plane. Ears 14, 15, extending toward each other at the ends of projections 12, 13 respectively, define a gap 16 and partially enclose a space 17 between the projections. Protuberances 18, 19 provide means for attaching the wire holder to a coil 20 as shown in FIG. 2 and described later. A second pair of projections 22, 23, similar to projections 12, 13 are separated from the latter by an insulating barrier 24, perpendicular to the base. The wire holder is preferably molded in one piece.
In FIG. 2 the wire holder 10 is mounted on a coil 20. The coil is formed by winding magnet wire 25 on a coil form or bobbin 26. The bobbin comprises a tubular portion 27 terminating in flanges 28, 29 -- all of insulating material. The wire holder 10 is positioned between flanges 28, 29 to prevent sidewise movement and the protuberances 18, 19 are engaged in holes, such as 31 in flange 28 receiving protuberance 18, to provide an interlocking mechanical fastening, preventing longitudinal motion.
FIG. 3 shows a covering 32 of resilient insulation, such as rubber or vinyl, on a stranded lead wire 33, joined to magnet wire 25 in side-by-side relationship by a solderless connector 34. The solderless connector shown was originally a cylindrical metal tube that was subsequently flattened over the bared adjacent ends of wires 25, 33 to form an electrical connection. Some solderless connectors do not require baring the ends of the wires. For this application at least one transverse dimension of the connection must be larger than the diameter of the insulation covering 32 for reasons to be presented later.
Going back to FIG. 1, the gap 16 between ears 14, 15 is narrower than the outside diameter of the insulation 32, but wide enough to permit passage of the insulated wire 33 laterally therethrough when the insulation is squeezed. The partially enclosed space 17 is of sufficient area to snugly confine the insulated wires 25, 33 and of such dimensions as to prevent passage of the connector 34 lengthwise therethrough. After the insulated wires 25, 33 have been passed laterally through the gap 16 into space 17, as seen in FIG. 2, they are prevented from transverse movement with respect to the base 11. Lengthwise movement of the wires 25, 33 through the space 17 when lead wire 33 is pulled is prevented after the enlarged connection 34 abuts the projections 12, 13, as shown. This relieves tension on magnet wire 25. The connector 34 is insulated from the magnet wire 25 wound on the bobbin 26 by the base 11 and from a similar adjacent connector (not shown) by barrier 24. Flange 28 provides insulation of the connector 34 from external conductors along the axis of the coil 20. The insulated lead wire 33 is passed through a hole 35 in flange 28 to limit the direction from which the lead wire 33 can be pulled with respect to the wire holder 10 and to further define the location of the lead wire. A layer 36 of insulation, such as electrical tape, formed over the magnet wire 25 wound on the bobbin 26, the wire holder 10 and connector 34, prevents outward movement of the wire holder 10 with respect to the coil 20, insulates the magnet wire 25 and the connector 34 from external electrical conductors and provides mechanical protection to the coil. Outward movement of the wire holder 10 from coil 20 could also be prevented by additional interlocking portions such as 18, 31.
FIG. 5 shows in plan another embodiment of the invention, in which the base 11 and projection 12, 13 are the same as in FIG. 1, but an insulating barrier 38, shown as comprising three straight sides, along with the base 11 and projections 12, 13 provide all the insulation required, except from the top, for a connector, such as 34, enclosed thereby. The projections could be integral with the barrier.
The embodiments shown and described are merely exemplary. They do not establish the limits of the invention, which are defined by the claims. Many other embodiments will be readily apparent to those skilled in the art. It will be obvious that the steps recited in the claims need not necessarily be performed in the order in which they are presented. | A method employing a wire holder to retain side-by-side lead and magnet wires, joined together at adjacent ends, in a fixed position with respect to and insulated from a magnet coil on which it is mounted. It relieves strain on the magnet wire. | 8 |
This is a continuation of Ser. No. 513,659 filed Oct. 10, 1974 a division of application Ser. No. 338,360 filed Mar. 5, 1973 now U.S. Pat. No. 3,854,200.
CROSS-REFERENCE TO A RELATED APPLICATION
This application is related to the application for an Improved Beta Brass Alloy and Method of Making Same, U.S. Ser. No. 107,118, filed Jan. 18, 1971 abandoned in lieu of continuation Ser. No. 508,098, now U.S. Pat. No. 4,014,716. Horace Pops is a common inventor for both applications. Both applications are owned by a common assignee.
BACKGROUND OF THE INVENTION
Many techniques have been employed to produce integrated circuit packages. Beam lead, spider, flip chip and others are methods known to those skilled in the art. These known methods are expensive, not entirely reliable and require many separate and distinct processing steps.
For example, the chip and wire technique involves ultrasonic welding of a large number of extremely fine aluminum wires as leads to pads on the semiconductor chip. In the even that any one of these bonds is defective, the entire package would be rejected as a product.
It has previously been suggested by Wetmore in U.S. Pat. No. 3,243,211 that a heat activated, recoverable nonconductive plastic may be used to fasten or hold wire leads together. The heat recoverable material upon being heated will encapsulate and hold the wire leads or conductors in a fixed relative position. Such a construction would be impractical for the small components of an integrated circuit package.
It has also been suggested by Otte in U.s. Pat. No. 3,588,618 that a conductive metal with a shape memory may be used as a lead material. The lead will normally be bent to connect with a second lead at a solder connection. Upon reheating the soldered connection to melt the solder, the leads will separate due to the shape memory effect of the particular alloy utilized to make the lead. As a result, components associated with the separated leads may be easily removed for repair or the like.
So far as it is known, however, no material or process has been devised utilizing the shape memory effect or similar effects for manufacture of integrated circuit packages. This invention is directed to such a process and product.
SUMMARY OF THE INVENTION
In a principal aspect, the present invention comprises an improved method for making an integrated circuit assembly of the type which includes at least one lead attached by a conductive bond such as a solder material to at least one component. The method of the invention utilizes the so-called "shape memory effect" as well as a new effect discovered by the inventors and defined as the "reverse shape memory effect." A lead is fabricated from a chosen alloy and then strained to a first position. Subsequently, the lead is heat treated to initiate the shape memory effect and cause the lead to be positioned for bonding with the component. Alternatively, the shape memory effect may be instituted following application of strain but before positioning the lead for contact with a conductive bond. The lead is then positioned and the reverse shape memory effect is initiated to move the lead into contact with a conductive bond material.
It is thus an object of the invention to provide an improved method for making an integrated circuit assembly which, by virtue of the composition of lead material and the steps in the method, provides a simple and economical process for manufacture of an integrated circuit assembly.
It is another object of the present invention to provide a method for effecting a reverse shape memory effect in a beta brass composition.
Still another object of the present invention is to provide a method for effecting a shape memory effect in a beta brass composition in order to manufacture an integrated circuit assembly.
One further object of the present invention is to provide a method of forming an integrated circuit assembly utilizing the shape memory effect of the beta brass composition.
These and other objects, advantages and features of the invention will be set forth in the detailed discussion which follows.
BRIEF DESCRIPTION OF THE DRAWING
In the detailed description which follows, reference will be made to the drawing comprised of the following figures:
FIG. 1 is a processing flow chart of the steps for fabrication of an integrated circuit assembly in accordance with the present invention;
FIG. 2 is a schematic flow diagram illustrating the methods of assembly set forth in the chart in FIG. 1;
FIG. 3 is a graph of angular movement versus strain, indicating the amount of shape memory and reverse shape memory observed in a number of alloys used to practice the invention;
FIG. 4 is a graph illustrating the amount of strain recovery from a strain manifested by various alloys utilized to practice the invention; and
FIG. 5 is a plan view of a typical lead frame made in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Incorporated herewith by reference is the application by co-inventor Pops, Ser. No. 107,118, filed Jan. 18, 1971. This copending application discloses a number of typical alloys which exhibit a shape memory characteristic. The definitions of shape memory and betatizing as set forth in this co-pending appliation are incorporated herewith by reference also. That is, betatizing constitutes heat treatment of the alloy to provide a substantially continuous beta phase.
Referring to FIGS. 2 and 5, a lead frame 10 is comprised of a frame member 11 and a plurality of leads or fingers 12 extending therefrom. Typically, the frame 10 is stamped or etched from a flat sheet of desired conductive metal or alloy material. The fingers 12 which extend from the frame member 11 connect to various portions or pads of a semiconductor chip 14 as illustrated schematically in FIG. 2. Thus, each of the fingers 12 is engaged by a conductive bond 16 which is, in this instance, solder, to effect an electrical connection with the chip 14.
The fingers 12 can engage the solder or bond composition 16 on the chip only if the fingers 12 move or are moved a sufficient distance out of the plane of the frame member 11 to engage and be bonded to the bond composition or molten solder 16. The movement of the fingers 12 is effected in accordance with the invention by either of two stress assisted, thermally activated processes.
The first of these processes is identified as the shape memory effect or characteristic. As a result of this effect, material which is strained at room temperature, for example, will nearly resume the original, unstrained configuration upon being heated. That is, it will move opposite to the direction of strain. Note also that the strained material is normally an alloy having a beta phase and a martensite phase and that the strain is effected at a temperature generally below the M s temperature or slightly above. This was described in some detail in the prior application cited above.
The second process is the reverse shape memory effect characteristic. This effect is not believed to have been observed or reported previously. The reverse shape memory effect provides that after being strained the material will move in the direction of the strain upon the application of heat. Movement is thus in a direction which is opposite to that due to the shape memory characteristic. Again, strained material is generally in a martensitic phase and the strain is effected at a temperature below the M s or slightly above.
It should be noted that the shape memory and reverse shape memory effects are distinct from the so-called rubber-like (pseudo-elastic or super-elastic) behavior observed in many materials. The rubber-like behavior occurs spontaneously upon release of a stress to substantially reverse the strain applied by a stress. Generally, the stress is applied above the M s temperature in order to observe "rubber-like" behavior.
Following are additional details regarding first the composition, and second, the specific steps in the method of the invention. This will be followed by specific examples of the invention.
Composition
Copper, zinc and silicon are the materials which provide an alloy that can be utilized to practice the method of the invention. Broadly, 62-65% by weight copper, 35-38% by weight zinc and 0.3-0.5% by weight silicon are combined to form a beta brass alloy. The specific composition utilized in most of the experimental work reported herein consists of (1) 62.19% by weight copper, 37.37% by weight zinc, and 0.44% by weight silicon or (2) 63.20% by weight copper, 36.18% by weight zinc and 0.46% by weight silicon. Both of these compositions provide a beta phase brass or mixed alpha plus beta brass at room temperature after betatization. The martensite transformation temperature of this brass is determined as reported in the previous application Ser. No. 107,118, filed Jan. 18, 1971. It is desirable to keep this transformation temperature near room temperature since the process of the invention is related, at least in part, to phase changes of the material. In the alloys discussed above, the start of the martensite transformation upon cooling occurs at temperature about -55° C ± 20° C and 13° C±20° C, respectively.
Method of the Invention
FIG. 1 illustrates three flow charts which show the method of the invention. All of these three methods represented by the flow chart utilize the shape memory effect of the alloy from which the lead frame is made. In addition, two of the methods utilize the reverse shape memory effect.
To review, inducing the shape memory effect in the alloys discussed above involves deformation of the betatized alloy at a temperature below the martensite transformation temperature or slightly above. In either case, the material should contain an appreciable quantity of martensite phase. Upon heating the alloy above the martensite transformation temperature, but generally less than 400° C., the deformed alloy material will almost resume its original configuration. This is illustrated in FIG. 3. The process involved is the transformation of the deformed martensite phase into the beta phase.
To initiate the reverse shape memory effect, deformation of the martensite phase when the alloy is below the transformation temperature is necessary. In addition, the material may also be deformed at temperatures slightly above the martensite transformation temperature. Following deformation, the material is heated to a higher temperature range than that employed to initiate the normal shape memory effect. Typically, this range is between 230° and 550° C. for the alloys tested. The process occurs isothermally, thereby requiring that the alloy be held at temperature for a minimum time. As a result of the reverse shape memory effect, the material moves in the direction of original strain.
The process involves decomposition of the deformed material into a bainitic phase. Relative movement of the alloy occurs during the transformation into the bainitic type phase in accordance with FIG. 3. In contrast to the shape memory effect, movement during the reverse shape memory effect takes place in the direction of original deformation.
For example, if a typical beta brass alloy of the type defined above is strained on the order of 10% at 25° C., it exhibits a 32% shape recovery at 200° C. It moves 32% toward its original position or away from the direction of bending upon heating to 200° C. The same material also exhibits a 45% movement toward the direction of bending or deformation upon continued heating for 1 second at 450° C. This continued movement toward the direction of deformation constitutes the reverse shape memory effect.
Examples
Method I
A ternary brass alloy composition of 63.2% copper, 36.1% zinc and 0.46% silicon was processed to 6 mil strip by conventional melting and rolling methods. In this form, it consists of a duplex mixture of α and β phases. Lead frames of the design shown in FIG. 5 were photo-chemically etched (fabrication by stamping or any other method is permissible) from the α+β material. The lead frame fingers 12 were bent 90° about a mandrel having a 0.040 inch bend radius (corresponding to a 7% strain on the outer fiber). Each of the lead frames was betatized by heating to 830° C. (any temperature in the β phase field is permissible, namely 800° → 850° C.) for 5 minutes, and quenched into water to retain the high temperature β phase.
Deformation of the martensite phase is accomplished by flattening the lead frames at ambient temperature. The lead frames are now positioned above the semiconductor chips 14 and heated to a temperature of 200° C. Shape-memory occurs during heating, causing each of the fingers to move simultaneously into the molten solder 16.
Method II
The α + β alloy strip is fabricated into lead frames by photo-chemical etching. They are betatized and quenched in an identical manner as described above. The same amount of bending (7% strain) is used on the fingers 12 but in this case, it is applied to a β phase material or martensite, if the Ms temperature is above room temperature. Heating to 200° C. produces shape-memory and tends to flatten the fingers. After cooling to room temperature, the (nearly) flat lead frames are positioned above the solder bumps, and the package is placed in a furnace at 450° C. Since "reverse-shape memory" occurs (within 2 minutes) the deformed fingers move in the direction of bending and hence, make contact with the molten solder 16. A minimum movement of 10 mils in the vertical direction is required; this is possible to achieve with the copper-zinc-silicon alloys.
Method III
Alternatively, Method III may be employed and, in fact, is the preferred procedure since betatization is accomplished continuously with minimum distortion. A description of the continuous fabrication technique is contained in the previous patent application Ser. No. 107,118. A strip of α+β is heated to its betatization temperature (830° C), discharged from the furnace, and immediately quenched by cold steel rolls or any other metallic conductor, and a coolant spray. Lead frames are fabricated from the heat treated strip, as described in Methods I and II. Bending of the fingers 90° (7% strain on the other fiber) is subsequently performed at room temperature.
Flattening occurs by a shape-memory process, and is produced by heating the deformed lead frames to 200° C. Following alignment above the chip, the package is placed in an oven for 2 minutes at 450° C. This final step simultaneously produces reverse-shape memory, movement of the fingers in a downward direction, and bonding of the lead frame to the chip.
Note that in each of the examples, the materials are polycrystalline, wrought or worked materials. That is, the product and process of the present invention is possible because the alloys chosen exhibit the reverse shape memory and shape memory characteristics when in a polycrystalline, worked condition. These phenomena are not generally observed in such worked materials nd therefore the product and process of the present invention is considered unexpected.
While in the foregoing there has been set forth a preferred number of embodiments of the invention, it is to be understood that the invention shall be limited only by the following claims and their equivalents. That is, other materials exhibit the shape memory characteristic. Consequently, the methods of the present invention may be utilized to practice the invention. | A method for making an integrated circuit package includes the steps of fabricating lead frames from a copper-zinc-silicon beta brass alloy and soldering the leads thereof to semi-conductor chips by use of the shape memory and reverse shape memory characteristic of the alloy. The composition of the lead frame material and the choice and sequence of fabrication steps may be varied. | 2 |
This application is a continuation of application Ser. No. 09/832,066, entitled “Modification of Portable Communications Device Operation in Vehicles,” filed Apr. 10, 2001, now U.S. Pat. No. 6,973,333, issued Dec. 6, 2005, which is related to the following non-provisional applications also filed on Apr. 10, 2001 by the present inventor:
RELATED APPLICATIONS
The present application is related to the following concurrently filed non-provisional applications filed of even date herewith by the present inventor:
(i) Modification of Portable Communications Device Operation in Identified Geographic Locations, and
(ii) Use of Mobile Terminals to Monitor Vehicular Traffic,
which non-provisional applications are assigned to the assignee of the present invention, and which non-provisional applications are hereby incorporated by reference into the present application as if set forth in their entirety herein.
FIELD OF THE INVENTION
The present invention relates to use of portable communications devices in vehicles. More particularly, the present invention relates to automatic modification of use of such portable communications devices in vehicles. Still more particularly, the present invention relates to modification of use under external control, including such controls as may be applied by a user, vehicle owner, or governmental or other authority.
BACKGROUND OF THE INVENTION
Recent years have witnessed explosive growth in the use of portable electronic devices, many of which include one or more types of voice and/or data communications capabilities. Perhaps the most visible examples of such devices are the virtually omnipresent cellular wireless telephones and personal communications devices. In the U.S. alone, approximately 100 million such devices are commonly in use. In addition, many pocket- or palm-sized devices originally directed to and used primarily for note-taking, personal information management, scheduling and similar activities have been augmented with wireless communications facilities for exchanging information—including exchanges over networks such as the Internet. In other aspects, portable communications devices now include laptop and other portable computers adapted to provide wireless voice and data communications access equivalent in most ways to computers having wired or optical network connections.
Though such widespread use of communications-enabled portable electronic devices has greatly expanded choice and efficiencies in personal and business contexts, such use has not been without some sacrifice in safety to users. In respect of wireless telephones, numerous examples have been reported of accidents occurring while users have been driving automobiles or other vehicles. The U.S. National Highway Traffic Safety Administration (NHTSA), in furtherance of its mission to seek ways to save lives and reduce economic and other traffic-related losses, has issued a report entitled An Investigation of the Safety Implications of Wireless Communications in Vehicles —available at http://www.nhtsa.dot.gov/people/injurv/research/wireless/. As noted in the NHTSA report, there is a body of evidence supporting cellular telephone use as a growing factor in automobile crashes. (In a manner similar to usage in the cited NHTSA report, the term cellular telephone (or cellular phone) will be used to indicate not only now-traditional cellular telephones, but also others in the full range of portable electronic devices having communications or other functionality requiring user attention beyond passive listening.)
Because driving of automobiles while using cellular telephones and similar devices can require a level of skill and care not achievable under all driving circumstances, a number of governmental entities have enacted statutes or ordinances prohibiting or limiting use of cellular telephones by drivers. Conditions under which such restrictions on cellular telephone use apply can vary from one location to another, and may also include restrictions such as those based on time-of-day or day-of-week considerations.
While not the subject of governmental action, other restrictions on use of cellular telephones may be desired, e.g., by parents of teenage children with respect to times or places in which cellular phones may be used. Thus, a parent may deem it appropriate to limit use of a cellular phone by a teenage neophyte driver to reduce distractions from the driving task at hand. In addition, individuals seeking to fully comply with governmental or other restrictions may find it difficult to associate particular restrictions with specific locations, times or vehicle operational parameters.
Heretofore, enforcement of governmental or other restrictions on cellular telephone use has been difficult and lacking in uniformity. Indeed, efforts to promote safety in the use of cellular telephones has been largely limited to cautionary warnings and devising ways to reduce the distracting effects of dialing calls or otherwise manipulating electronic equipment controls. See, for example, “Delphi Attacks Car-Phone Safety Issue,” Information Week , Jan. 15, 2001, p. 30, and “Cell phone regulations: More talk than action,” The Star-Ledger, Jan. 22, 2001, p. 15.
Location-based controls, such as those using global positioning satellite (GPS) functionality, have previously been applied to aspects of vehicle operation, e.g., engine settings or the turning on of operating lights on a vehicle in accordance with changes in location. See, for example, U.S. Pat. No. 5,247,440 issued Sep. 21, 1993 to Capurka, et al. In a related manner, U.S. Pat. No. 5,223,844 issued Jun. 29, 1993 to Mansell discloses use of GPS-derived location information and vehicle status information in reporting to a centralized control center. See further, H. Koshima, et al, “Personal Locator Services Emerge,” IEEE Spectrum , February, 2000, pp. 41-48; and E. A. Bretz, “X marks the spot, maybe,” IEEE Spectrum , April, 2000, pp. 26-36.
One attempt at controlling cell phone use pursued by Bluelinx, Inc. applies a local fixed-position radio source (using well-known Bluetooth technologies) to adjust or switch off cell phones in a defined area. See further, http://www.bluelinx.com and “Taking the Offensive Against Cell Phones,” The New York Times , Jan. 11, 2001, p. Gland G7. The latter reference also describes efforts to discourage use of cell phones by employing local jamming techniques, even at the expense of restricting emergency service calling.
Such prior art location monitoring and control techniques have not readily permitted control of cell phone use for users in transit from place to place, nor has it provided desired flexibility in dealing with emergency conditions or in permitting use in accordance with a range of exceptions to otherwise applicable control regimes.
There exists a need, therefore, for flexible control mechanisms and processes for automatically restricting use of cellular telephones (and other electronic communications devices) in accordance with health, safety, or other management or governmental directives, or in accordance with user (or other) preferences.
SUMMARY OF THE INVENTION
Limitations of the prior art are overcome and a technical advance is achieved in accordance with the present invention, wherein location-determining devices are combined with wireless communications facilities to access database information regarding use of cellular telephones (cell phones) and related devices by individuals in vehicles, subject to desired or imposed conditions.
In accordance with an illustrative embodiment, the present invention employs a global position system (GPS) device to determine the location of a cellular telephone. Cellular communications links (not requiring human participation) then provides location information to a network location having connections to one or more databases describing geographic and/or temporal (or other) limitations on use of cellular telephones. Location-specific information regarding limitations on cellular telephone use is then returned to the target cellular telephone to control its use.
In typical operation, a hand-held cellular telephone for use in illustrative embodiments of the present invention includes both GPS and normal cellular telephone functionality. Also included in such a hand-held device is a controller for directing transmission and reception of information between the cellular telephone and one or more network-based databases and for enforcing restrictions relayed to the target cellular telephone. As will be appreciated, automatic determination of location and applicable local cell phone restrictions permits enforcement of these restrictions at a cellular telephone without active user participation.
Provision is also advantageously made to accommodate emergency or other special circumstances, such as initiating an emergency (e.g., 911) call, by permitting override of, or exceptions to, local restrictions, as appropriate in particular circumstances. In accordance with an optional feature, provision is made to accommodate relaxed restrictions that may apply under prescribed conditions, e.g., when more than one passenger is riding in a vehicle, or when a vehicle is stationary.
Alternative embodiments provide similar control of use of cellular phones (cell phones) using location, restriction and conditions/exemption information evaluated at a vehicle-based or network-based controller, with control messages forwarded to the cell phone for enforcement of use restrictions.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be more completely understood when read in conjunction with the attached drawing, wherein:
FIG. 1 shows an illustrative system arrangement for control of cellular telephone use in accordance with one aspect of the present invention.
FIG. 2 illustrates one mode of operation of a link between automobile traffic on a roadway and a local-restrictions database (LRDB).
FIG. 3 shows another mode of illustrative system operation for effecting cell phone controls using a customer restriction server and aspects of a communications billing system.
FIG. 4 shows an illustrative cell phone organization, including normal cell phone functionality as well as additional functional elements selectively employed in embodiments of the present invention.
FIG. 5 shows an illustrative regions table for use in illustrative embodiments of the present invention.
FIG. 6 shows an illustrative legal restrictions table for use in illustrative embodiments of the present invention.
FIG. 7 shows an illustrative customer restrictions table for use in illustrative embodiments of the present invention.
FIGS. 8A-C show flowcharts for illustrative update procedures to regions, legal restrictions and customer restrictions tables of the type shown in FIGS. 5 , 6 and 7 , respectively.
FIG. 9 is a flowchart of an illustrative average speed determining routine useful in some embodiments of the present invention.
FIGS. 10-17 are flowcharts of illustrative processing for use with the illustrative routine of FIG. 9 for determining the state of variables for use in imposing restrictions on cell phone use.
FIG. 18 is a flowchart of an illustrative routine for imposing restrictions on cell phone use based on the states of illustrative variables determined in the processing of FIGS. 10-17 and on other conditions and determinations.
FIGS. 19 and 20 are flowcharts of other routines for imposing restrictions on cell phone use based on the states of illustrative variables determined in the processing of FIGS. 10-17 and on other conditions and determinations.
FIG. 21 is an illustrative screen for submitting customer restrictions to a customer restrictions database using a web browser interface.
FIG. 22 is an alternative restrictions processing system for in-vehicle use that permits simplification of cell phone configurations.
DETAILED DESCRIPTION
FIG. 1 shows an illustrative system architecture for control of cellular telephone use within an operating space (illustratively, a cell) in accordance with aspects of the present invention. There, a representative wireless cell 100 is shown as including within its boundaries a plurality of cellular phones (cell phones), identified as 110 - 1 through 110 - n . These cell phones communicate via antenna 120 in well-known fashion with cellular base station 125 or mobile telephone switching office (MTSO). While standard analog or digital cellular signals and protocols, or any of a variety of other mobile communications devices, signals and protocols may be used to communicate between cell phones 110 - i and base station 125 , the present description will illustratively proceed in terms of well-known TDMA or CDMA practice and procedures when any such election of formats and protocol may be necessary or appropriate.
Cell phones 110 - i in FIG. 1 are advantageously augmented in accordance with an aspect of the present invention with global positioning system (GPS) receiving functionality for receiving one or a plurality of position-indicating signals from external sources, typically satellite sources well known in the art. Though standard GPS satellite signals, such as those employed in the widely used NAVSTAR system, are well adapted for use at a GPS receiver included in cell phones 110 - i , local or regional terrestrial signals may be used in some applications of the present inventive techniques. Such terrestrial signals provide location information transmitted from fixed or identified locations to cell phone-based receivers.
Messages received at base station 125 from one or more cell phones are advantageously forwarded to a legal restrictions server (LRS) 150 . LRS 150 is arranged to store information relating to restrictions on cellular telephone usage in cell 100 and/or other designated geographical area(s). Further, LRS 150 includes standard message handling facilities for delivering relevant information about such local restrictions to cell phones within respective designated geographic areas.
Access to LRS 150 may be by direct local connection or by land line (or wireless, including satellite) links to a remote server location. In some illustrative embodiments, messages received at base station 125 will be connected via a voice/data network 140 to LRS 150 . Network 140 will, as particular application requirements may require, assume the form of the public switched telephone network (PSTN), the Internet, or more specialized voice and/or data networks. In a typical application, network 140 will be the PSTN and messages between LRS 150 and cell phones 110 - i will be converted to/from signaling messages, such as Signaling System 7 (SS7) TCAP messages of a form well known in the network arts. Other particular messaging formats and protocols will be employed for all or some of the links between cell phones 110 - i and LRS 150 when Internet Protocol (IP) or other data messages are employed. Messages between base station 125 and cell phones will, of course, be in whatever form is appropriate to the wireless link 120 , base station 125 and the respective cell phones. In appropriate cases, wireless link 120 may include analog, personal communications system (PCS) or other digital formatted signals.
Based on messages including location and cell phone identification information, which messages are initiated by powered-up cell phones among the cell phones 110 - i , and which messages are delivered to LRS 150 , determinations are made as to restrictions to be imposed on use of the respective cell phones. Thus, if a determination that cell phone 110 - 4 is in a vehicle in a governmental jurisdiction that prohibits use of cell phones in vehicles, then one or more control messages are sent to cell phone 110 - 4 to render the cell phone inoperative. However, if cell phone 110 - 4 is identified in LRS 150 as being under the control of a police (or other safety or emergency agency), or if it is otherwise identified as exceptional under governing ordinances, then such control messages will be modified to permit the agency function to be performed using the cell phone. Other control aspects of determining status of a cell phone and in using a message control structure to effect desired controls will be discussed in the sequel.
FIG. 2 shows an illustrative application of principles of the present invention employing local terrestrial signals from a short-range wireless transmitter 230 via antenna 240 , which antenna is arranged to provide control signal propagation over a portion of a roadway 200 defined approximately by a radius from antenna 240 based on the transmission range transmitter 230 . Vehicles 220 - i moving to the left (such as 220 - 1 and 220 - 2 ) and to the right (such as 220 - 3 through 220 - 5 ) on roadway 200 are within the range of influence of transmitter 230 . Messages based on restrictions applicable to vehicles in the range of transmitter 230 are received by powered-up cell phones in vehicles 220 - i . Thus, restrictions articulated by LRS 250 are imposed by these messages on cell phones seeking to operate within the jurisdiction of the transmission range. Of course, the transmission range 210 need not be restricted to the dimensions suggested by FIG. 2 , but may extend over a larger area. Applicability of restrictions for particular cell phones may be determined at LRS 250 using messages received from handshaking messages sent from powered-on cell phones and forwarded to LRS 250 using a network such as 140 in FIG. 1 , or restrictions may be applicable to all non-exempt cell phones. In the latter circumstance, LRS will again determine which, if any, cell phones are exempt from some or all restrictions based on criteria known at LRS 250 .
FIG. 3 further illustrates the manner in which use restrictions may be imposed on cell phones, including location-aware cell phones, such as illustrative cell phone 310 in communication with cellular base station 320 (and from there to the PSTN and/or other wired or wireless networks). In particular, it proves convenient to provide control messages from customer restrictions server 330 to base station 320 to effect desired controls in the same manner as messages from LRS 250 in FIG. 2 and LRS 150 in FIG. 1 . Server 330 , in turn, is conditioned by messages from a control console or other system control terminal (illustratively represented by web browser 350 ) in FIG. 3 . Messages from browser 350 are conveniently directed over a network, illustratively the Internet 340 or such other messaging network as may prove convenient.
In operation, the illustrative configuration shown in FIG. 3 is arranged to receive messages under the control of an operator or automatic provisioning system (or other control system) to direct CRS 330 to send appropriate control messages to respective cell phones, such as 310 in FIG. 3 . CRS 330 , in turn, receives information from billing system 360 regarding the state of the subscriber account associated with cell phone 310 . Billing system 360 employs normal resources of billing systems, such as database facilities 370 for storing cell phone identification, customer identification, cell phone usage restrictions and cell phone usage data. Restrictions, or exceptions to restrictions, on cell phone usage associated with a particular subscriber account may be entered as part of the normal provisioning of subscriber service accounts, or may from time-to-time be modified or overridden by commands included in messages from system administrators, governmental authorities, or other authorized persons operating through web browser 350 .
Any restrictions imposed on cell phones interacting with base station 320 may, of course, be location dependent. In particular, location information supplied by cell phones (using GPS or other location determinations) forwarded to base station 320 (and thence to CRS 330 ) may be applied as a condition on restrictions to be applied to particular cell phones. Thus, when a subscriber powers-on a cell phone in a locale where cell phone use is restricted, or where a cell phone is operated while entering such a locale, the location information supplied from the cell phone is advantageously used in determining the applicability of restrictions to the subject cell phone.
While system operator control (including normal provisioning and governmental directives) has been described as being a primary controlling factor in determining restrictions in the preceding illustrative network arrangements, it will be understood that, in appropriate cases, a subscriber (including a corporate or other group subscriber) may direct that cell phone use be restricted during operation of a vehicle. Thus, browser 350 may be operated under the control of the subscriber. Motivation for such restrictions as may originate with a subscriber will include an undertaking by the subscriber to obtain lower insurance rates for operated vehicles, or because of prior adverse experience with operation of motor vehicles in all or designated locations.
FIG. 4 is a block diagram of an illustrative cell phone for use in illustrative embodiments of the present invention. Shown there is a cell phone 400 communicating with a base station over link 410 using a so-called long-range wireless channel transceiver 430 . Transmitter-receiver arrangement 430 is a traditional receiver-transmitter structure well known in the art tailored to the particular system structure and organization (e.g., CDMA, TDMA or other). Link 410 provides user voice and data communications information as well as control messages and downloaded table information to be described below.
The term “long-range” channel transceiver 430 is used to distinguish from transceiver 460 styled a “short-range” wireless channel transceiver. In practice, transceiver 460 is used to communicate over link 405 in exchanging information locally with a transceiver such as one adhering to the Bluetooth interface standard promulgated by the Bluetooth Special Interest Group (SIG). See generally, Miller, B. A, and C. Bisdikian, Bluetooth Revealed , Prentice-Hall, Inc., 2001; and the official Bluetooth Website at www.bluetooth.com. As noted there, Bluetooth radio functionality is advantageously built into a small microchip and operates in a globally available frequency band. Examples of Bluetooth-compatible products and development tools announced by vendors include those by Ericsson and Toshiba (such as Part #PA3053U-1PCC Bluetooth wireless PC card for personal computers).
Bluetooth or similar short-range transceivers 460 provide links to transmitters such as transmitter 230 in FIG. 2 described above, and to external sensors, data collectors and decision elements (including computers). As will be described below, it also proves advantageous to include short-range communications links between a cell phone of the type shown in FIG. 4 and local transceivers (or transmitters) in vehicles in which cell phone use is to be subject to control in accordance with present inventive teachings.
Block 440 in FIG. 4 represents the normal voice interface for user communications over a cellular or similar wireless network. Graphical user interface (GUI) 450 provides well-known graphical output to cell phone users. In appropriate cases, graphical input can likewise be provided in the manner of well-known hand-held personal digital assistants (PDIs) using a stylus or menu selections by hand or other pointing device.
Block 415 represents a geographic location sensor, such as a global positioning satellite (GPS) receiver. GPS receiver functionality has previously been combined with cell phone functionality in a single hand-held unit as described, for example, in U.S. Pat. No. 6,128,515, issued Oct. 3, 2000 to Kabler, et al. Such combination described in the last-cited patent to Kabler, et al is not directed to control of cell phone use in accordance with present inventive principles. Blocks 425 , 420 and 470 represent storage for tabular or otherwise structured information representing user or customer (e.g., subscriber) restrictions, legal restrictions, and region definitions, respectively. Other particular control information reflecting other requirements, preferences, constraints or conditions for use of cell phone 400 will, of course, occur to those skilled in the art to meet particular location (including altitude or spatial), temporal or other requirements. Thus, blocks 425 , 420 and 470 (and corresponding tables or other data structures) are merely illustrative. It proves advantageous to have storage and corresponding data structures represented by blocks 425 , 420 and 470 populated by data stored in accordance with user preferences upon subscription or initial account provisioning, or as received over channels 405 and 410 in the course of use and relocation of cell phone 400 .
Controller block 475 represents system control for the functional blocks shown in the illustrative cell phone of FIG. 4 . Controller 475 will, as is typical of many such systems, include a processor and memory for storing control routines and data. Such control routines are advantageously programmable by user or system input to expand, and otherwise alter operation of cell phone 400 as required or desired by user or wireless system operators, or as a result of new or replacement laws, regulations or other constraints on cell phone use. Other functional units shown in FIG. 4 may include separate processors and memory, or one or more such functional units may share processors with each other or with controller 475 .
FIGS. 5 , 6 and 7 show illustrative data entries and table formats for contents of memory represented by blocks 425 , 420 and 470 shown in FIG. 4 .
In particular, FIG. 5 illustrates one format and illustrative region information. A region is a geographic area in which particular rules relating to restrictions on cell-phone use apply. In FIG. 5 , the geographic regions are conveniently defined in terms of a 6-tuple of latitude and longitude coordinates (i.e., three coordinate pairs) in the right-hand column. Each region is identified in the left-hand column by a Region ID associated with the associated three-coordinate (triangular) boundaries of a region. While only one region is shown explicitly, it will be understood that many such regions will typically be defined by respective sets of coordinates. The illustrative format is consistent with the International Standards Organization (ISO) document 6709 Information Processing—Representation of Latitude and Longitude . See further, http://www.iso.ch for more details.
While the particular triangular regions used by way of example prove convenient in many contexts, no such geometrical limitation is inherent in application of present inventive teachings. Thus, in particular cases it may prove convenient to employ rectangular, hexagonal, or other readily defined geographic regions. The shape and size of regions will vary from one application to another, as well as from one location to another, and need have no necessary relationship to cell phone cell boundaries (or micro cell boundaries in other wireless organizations). In particular cases, one or more regions will correspond to a municipality, state or other governmental entity.
Some regions may be localized to a school zone or other area in which exceptional care is required while driving. If regions are not mutually exclusive, and if a high-restriction region, such as a school zone, is included in a larger region, such as a moderate-restriction municipality, then it proves appropriate in most cases to test for conditions applicable to the use of a cell-phone in a vehicle in all applicable regions. This may include, e.g., a state-wide region, a municipal region and a school zone region. The restrictions of the region having the most stringent restrictions will usually then be applied.
Other techniques for defining boundaries and locating cell phone users may also be used in connection with embodiments of the present invention. Thus, for example, location information available from MapInfo Corporation that is used for locating callers (including wireless callers) to emergency telephone numbers (such as 911) may be employed in appropriate cases.
As noted above, it proves advantageous to store region information in tables or other data structures in a cell phone for use in embodiments of the present information. To avoid the need for irrelevant region information, it proves convenient upon powering on a cell phone or upon passing from one cell (or other wireless area) to receive new or updated region boundary information for those regions that are likely to be of current interest from base stations acknowledging the presence of a cell phone. In the case of cell phones interacting over a link such as 410 in FIG. 4 with a base station, such downloaded information may wholly or partially overwrite or augment information previously stored in a regions table or the like shown in FIG. 4 as 470 . In other cases, it proves convenient to have such region information downloaded (e.g., over links such as 405 in FIG. 4 ) from short-range wireless transmitters associated with an area in which a cell phone is currently present.
In similar manner, Legal Restrictions Table 420 or other appropriate data structure stores information relating to legal restrictions on cell phone use in particular geographical regions, subject to conditions appropriate to particular circumstances, as illustrated in FIG. 6 . That figure shows a tabular format with three columns: Region ID, Restriction Type, and (illustratively) Speed Threshold. As in illustrative region table shown in FIG. 5 , a region is conveniently referred to in terms of an integer Region ID, as are Restriction Types. Exemplary restriction types are assigned illustrative integer values and corresponding restrictions illustratively assume numerical values, as:
Type 1—Provide periodic warning signals (e.g., a tone or multi-tone signal generated by controller 475 and supplied to audio interface 440 ) when a prescribed threshold speed value is exceeded. For the example of region 3204 and for restriction type 1, the threshold speed is 20 km/hr.
Type 2—Provide notification and terminate an active call. Again, an illustrative threshold speed (30 km/hr) is given as a condition in FIG. 6 ; when this speed threshold is exceeded controller 475 advises the cell phone user that cell phone use is restricted under present circumstances and that the call is about to be terminated; the call is then automatically terminated.
Type 3—Block call origination with or without audio announcement. When a user attempts to place a call during a period when restrictions apply, controller 475 in FIG. 4 provides an audio tone or recorded announcement.
Type 4—Block call reception without notice. Calls to the target user will be treated in the same manner as when the cell phone is not powered on. Thus, calls may simply not be answered, or sent to a voice message recorder or be otherwise redirected.
FIG. 7 shows an illustrative customer restrictions table, which is similar in format to legal restrictions table shown in FIG. 6 . Again, the format and particular restrictions and conditions will vary from customer to customer, and also may vary from one time to another, as customer's preferences may dictate. The entries in the table of FIG. 7 need not differ in kind from those in the legal restrictions table of FIG. 6 , but the source of the restrictions is the cell phone customer, typically the actual user of the cell phone.
Customer inputs may reflect many of the same concerns as those to which legal restrictions are addressed, i.e., speed, proximity to school zones, hazardous weather conditions and the like, but may be more restrictive than legal restrictions generally applicable to all. In addition, customer restrictions may act as a reminder to a customer of conditions that may apply with particular force to certain users of a cell phone. Thus, for example, when a late hour or low light conditions cause driving to be especially challenging for a particular subscriber, restrictions imposed by that customer serve as a reminder (when cell phone use is restricted) that extra care may be required.
In other cases, a customer may wish to apply such higher restrictions on teenage or beginning drivers who have yet to develop the necessary skills to use cell phones when driving under conditions appropriate for more experienced drivers. Employer-customers may seek to encourage safe driving practices by controlling use of cell phones by employees while in vehicles. Particular customer-defined restrictions on cell phone use may prove attractive by making such customers eligible for reduced vehicle insurance rates.
As with legal restrictions, customer-defined restrictions are advantageously downloaded over short-range link 405 or long-range link 410 during active calling or power-on conditions. Such customer restrictions are not, however, broadcast to all active users in a region or cell (or microcell, etc.) or all active users in a set of regions in the vicinity of a cell, but rather are communicated only to the customer setting restrictions on the use of his/her cell phone.
FIGS. 8A-C present flowcharts of illustrative operations at cell phones, upon powering on, or from time-to-time, associated with receipt of updates to over short-range wireless links from a source within or external to a vehicle, or over long-range wireless links (e.g., from a wireless system base station). FIG. 8A relates to regions table updates, FIG. 8B relates to legal restrictions table updates, and FIG. 8C relates to customer restrictions table updates.
FIG. 9 presents a flowchart of a routine for determining average speed as an input to be tested against legal or customer restrictions entries, e.g., entries in tables shown in FIGS. 6 and 7 . Basically, position determinations are made at steps 910 and 940 using the GPS functionality at times s seconds apart and the distance between the two points is determined. Knowing this distance and the time, s, average speed is readily determined.
FIGS. 10-20 are flowcharts illustrating operations useful in determining and effecting legal and customer-imposed restrictions on cell phone use. These flowcharts are conveniently connected by exit and entry points A, B, . . . , as part of an infinite loop with multiple entry points. Further, it proves convenient for discussion of these FIGS. to define four Boolean variables corresponding to the restriction types 1-4 described above. Thus, the illustrative variables and corresponding meanings are:
Active Warning—Provide periodic warnings during an active call;
Active Disconnect—Provide a notification, then disconnect an active call;
Block Origination—Block attempts to originate calls; and
Block Call Reception—Block reception of all calls to the subject cell phone.
In FIG. 10 , as in following flowcharts, it is assumed that a determination of the region ID for the region in which the subject cell phone is located has been made. Then, in FIG. 10 , a test is made at step 1000 for a legal restriction matching the region ID. If the test yields a Yes result, a further test is made at 1010 for an average speed in excess of the threshold for the current legal restriction. If the latter test yields a yes result, Active Warning is set to TRUE at 1020 . If the average speed test at 1010 yields a No result, then a return is effected to entry point C.
Continuing in FIG. 10 , if a legal restriction is to apply in all regions, the variable Region ID=0 for all regions. Again, restriction Type 1 is tested for at 1030 , and a speed test performed at 1040 . If the speed test yields a true result, then Active Warning is set to TRUE at 1050 and a return to entry D is effected; otherwise, a return to entry C is effected with Active Warning not set.
FIG. 11 illustrates the same form of testing as in FIG. 10 , except entries in customer restrictions table, e.g., those in the table of FIG. 7 , are used for comparison. All returns are to entry point D. Additionally, a NO result at tests 1110 and 1140 is used to explicitly set the Active Warning variable to FALSE before returning to entry D, thus inhibiting or preventing the issuance of a warning to a user.
FIG. 12 shows testing for Type 2 restrictions, and setting of Active Disconnect to TRUE. Otherwise, processing shown in FIG. 12 is the same as that shown in FIG. 10 , but returns are to entry points E or F, as appropriate to results shown in FIG. 12 .
In like manner, FIG. 13 shows testing for Type 2 restrictions, and setting of Active Disconnect to TRUE or FALSE based on restrictions found in a customer restrictions table. In this respect processing shown in FIG. 13 is the same as that shown in FIG. 11 , but returns are to entry point F.
FIGS. 14 and 15 repeat the tests of FIGS. 10 and 11 , respectively, in testing for restriction Type 3, and set Block Origination to TRUE when condition thresholds are exceeded. Returns are to entry points G or H ( FIG. 14 ), or only to H ( FIG. 15 ).
FIGS. 16 and 17 again repeat the tests of FIGS. 10 and 11 , respectively, in testing for restriction Type 4, and set Block Call Reception to TRUE when condition thresholds are exceeded. Returns are to entry points I or A ( FIG. 16 ), or only to A ( FIG. 17 ).
FIG. 18 is a flowchart showing illustrative processing during an active call. After start ( 1800 ) a waiting period of M seconds is introduced at 1810 , after which a test for an active call is made at 1820 . If this test yields a NO, a return to 1810 is effected. If the test at 1820 yields a YES result a test is made at 1830 for a TRUE value for Active Disconnect. If this test yields a YES, then a further test is made at 1840 for the existence of an emergency call, such as 911. If the test at 1840 yields a YES, then a return to 1810 is effected. If the test at 1830 yields a NO, then a further test is made at 1850 for a TRUE value for Active Warning. If Active. Warning is not TRUE, then processing at 1850 returns to 1810 ; if the test at 1850 yields a YES result, then the same kind of test made at 1840 for an emergency call is made at 1855 . If the test at 1855 yields a YES result, then processing again returns to 1810 , otherwise, a warning is issued at 1860 in the form of a tone or tones, or as a recorded voice announcement to the cell phone user. After a P-second delay introduced at 1870 , processing is returned to 1810 . The closed loop back to 1810 is then repeated.
If upon testing at 1840 a NO result is obtained, indicating that the call is not an emergency call then a warning is issued to the cell phone user and, after an N-second delay introduced at 1880 , the call is disconnected at 1890 . Then a return to 1810 causes renewed testing for an active call.
While the tests at 1840 and 1855 in FIG. 18 are illustratively shown as tests for 911 emergency calls, the test can be for any number of other special conditions, such as call to specified numbers for emergency auto repairs, calls by a police or other emergency worker or the like. While audio (tones or voice messages) are described as illustrative warning indications, graphical outputs through GUI 450 may as well be used (or used in addition to audio outputs) to signal a warning. Further, more than one type of warning, can be issued to indicate warnings of particular conditions.
FIG. 19 is a flowchart depicting illustrative processing for an incoming wireless call. There, after starting at 1960 , block 1970 indicates waiting for an incoming call. If a Block Call Reception=True condition exists, when the test at 1980 is performed, then notice of the incoming call (as by ringing, tones, etc.) is inhibited, as shown at 1985 . If Block Call Reception=False, the user is alerted to the arrival of the incoming call in the usual manner, as shown at 1990 .
FIG. 20 is a flowchart depicting illustrative processing for an outgoing wireless calls. There, after starting at 2000 , block 2010 indicates waiting (e.g., in a loop) for an outgoing call. If a Block Origination=True condition exists, when the test at 2020 is performed, then a further test for an emergency call is performed at 2030 . If the call is an emergency call, then origination of the call is accomplished as shown by 2050 . If the call sought to be originated is not a qualifying emergency call, then origination is not allowed, and waiting for an outgoing call is continued at 2040 and 2010 . If a Block Origination=True condition is not found at 2020 , then the call origination is allowed, as indicated again at 2050 .
As described above in connection with FIG. 2 , a Legal Restrictions Server (LRS) is conveniently employed to store information regarding definitions of geographic regions and applicable legal restriction to each of the respective regions. While shown in FIG. 2 as a single discrete server connected directly to a short-range transmitter, LRS 250 is advantageously connected as part of a network of servers. Thus, a plurality of LRS servers may serve a local area, such as a municipality, and some may be located in critical areas where legal restrictions are different from those in adjacent areas. Thus, an LRS may be located on approaches to a school zone, a portion of a highway or through road having a need for critical or variable traffic restrictions. Similarly, LRS servers will advantageously be networked to other LRS servers in a local area and in broader geographical areas to reflect emerging or wide-area needs for cell phone restrictions. It will prove convenient to provide for short- and long-term updates to LRS databases by police and/or other governmental authorities.
Flexibility in imposing restrictions on cell phone use is also provided, in accordance with present inventive teachings, in respect of customer restrictions servers (CRSs). As described above in connection with FIG. 3 , it proves convenient to provide means for introducing and updating customer restrictions through a web browser, such as 350 in FIG. 3 . FIG. 21 shows an illustrative browser page downloaded to a customer (after normal authentication) by a CRS, such as 330 in FIG. 3 . In FIG. 21 , provision is made to enter the cell phone number of the subject cell phone, and selections for restrictions to be applied. Since the provision of warnings for an active call (without disconnect) and disconnecting after notification are mutually exclusive options, these are presented as customer selectable radio buttons or the like in FIG. 21 . Blocking call originations and blocking incoming calls are illustratively individually selectable by a customer.
While FIG. 3 suggests access to the CRS via a separate network link, such as a personal computer hosting a web browser, it will be understood that browsers may also be installed in cell phones—with web pages displayed on graphical user interfaces, such as GUI 450 in FIG. 4 . Thus a customer may choose to log in to the CRS website using a web-enabled cell phone to effect changes to CRS database entries for the calling cell phone or another cell phone owned or controlled by the customer.
While processing of inputs and storage of table or other structured information relating to cell phone restrictions has been described above as advantageously being performed in the subject cell phone itself, this is not always preferred. Thus, it proves advantageous in some embodiments of the present invention for a cell phone that is powered on while in a vehicle to exchange messages with a short-range transceiver located in the vehicle for purposes of off-loading at least some of the required processing and storage. FIG. 22 shows an arrangement including a vehicle-based transceiver for communicating with a plurality of sensors and a vehicle-borne cell phone, all elements being conveniently arranged to share a common bus 2200 .
The desirability of employing vehicle-based processing in place of having all data collecting, storage, analysis and messaging relating to cell phone use restrictions present in the cell phone itself becomes evident in a number of illustrative embodiments. In a first aspect, it proves simpler to have reduced storage and processing resources on the cell phone; such simplifications reduce cost, increase reliability and permit functionality and design of cell phones to be more standardized. Moreover, vehicle-based processing, sensing, and storage addresses the problem of in-vehicle use more directly; it does not require functionality in a cell phone not always or frequently being used in a vehicle under operation.
Still further, a growing number of automobiles include GPS functionality for assisting in vehicle location, providing traveling directions, and for other purposes. Thus, some embodiments of the present invention will not require cell phones that include GPS functionality—in addition to permitting a reduction in memory and processing resources. In fact, use of other vehicle-borne processor memory for such purposes as engine monitoring, other mechanical system monitoring and warning systems, hands-free dialing of cell phones and other purposes can be shared in appropriate cases to include processing of cell phone use restrictions.
Accordingly, FIG. 22 shows a block diagram of an illustrative in-vehicle system for gathering information relating to cell phone use restrictions applicable to cell phones in a vehicle. Provision will be made in appropriate cases to provide power to the system of FIG. 22 , to the extent it may require powering, whether the vehicle is operating or not. Such stationary operation of the system of FIG. 22 permits in-vehicle cell phones that are powered on to perform a registration or interactive hand-shaking sequence with the system of FIG. 22 . Thus, it proves advantageous to have short-range transceiver 460 in the cell phone of FIG. 4 identify itself through short-range transceiver 2230 (shown with in-vehicle antenna 2235 ) to processor 2210 , and to provide legal and customer restriction information of the type shown by way of illustration in FIGS. 6 and 7 and described above for storage in memory 2220 .
Identification of in-vehicle cell phones will be with respect to cell phone number or other convenient identification indicia. Such identification and related legal and customer restriction information, in combination with other information available to the system of FIG. 22 , enables processor 2210 to form command messages for transmission to in-vehicle cell phones to enforce appropriate warnings and/or prohibitions on originating or receiving cell phone calls. These command messages are advantageously delivered over a link from transceiver 2230 to respective ones of short-range transceivers (such as 460 in FIG. 4 ) in cell phones that have identified themselves to the in-vehicle system of FIG. 22 and have supplied appropriate restrictions information.
Receipt of legal and customer restrictions information is advantageously accomplished by each cell phone in a vehicle as described above over long-range links such as that to cell base stations, or over links between a short-range transmitters (such as 230 in FIG. 2 ) to transceivers (such as 460 in FIG. 4 ) in each reporting cell phone. Such restrictions information received at the cell phones is forwarded to the in-vehicle system of FIG. 22 over short range links between transceiver 2230 and short-range transceivers (such as 460 ) in the respective cell phones.
Processor 2210 is a general-purpose processor capable of performing selected ones of the operations performed by cell phone controller 475 , in the previous descriptions of that controller. The selection of functions to be performed by processor 2210 will, of course, depend on which operations are reserved for inclusion in a reduced-complexity cell phone. Processor 2210 will generally support and supervise the various sensors and communications elements shown in FIG. 22 (and their outputs). In appropriate cases processor 2210 will supplement or replace processors typically found in one or more of the sensors 2240 , 2245 , 2250 and other sensors represented by block 2290 .
GPS receiver 2280 advantageously derives vehicle position information through interaction with the GPS system. Vehicle-based GPS receivers are, of course, well known, and will illustratively assume the form of a NAVSYS Corporation Automatic Vehicle Locating System GPS receiver. Outputs from GPS receiver 2280 are used to determine vehicle position for comparison with region information downloaded by cell phones located in the vehicle, downloading being accomplished as described above, and delivery to the in-vehicle system of FIG. 22 being accomplished over short-range links in the same manner as for restrictions information. Efficiencies are realized in the use of an in-vehicle system in accordance with the illustrative embodiment of FIG. 22 because only one set of applicable regions information need be retained; all cell phones are obviously in or near the same regions.
Average speed determinations described above in connection with FIG. 9 may, of course, be performed as well in the system of FIG. 22 , but appropriate speed determinations also are advantageously derived from a vehicle sensor 2245 , using other resources available in the vehicle, such as a digital readout from the vehicle's speedometer. Such speedometers and averaging of successive speed samples over an interval are well known in the art.
As will be understood from the prior discussions, restriction conditions relating to speed thresholds are merely illustrative of the broader class of legal and customer restrictions. Speed thresholds of zero (0 km/hr), or vehicle motion of any kind, may prove appropriate as conditions associated with particular restrictions in some applications of the present inventive principles. One particular motion-related condition that proves useful in restricting use of cell phones in automobiles is the occurrence of reverse motion, i.e., backing-up of an auto, as when parallel parking or when leaving a parking slot in a parking lot.
In fact, it will prove convenient in some cases to place restrictions on cell phone use when an automobile has its reverse gear engaged. In other cases, restrictions will apply when any gear state other than Neutral or Park is extant. Gear status readouts from automobile transmissions are described, for example, in U.S. Pat. No. 6,018,294 issued Jan. 25, 2000 to Vogel, et al.
Those skilled in the art will choose from among the illustrative conditions (and other conditions appropriate for effecting particular legal restrictions) along with vehicle location (region). In some cases, location will become irrelevant to a determination of restrictions to be imposed—as when an exceptionally high vehicle speed is detected, a condition warranting cell phone use restriction in any region. Other restrictions will be provided over short-range or long-range wireless links to a vehicle when unusual circumstances are reported. Thus, if a portion of a road or bridge is determined by traffic authorities to be dangerous due, for example, to a prior accident or icy conditions, then a region will advantageously be defined where cell phone use restrictions are imposed to encourage a higher degree of attention to driving. As with other legal restrictions, these conditions are advantageously downloaded over short-range link 405 or long-range link 410 during active calling or power-on conditions. When in-vehicle systems like those shown in FIG. 22 are used, such ad hoc restriction conditions are conveniently passed to the system using short-range links, as for normal restriction information.
Automobile anti-skid devices can also be used to indicate conditions that may warrant restrictions on cell phone use when none would otherwise apply. Thus, for example, if an anti-skid device in a vehicle (illustratively represented by Anti-Skid sensor 2240 in FIG. 22 ) reports a predetermined number of skid incidents over a predetermined period of time, then that device advantageously indicates the need for heightened attention to driving conditions necessitating a termination (with or without warning) of any ongoing call, and blocks future call originations for a predetermined time, or until the anti-skid device reports changed circumstances. In operation, each such skid operation will be reported to processor 2210 , which will accumulate such reports and test for the number of such incidents in a predetermined time interval, or for the severity (e.g., the duration of any such incident) and issue a command to the cell phone to appropriately restrict cell phone usage.
Though many other sensors may be used to supply information for testing by processor 2210 , a seat occupancy sensor may prove especially useful in modifying cell phone use restrictions. Thus sensors associated with each seat position in a vehicle are used to determine which seats are occupied. Some sensors are weight-threshold-sensitive so that a seat occupied by a small child are separately indicated from those occupied by adults or older children. In any event, when a cell phone is used in a vehicle in which only the driver's seat is occupied, then it may be assumed that the driver is the person using the cell phone. In that event, restrictions are imposed in the normal course, depending on location, legal and customer restrictions and any other available relevant information, e.g., skidding. If, on the other hand, more than one adult person is found to be seated, a modified application of the cell phone use restrictions may be imposed. To further refine the identification of the user of an active cell phone it will prove useful in some cases to employ a plurality of antennas at short-range transceiver 2230 to locate the source of signals from individual cell phones powered on in the vehicle.
Another useful technique for identifying the location within a vehicle from which particular attempts at cell phone use are attempted employs the coupling of infra-red sensors with short-range radio links (e.g., Bluetooth technology). In particular, one or more directional infra-red sensors are arranged to receive infra-red signals from infra-red transmitters or transceivers built into cell phones in the vehicle. The Bluetooth standard includes specifications and a Bluetooth profile (illustratively, the so-called Generic Object Exchange Profile, or GOEP) for interfacing well-known IrDA infra-red devices with Bluetooth devices. See, for example, the Miller, et al book, supra at pp. 243-245. By combining signals from one or more infra-red signal transmitters in cell phones at a plurality of IrDA receivers (advantageously combined with any directional information available from Bluetooth or similar radio receivers in the vehicle), more certain location of a cell phone user is derived.
Further off-loading of computational and memory requirements may be effected by providing location information from a vehicle to a base station, such as 125 in FIG. 1 , which is in possession of legal and/or customer restrictions (and any appropriate external condition information such as weather or traffic accident information) from network databases. Network processor(s) then determines appropriate restrictions to be imposed on particular cell phones and sends message commands to respective ones of powered-on cell phones. Alternatively, restrictions derived by network processors can be imposed (with or without warnings) at the base station end of a link to the cell phone.
While the foregoing descriptions of determining and imposing restrictions on cell phone use have proceeded in terms of now traditional cell phones structures and protocols, including TDMA, CDMA, GSM, IS-136, Personal Digital Cellular (PDC) and PCS and other well-known schemes, it should be understood that present inventive principles are applicable to a wide range of mobile communications, computing, digital assistant and entertainment devices and systems.
Further, not all devices subject to control using present inventive teachings need be primarily communications devices. Controls on use of portable devices using present inventive teachings will be effected in some cases though simple communications features and facilities in the controlled portable devices after determinations of location and related restrictions information external to the controlled devices.
Moreover, such inventive principles and techniques are applicable to such devices and systems using emerging and future communications structures, techniques and protocols. Thus, for example, so-called Third-Generation Wireless systems and techniques are readily adapted to include functionality and methodologies described in illustrative embodiments above. Such Third Generation Wireless are described, for example, in “The Complete Solution for Third-Generation Wireless Communications: Two Modes on Air, One Winning Strategy,” IEEE Personal Communications , December 2000, pp. 18-24 and references cited therein. Use of Location Management techniques useful in applying present inventive techniques in next generation wireless communications systems is discussed in V. W-S. Wong, et al, “Location Management for Next-Generation Personal Communications Networks,” IEEE Network , September/October 2000, pp. 18-24. | Restrictions on use of a cellular telephone in a vehicle, such as an automobile, are imposed using a global position system (GPS) device to determine the location of a vehicle in relation to geographic regions in which legal or customer restrictions on cellular telephone use are to be imposed. Network or local short-range wireless transmitters supply information to a cellular telephone describing potentially applicable restriction information retrieved from network databases. In response, a cellular telephone determines applicability of such restrictions and applies them to further use of the cellular telephone while such restrictions continue to apply. Alternative arrangements allow vehicle-based or network based processing of region and restrictions information to yield command messages to cellular telephones to control their further use. | 7 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to a navigation system used to navigate a hierarchical menu such as a directory structure or a pull-down menu. The menu navigation system of the present invention may be implemented in software executing on a standalone software program or on a client server application. More particularly, the menu navigation system of the present invention allows a user to access different levels in a hierarchical menu system without retracing back to the top level of the hierarchy.
BACKGROUND OF THE INVENTION
[0002] Hierarchical systems are used to organize items by function or theme in order to facilitate efficient locating of functions or locations. Hierarchical systems are used to organize documents into directories or folders and to organize functions into pull-down menus.
[0003] Conventionally one of two navigation systems are used to navigate through the various levels of a menu tree. By far the most popular menu navigation system is the so-called collapsing menu system which, for example, is used by many traditional personal computer applications. The distinguishing characteristics of this system are that the navigation always commences from the initial or root level and that the menu collapses or disappears after a selection is made.
[0004] Computer software frequently includes dozens of functions. The sheer number of features makes it desirable to organize the functions into a hierarchy of categories to facilitate efficient searching. In a collapsing menu system each level in the hierarchy is presented as a level in the pull-down menu.
[0005] [0005]FIG. 1A shows a top or root level 10 of a hypothetical menu. Each level 10 of the menu provides a list of menu choices 12 . Each menu choice 12 could be an end node such as a function whose selection initiates some action, or the menu choice 12 could lead (point) to another level 10 providing a further list of menu choices 12 . Selection of an end node will cause the pull-down menu to collapse back to the root level.
[0006] [0006]FIG. 1B shows the pull-down menu of FIG. 1A with several levels of the hierarchical menu expanded. The menu structure of FIG. 1B collapses back to the root level shown in FIG. 1A once an end node is selected. The defining characteristic of such a conventional navigation system is that navigation is one-way, and always starts from the root level to an end node. This method of navigation becomes cumbersome if the desired function or destination is buried several levels down from the root directory.
[0007] To address this shortcoming, conventional operating systems such as Microsoft Windows® provide short-cuts in the form of pre-defined function keys or icons. Such short-cuts enable the user to directly access the desired function associated with the short-cut.
[0008] In the absence of a pre-defined short-cut, the user must resort to navigating the menu structure. The problem with the collapsing menu system is that navigation must always commence from the root level. Consequently more experienced users are unable to take advantage of their knowledge of the hierarchical structure to directly access a given level.
[0009] [0009]FIG. 2A shows a conventional path menu system 20 used to navigate through the directory structure of a disk. Similarly, FIG. 2B shows a conventional universal resource locator (URL) command which operates similarly to the DOS path command of FIG. 2A. The conventional disk operating system (DOS) uses a path menu system 20 to navigate between various folders. Each folder represents a different level in the hierarchy. A given folder may contain one or more sub-folders. To access a target or destination level the user must know the path, i.e., the names of the each of the folders from the root folder to the target folder. A system of displaying the contents of each folder is provided to guide the user through the hierarchy. Namely, by typing a command such as DIRECTORY (DIR) the user is provided with the contents of the present folder and the path leading to the present folder. The user may proceed to a sub-level in the hierarchy or may retrace his/her steps to a preceding level by knowing the path.
[0010] Navigation using the path menu system requires the user to memorize and enter complex hierarchical sequences. This method of navigation is time consuming not suitable for users who have not memorized the path. Moreover, this method becomes extremely cumbersome as the number of levels increases.
[0011] Accordingly, one object of the present invention is to provide a more efficient way of navigating hierarchical menu systems.
SUMMARY OF THE INVENTION
[0012] A method for navigating within a multi-level hierarchical collapsing menu structure is disclosed. Each level in the menu structure contains plural items, each item being at least one of a function, a pointer to a location, and a pointer to another level.
[0013] The method of the present invention includes a step of providing a graphical user menu system displaying the items of a given level and enabling selection thereof, wherein access of the given level requires sequential access of each of the levels preceding the given level in the hierarchy. An Active Path is dynamically constructed as a sequence of active links as items are selected using the graphical user menu system, with one active link correspond to each of the items selected. The active links provide direct access to a function corresponding level or menu item without the need to navigate using the graphical user menu system.
[0014] According to a further aspect of the invention, pre-defined short-cuts are provided which enable direct access to a given menu item. The Active Path is dynamically constructed when one of the pre-defined short-cuts are executed, with one active link corresponding to each of the menu items necessary to access the given menu item using the graphical user menu system.
[0015] Navigation using the Active Path is accomplished by at least of one of rolling over and selecting an active link using a pointing device. Rolling over a given active link triggers the display of sibling menu items on the level associated with the given active link. Selecting a given active link triggers the execution of a function associated with the given active link.
[0016] These and other aspects of the present invention will be explained with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIGS. 1A and 1B are view of a conventional collapsing menu system;
[0018] [0018]FIG. 2A is a view of a conventional path menu system;
[0019] [0019]FIG. 2B is a view of a conventional universal resource locator address;
[0020] [0020]FIG. 3 is a block diagram of a conventional computer architecture;
[0021] [0021]FIG. 4 is a view of the Active Path menu system of the present invention;
[0022] [0022]FIGS. 5A and 5B are views showing how the Active Path is assembled as the user navigates the collapsing menu system; and
[0023] FIGS. 5 C- 5 F are views showing how the Active Path is used to navigate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] [0024]FIG. 3 is a block diagram of a computer 32 on which the software of the present invention operates. In the preferred embodiment, the main logic of the computer 32 is embodied by a general-purpose, programmable microprocessor 34 , which in conventional practice will have an on-board memory cache (not shown) and which may be associated with one or more mathematics or other special-purpose coprocessors (not shown).
[0025] The processing logic generally represented by processor 34 is connected by a bus structure 36 to the various other components of the computer 32 . The schematic representation of bus 36 is shown in FIG. 3 as a simple and unitary structure, but in conventional practice, as is known to those in the art, there usually are several buses and communication pathways 36 , operating at different speeds and having different purposes. Further, bus 36 may be segmented and controlled by respective bus controllers, as is also known in the art.
[0026] Computer 32 will also have a random access memory unit or units 38 connected to the bus 36 . RAM 38 (which may be DRAM, SDRAM or other known types) typically has loaded into it the operating system of the computer 32 and executable instructions for one or more special applications designed to carry out the invention. Computer 32 also has electronic read-only memory 40 for storing those programs such as the BIOS which are non-volatile and persist after the computer 32 is shut down.
[0027] In alternative embodiments of the invention, one or more components of the invention's logic may be “hard-wired” into the ROM 40 instead of loaded as software instructions into RAM 38 . ROM 40 can consist of or comprise electrically programmable read-only memory (EPROM), electrically erasable and programmable read-only memory (EEPROM) of either flash or nonflash varieties, or other sorts of read-only memory such as programmable fuse or antifuse arrays.
[0028] In a typical architecture, a computer program suitable for carrying out the invention will be stored on a mass storage device 42 , such as an optical disk or magnetic hard drive. Bus 106 connects mass storage device 42 to RAM 38 . The computer 32 is connected to various peripheral devices used to communicate with an operator, such as display 44 , keyboard 46 , and pointing device (mouse) 48 .
[0029] In operation, operating system software such as Microsoft Windows® executes on the computer 32 , and the user interacts with the operating system using the display 44 , keyboard 46 , and pointing device (mouse) 48 .
[0030] [0030]FIG. 4 shows the Active Path menu system 100 of the present invention which is visually similar to the conventional (DOS) path menu system of FIG. 2. However, whereas the conventional DOS path is merely a passive display of the hierarchical levels, the Active Path 100 is a graphical user interface enabling the user to directly access any of the hierarchical levels in a given path. Moreover, the Active Path 100 enables the user to directly re-execute the last function without the need to navigate to the function through the menu system, and without the need for a pre-defined short-cut.
[0031] As will be explained below, the Active Path 100 may be used in conjunction with a conventional navigation system such as the above-described collapsing menu system or path menu system.
[0032] The Active Path 100 consists of a sequential listing of active links 102 , each active link 102 providing direct access to a corresponding level in the hierarchical path and to all of the menu items on the level (sibling menu items). The last active link 102 in the Active Path 100 is termed an end link 103 . The Active Path 100 is dynamically assembled and displayed as the user navigates using the conventional menu screens. The Active Path 100 is assembled automatically without the need for any additional user interaction as the user navigates using the collapsing menu system.
[0033] In contrast, a conventional short-cut such as a function key, icon, or the like is static in that it only provides access to a single pre-defined item (function/location) within a given level and does not provide the user with the full range of items available within a given level. Moreover, the definition of a short-cut requires user interaction.
[0034] The Active Path 100 is automatically constructed as the user navigates between the various levels 10 of the conventional collapsing menu system. The first active link 102 corresponds to the root level, and each subsequent active link 102 corresponds to a user selected menu item 12 which may be a location or a classification (sublevel) of functions. As will be explained below, the end link 103 points either to a function or a location.
[0035] The Active Path 100 of the present invention may be used in place of the menu system 10 to navigate through classes of functions and execute a selected function. Moreover, the Active Path 100 may also be used to navigate to a desired location such as a web address or directory folder.
[0036] FIGS. 5 A- 5 E show how the Active Path 100 may be used to navigate to classes of functions. In the embodiment depicted in FIGS. 5 A- 5 D the Active Path 100 is used in conjunction with a conventional collapsing menu system. One of ordinary skill in the art will appreciate that the location of the Active Path 100 in relation to the collapsing menu system 10 and its graphical representation are not critical to the operation of the Active Path 100 .
[0037] By manner of illustration, FIG. 5A shows how the Active Path 100 is sequentially assembled as menu items 12 - a, 12 - b, and 12 - c are selected from the collapsing menu system. Active link 102 - a corresponds to menu item 12 - a selected from the initial or root level 10 - a. Likewise, active link 102 - b corresponds to menu item 12 - b selected from level 10 - b, and active link 102 - c corresponds to menu item 12 - c selected from level 10 - c. Construction of the Active Path 100 occurs automatically as the user navigates through the menu system 10 . It should be noted that active link 102 - c is the end link 103 in the Active Path 100 .
[0038] Turning now to FIG. 5B, the menu system (pull-down menu tree) 10 collapses when the user selects end node 12 - c, whereas the Active Path 100 persists. As will be described, the active links 102 enable the user to directly access levels 10 - b and 10 - c, without having to navigate from the root level 10 - a. Moreover, end link 103 enables the user to re-execute the function associated with 12 - c directly without the need for a pre-defined short-cut.
[0039] In operation, the active links 102 of Active Path 100 are accessed using the mouse 48 and mouse buttons 48 a, 48 - b (FIG. 3).
[0040] Each of the active links 102 in the Active Path 100 may be accessed by either rolling over the active link 102 with the pointer of the pointing device 38 , or by immediately selecting the active link 102 . As shown in FIG. 5C rolling over the active 102 simply entails manipulating the mouse 48 to position the software pointer 50 over the active link 102 . Rolling over an active link 102 - b causes the sibling menu items on the level corresponding the active link 102 - b to be displayed. It should be noted that simply rolling over an active link 102 does not alter the Active Path 100 , it merely causes the sibling menu items to be displayed.
[0041] Selection of an active link 102 is accomplished by, for example, positioning the software pointer 50 over the active link 102 and actuating (and releasing) one of the mouse buttons 48 - a, 48 - b. Selection of an active link 102 causes different results depending on whether or not the selected active link 102 is the end link 103 in the Active Path 100 . If the selected active link 102 is not the end link 103 , then selection will cause the sibling menu items 12 on the associated level 10 to be displayed and will trigger the construction of a new Active Path 100 . For example, selection of menu item 12 - b in FIG. 5C will result in the generation of the Active Path 100 shown in FIG. 5D.
[0042] Selection of an end link 103 will cause the immediate execution of the associated function (last function executed). Thus, the last executed function may be re-executed by simply selecting the end link 103 in the Active Path 100 (FIG. 5C).
[0043] As described above, the Active Path 100 is dynamically constructed as the user navigates the collapsing menu system, and is subsequently retained after the menu tree collapses back to the root level. In addition, the Active Path 100 may optionally be constructed each time a short-cut such as a function key or the like is used. This requires the use of a look-up table 38 a (FIG. 3) stored in RAM 38 . The look-up table 38 a stores each of the pre-defined shortcuts and the associated data necessary to create the active path 100 . According to a presently preferred embodiment, the Active Path 100 constructed is the same as would be constructed by accessing the function through the collapsing menu system.
[0044] In operation, the look-up table 38 a would originally be created by the software developer during initial definition of each of the pre-defined short-cuts (function keys). Moreover, as will be explained, the look-up table 38 a may be updated by the user to reference newly created short-cuts.
[0045] According to a further aspect of the present invention, the Active Path 100 may be used to define a short-cut on-the-fly. Once the Active Path 100 has been constructed, for example, by navigating the conventional collapsing menu system, the user may store the end link 103 as a shortcut within the lookup table 38 a. According to a presently preferred embodiment, this is accomplished by a combination of commands. Thus, for example, the user could be prompted to define a short-cut identifier by clicking mouse button 48 - b over end link 103 . The Active Path 100 then stores the association between the function (or location) and the user-selected shortcut in the rewriteable table 38 a.
[0046] As noted previously, the Active Path 100 of the present invention may similarly be used to navigate to a location. Notably, the Active Path 100 is created in the same manner regardless of whether the menu items 12 are functions or locations. The difference in using the Active Path 100 to navigate to locations arises after the Active Path 100 has been generated when the user selects an active link 102 . More particularly, the difference is only manifested if the selected active link 102 is not the end link 103 .
[0047] Notably, in the case of navigating to a location, selecting an active link 102 (other than the end link 103 ) triggers the access of the associated location. In contrast, when navigating to a class of functions, selection of an active link 102 (other than the end link 103 ) merely triggers the display of the sibling menu items on the associated level. See, FIG. 5C.
[0048] By manner of illustration, FIG. 5E shows a user selecting a location 102 b 1 by manipulating the pointing device 48 to position the pointer 50 over 102 b 1 and actuating the mouse key 48 a (or 48 b ). As shown, the selection of a location results in the creation of a new active path 100 .
[0049] [0049]FIG. 5F shows a user selecting an active link 102 b 2 where the active link 102 points to a classification of items, i.e., to a sublevel in the hierarchy. Notably, in FIG. 5E 102 b 1 was a location, and its selection within the active path 100 results in the direct navigation to the associated location. In contrast, in FIG. 5F 102 b 2 is a classification of functions, and its selection results in the display of the sibling menu items. Again, the selection of active link 102 b 2 is accomplished by selecting a location 102 b 2 by manipulating the pointing device 48 to position the pointer 50 over 102 b 2 and actuating the mouse key 48 a (or 48 b ).
[0050] One of ordinary skill in the art will appreciate that the Active Path 100 of the present invention may be used in standalone applications such as operating systems, word processors, spreadsheets or the like. Moreover, the Active Path may also be used in a client-server environment. Notably, the Active Path 100 may be used to navigate functions provided on a web site or to navigate between different web addresses.
[0051] In standalone applications, a range of Windows Application Programming Interface functions such as “CreateWindow” and other graphics library function calls may be used to create the graphic components of the Active Path. Any combination of mainstream programming languages such as Visual Basic, Java, C, or Delphi may be used to create the dynamic components and rollover effects.
[0052] In client server applications, the code for the Active Path may be part of the initial HTML file in form of a JavaScript/DHTML combination or separate JavaScript files (.js) containing the arrays describing the Active Path 100 and Cascading Style Sheets files (.css) containing the graphic attributes of the Active Path 100 . This data may be cached locally after the initial server call.
[0053] For internet browser applications, such as Internet Explorer or Mozilla the referred embodiment foresees a replacement of the address bar with the Active Path 100 to avoid redundancy, allow the user to focus on the content and make browsing more efficient. For Internet Explorer, this would involve utilizing its custom Explorer Bars integration feature.
[0054] In standalone applications, a range of Windows Application Programming Interface functions such as “CreateWindow” and other graphics library function calls may be used to create the graphic components of the Active Path. Any combination of mainstream programming languages such as Visual Basic, Java, C, or Delphi may be used to create the dynamic components and rollover effects.
[0055] Windows Explorer may replace the Address Bar with the Active Path. This could make the display of the folder window redundant. The user may better take advantage of the screen real-estate by rolling over and “browsing” through the levels of the collapsing menu system.
[0056] In client server applications, the code for the Active Path may be part of the initial HTML file in form of a JavaScript/DHTML combination or separate JavaScript files (.js) containing the arrays describing the Active Path and Cascading Style Sheets files (.css) containing the graphic attributes of the Active Path. This data may be cached locally after the initial server call.
[0057] For internet browser applications, such as Internet Explorer or Mozilla the preferred embodiment foresees a replacement of the address bar with the Active Path to avoid redundancy, allow the user to focus on the content and to make browsing more efficient. For Internet Explorer, this would involve utilizing its custom Explorer Bars integration feature.
[0058] The Active Path of the present invention may also be used to navigate audio interfaces. A preferred embodiment for audio interfaces would allow users to navigate to the end point of a path. A certain input command, such as pressing a certain key, would read the sequence and level of the selected path. Users can then select any level of the path and navigate to a new endpoint.
[0059] Although a preferred embodiment of the Active Path navigation system of the present invention has been specifically described and illustrated, it is to be understood that variations or alternative embodiments apparent to those skilled in the art are within the scope of this invention. Since many such variations may be made, it is to be understood that within the scope of the following claims, this invention may be practiced otherwise than specifically described. | A method for navigating within a multi-level hierarchical collapsing menu structure is disclosed. Each level in the menu structure contains plural items, each item being at least one of a function, a pointer to a location, and a pointer to another level. The method of the present invention includes a step of providing a graphical user menu system displaying the items of a given level and enabling selection thereof, wherein access of the given level requires sequential access of each of the levels preceding the given level in the hierarchy. An Active Path is dynamically constructed as a sequence of active links as items are selected using the graphical user menu system, with one active link correspond to each of the items selected. The active links provide direct access to a function corresponding level or menu item without the need to navigate using the graphical user menu system. | 6 |
BACKGROUND OF THE INVENTION
Digital television networks enable two-way communication so that a subscriber can interact or “request” information from the network equipment. Typically, a menu—also called an interactive program guide (IPG) or electronic program guide (EPG), is employed to list the content available for viewing. The IPG application enables a viewer to browse listings of available programming and associated information and to select content for viewing. The subscriber can utilize the menu to request additional information regarding the offerings.
Typically, the menu has a numeric listing by channel of broadcast television programming. Additionally, a subscriber may have access to narrowcast applications. Narrowcast programming is point-to-point streaming of video from a storage point in the network to a specific subscriber. Narrowcast applications are made possible by compression techniques such as the standards developed by the Moving Picture Experts Group (MPEG), which enables more content to be delivered to viewers with little or no degradation in picture quality. The resulting increase in transmission capacity allows narrowcast programming to be placed alongside broadcast programming for delivery to viewers.
A dominant narrowcast application is the delivery of content on demand (COD). This content may span many categories, including movies on demand (MOD), video on demand (VOD), subscription video on demand (SVOD), free on demand (FOD), and network-based digital video recording (NDVR). The ability to deliver narrowcast content to viewers creates the opportunity to provide a targeted viewing experience that allows advertisement and promotional content to be selected for and delivered to each viewer.
In a narrowcast serving environment, it is desirable that large communities of set-top boxes can access the same library of content. Typically, arrays of servers are formed to address a given set of set-top boxes and any set-top that has access to the array has access to the same set of media titles. If COD is available, the subscriber can order the content and watch it on his/her television or monitor. Otherwise, the subscriber would need to rent, purchase, or view the movie from another source.
When a customer, via his set-top box, orders a particular media title, a session is said to have been created. That session may be composed of several smaller “title sessions”—title sessions are discrete packages of content or data that collectively makeup the content requested for the overall session—e.g. one title session for the advertisement prior to the main program and another for the main program. Each title session is served by a single node on the array and all the data associated with the particular title is served through that node to a particular set-top box.
Historically, there have been several limitations to media arrays. First, the assignment of the serving of the title session to a particular node on the array makes that node a single point of failure with respect to the title session. For example, if a viewer was watching the Super Bowl on a stream being served from a node in the array and that node has a failure, then the viewer's stream would be lost and his session would be interrupted.
While the array implementations presently known in the art have collaboration between content storage devices for the purposes of reading data (e.g. RAID55, IO Shipping, and network RAID), these architectures still require that all the data pass through the assigned serving node. Thus, the serving nodes do not collaborate on the output of a single file or title session to a given client session. The serving node is therefore a single point of failure with regard to a particular client session despite the resilience of the content storage devices accessible by the serving node.
Thus, there is a need in the art for methods, systems, and apparatuses for sending content that provides for the seamless delivery of content to a user when a serving node fails. Similarly, there is a need in the art for methods, systems, and apparatuses for allocating partitioned content among two or more nodes to provide a fault resilient content delivery system.
SUMMARY OF THE INVENTION
The present invention provides methods, systems, and apparatuses (hereinafter “method” or “methods” for convenience) for delivering content to a user. One embodiment of the present invention provides a system for delivering content comprising a plurality of nodes comprising at least a first node and a second node; a content file that has been partitioned into an ordered list of parts comprising at least a first part and a second part; and a client device for receiving the parts over the network, wherein the first node and the second node are synchronized to send the fist part and the second part to the client device in-order over a network.
Another embodiment of the present invention provides a node for delivering content to a user, wherein the content is partitioned into an ordered list of parts with one or more parts allocated to each of a plurality of nodes so that the user can play the parts in the order that they are received, with the node comprising a stream pump for sending one or more parts in-order to the user over a downstream network; a processor for determining when the node should send the one or more parts over the network; a first communications interface for connecting the to the network; and a data retriever for receiving the one or more parts allocated to the node.
Yet another embodiment of the present invention provides a method for delivering content over a network, the method comprising the steps of partitioning the content into an ordered list of parts; allocating the parts among a plurality of nodes; synchronizing the plurality of nodes so that the parts can be sent in-order form the plurality of nodes to a user; and delivering the content to the user by sending the parts in-order from the plurality of nodes over the network to the user.
A further embodiment of the present invention provides a method for sending content to a user, the method comprising the steps of partitioning the content into an ordered list of parts comprising a first part and a second part; allocating the first part to the first node; allocating the second part to the second node; sending the first part from the first node to the user; determining which of a plurality of nodes is the second node; indicating to the second node that it should send the second part to the user; and sending the second part from the second node to the user.
Another embodiment of the present invention provides a method for recovering from fault in a content serving array comprising at least a first node, a second node, and the third node, the method comprising the steps of partitioning the content into an ordered list of parts comprising at least a first part and a second part; allocating the first part to the first node; allocating the second part to the second node; indicating to the first node that it should send the first part to a client device; failing to receive by the second node an indication that the first node has sent the first part to the client device; indicating to the third node that it should send the first part to the client device; sending by the third node the first part to the client device; and sending by the second node the second part to the client device.
It will be apparent to those skilled in the art that various devices may be used to carry out the methods, systems, and apparatuses of the present invention, including cell phones, personal digital assistants, wireless communication devices, personal computers, set-top boxes, or dedicated hardware devices designed specifically to carry out embodiments of the present invention. While embodiments of the present invention may be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each embodiment of the present invention can be described and claimed in any statutory class, including systems, apparatuses, methods, and computer program products.
Unless otherwise expressly stated, it is in no way intended that any method or embodiment set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method, system, or apparatus claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of embodiments described in the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other advantages and features of the invention will become more apparent from the detailed description of exemplary embodiments of the invention given below with reference to the accompanying drawings.
FIG. 1A illustrates one embodiment of a system in which various embodiments of the present invention may be implemented.
FIG. 1B shows a logical overview of a computer system which may be used to carry out various embodiments of the present invention.
FIG. 2A illustrates a system for delivering content according to one embodiment of the present invention.
FIG. 2B illustrates another system for delivering content according to one embodiment of the present invention.
FIG. 3 illustrates the components of a node of one embodiment of the present invention.
FIG. 4 illustrates one embodiment of the present invention for delivering content over a network.
FIG. 5 illustrates one embodiment of the present invention for sending content to a user.
FIG. 6 illustrates one embodiment of the present invention for recovering from fault in a content serving array.
FIG. 7 illustrates one embodiment of the present invention for determining a firing order.
FIG. 8 illustrates one embodiment of the present invention for delivering information from a single node in the system.
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration of specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized, and that structural, logical and programming changes may be made without departing from the spirit and scope of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Before the present methods, systems, and computer program products are disclosed and described, it is to be understood that this invention is not limited to specific methods, specific components, or to particular compositions, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.
As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an encoder” includes mixtures of encoders, reference to “an encoder” includes mixtures of two or more such encoders, and the like.
The methods of the present invention can be carried out using a processor programmed to carry out the various embodiments of the present invention. FIG. 1A is a block diagram illustrating a computing device for performing the various embodiments. This exemplary computing device is only an example of an operating environment and is not intended to suggest any limitation as to the scope of use or functionality of operating environment architecture. Neither should the operating environment be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the disclosed computing device.
The methods can be operational with numerous general purpose or special purpose computing system environments or configurations. Examples of well known computing systems, environments, and/or configurations that may be suitable for use with the method include, but are not limited to, personal computers, server computers, laptop devices, set-top boxes, and multiprocessor systems. Additional examples include set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
The methods may be described in the general context of computer instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. The method may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices.
The methods disclosed herein can be implemented via a general-purpose computing device in the form of a computer 101 . The components of the computer 101 can include, but are not limited to, one or more processors or processing units 103 , a system memory 112 , and a system bus 113 that couples various system components including the processor 103 to the system memory 112 .
The processor 103 in FIG. 1A can be an x-86 compatible processor, including a PENTIUM IV, manufactured by Intel Corporation, or an ATHLON 64 processor, manufactured by Advanced Micro Devices Corporation. Processors utilizing other instruction sets may also be used, including those manufactured by Apple, IBM, or NEC.
The system bus 113 represents one or more of several possible types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures. By way of example, such architectures can include an Industry Standard Architecture (ISA) bus, a Micro Channel Architecture (MCA) bus, an Enhanced ISA (EISA) bus, a Video Electronics Standards Association (VESA) local bus, and a Peripheral Component Interconnects (PCI) bus also known as a Mezzanine bus. This bus, and all buses specified in this description can also be implemented over a wired or wireless network connection. The bus 113 , and all buses specified in this description can also be implemented over a wired or wireless network connection and each of the subsystems, including the processor 103 , a mass storage device 104 , an operating system 105 , application software 106 , data 107 , a network adapter 108 , system memory 112 , an Input/Output Interface 110 , a display adapter 109 , a display device 111 , and a human machine interface 102 , can be contained within one or more remote computing devices at physically separate locations, connected through buses of this form, in effect implementing a fully distributed system.
The operating system 105 in FIG. 1A includes operating systems such as MICROSOFT WINDOWS XP, WINDOWS 2000, WINDOWS NT, or WINDOWS 98, and REDHAT LINUX, REDHAWK LINUX, FREE BSD, or SUN MICROSYSTEMS SOLARIS. Additionally, the application software 106 may include web browsing software, such as MICROSOFT INTERNET EXPLORER or MOZILLA FIREFOX, enabling a user to view HTML, SGML, XML, or any other suitably constructed document language on the display device 111 .
The computer 101 typically includes a variety of computer readable media. Such media can be any available media that is accessible by the computer 101 and includes both volatile and non-volatile media, removable and non-removable media. The system memory 112 includes computer readable media in the form of volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read only memory (ROM). The system memory 112 typically contains data such as data 107 and and/or program modules such as operating system 105 and application software 106 that are immediately accessible to and/or are presently operated on by the processing unit 103 .
The computer 101 may also include other removable/non-removable, volatile/non-volatile computer storage media. By way of example, FIG. 1A illustrates a mass storage device 104 which can provide non-volatile storage of computer code, computer readable instructions, data structures, program modules, and other data for the computer 101 . For example, a mass storage device 104 can be a hard disk, a removable magnetic disk, a removable optical disk, magnetic cassette, magnetic storage device, flash memory device, CD-ROM, digital versatile disk (DVD) or other optical storage, random access memories (RAM), read only memories (ROM), solid state storage units, electrically erasable programmable read-only memory (EEPROM), and the like.
Any number of program modules can be stored on the mass storage device 104 , including by way of example, an operating system 105 and application software 106 . Each of the operating system 105 and application software 106 (or some combination thereof) may include elements of the programming and the application software 106 . Data 107 can also be stored on the mass storage device 104 . Data 104 can be stored in any of one or more databases known in the art. Examples of such databases include, DB2®, Microsoft® Access, Microsoft® SQL Server, Oracle®, mySQL, PostgreSQL, and the like. The databases can be centralized or distributed across multiple systems.
A user can enter commands and information into the computer 101 via an input device (not shown). Examples of such input devices include, but are not limited to, a keyboard, pointing device (e.g., a “mouse”), a microphone, a joystick, a serial port, a scanner, and the like. These and other input devices can be connected to the processing unit 103 via a human machine interface 102 that is coupled to the system bus 113 , but may be connected by other interface and bus structures, such as a parallel port, serial port, game port, or a universal serial bus (USB).
A display device 111 can also be connected to the system bus 113 via an interface, such as a display adapter 109 . For example, a display device can be a cathode ray tube (CRT) monitor, a Liquid Crystal Display (LCD), or a television. In addition to the display device 111 , other output peripheral devices can include components such as speakers (not shown) and a printer (not shown) which can be connected to the computer 101 via Input/Output Interface 110 .
The computer 101 can operate in a networked environment using logical connections to one or more remote computing devices. By way of example, a remote computing device can be a personal computer, portable computer, a server, a router, a set top box, a network computer, a peer device or other common network node, and so on. Logical connections between the computer 101 and a remote computing device can be made via a local area network (LAN) and a general wide area network (WAN). Such network connections can be through a network adapter 108 . A network adapter 108 can be implemented in both wired and wireless environments. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets, and the Internet 115 .
For purposes of illustration, application programs and other executable program components such as the operating system 105 are illustrated herein as discrete blocks, although it is recognized that such programs and components reside at various times in different storage components of the computing device 101 , and are executed by the data processor(s) of the computer. An implementation of application software 106 may be stored on or transmitted across some form of computer readable media. An implementation of the disclosed methods may also be stored on or transmitted across some form of computer readable media. Computer readable media can be any available media that can be accessed by a computer. By way of example, and not limitation, computer readable media may comprise “computer storage media” and “communications media.” “Computer storage media” include volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, solid state devices, or any other medium which can be used to store the desired information and which can be accessed by a computer.
According to one embodiment of the present invention, a title session is broken down into an order list of parts, with one or more parts allocated to one or more nodes according to a predetermined plan. The determination of the plan may be made prior to or during the user's request for a given part of content, or while the user is receiving the content. A selection representing the content of potential interest to the user, such as a movie, is made by the user and the parts comprising the content are served to the user according to the predetermined plan by the nodes prescribed by the plan.
FIG. 1B illustrates a content-on-demand (COD) content serving array 200 of one embodiment of the present invention. In the system shown in FIG. 1B , one or more content provider(s) 110 provide content to a COD content serving array 200 in various formats via various communication means 115 . For example, the content serving array 200 may receive RF signals by satellite, ATM data from ATM networks, local feeds, and other information via terrestrial link. The content provider 110 may also provide the content by tape, DVD, or any other desired or suitable media.
The content is received by a content receiver 130 and forwarded to the content serving array 200 for storage in the content storage 220 . Although depicted as being distinct from the content serving array 200 , the content receiver 130 may be included in the content serving array in various embodiments of the present invention. In the content serving array 200 , the content can be processed and reformatted as necessary in various embodiments of the present invention. For example, content can be received in digitally compressed format, de-multiplexed by a de-multiplexer, and stored in any convenient format or formats, such as MPEG-1 or MPEG-2. It will be appreciated, however, that the present invention is not limited to any particular content format.
Content is stored on the content storage devices 220 - 1 . . . 220 - n of the current embodiment. Each of the content storage devices may include a tape drive, a JBOD just a bunch of disks), a RAID (redundant array of inexpensive disks), a JBOD of solid state disks, a RAID of RAM disks, or any suitable type of storage device. The content may be stored in an encrypted format and then may be streamed in an encrypted format via a network 300 to premises devices 400 - 1 , . . . , 400 - n . Alternatively, the content may be encrypted as each session is streamed or may not be encrypted at all.
The data received by the content serving array 200 may include, in addition to the content itself, barkers and content descriptive data regarding the content received in various embodiments of the present invention. This content descriptive data may include, for example, information indicative of the content type, title, source, participants, summary, rating, time length, etc., herein referred to as “metadata.”
In addition, the data received by the content serving array 200 may include trick files in various embodiments of the present invention. Trick files are precompiled files used in narrowcast systems to implement trick mode playback, such as fast-forward and rewind, in an efficient fashion. Rewinding or fast forwarding by playing the normal playback file at a higher rate of speed, in the manner done by cassette players and VCRs, is not an ideal or efficient choice when servicing multiple users, since it places significantly higher demands on the components in the system. In a COD system that services multiple users, trick files are used to achieve fast forwarding and rewinding. The trick files are composed of a subset, for example every other complete frames, of the normal content file. When the trick file is played at normal speed, it appears that the normal playback file is being played back at a faster speed.
The content serving array 200 may include a CPU or other processing device (not shown) and a relational database management system (RDBMS) 260 in some embodiments of the present invention. The RDBMS 260 functions as a server or storage device and has appropriate software and storage devices. The storage devices of the RDBMS 260 can contain a listing or table of one or more of the following: the content providers, the subscribers, the servers upon which the content is located, the orders, the purchase history of each subscriber, the content files, metadata related to the content files, and data regarding the usage (demand) of the content. The RDBMS 260 in one embodiment can be managed by a business manager 230 which additionally may interface with a billing system 140 to provide billing information to the billing system for the system operator. The business manager 230 may also provide reports regarding the operation of the server complex and/or coordinate with a reports server 150 for generating reports. In addition, the business manager 230 may maintain an authorization system (not shown) in various embodiments, wherein the business manager 230 contains information on the features, privileges, benefits, bonuses, space, tiers, etc., available to each customer and/or to each content provider. The authorization system may be external or may be included within another server, such as part of the RDBMS 260 . Thus, when a customer requests content in one embodiment of the present invention, the system queries the business manager 230 to determine whether or not the customer is authorized to receive the content. If so, then the request may be approved. If not, then the request may be denied. Likewise, if a content provider 110 wishes to store a movie, that request may be granted, denied, or granted only with certain restrictions, such as to size or location. The RDBMS 260 may further capture every viewing event by each premises device identification, time, location, and other contextual data in various embodiments of the present invention.
According to one embodiment of the present invention, the customer requests a program via a premises device 400 - 1 . . . 400 - n , such as, but not limited to, a set-top-box, personal computer, lap-top, personal digital assistant, cellular phone, or the computing device depicted in the embodiment of FIG. 1A . The request is sent over the network 300 . The network 300 may be any type of network capable of transferring data electronically, such as, but not limited to, cable networks, the Internet, wireless networks, Telco networks, or satellite networks. For ease of explanation, this description shall use the terminology for a cable network, but one of skill in the art will understand that embodiments of the present invention can be implemented on any suitable type of wired or wireless network.
In the current embodiment of the present invention, a request for content or a menu sent by a user from a premises device 400 - 1 , . . . 400 - n is received by the server complex 200 and processed by the business manager 230 . If authorized, the business manger 230 prompts the video stream engine 250 - 1 , . . . , 250 - n to send the requested content to the premises device 400 - 1 , . . . , 400 - n . The content is sent via network equipment that provides the managing, processing, and modulation, as appropriate, for the delivery of the video content across the network to the premises device 400 - 1 , . . . , 400 - n.
According to one embodiment, menus 410 - 1 , . . . , 410 - n may be narrowcast to the customer. Narrowcast or streaming of the menu to the customer, as well as combination of the narrowcast menu with a barker, may be performed as described in co-pending U.S. patent application Ser. No. 10/685,354. Using the combination technique described in the co-pending application, or any other suitable combination technique, any specific content may be narrowcast to the user as he/she is viewing the menu.
FIG. 2A illustrates one embodiment of the present invention that provides for the collaboration among a plurality of nodes to serve a content file that has been partitioned into an ordered list of parts. Node 2010 is the first node to serve a part of content. Servers 2020 through 2050 each then fire successively in the order B, C, D, and E. 2010 's part is transmitted first over the network 300 through the switch 2310 . Since nodes 2020 through 2050 each fire successively after 2010 , their parts should each leave the switch 2310 in succession. Thus, a client receiving the content file will perceive the stream of parts as having come from a single source sending successive parts of the content file. In various embodiments of the present invention, the content file can comprise at least one of video data, audio data, multimedia data, MPEG data, MPEG-2 data, MPEG-4 data, one or more Groups of Pictures, binary data, or text data. For example, a content file may comprise a title session of MPEG-2 data.
One skilled in the art will appreciate the difficulty of maintaining successive chronological firing as between nodes 2010 through 2050 given that the bit rate for video streams is commonly in the range of 1 to 20 mega-bits per second. To accomplish this, FIG. 2A presents one embodiment using tokens 2060 a through 2060 e . Token 2060 a is passed from node 2010 to node 2020 at a time proximate to when server 2010 is to fire. Similarly at a time proximate to when server 2020 is to fire it passes a token 2060 b to server 2030 , and so on.
FIG. 2B provides one alternate embodiment for maintaining successive chronological firing as between 2010 through 2050 . In the current embodiment, nodes 2010 through 2050 use a common time reference 2070 to maintain a synchronous time base. Each node refers to this common time reference to independently determine when to fire their respective part of the content file.
FIG. 3 shows a node 250 - 1 of one embodiment of the present invention. The node 250 - 1 contains a low latency stream pump 3040 that “reads” parts of each content file for every stream and “fires” them out to the destination through the low latency network switch 2310 depicted in FIGS. 2A and 2B . The stream pump streams parts of content served by the content serving array 200 . Those skilled in the art will understand that prior to embodiments of the present invention, a media server could only deliver a number of streams equivalent to the number of output ports multiplied by streams per output port. In embodiments of the present invention a single node, such as 250 -A, does not just deliver a given number of streams, it can deliver a part of every stream in the content serving array of which it is a part. Besides handling firing order, the stream pump 3040 may also handle failover and interoperate with other components to maintain a coherent stream of parts as perceived by the consumers.
In the embodiment of FIG. 3 , the Token Receiver 3030 and Sender 3090 are used to pass tokens representing the current node that must fire a part of content. A Firing Queue 3060 is shown that functionally decouples the reception of tokens from the stream pump 3040 . The stream pump 3040 can pass a token on to the next node in the firing order through the Token Sender 3090 when it has delivered its current part. Actual token delivery may precede the delivery of the final part as is necessary to ensure that the client will receive an uninterrupted stream of parts as if the parts are coming from a single source. In some embodiments of the present invention the Token Receivers and Senders may be the only component directly aware of the firing order.
The Command Receiver 3020 and Sender 3080 of the current embodiment are used to quickly pass control commands received from a consumer (start, stop, pause, write, delete, etc. pertinent to the content being served in the title-session) to every node in the content serving array 200 . The lead node passes on these commands using the Command Sender 3080 . In one embodiment of the present invention, once a command has cycled through every node and returned to the lead node, the command is considered to be completed. Other means of passing and actually or probabilistically verifying receipt of commands can also be used by the present invention.
The Fault Detector 3040 of the current embodiment is responsible for identifying faults in the content serving array 200 or an output switch. It listens for notification of faults from sources including but not limited to: other nodes 250 - n ; a network switch 2310 ; or a Token timeout from the Token Receiver 3030 . Once a fault is detected, it informs the stream pump 3040 and passes the fault on through the chain of nodes.
In one embodiment of the present invention a Data Retriever 3020 retrieves data for the stream pump 3040 to consume. Said data may be placed into a Buffer Manager 3070 and sent out at a time determined by the Burst Interleaver 3050 in the order prescribed by the Firing Queue 3060 .
FIG. 2A shows one embodiment wherein each node delivers parts of content and passes on a token to the next node to continue the stream. FIG. 2B shows another embodiment wherein each node delivering parts of content uses a common time reference. The chaining of nodes described in the various embodiments is referred to as “firing order”. In FIGS. 2A and 2B the firing order is A-B-C-D-E-A. However, not every stream is delivered with this single firing order pattern in embodiments of the present invention. For example, in one embodiment of the present invention having 5 nodes there are 5! (five factorial) firing order patterns. It is desirable in some embodiments that for each content file a firing order is chosen such that its order and timing do not duplicate that of a previously assigned firing order for an existing content file. Varying the firing order of the nodes is useful because, as documented below, when a node or link fails the other remaining nodes must pick up its responsibilities. By varying the firing order each remaining node picks up 1/(N−1) of the load, rather than just one of the nodes picking up the responsibility and doubling its work load.
FIG. 4 illustrates a method of one embodiment of the present invention useful for delivering content over a network. First, content is partitioned into an ordered list of parts 401 . Second, the parts are allocated 402 among a plurality of nodes. In one embodiment based on the embodiment of FIG. 4 , the nodes can be the nodes 250 - 1 to 250 - n and the network can be the network 300 , each as depicted in the embodiment of FIG. 1B . Third, the plurality of nodes are synchronized 403 so that the parts can be sent in-order from the plurality of nodes to the user. Finally, the parts are sent 404 in-order from the plurality of nodes to the user over the network.
In some embodiments of the present invention the parts can be allocated among the plurality of nodes before the parts are delivered to the user, such as in embodiments based on the embodiment of FIG. 4 . In the alternative, the parts can be allocated dynamically among the plurality of nodes during delivery of content to the user. In some embodiments, the user is not aware that the content will be delivered from a plurality of nodes.
The plurality of nodes may have separate memory in various embodiments of the present invention, such as in embodiments based on the embodiment of FIG. 4 . The memory of each node may comprise random access memory. Further, the user of any embodiment of the present invention may be participating in an on-demand session, the on-demand session being one of content-on-demand, movie-on-demand, video-on-demand, subscription video-on-demand, free-on-demand, or network-based digital video recording session. A content file can be a single content file, and the content file may comprise at least one of video content, audio content, multimedia content, trick content, binary content, or text content in embodiments of the present invention.
The parts can be allocated among the plurality of nodes according to a deterministic algorithm in various embodiments of the present invention, such as in embodiments extending the embodiment of FIG. 4 . One of skill in the art will understand that numerous deterministic algorithms can be used with embodiments of the present invention, such as a round robin algorithm. A non-deterministic algorithm, such as a random or pseudo-random algorithm, can also be used to allocate parts among nodes in various embodiments of the present invention.
In a further embodiment of the present invention, such as in embodiments based on the embodiment of FIG. 4 , the plurality of nodes may be synchronized so that the parts are sent in-order from the plurality of nodes to the user by passing a token among the plurality of nodes, with the token indicating when a receiving node should send its one or more parts to the user. In the alternative, the plurality of nodes can be synchronized using a common time reference.
FIG. 5 illustrates the method of one embodiment of the present invention useful for sending content to a user. First in the embodiment of FIG. 5 , the content is partitioned 501 into an ordered list of parts comprising a first part and a second part. The first part is allocated 502 to the first node and the second part is allocated 503 to the second node. Then, the first part is sent 504 form the first node to the user. Fifth, it is determined 505 which of the plurality of nodes is the second node, and it is then indicated 506 to the second node that it should send the second part to the user. Finally, the second part is sent 507 from the second node to the user.
In some embodiments of the present invention, such as in embodiments extending the embodiment of FIG. 5 , a broker determines which of the plurality of nodes the second node is. Further, the broker can indicate to the second node that is should send the second part to the user by sending a token form the broker to the second node. In the alternative, a common time reference can be used to indicate to the second node that it should send the second part to the user. In further embodiments of the present invention, such as embodiments extending the embodiment of FIG. 5 , the first node can determine independently which of the plurality of nodes the second node is, which can be accomplished, for example, using seed information such as the number of nodes which contain one or more parts of content, metadata describing the content, a common time reference, or a firing map that indicates the time order that each node should send its one or more parts in. Further, the first node can then indicate to the second node that it should send the second part by having a token sent to the second node, or a common time reference can be used to indicate to the second node that it should send the second part to the user.
FIG. 6 illustrates one embodiment of the present invention for recovering from fault in a content serving array comprising at least a first node, a second node, and a third node. First in the embodiment of FIG. 6 , the content is partitioned 601 into an ordered list of parts comprising at least a first part and a second part. Next, the first part is allocated 602 to the first node and the second part is allocated 603 to the second node. Fourth, it is indicated 604 to the first node that it should send the first part to a client device. Fifth, the second node fails 605 to receive an indication that the first node has sent the first part to the client device. It is then indicated 606 to the third node that it should send the first part to the client device. Finally, the third node sends 607 the first part to the client device and the second node sends 608 the second part to the client device.
In one embodiment of the present invention based on the embodiment of FIG. 6 , the third node is the second node, and/or the first part may be reallocated to the third node. In various embodiments of the present invention, the client device buffers at least some of the received content. The client device can also present received parts in the order that they are received. In further embodiments based on the embodiment of FIG. 6 , the parts can be allocated among the first, second, and third nodes using either a deterministic or non-deterministic algorithm.
FIG. 7 illustrates one embodiment of the present invention for determining a firing order for a title session using a deterministic algorithm. First, after start-up of the title-session 701 a set of seed information such as, but not limited to, the content id of the content file, the content serving array size, and the lead nodes ordinal position, is received 702 by a node. An algorithm is then applied 703 which deterministically outputs 704 the successor of that node for that title-session. While other embodiments of the invention could alternatively use a centralized broker for determining firing order, the current embodiment shows how each node can independently determine the firing order, thereby lessening or removing the need for a centralized broker.
FIG. 8 illustrates one embodiment of the present invention for delivering information from a single node in the system. First, at step 810 the server 250 - n will for each title-session determine at each cycle whether the time has arrived for delivery of a part of content for that title-session. If at step 820 the node has received a token from the previous node in the firing order and if at 830 no external component reports a condition that would prevent partition delivery, and additionally no internal condition is detected at step 840 , then the process may advance to step 880 and fire the part designated at step 890 and pass 895 a token to the successor node in the firing order before starting the process again. If a fault has been detected in one of steps 820 , 830 , or 840 then the process must advance to step 860 and propagate the fault to the successor node and then it must assume the work 870 , if possible, necessary to correct the fault for firing at step 880 the necessary part at 890 to fulfill both its own quota and that of any failed nodes in that cycle. The successor node to a failed node within a title-session firing order thereby takes over for the failed node's work until the failed node is restored to health.
While the present invention has been described in detail in connection with various embodiments, it should be understood that the present invention is not limited to the above-disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alternations, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. | Embodiments of the present invention provide methods, systems, and apparatuses for a fault resilient collaborative media serving array comprising a plurality of nodes. In one embodiment, the present invention provides a method for creating a fault resilient collaborative media serving array where the array nodes do not share memory, the serving of a content file is accomplished by the collaborative efforts of many nodes in the array, and where there is no fixed allocation of sessions to nodes. | 7 |
This application is a continuation of Ser. No. 07/591,812, filed on Oct. 2, 1990, now abandoned.
BACKGROUND OF THE INVENTION
In the manufacture of tissue and towel products, a common step is the creping of the product. This creping is done to provide desired aesthetic and performance properties to the product. Many of the aesthetic properties of tissue and towel products rely more upon the perceptions of the consumer than on properties that can be measured quantitatively. Such things as softness, and perceived bulk are not easily quantified, but have significant impacts on consumer acceptance. Since many of the properties of tissue and towel products are controlled or are at least influenced by the creping process, it is of interest to develop methods for controlling the creping process. Although the creping process is not well understood, it is known that changes in the process can result in significant changes in the product properties. A need exists to provide a method for influencing the creping process by allowing the control of the adhesion of the tissue or towel substrate to the surface from which it is creped, most usually large cylindrical dryers known in the industry as Yankee dryers.
Obtaining and maintaining adhesion of tissue and towel products to Yankee dryers is an important factor in determining crepe quality. Inadequate adhesion results in poor or non-existing creping, whereas excessive adhesion may result in poor sheet quality and operational difficulties. Traditionally, creping adhesives alone or in combination with release agents have been applied either to the sheet or to the surface of the dryer in order to provide the appropriate adhesion to produce the desired crepe.
Various types of creping adhesives have been used to adhere fibrous webs to dryer surfaces such as Yankee dryers. Prior art creping adhesives rely upon combinations of self-crosslinkable soft polymers having a T g of less than 10° C. with a non-film forming hard polymer emulsion having a T g greater than 50° C. (U.S. Pat. No. 4,886,579) or thermoset resins (U.S. Pat. Nos. 4,528,316 and 4,501,640). The ability to control the mechanical properties of the polymers, as well as the adhesion and release of the fibrous web from the Yankee dryer, is limited when using these types of creping adhesives.
SUMMARY OF THE INVENTION
The present invention provides an improved creping adhesive which provides the ability to readily control Tg and adhesion and which can be more easily removed from dryer surfaces. Thus, the adhesive can provide high adhesion of a fibrous web to a dryer surface with low "friction", i.e., the fibrous web can be easily removed from the dryer surface. This can be accomplished while at the same time reducing or inhibiting corrosion of the dryer surface.
The essence of the present invention is that the adhesion properties of specific types of polymers can be systematically changed by varying the amount of crosslinking that may occur when the polymer is dried onto the surface of a Yankee dryer. Because crosslink density influences the mechanical properties (i.e., modulus, brittleness, Tg), this permits the adjustment of adhesion/release of the fibrous substrate onto the surface of the dryer. The nature of the polymers and types of crosslinkers used permits the incorporation of anti-corrosion components in the formulations of the present invention. This can have significant benefits in that corrosion of dryer surfaces can be a major problem in some tissue and towel mills.
The method of the present invention includes the steps of providing to the interface of a fibrous web and a support surface for the fibrous web a creping adhesive which contains a non-self-crosslinkable material and a crosslinking agent and removing the fibrous web from the support surface by creping. The process preferably includes the steps of providing to the interface of a fibrous web and a drying surface a creping adhesive which contains a polymer or oligomer having functional groups which can be crosslinked by ionic crosslinking and an ionic crosslinking agent which contains metal cations having a valence of three or more and removing the fibrous web from the drying surface with a creping blade to thereby crepe the fibrous web.
The adhesive of the present invention preferably comprises a crosslinkable polymer, oligomer or mixture thereof, metal cations having a valence of three or more to crosslink the polymer and/or oligomer and an aqueous solvent.
BRIEF DESCRIPTION OF THE DRAWING
The sole drawing FIGURE is a schematic illustration of a Yankee dryer to which a tissue web is presented, dried, creped and then wound into a soft roll.
DETAILED DESCRIPTION OF THE INVENTION
The drawing FIGURE illustrates the conventional steps in formation of a tissue paper web suitable for use as a facial tissue. This conventional process includes the steps of preforming a fibrous web, applying a creping adhesive to the surface of a Yankee dryer, applying the fibrous web to the surface of the Yankee dryer having the creping adhesive on the external surface thereof, removing the fibrous web from the Yankee dryer by use of a creping blade and winding the dried fibrous web onto a roll. Alternatively, the creping adhesive can be applied to the surface of the fibrous web that will contact the dryer, before the fibrous web is presented to the dryer.
Referring to the drawing FIGURE, this represents one of a number of possible configurations used in processing tissue products. In this particular arrangement, the transfer and impression fabric designated at 1 carries the formed, dewatered web 2 around turning roll 3 to the nip between press roll 4 and Yankee dryer 5. The fabric, web and dryer move in the directions indicated by the arrows. The entry of the web to the dryer is well around the roll from creping blade 6 which, as schematically indicated, crepes the traveling web from the dryer as indicated at 7. The creped web 7 exiting from the dryer is wound into a soft creped tissue roll 8. To adhere the nascent web 2 to the surface of the dryer, a spray 9 of adhesive is applied to the surface ahead of the nip between the press roll 4 and Yankee 5. Alternately, the spray may be applied to the traveling web 2 directly as shown at 9'. Suitable apparatus for use with the present invention are disclosed in U.S. Pat. Nos. 4,304,625 and 4,064,213, which are hereby incorporated by reference.
This illustration does not incorporate all the possible configurations used in presenting a nascent web to a Yankee dryer. It is used only to describe how the adhesive of the present invention can be used to promote adhesion and thereby influence the crepe of the product. The present invention can be used with all other known processes that rely upon creping the web from a dryer surface. In the same manner, the method of application of the adhesive to the surface of the dryer or the web is not restricted to spray applications, although these are generally the simplest method for adhesive application.
The present invention is useful for the preparation of fibrous webs which are creped to increase the thickness of the web and to provide texture to the web. The invention is particularly useful in the preparation of final products such as facial tissue, toilet tissue, paper towels and the like. The fibrous web can be formed from various types of wood pulp based fibers which are used to make the above products such as hardwood kraft fibers, softwood kraft fibers, hardwood sulfite fibers, softwood sulfite fibers, high yield fibers such as chemithermo-mechanical pulps (CTMP), thermomechanical pulps (TMP) or refiner mechanical pulps (RMP). Furnishes used may also contain or be totally comprised of recycled fibers (i.e., secondary fibers). The fibrous web, prior to application to the Yankee dryer, usually has a water content of 40 to 80 wt. %, more preferably 50 to 70 wt. %. At the creping stage, the fibrous web usually has a water content of less than 7 wt. %, preferably less than 5 wt. %. The final product, after creping and drying, has a base weight of 7 to 80 pounds per ream.
The creping operation itself can be conducted under conventional conditions except that the creping adhesive of the present invention is substituted for a conventional creping adhesive.
The non-self-crosslinkable material of the present invention is a polymer or oligomer which contains crosslinkable functional groups. Exemplary crosslinkable functional groups include hydroxyl, carboxyl, sulfonate, sulfate, phosphate and other functional groups containing active hydrogens and mixtures thereof.
Examples of hydroxylated polymers and oligomers that can be used in the process include polysaccharides and oligosaccharides such as starch, modified starches, partially hydrolyzed or oxidized starches, alginic acid, carageenans, water soluble derivatives of cellulose, dextrins, maltodextrins, and naturally occurring water soluble polysaccharides. Other useful hydroxylated polymers include polyvinyl alcohols, partially hydrolyzed polyvinyl acetates, and ethylenevinyl alcohols.
Examples of carboxylated polymers useful in this invention include homopolymers of acrylic and methacrylic acids, acrylic acid/methacrylic acid copolymers, partially hydrolyzed polyacrylamides and polymethylacrylamides, carboxylated polymers and copolymers obtained by polymerization or copolymerization of acrylic, methacrylic, maleic, itaconic, fumaric, crotonic, and other ethylenically unsaturated acids with suitable ethylenically unsaturated monomers. Suitable carboxylated polymers and copolymers can also be obtained through polymerization or copolymerization of unsaturated anhydrides such as maleic or itaconic anhydrides with suitable unsaturated monomers followed by hydrolysis.
Examples of sulfonate containing polymers are those derived from polymerization or suitable copolymerization of unsaturated sulfonic acids such as styrene sulfonic acid, 2-vinyl-3-bromo benzenesulfonic acid, 2-allyl-benzenesulfonic acid, vinyl phenylmethane-sulfonic acid, ethylene sulfonic acid, phenylethylene sulfonic acid, 2-sulfo-vinylfurane, 2-sulfo-5-allylfurane and 1-phenylethylene sulfonic acid.
Examples of phosphate containing polymers include homopolymers or copolymers of unsaturated monomers containing a phosphoric acid moiety such as methacryloxy phosphate. Sulfated polymers useful in the invention may be derived from treatment of hydroxylated or unsaturated polymers with either sulfuric acid or sulfur trioxide/H 2 SO 4 mixtures.
Polymers containing more than one type of functional group can also be used in this invention. Oxidized starches, carboxymethyl celluloses, potato starches, sulfated polyvinyl alcohols, gelatin, casein, protein as well as sulfated and phosphated derivatives of celluloses or starches could all find application in this invention.
Although in certain instances, some of the polymers containing more than one functional group could conceivably crosslink, e.g., internal esterification of a carboxylated cellulose, the present invention is drawn to rely upon the ability to finely control the level of crosslinking through addition of an appropriate amount of crosslinking agent. In addition to having crosslinkable functional groups, the polymer or oligomer should be water-soluble, water dispersable or capable of being formed into a water-based emulsion. The polymer or oligomer is preferably water soluble.
The non-self-crosslinkable material should be present in the creping adhesive in an amount sufficient to provide the desired results in the creping operation. If it is intended to spray the creping adhesive onto the surface of Yankee dryer, the creping adhesive should have a viscosity low enough to be easily sprayed yet high enough to provide a sufficient amount of adhesion. If the creping adhesive will be sprayed onto the surface of the Yankee dryer, it will probably have a total solids content of about 0.01 to 0.5, preferably 0.03 to 0.2% by weight based on the total weight of the adhesive. The solids content is constituted primarily by the polymer or oligomer, i.e., the crosslinkable material and the crosslinker.
Various types of crosslinking agents may be used in accordance with the present invention. Preferred crosslinking agents are ionic crosslinking agents which provide ionic crosslinking between functional groups of polymers. An added benefit of ionic crosslinking is that it is reversible at high pH. This is in contrast with many other crosslinking resins that have been used as adhesives that are thermoset resins. The reversibility of the crosslinking provides the flexibility to remove excess amounts of material that may have built up on dryer surfaces as a result of machine operational problems. For example, if it is desired to remove built up adhesives, the adhesive can be treated with a basic solution, which preferably is an aqueous basic solution having a non-volatile base dissolved therein As the water evaporates, the pH of the solution will rise causing the crosslinks to hydrolyze thereby allowing easier removal of the built up layer(s) of polymer from the machine.
Metal cations with a valency of 3 or more, and more preferably 4 or more may be used as crosslinking agents. Exemplary cations are Fe +3 , Cr +4 , Cr +6 , Ti +4 , Zr +4 , etc. Zirconium has been found to be a particularly useful crosslinking agent because it is capable of crosslinking hydroxylated polymers as well as the more acidic carboxylated and sulfonated polymers.
Although zirconium compound cations are the preferred crosslinkers, it has been found that mixtures of zirconium and aluminum ions are effective in providing crosslinking of complex polymers containing more than one type of functional group. For example, aluminum will crosslink carboxyl and sulfonate groups. Mixtures of polymers, for example, polyvinyl alcohol and polyacrylamides (partially hydrolyzed) can be effectively crosslinked using mixtures of aluminum and zirconium ions.
The crosslinker will usually be added to the creping adhesive in the form of a water-soluble salt or water-soluble "complex" which provides cations upon dissolution in water. An example of one type of complex is ammonium zirconium carbonate.
The crosslinker should be present in the creping adhesive in an amount sufficient to provide changes in the mechanical properties of the polymer once the solution has been evaporated and the polymer crosslinked. As the level of crosslinking increases, the mechanical properties change with the crosslink density. Increased crosslinking generally will increase the T g , increase the brittleness and provide different responses to mechanical stresses than uncrosslinked polymers. Obtaining the appropriate crosslink density will depend not only on the relative concentration of added crosslinker but also on the type of polymer employed, the functional groups present, and the molecular weight of the polymer. Early work demonstrated that, in general, as the molecular weight of the starting polymer increases, the amount of crosslinker necessary to provide particular levels of final properties (i.e., T g , brittleness, etc.) decreases. A discussion concerning the relationship between T g and crosslinking of polymers is contained in the article by Stutz et al, Journal of Polymer Science, 28, 1483-1498 (1990), the entire contents of which is hereby incorporated by reference.
For most of the polymers used in the present invention, the amount of crosslinker, i.e., the compound which provides the cations, necessary to promote improvements in adhesion is in the range of 0.5 to 10% by weight based on the weight of the polymer to be crosslinked. The ability to control the mechanical properties of crosslinked polymers by varying the amount of crosslinker is the essential part of the invention. It is believed that a key property influenced by crosslink density is the T g . Since prior work has claimed that T g does influence adhesive properties (see U.S. Pat. Nos. 4,064,213; 4,886,579; 4,063,995; 4,304,625), the ability to change or modify T g through crosslink density offers an opportunity to control the adhesion and subsequent creping. The exact amount of crosslinker will depend upon the desired properties of the adhesive, the type of non-self-crosslinking material, and the molecular weight of the non-self-crosslinking material.
While the polymer and crosslinker are the major "active" ingredients of the present invention, other materials can be incorporated with beneficial results. Materials can be added to modify the mechanical properties of the crosslinked polymers. Some of these materials may actually be incorporated into the crosslinked polymer. Examples would include glycols (ethylene glycol, propylene glycol, etc.), polyethylene glycols, and other polyols (simple sugars and oligosaccharides). Other components can be added to modify interfacial phenomena such as surface tension or wetting of the adhesive solution. Nonionic surfactants such as the octyl phenoxy based Triton (Rohm & Haas, Inc.) surfactants or the Pluronic or Tetronic (BASF Corp.) surfactants can be incorporated in the present invention to improve surface spreading or wetting capabilities. Mineral oils or other low molecular weight hydrocarbon oils or waxes can be included to modify interfacial phenomena.
Finally, one additional class of materials can be added to the formulation. These are phosphate salts or salts of phosphate oligomers. Addition of these materials will provide some buffering capability as well as provide changes in the surface tension of the solution. The major purpose for inclusion is, however, the anti-corrosive properties of phosphates. While some of the other materials used in the formulations of the present invention provide anti-corrosive properties (most notably the zirconium containing crosslinkers), it is expected that the addition of phosphates to the formulation will enhance the overall anti-corrosive properties of the adhesive formulation. If phosphate is incorporated, it should be added in an amount of 5 to 15 wt. %, preferably 5 to 10 wt. % based on the total weight of the adhesive formulation.
The various components of the adhesive formulation, i.e., non-self-crosslinking polymer, crosslinking agent, polymer modifiers, surfactants, and anti-corrosive additives, will all be dissolved, dispersed, suspended, or emulsified in a liquid carrying fluid. This liquid will usually be a non-toxic solvent such as water.
The liquid component is usually present in an amount of 90 to 99.98 wt. %, preferably 99 to 99.9 wt. % based on the total weight of the creping adhesive. The pH of the adhesive when it is applied to the desired surface in the papermaking operation will usually be about 7.5 to 11. The solvent preferably consists essentially (or completely) of water. If other types of solvents are added, they are preferably added in small amounts.
EXAMPLES
In the following Examples, the adhesive is prepared by dissolving the indicated ingredients in water in the amounts indicated. The creping adhesive is applied to a small hand sheet which is then applied to a hot oil-heated cylinder which can be rotated at a controlled speed. This small lab-sized piece of equipment is used to simulate a Yankee dryer. The drum is rotated until the sheet is virtually dry, and a creping blade is placed on the surface of the drum to crepe the sheet from the drum. During this creping, the torque necessary to bring about creping is measured. This measurement allows the calculation of a torque-adhesion relationship and provides indications of the lubrication and release characteristics of the coating adhesive. Torque, adhesion and polymer buildup/release observations and calculations are shown in Table 1. The properties of some of these products are shown in Table 2.
TABLE 1__________________________________________________________________________ t.sub.1 T t.sub.2 (T-t.sub.2) (t.sub.2 -t.sub.1)Sample AVG STD AVG STD AVG STD AVG STD AVG STD# Combinations (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm)__________________________________________________________________________1 3 g ZrO.sub.2 3.24 0.29 5.84 0.44 5.32 0.38 0.52 0.32 2.08 0.192 3 g PVA 3.07 0.10 4.88 0.08 2.78 0.06 2.10 0.11 -0.29 0.123 3 g PVA + 1.5 g ZrO.sub.2 3.43 0.25 6.24 0.20 3.58 0.19 2.66 0.18 0.15 0.174 3 g PVA + 1.5 g Na.sub.3 PO.sub.4 3.56 0.07 4.45 0.21 2.38 0.09 2.07 0.17 -1.18 0.125 .75 g ZrO.sub.2 + 1.5 g 3.06 0.04 5.86 0.13 3.09 0.08 2.77 0.12 0.02 0.07 Na.sub.3 PO.sub.4 + 3 g PVA6 3 g PVA + .75 g ZrO.sub.2 3.13 0.10 5.73 0.25 3.23 0.11 2.50 0.25 0.01 0.06__________________________________________________________________________ t.sub.1 - torque on cylinder before application of adhesive and sample T torque on cylinder during creping of sample (with adhesive) from cylinder t.sub.2 - torque on cylinder after removal of sample (T-t.sub.2) sample adhesion (t.sub.2 -t.sub.1) Polymer buildup/release ZrO.sub.2 - Ammonium zirconium carbonate or BaCote 20, Magnesium Electron Corp. PVA Polyvinyl Alcohol Airvol 540, Air Products Corp. Na.sub.3 PO.sub.4 - trisodium phosphate reagent grade.
TABLE 2__________________________________________________________________________The properties of some of these products are shown in Table 2. Unit Sample 1 Sample 2 Sample 3 Sample 4 Sample 5__________________________________________________________________________Wave Length (uM) 176.75 175.540 173.260 165.670 179.850Crepe/Cm (#) 56.045 56.678 58.745 59.445 55.468% Void-Area (%) 3.181 3.265 3.401 2.037 4.651Basis Weight (lbs./R) 11.009 11.156 11.203 11.163 11.003Caliper (0.001) 4.167 4.050 4.144 4.056 4.161Bulk (cm.sup.3 /g) 5.907 5.666 5.773 5.671 5.902Water ABS Rate (Sec) 2.052 2.833 2.5 3.218 2.548MD-Tensil (G) 1483 1573 1446 1688 1549CD-Tensil (G) 796 885 788 888 809Breaking Length (Km) 0.795 0.852 0.768 0.884 0.820MD-% Disp. (%) 15.79 16.858 16.416 16.83 17.16CD-% Disp. (%) 2.943 2.871 2.924 2.702 2.863__________________________________________________________________________ | A creping adhesive is described which provides the ability to readily control glass transition temperature (Tg) and adhesion and which can be easily removed from dryer surfaces. The creping adhesive contains a crosslinkable polymer and preferably an ionic crosslinking agent such as metal cations having a valence of three or more. | 3 |
The present invention relates to control valves and more particularly to a servo type control valve construction for use in a water driven waste disposal unit such as shown in U.S. Pat. No. 4,082,229.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,082,229 discloses a waste disposal unit operated entirely by water from a domestic water supply. A piston moving in a toroidal chamber and driven by water pressure is coupled to a stack of alternately moving and stationary cutters. The moving cutters have a reciprocating rotary motion and are provided with staggered interfitting teeth which reduce waste material progressively to small particles. The lowermost cutter has restricted openings which will not pass any large particles, or silverware or the like which may accidentally fall into the unit.
A servo controlled valve, responsive to differential pressure on opposite sides of the piston, reverses the water flow and the piston direction automatically at each end of a stroke. The automatic reversal also occurs if an obstruction jams the cutters, the cutters then oscillating with a reduced stroke until the obstruction is cut off or removed.
The driving water is exhausted through the valve into a manifold from where it is sprayed into the cutting chamber to flush waste material through the cutters.
The device described in Pat. No. 4,082,229 is a very efficient device that requires effective sealing and the minimizing of cross leakage between the channels and passages which conduct the water for the operation of the waste disposal unit. It is also desirable that the device by constructed and arranged so that the cycle time for rotation of the cutters is as short as possible.
SUMMARY OF THE INVENTION
Therefore, it is a principle object of the present invention to provide a new and improved valve arrangement for a water driven waste disposal unit which minimizes leakage of water between channels and passages.
It is another object of the present invention to provide a new and improved valve arrangement for a water driven waste disposal unit that makes maximum use of the energy provided by the water pressure in operating the device.
It is another object of the present invention to provide a new and improved valve arrangements for a water driven waste disposal unit that is fast and dependable in operation and that minimizes cycle time of the waste disposal unit.
It is a further object of the present invention to provide a new and improved valve arrangement for a water driven waste disposal unit wherein sticking of the servo valve mechanism can be quickly and easily relieved without disassembling the valve construction.
Other objects of the invention will appear from a reading of the following specification which makes reference to the accompanying drawings.
The above objects are attained with an exemplary embodiment of the present invention wherein water is directed to a pilot piston means which passes the water to the control piston means for operating the cutters. The control piston means is reversed by the action of the pilot piston means. The housing for the control piston means and pilot piston means is sturdy to avoid distortion and the various piston means are provided with seals to provide smooth, efficient sealing. The passage means for directing water flow through the control and pilot piston means are arranged to minimize cross leakage.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a valve constructed according to the present invention.
FIG. 2 is a right end elevation of the valve shown in FIG. 1.
FIG. 3 is a sectional view taken along the line 3--3 in FIG. 2.
FIG. 4 is a sectional view taken along the line 4--4 in FIG. 2.
FIG. 5 is a schematic view, in section, demonstrating the operation of the valve arrangement of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 5 of the drawings, the waste disposal unit such as shown in U.S. Pat. No. 4,082,229 includes a toroidal chamber 11 with an operating piston 13 slidably disposed therein. A stop plug or bulkhead 15 is positioned in the chamber 11. Water pressure moves the piston 13 first in one direction and then in the reverse direction in the chamber 11 as explained hereafter. Cutters (not shown) are connected to the piston 13 as described in U.S. Pat. No. 4,082,229. The pilot piston 31 and control piston 24 of the valve assembly 23 are positioned to drive piston 13 in a counterclockwise direction. The cylinder walls in the valve assembly 23 are sufficiently thick so that they will not distort under water pressure. In the position shown in the drawings, water from the water supply (not shown) is introduced from the inlet 19, through the passage 26 and into chamber 11. This moves the piston 13 in a counterclockwise direction. The inlet water is also directed through channel 22 in control piston 24, through passage 27 in the valve body to the opening 29 in pilot piston 31, through internal passage 33 in the pilot piston and out the opening 35 to passage 37 which introduces the inlet water to the right end of control piston 24. Control piston 24 is held to the left and the passages are aligned as shown. Inlet water also passes through passage 39 to the left end of pilot cylinder 41, and the right end of pilot cylinder 41 is connected through passage 42 to exhaust.
Water which is pushed ahead of operating piston 13 in chamber 11 exhausts through passage 43 and through passages 44, 45 and 47 to the shower cone passage 49 where it flushes the waste in the disposal unit as described in U.S. Pat. No. 4,082,229. Water at the left end of control piston 24 exhausts through passage 65 to the shower cone passage 49.
Inlet pressure also is fed through passage 50 and orifice 51 into chamber 53. A spring 55 is disposed in chamber 53 and urges piston 57 against detent ball 59 which seats in one of the detent pockets 61.
Thus, a pressure differential exists between the ends of pilot cylinder 41. However, pilot piston 31 is retained by spring-loaded detent ball 59. The pressure through line 50 in chamber 53 from water supply adds to the spring pressure so that the detent is preloaded in accordance with the existing supply pressure.
During a normal stroke, a back pressure is created by the resistance of the water exhausting through a restricted outlet while the supply water has a slight drop through the valve unit and the differential is insufficient to overcome the detent. As the operating piston 13 reaches the end of its travel and the water being pushed ahead of the piston is exhausted, the back pressure drops significantly and the supply pressure driving the piston causes a large pressure differential across the pilot piston 31. Pressure from the supply inlet to the left end of pilot cylinder 41 becomes sufficient to overcome the detent and drive pilot piston 31 to the other end of the cylinder. As the piston 13 engages bulkhead 15, a pressure spike is created. However, because of the orifice 51, the pressure spike is not sensed inside detent chamber 53. The spring 55 is compressed as the pilot piston 31 moves to the right and the ball 59 seats in the left detent 61 in the pilot piston 31.
As the pilot piston 31 moves to the right, the passages are aligned so that passage 63 aligns with passages 27 and 65 and inlet pressure is directed through these passages. Passage 37 now becomes the outlet or exhaust passage for the control cylinder 24. Control piston 24 is shifted to the right so that land 67 on piston 24 seats on land 69 and land 71 moves to the right of passage 43. The inlet passages become the outlet passages and the outlet passages become the inlet passages.
At each end of the piston travel, reversal is automatically initiated by the pressure differential across the servo spool. Reversal will also occur if the cutters are jammed by an obstruction or object too hard to cut, resulting in a sudden increase in pressure differential on opposite sides of the piston. The action is automatic at any supply pressure, since the pilot piston detent is pressure balanced to the supply. It has been found that the cutters will continue to oscillate through any length of stroke until the obstruction is eventually cut off or removed.
Referring to FIGS. 3 and 4, it will be noted that control piston 24 includes contains rubber cup seals 73 and 75 at each end. Contained rubber cup seals 77 and 79 are provided at each end of pilot piston 31 and a rubber cup seal 81 is engaged by spring 55 in chamber 53. These rubber cup seals provide maximum protection against leakage and accommodate movement with a minimum of friction and binding.
A reset rod 83 extends out the left end of pilot cylinder 41 and is in sliding engagement with Teflon sleeve 85 which is press fitted into end cap 87 of the valve assembly 23. A cup seal 89 is positioned inside the sleeve 85 to protect against leakage when the rod 83 is moved. If for some reason the pilot piston 31 becomes stuck because of a particle in the water, the reset rod 83 can be pushed in against the left end of pilot piston 31 to move the piston and reactivate the system. An identical reset rod 91 and accompanying structure is supplied at the right end of the pilot cylinder 41 to move the piston to the left.
The valve assembly 23 is connected in place by connecting passages 26 and 43 to the waste disposal unit and connecting passage 19 to the water supply.
The disk portions 93 on control piston 24 provide a good sealing engagement with the walls of control cylinder 21 without binding and help maintain alignment of the piston within the cylinder. The passages are made large enough so that, in cooperation with other features of the present invention, the cycle time of the control piston 24 from one position to the other is minimized. A cycle time of approximately two seconds has been obtained with the valve assembly shown in the drawings. | A valve mechanism for a water actuated waste disposal unit includes a reciprocating control valve for actuating an operating piston with cutters attached thereto. The control valve is cycled by a pilot valve. Passages in the valve mechanism are constructed and arranged for optimum operation and cycle time with minimum leakage. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a time-base correction applied when an electric signal, for example a video signal, is read from a magnetic record carrier by means of a helical scan video recorder.
2. Description of the Related Art
The magazine "Monitor-Proc. IREE" of Apr. 1976, pp. 118-122, describes such a time-base correction. The time-base errors are corrected in such a way that the video signal, which exhibits time-base errors after being read, is digitized with a variable sampling rate and is stored in a memory with the same variable frequency. Subsequently, the video signal stored in the memory is read out with a fixed frequency. The variable sampling rate, and hence the read-in frequency, is generated depending on the instantaneous time-base error. Read-out of the memory results in a video signal which is rid of time-base errors and which can subsequently be reconverted into an analog video signal for display on a TV screen.
The invention aims at providing a device for generating a variable sampling rate frequency and read-in frequency depending upon the time-base errors. The paper entitled "An Analog Segment Recording System for Home Use MUSE VTR" by Owashi et al, read to the "Technical group on video recording of ITEJ" in Tokyo on Aug. 29, 1985 (paper VR 70-4), describes a device for deriving a sampling rate from an electric signal, for example a video signal, which device comprises an input terminal for receiving the electric signal, which input terminal is coupled to an input of a synchronizing signal separator which is constructed to derive a synchronizing signal from the electric signal applied to its input and to supply the synchronizing signal to an output coupled to a first input of a phase comparator of a phase-locked loop, which further comprises a voltage-controlled oscillator having an input coupled to an output of the phase comparator, an output of the oscillator being coupled to an output terminal of the device, to supply the variable sampling rate, and to an input of a frequency divider comprising a counter, an output of the frequency divider being coupled to a second input of the phase comparator. The sampling rate generated by the known device is susceptible to interference.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a device which is less susceptible to interference. To this end the device in accordance with the invention is characterized in that the device further comprises a gate circuit having a first input coupled to the output of the synchronizing-signal separator, a second input for receiving a head-change signal, and an output for supplying a control signal, which output is coupled to a control-signal input of the frequency divider, in that the gate circuit is adapted to generate the control signal at a first instant after a head change and to sustain the control signal until a second instant of detection of the n-th synchronizing signal after the head change, and in that the frequency divider is adapted to set the count of the counter to a specific value in response to the control signal and to enable the counter at the second instant in order to provide frequency-division.
Preferably, the frequency divider is further adapted to inhibit the output signal under the influence of the control signal.
The invention is based on the recognition of the fact that the operation of the known device is disturbed by the head change during the read process in the video recorder. During a head change, a phase jump, and hence a (substantial) time error, will occur in the signal read from the record carrier, which disturbs the operation of the phase-locked loop in the device. The object of the invention is to ensure that the phase-locked loop does not respond to phase disturbances produced in the video signal as a result of the head changes. This is achieved by the step in accordance with the invention, namely by inhibiting the output signal of the frequency divider during a head change and after the detection of the n-th synchronizing signal, preferably the first synchronizing signal after the head change, presetting said divider in such a way that the phase comparator again measures substantially the same phase error as before the head change. The phase-locked loop then directly locks to the (line) synchronizing signal and can again correctly follow the time-base errors in said signal and supply a corresponding sampling rate and read-in frequency, while the phase-locked loop has not responded to disturbances caused by the head change.
A delay unit may be arranged between the output of the synchronizing-signal separator and the input of the phase comparator. Thus, it can be achieved that the phase-locked loop locks in more rapidly after the head change. The time delay produced by the delay unit should then be substantially equal to the delays caused by the gate circuit and the frequency divider. In the absence of the delay unit, these delays prevent the count of the counter in the frequency divider from being set in such a way that the phase comparator measures the correct phase error immediately when the first synchronizing signal is received. This becomes possible by adding the delay unit.
BRIEF DESCRIPTION OF THE DRAWINGS
Some embodiments of the invention will now be described in more detail, by way of example, with reference to the accompanying drawings. In the drawings:
FIG. 1 shows a time-base correction circuit employing the device in accordance with the invention;
FIG. 2 represents diagrammatically a video signal;
FIG. 3 shows an embodiment of the device in accordance with the invention;
FIG. 4 shows an example of the frequency divider in the device shown in FIG. 3;
FIGS. 5a-5e and 6a-6e show signal waveforms which can appear at various points in the device for two different head-change situations;
FIG. 7 shows the device of FIG. 3 provided with an additional delay unit between the synchronizing-signal separator and the phase comparator;
FIGS. 8a-8e signal waveforms at various points in the device of FIG. 7; and
FIG. 9 shows an example of the phase comparator used in the device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows diagrammatically a time-base correction circuit. Two heads K 1 and K 2 , which are arranged diametrally opposite one another on a rotatable head drum (not shown), read a video signal from tracks (not shown) which are inclined relative to the longitudinal direction of a magnetic record carrier (not shown). For this purpose the record carrier is wrapped around the head drum with a wrapping angle slightly larger than 180°. The head K 1 reads a video signal from a track and applies it to an analog-to-digital converter 1 via the switch S, which is in the upper position. Subsequently, a video signal is read from a subsequent track by the head K 2 . The switch S is then in the lower position. This video signal is also applied to the A-D converter 1. The video signal read from the record carrier exhibits time errors, for example as a result of inaccuracies in the record-carrier transport or as a result of record-carrier stretch.
The circuit arrangement shown in FIG. 1 serves to provide a correction for these time errors. For this purpose the video signal is sampled and is digitized in the A-D converter 1. The sampling rate is fs'. The samples are read into a memory 2 with a frequency equal to this sampling rate. To this end, said sampling rate is applied to the input 3 of the A-D converter 1 and to the input 4 of the memory 2. The frequency fs' is variable. The variations in the frequency fs' are dictated by the time errors in the video signal. In fact, fs' follows these time errors. For this purpose, the frequency fs' is derived from the video signal which exhibits the time errors and is obtained by means of elements to be described hereinafter and bearing the reference numerals 5, 6 and 7.
Subsequently, the samples read into the memory 2 with a variable frequency fs' are read out with a fixed frequency fs. For this purpose, the circuit comprises an oscillator 8 which generates the fixed frequency fs and applies it to the input 9 of the memory 2. The memory 2 may be constructed as a shift register in the form of a FIFO, the frequency fs' dictating the read-in rate and the frequency fs dictating the read-out rate. The samples read from the memory 2 are applied to a digital-analog converter 10, which converts the digital samples into an analog signal, which is applied to the output terminal 11. The signal on the terminal 11 is exempt from time errors.
In fact, the variable frequency fs' is generated in the device bearing the reference numeral 5.
FIG. 3 shows an embodiment of this device. The video signal is applied to the input terminal 15. This video signal comprises consecutive lines L, see FIG. 2, each line containing one line-synchronizing signal (or line pulse) 16, a burst, represented diagrammatically by 17, and the chrominance and luminance information, represented diagrammatically by 18.
The input terminal 15 is coupled to the input of a synchronizing-signal separator 20, which derives the synchronizing signal (the line pulses) 16 from the video signal and supplies it (them) to its output 21. The output 21 is coupled to the input 24 of a phase comparator 25 via a monostable multivibrator (one shot) 22, which comparator is constructed as a sample-and-hold phase comparator and forms part of a phase-locked loop 23. An example of such a phase comparator is shown in FIG. 9 and will be described hereinafter.
The output 21 is also coupled to an input of a gate circuit 26, i.e. the reset input of an S-R (set-reset) flip-flop. The output 27 of the phase comparator 25 is coupled to the output terminal 29 and to an input 30 of a frequency divider 31 via voltage-controlled oscillator 28. The output 32 of the frequency divider 31 is coupled to a second input 33 of the phase comparator 25.
An additional input 35 of the device is coupled to a second input, namely the set input, of the gate circuit 26. The output 36 of the gate circuit is coupled to the control signal input 37 of the frequency divider 31.
The operation of the device shown in FIG. 3 will be explained with reference to FIGS. 1, 5(a)-5(e) and 6(a)-6(e), which show some signal waveforms.
The synchronizing-signal separator 20 extracts the synchronizing signals (line pulses) 16 from the video signal applied to its input and transfers these to its output 21. These line pulses are represented diagrammatically as arrows in FIG. 5(b). The monostable multivibrator 22 transforms these line pulses into a squarewave signal having a duty cycle of, for example 50%, see FIG. 5(c). The frequency of the line pulses and hence that of the squarewave signal is f H . This frequency f H varies to some extent on account of time-base errors in the video signal.
The phase-locked loop 23 generates a squarewave signal of a frequency N.f H on the output 29. The frequency divider 31 divides this frequency by N, so that a squarewave having a frequency f H and a duty cycle of, for example, 50% is obtained again on the output 32, see FIG. 5(d).
The duty cycles of the signals in FIGS. 5(c) and 5(d) need not be equal to each other. However, suitably the sum of the duty cycles of the two signals is 100%. For example, if the signal of FIG. 5(c) has a 25% duty cycle, the signal of FIG. 5(d) preferably has a 75% duty cycle.
The head-change pulses, see FIG. 5(a), are applied to the input 35. The switch S is changed over to another position under the influence of these head-change pulses.
As a result of the head change, at the instant t 1 a synchronizing signal delayed by T, see FIG. 5(b), is applied to the phase-locked loop 23. Now the control signal is generated at the instant t 1 and the flip-flop 26 is set. The output goes "high", see FIG. 5(e). Under the influence of this "high" control signal, which is applied to the control-signal input 37 of the frequency divider 31, the output signal of the divider 31 is inhibited. This means that if the output signal is "high", it will go "low"--see FIG. 6(d) !--, and if the output signal is "low" it will remain low, see FIG. 5(d).
Under the influence of the next line pulse after the head change at the instant t 2 the flip-flop 26 is reset, causing the output signal to go "low", see FIG. 5(e). The output of the frequency divider 31 is now enabled.
From the following description of the frequency divider 31, it will become apparent that it comprises a counter. At a given instant during the apperance of the control signal, for example at the instant t 1 , this counter will have to be set to a specific count. After the instant t 2 at which the control signal has disappeared the counter is free to count. In view of the specific construction of the frequency divider 31, this means that the frequency divider 31 will not generate the squarewave again until the instant at which the second line pulse after the head change appears, i.e. at the instant t 3 . From this instant the phase-locked loop again locks to the input signal of FIG. 5(c).
FIG. 4 shows an example of the frequency divider 31. The frequency divider comprises a counter 40 which counts up or down under the influence of pulses applied to its input 41. Consequently, n-bit linear numbers will appear on the output 42 which in the case of an up-counter range from 000 . . . 00 (the decimal number 0) to 111 . . . 11 (the decimal number 2 n -1), after which the counter recommences with 000 . . . 00. Now it is assumed that N=2 n . (However, this is not necessarily so). The output 42 of the counter is fed to inputs of two detectors 43 and 44. These two detectors gate out two counts, for example the counts 000 . . . 00 (decimal "0") and 100 . . . 00 (decimal "N/2"). For the decimal "0" count, for example, the detector 43 supplies a pulse causing the set-reset flip-flop 45 to be set. The signal on the output 32 then goes "high". For the count decimal "N/2" the detector 44 supplies a pulse causing the flip-flop 45 to be reset. The output 32 then goes "low". In this way frequency division by a factor N is achieved.
Now the control signal from the gate circuit 26 is applied to an input of an OR gate 46 arranged between the detector 44 and the flip-flop 45. This means that the flip-flop is reset upon the rising edge of the control signal at the instant t 1 . If the output 32 is "high" it will go "low". If the output is already "low" it will remain "low".
Moreover, on account of the specific construction of the frequency divider shown in FIG. 4, the supply of the pulses Nf h to the input 30 should be inhibited at the instant at which the control signal appears. This is achieved by means of the AND gate 47, which via a second input receives the control signal which has been inverted in the inverter 48. Consequently, the counter 40 will no longer count from the instant t 1 . The control signal is also applied to a load input 55 of the counter. On a falling edge in the control signal, i.e. at the instant t 2 , the number a o . . . a n applied to the input 50 of the counter is loaded into the counter 40, after which the counter can resume counting. Owing to various delays in the circuit the count cannot be set to decimal 0 at this instant t 2 , but to decimal 1 or 2 or another value. This means that the output signal remains low in the first cycle of the counter and the counter does not for the first time reach the count decimal 0 until the instant at which the second line pulse after the head change occurs, i.e. at the instant t=t 3 , so that the flip-flop 45 cannot be set until this instant and the output 32 goes "high". Since the counter 40 stops in the time interval between t=t 1 and t=t 2 to count a o . . . a n can also be loaded into the counter 40 at another instant within this time interval.
FIGS. 6(a)-6(e) require no further explanation, because the signals shown in this Figure can be readily derived, utilizing the description of the operation of the device as given hereinbefore. The only difference with FIGS. 5(a)-5(e) is that in FIGS. 6(a)-6(e) the input signal for the phase-locked loop 23 is now high at the instant at which the head change occurs.
FIG. 7 shows a part of the device of FIG. 3. The only difference is that now that an additional delay unit 55 is arranged between the monostable multivibrator 22 and the phase comparator 25, to provide an additional delay of T'.
FIGS. 8(a)-8(e) show the various signal waveforms in the device shown in FIG. 7. It is clearly visible that the input signal, FIG. 8(c), of the phase-locked loop 23 is delayed by a time interval T' relative to the line-synchronizing signal. At the instant t 2 at which the first line pulse after the head change appears, the counter 40 in the frequency divider 31 is set to a different value, namely to a high value, say in the proximity of the decimal number 3/4N or higher, for example N-3 or N-2. The counter 40 now begins to count and when the decimal 0 count is detected for the first time, it will again cause the output signal on the output 32 of the frequency divider 31 to go "high". However, now this is effected already at the instant at which the first squarewave after the head change is applied to the phase-locked loop, see FIG. 8(c). It is evident that locking-in will now proceed even more rapidly. It will also be evident that the counter 40 setting is selected in such a way that the first squarewave in the signal shown in FIG. 8(d) is in the same relationship to the signal shown in FIG. 8(e) as before the head change. Thus, by means of the device shown in FIG. 3 or 7, it is possible to obtain a variable frequency Nf H which tracks the time-base errors in the video signal but which does not respond to disturbances caused by the head change.
The elements 6 and 7 in FIG. 1 constitute an additional control means for deriving the frequency f s ' from the frequency Nf H supplied by the device 5. The output signal of the device 5 is fed to a variable delay line 6. This delay line 6 enables a delay to be obtained which is variable under the influence of a control signal generated by the control signal generator 7, which control signal is applied to a control signal input 60 of the delay line 6. This additional control may be necessary because the instants at which the rising or falling edges of the line pulses 16 appear, see FIG. 2, cannot always be detected with adequate accuracy as a result of noise in the electric signal. The control signal for the delay line 6 can now be derived from a measurement of the burst 17. The burst comprises, for example, ten periods of a frequency which is in a fixed relationship with the sampling rate employed in the D/A converter during recording. By taking a number of samples of this burst, it is possible to derive a control signal which is a measure of the phase difference between the actual sampling instant and the desired sampling instant. By setting the delay line 6 to correct the delay time, it is possible to compensate for this phase difference, so that the sampling instant actually occurs at the desired instant. This brief description will suffice because this control system falls beyond the scope of the present invention. Moreover, it is to be noted that such a control system is known per se, so that also for this reason no further explanation is required.
FIG. 9 shows an example of the phase comparator 25 of FIG. 3. The phase comparator comprises four switches 60 to 63, a sampling capacitor 64, a hold capacitor 65, and an amplifier stage 66. The signals (c) and (d) are applied to the first input 24 and the second input 33, respectively, see FIG. 3. In fact the signals (c) and (d) are control signals for controlling the switches 60 to 63. The switch 60 is closed if the signal (c) is "high" or logic "1" and the signal (d) is "low" or logic "0". In all the other cases, the switch 60 is open. The switch 61 is closed if the signal (c) is "low" or logic "0" and the signal (d) is logic "0". In all the other cases, the switch 61 is open. The switch 62 is closed if (c) and (d) are both logic "1". In all the other cases, the switch 62 is open. The switch 63 is closed if (c) is logic "0" and (d) is logic "1". In the other cases, the switch 63 is open.
When the switch 60 is closed, point 67 is charged to the positive voltage (+) appearing on point 68. When the switch 63 is closed, this point is charged to the negative voltage (-) appearing on point 69. If the switch 61 is closed, the point 67 is charged to the voltage V ref appearing on point 70. V ref may be, for example, zero volts. If the switch 62 is closed, the hold capacitor 65 is charged to the voltage on point 67 and holds said voltage after the switch 62 has opened again.
It is to be noted that the invention is not limited to the embodiments disclosed herein. The invention also applies to those embodiments which differ from the disclosed embodiments in respects which are not relevant to the invention. For example, the input signal applied to the input terminal 15 need not necessarily be a video signal. It may also be an audio signal with associated synchronizing signals. | The device includes a synchronizing-signal separator (20), a phase-locked loop (23), having a phase comparator (25), a voltage-controlled oscillator (28) and a frequency divider (31). The device further includes a gate circuit (26) having an input (S) coupled to the output of the synchronizing-signal separator (20), and an input (5) for receiving a head-change signal (a). The output (36) of the gate circuit (26) is coupled to a control-signal input (37) of the frequency divider (31). The gate circuit (26) is adapted to generate the control signal at a first instant (t 1 ) of a head change and to sustain this control signal until a second instant (t 2 ) of detection of the n-th (preferably the first) synchronizing signal after the head change. The frequency divider (31), which includes a counter (40), is adapted to inhibit the output signal (d) in response to the control signal, to set the count to a specific value, and to enable the counter at the second instant in order to realize frequency-division. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to telephone line circuits and to battery feed circuits for such telephone lines.
In a telephone subscriber loop comprising a telephone line a subscriber subset and central office circuits it is necessary to supply a dc voltage in order to provide talking current. It is also necessary to provide some means of reducing noise signals which are induced onto the telephone line and are characteristically common mode signals in contrast to the differential mode talking signals. Prior battery feed, common mode interference reduction circuits comprise one large inductor with two windings, one connected from a first wire of the telephone line to ground and one connected from a second wire of the telephone line to battery. The two windings are closely coupled whereby a high impedance is presented to differential signals and a low impedance to longitudinal signals. Although the inductor is relatively inexpensive it is physically bulky and therefore results in large secondary costs in the area of packaging. It is desirable to implement a telephone line battery feed circuit using integrated or discrete circuit technology rather than the prior discrete inductor.
SUMMARY OF THE INVENTION
In accordance with this invention a telephone line battery feed circuit accomplishes the reduction of common mode signals while supplying talking current to the subscriber subset utilizing only integrated circuit components. A coupling circuit couples a power supply to the telephone line whereby talking current is provided in the telephone line loop circuit. A differential operational amplifier comprises two inputs, ac coupled to respective lines of the telephone circuit and outputs connected to the coupling circuit whereby a high impedance from line to power supply is presented to differential mode signals appearing on the telephone line wires which are therefore transmitted without attenuation but a low impedance is presented to common mode signals on the telephone line wires which are therefore attenuated.
BRIEF DESCRIPTION OF THE DRAWING
A telephone line battery feed circuit according to this invention will be better understood from a consideration of the detailed description of the organization and operation of one illustrative embodiment thereof which follows when taken in conjunction with the accompanying drawing in which:
FIG. 1 is a circuit diagram of a telephone line battery feed circuit.
DETAILED DESCRIPTION
In the illustrative line battery feed circuit of FIG. 1 the path for the subscriber loop current comprises the following serially connected elements: the positive grounded terminal of a battery 10, a transistor 11, a resistor 12, a transmission line 13, a subscriber set 14, a transmission line 15, a resistor 16, a transistor 17, and the negative terminal of battery 10. Acoustic signals applied to the transmitter of the subscriber set 14 produce corresponding changes in the resistance of the transmitter element and, therefore, cause corresponding changes in the current flowing through the transmitter and therefore in the voltage across the two terminals of the transmitter 14. As shown in FIG. 1 a receiving circuit 20 is connected in parallel with the transmitter of the subscriber set 14 by way of transmission wires 13, 15. Accordingly, variations in voltage across the transmitter of the subscriber set 14 cause corresponding acoustic signals at receiving circuit 20.
An interference source 21 is coupled in such a way that it appears as a current source on wires 13 and 15 of the transmission line.
A number of different receiving circuits may be connected in the circuit of FIG. 1 some being balanced and therefore relatively insensitive to common mode interference signals and some being unbalanced and therefore relatively sensitive to common mode signals. An example of an unbalanced receiving circuit is a dial pulse receiver whose pulse detector is connected only to the ring wire of the two-wire transmission path. The pulse detector detects the making and breaking of a dial pulse transmitter in the subscriber subset by sensing voltage differences on the ring wire due to the presence or absence of loop current. If a large common mode interference signal is present the detector would falsely indicate make and break conditions according to the frequency of the common mode interference signal.
Since interference source 21 acts like a current source it will generate a large voltage signal if it is connected to a high impedance receiving circuit and there is no low impedance path to battery associated therewith. Even assuming a receiving circuit which is insensitive to common mode signals, for example a transformer coupling, if there is no low impedance path to battery the high voltage signal generated by interference source 21 will tend to create interference through other means, for example, by exceeding the interwinding breakdown voltage of such a transformer. Although a line is designed to be balanced, any of a number of factors, such as the tolerance of components utilized, can result in a degree of unbalance which can result in common mode interference signals being transformed into differential mode interference signals. As a result, it is desirable to provide a low impedance path to battery for common mode signals regardless of whether the receiving circuit connected through the network is inherently sensitive or insensitive to common mode signals.
The operation of the circuit of FIG. 1 must be considered with respect to: the supply of dc talking battery for the subscriber set 14 and the suppression of common mode noise signals by the isolation of the battery supply 10 from the transmission wires 13 and 15 with respect to differential mode signals such as are generated by the application of voice to the transmitter of the subscriber set 14. The operation of the circuit of FIG. 1 will be considered with respect to common mode and differential mode signals on an individual basis, however, signals which result on the line in these cases are additive.
As previously indicated the serial path for the supply of talking battery from the potential source 10 to the subscriber set 14 includes the transistors 11 and 17. As shown in FIG. 1 the transistor 11 is a NPN transistor with the emitter connected to the resistor 12 which in turn is connected to the line 13, and the transistor 17 is a PNP transistor having the emitter connected to the resistor 16 which is in turn connected to the wire 15. The transistors 11 and 17 are operated in the active or linear range and typically provide a voltage drop between emitter and collector.
The battery supply circuit of FIG. 1 is arranged to suppress common mode signals such as are induced into wires 13 and 15 by an interference source 21 and to permit differential mode signals to be transmitted from the subscriber set 14 to the receiving circuit 20 without substantial attenuation.
In order to understand the operation of the circuit of FIG. 1 with respect to differential and common mode signals the operation of the differential amplifier 30 and the feedback circuitry must be understood. It is an inherent characteristic of differential amplifier 30 that the application of substantially identical signals (such signals are characteristic of common mode noise signals) to the plus and minus input terminals of the differential amplifier 30 results in no change in potential at the output terminals 50 and 51. Accordingly, in the presence of common mode signals, the operation of the differential amplifier 30 is such that there are no resulting variations at the points marked A and B in FIG. 1. Therefore, these points, which are respectively coupled by the resistors 12 and 16, present a relatively low impedance path between the wires 13 and 15 and the terminals of the battery 10.
The differential amplifier 30, in the absence of the feedback resistors 31 and 32, will provide a very large gain between the respective input terminals and output terminals. That is, in the absence of the resistors 31 and 32, a signal applied to the plus terminal will appear as a very large signal at the plus output terminal 50 and a corresponding differential mode signal applied to the minus terminal will appear as a very large signal at the negative output terminal 51. In the circuit of FIG. 1, including the feedback resistors 12 and 16 the gains of the two paths through the differential amplifier 30 are determined by the ratio of the value of the feedback resistor, e.g., resistor 31 and the input coupling resistor, e.g., resistor 37. Similarly the gain from the negative input terminal to the negative output terminal of the differential amplifier is determined by the values of the resistors 32 and 39. In the illustrative example of FIG. 1 these ratios are chosen such that in the presence of differential mode signals the gain of each of the two legs is approximately unity.
Accordingly, in the case of differential mode signals (such as are characteristic of voice or other intelligence) the output terminals 50 and 51 of differential amplifier 30 will track the signals on wires 13 and 15 which are respectively coupled to the plus and minus terminals of the amplifier 30. Since the signals at the terminals 50 and 51 control the current flow through the transistors 11 and 17 the potentials at the points A and B will similarly track the input signals. Since the potentials at the points marked A and B track, on a substantially one for one basis, the potentials at the points C and D, there is no shunting of the differential mode signals by the talking battery supply circuit of FIG. 1.
In the case of common mode signals such as are generated by interference source 21, differential amplifier 30 will be unresponsive and therefore output terminals 50 and 51 will be unresponsive. Resistors 12 and 16 will appear to be connected to battery 10 and therefore will provide a low impedance path to battery 10 for common mode signals. Since the path provided by resistors 12 and 16 is a considerably lower impedance path than that presented by receiving circuit 20, the current source signal presented by interference source 21 will be substantially shunted to battery as is desired.
What has been described is considered to be only a specific illustrative embodiment of the invention and it is to be understood that various other arrangements may be devised by one skilled in the art without departing from the spirit and scope thereof as defined by the accompanying claims. | A telephone line battery feed circuit for supplying talking current to a subscriber subset and at the same time reducing common mode interference signals. The inputs of a differential operational amplifier are coupled to a telephone line and the outputs of the differential operational amplifier are coupled to a battery feed circuit. The battery feed circuit provides talking current to the subscriber subset and the differential operational amplifier presents a high impedance between the battery and the telephone line to differential voice signals while at the same time presenting a low impedance between the telephone line and the battery for common mode interference signals thereby reducing the latter. | 7 |
REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 577,563 of Ciarniello et al. filed May 14, 1975 and entitled An Automatic Cut-Out Device, the entirety of which is incorporated herein by reference; the application has matured as U.S. Pat. No. 4,088,940 on May 9, 1978.
BACKGROUND OF THE INVENTION
The invention refers to a device which automatically cuts out non-essential loads in a generator and storagebattery fed electric circuit when the overall load on the circuit absorbs more power than the power fed by the generator to the battery, in order to prevent the battery charge from sinking below a critical level, i.e. the level below which the battery would become irremediably damaged.
The invention has its main field of application in motor vehicles, to whose electric circuits there are applied additional, non-essential fixtures such as air conditioners, electrically heated windows, a refrigerator etc.
The power plant of modern motor craft is designed to handle under normal operating conditions such additional loads without letting the charge of the storage battery sink below this critical level. However, conditions may occur in which, because of the simultaneous insertion of too many loads into the circuit or because of a reduction in the generator output, the electric power absorbed from the storage battery may exceed the power supplied to it by the generator and consequently its charge may sink to a level where the battery is irreparably damaged.
It is true that the electric plant of today's motor vehicles is provided with a warning lamp which lights up when the generator delivers to the storage battery no power or insufficient power because it stands still, is defective or runs at low speed, thereby signalling to reduce the loads on the electric plant of the vehicle. But there occur also conditions, in which the generator, although operating at full capacity, is still unable to deliver to the battery all the power absorbed therefrom by the loads. In this case, the warning lamp gives no warning, even after the battery has been discharged beyond the critical level, beneath which it becomes irreparably damaged.
The invention provides a device which automatically switches the non-essential loads off the electric circuit of a motor vehicle in those conditions in which the power absorption of the circuit exceeds the available power supply from the generator and switches them on again when these conditions cease.
BRIEF DESCRIPTION OF THE DRAWINGS
For a purely illustrative and in no way limitative purpose, the invention is described with reference to the attached drawings, wherein:
FIG. 1 shows a first embodiment of a generator and battery fed electric plant.
FIG. 2 shows a second embodiment of a generator and battery fed plant incorporating a voltage responsive circuit arranged to effect disconnection of non-essential loads via relay contacts.
FIG. 3 shows a control circuit suitable for use in the circuit of FIG. 2.
FIG. 4 shows a diagram illustrating the operation of the control circuit of FIG. 3.
FIG. 5 shows another control circuit suitable for use in the circuit of FIG. 2.
FIG. 6 shows a diagram illustrating the operation of the control circuit of FIG. 5.
FIG. 7 shows a third possible control circuit for the circuit of FIG. 2 in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment shown in FIG. 1 is extremely simple and easy to install in existing motor vehicle circuits. In it, the circuit 1 of the non-essential or optional loads, as symbolized by a resistor 2, is controlled by the circuit of the usual warning lamp 4, which lamp lights up when the generator produces no current or runs at a slow speed. The solenoid 6 of a relay is connected in parallel with lamp 4. The current supply generator lighting the lamp 4 also energizes the relay to open the circuit 1. A switch 8 for the manual control of circuit 1, an indicator lamp 10 signalling when said circuit is in operation, and a fuse 12 may complete the circuit 1.
However, when there occur the last mentioned conditions for instance during night driving, in which, although the generator runs at full speed, the total load on the electric plant of the vehicle, i.e. the sum of the essential plus the optional loads, absorbs more power than the generator can deliver. In such cases no current will flow through the warning lamp 4 nor through the solenoid 6 to switch off the circuit 1 of the optional loads, with the result that the power absorption by the optional loads would cause the battery charge to sink below its critical level.
The circuitry 14 shown in FIG. 2 obviates this drawback. In addition to this circuit, FIG. 2 shows schematically the generator 16, the storage battery 18 and the known circuit 20, in which the essential loads 22 are inserted through switches and fuses. The circuitry 14 which includes additionally one or more optional loads 24, is closed, when desired, by a manual switch 26. A transistorized control unit A, which will be discussed in greater detail with reference to FIGS. 3 and 7, opens relay contacts 28 of the circuit 14 when the charge of the storage battery 18 passes below the already mentioned critical level and closes them again once the charge rises again beyond it.
Three convenient forms of control unit A (FIG. 2) are shown in FIGS. 3, 5 and 7.
The circuit of the control unit shown in FIG. 3 has an ON state and an OFF state and furthermore the voltage levels to which the passage from the ON to the OFF state corresponds are adjustable by two potentiometers P 1 and P 2 , and therefore the interval in which the OFF state subsists may be adjusted according to requirements.
FIG. 4 shows a time vs voltage diagram. The circuit of FIG. 3 is in the ON state above a Vs or Vs 1 voltage level respectively during the battery charge period a or the battery discharge period b, and is in the OFF state for voltage values lower than these voltage levels. Therefore the optional loads will be inserted into the circuit only when the net voltage lies above said threshold voltages Vs and Vs 1 . As stated, these threshold voltages are adjustable by the potentiometers P 1 and P 2 .
It is known that a storage battery (such as a lead battery) has during the charging phase, from 2.2 V/cell to 2.6 V/cell, while during the discharge stage its voltage output is from 2.2 V/cell to 1.8 V/cell and for lower values the battery is in a substantially discharged state and, if in this state more power is absorbed from it, its cells become irreversibly damaged.
So, for instance, the circuit of FIG. 3 may control the insertion of optional load or loads only at a predetermined level, for instance from 13.2 to 15.6 V for a 12 V lead battery, while for voltages below 13.2 V the optional loads are excluded.
The unit circuit shown in FIG. 3 further permits two threshold values for each charging period and each discharging stage in order to utilize a change of state of the final relay R each time these threshold values are exceeded. Therefore, by using the contacts 28 of the relay R, by the change of state of the relay one may control the switching-in and switcing-off of the optional loads, and, below the lower threshold values Vo and Vo 1 , one may obtain, by the installation of an optical or acoustical device emitting a warning signal in the case of a discharge of the battery for unforeseen reasons (such as shortcircuits, loads fed but not controlled by the units), the result of realizing, in addition to an automatic safeguard, also a control which signals that the battery is being discharged.
In the circuit of FIG. 3, the variation of the feed voltage causes a variation of the base potential of the transistors T 2 and T 3 so as to carry them into conduction in relation to predetermined threshold levels established by the potentiometers P 1 and P 2 and by switching the power transistor T 1 , which energizes the relay R.
Furthermore, the circuit is fitted with a safety device to safeguard it against thermal surges thanks to a thermistor NTC, while a diode D protects the transistor T 1 , from the voltage surges caused by inductive loads.
A simplified version of the circuit of the control unit shown in FIG. 3 is illustrated in FIG. 5. Here a relay is utilized, which for corresponding voltage intervals is in states which are opposite to those illustrated in FIGS. 3 and 4, although it performs the same functions described with reference to FIGS. 3 and 4.
This version presents the advantage of using a smaller number of components and of dissipating less energy, inasmuch as the relay R, in its normal operating condition, is for the greater part of the time, fed at voltages which are higher than the threshold voltages, that is in the OFF zone, as illustrated in FIG. 6. In FIG. 5 the components of the circuit are indicated with reference signs similar to those used for the circuit of FIG. 3.
Therefore, with reference to FIG. 6, the non-essential or optional loads are inserted in the range Vs-VM and VM-Vs 1 (for instance between 13.5 and 15.6 Volt), while in the range Vo-Vs and Vo 1 and Vs 1 only the essential loads are inserted (for instance between 11.8 and 13.5 Volt).
The circuit illustrated in FIG. 5 performs the control of the voltage by determining the change of state of the final relay R each time the applied voltage exceed the threshold voltage Vs, which can be pre-established by the potentiometer P, while the voltage Vs 1 , is the threshold voltage in the discharge phase, corresponding to the voltage Vs during the charging stage.
The circuit has been constructed in such a manner that for applied voltages below Vs the base current of the transistor T 1 is sufficient to keep it in the conduction phase (ON). When the threshold voltage Vs is reached, the transistor T 1 blocks, since the base current is shortcircuited by the transistor T 2 . A thermistor NTC and a resistor series connected with the thermistor provide for the compensation of thermal surges; the diode D protects the transistor T 1 during the voltage surges due to inductive loads.
Therefore the essential purpose of the two units shown in FIGS. 3 and 5 is that of permitting the switching in of the optional loads only when the battery has reached a predetermined level of charge, thereby safeguarding the state of the battery and improving the utilization of the generator, the battery and also improving the power balance of the plant.
In FIG. 7 an integrated unit 30 including a differential amplifier circuit 30a is inserted between the terminals of the battery. The circuit 30 also includes a reference voltage, shown schematically as a battery 30b. It is to be appreciated that in practice, the reference voltage source could in fact be a battery, a voltage regulated circuit or the like. For example, a reversely connected Zener diode could be positioned between the loads shown connected to the battery 30b, in place of the battery with one terminal also being connected to the 12V terminal of the battery. The threshold voltage of the battery, correspondingly to which the integrated unit turns a transistor T 4 on, is fed by a potentiometer P, consisting of three resistors connected in series across the terminals of the battery. The middle resistor is provided with a movable tap which is connected to a first input terminal of the amplifier circuit 30a. The second input terminal of the differencial amplifier is connected to a junction point between two resistors which are connected in series with one another across the reference voltage source, illustrated diagrammatically as the battery 30b. When the battery voltage reaches this threshold level, the current which passes through transistor T 4 will actuate a relay R which closes contacts 28 which insert, into the battery fed circuit, the circuit of the optional loads, one optional load 24 being shown in FIG. 7. Also this version may be equipped with a diode D connected across the relay R and which protects the power transistor T 4 from the current surges of the inductive loads.
In operation the differential amplifier 30a, produces an output signal only in particular conditions of the input signals. On the first input terminal of the amplifier 30a there is present a signal provided by the potentiometer P inserted into the voltage divider fed in parallel with the feed voltage of the vehicle. Only when this voltage exceeds the value pre-established by the second voltage divider connected across the reference voltage source 30b does an output of the differential amplifier 30a appear. This signal is capable of switching on the transistor T 4 which in turn actuates the relay R. When the relay R is energized and therefore the current available from the generator 16 exceeds the current abosrbed by the battery 18 (in order to prevent the optional loads from being fed from the battery instead of from the generator) the contacts 28 of relay R, which is series connected with the switch 26 of the optional loads permits the insertion of these loads.
As soon as the feed voltage of the vehicle sinks, the level of the voltage to the second input of the differential amplifier 30a becomes greater than that on its first input thereby blocking the differential amplifier 30a.
Consequently transistor T 4 is switched off and relay R reverts to its rest position, thereby reopening contacts 28. Under these conditions, even if the switch 26 for the optional loads has been left closed, these loads are cut off, since the contacts 28 have opened. This condition prevails until the battery 18 becomes sufficiently charged or load condition change so that the second input no longer exceeds that first input, then the optional load or loads 24 are again connected.
It is understood that the differential amplifier circuit 30a, with its associated reference voltage source 30b may be carried into practice in different manners according to the known technique. Furthermore, the integrated unit 30 may be dimensioned so as to permit the eliminating of the power transistor T 4 , in effect portions of unit 30 acting as the transistor T 4 .
It is clear that the exemplary embodiment illustrated in FIGS. 2, 7 is for a purely illustrative purpose and in no way limitative. Many variants and changes may be applied to them without departing from the scope of the present invention, its scope being defined in the appended claims.
It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is known in the drawings and described in the specification. | A device for cutting out non-essential loads in a generator and battery-fed electric plant includes a voltage detecting unit connected across the terminals of the battery. The detecting unit may be a relay. Whenever the voltage at the terminals falls below a predetermined level, the detecting unit effects the disconnection of the non-essential load or loads from the terminals of the battery and generator, while allowing the essential load or loads. The detecting unit preferably includes a differential amplifier having one of its inputs connected to a voltage divider connected in parallel with the battery and its second input coupled to a source of reference potential. | 8 |
INTRODUCTION
[0001] The present invention relates generally to printing mechanisms, such as inkjet printers or inkjet plotters. Printing mechanisms often include an inkjet printhead which is capable of forming an image on many different types of media. The inkjet printhead ejects droplets of colored ink through a plurality of orifices and onto a given media as the media is advanced through a printzone. The printzone is defined by the plane created by the printhead orifices and any scanning or reciprocating movement the printhead may have back-and-forth and perpendicular to the movement of the media. Conventional methods for expelling ink from the printhead orifices, or nozzles, include piezo-electric and thermal techniques which are well-known to those skilled in the art. For instance, two earlier thermal ink ejection mechanisms are shown in U.S. Pat. Nos. 5,278,584 and 4,683,481, both assigned to the present assignee, the Hewlett-Packard Company.
[0002] In a thermal inkjet system, a barrier layer containing ink channels and vaporization chambers is located between a nozzle orifice plate and a substrate layer. This substrate layer typically contains linear arrays of heater elements, such as resistors, which are individually addressable and energized to heat ink within the vaporization chambers. Upon heating, an ink droplet is ejected from a nozzle associated with the energized resistor. The inkjet printhead nozzles are typically aligned in one or more linear arrays substantially parallel to the motion of the print media as the media travels through the printzone. The length of the linear nozzle arrays defines the maximum height, or “swath” height of an imaged bar that would be printed in a single pass of the printhead across the media if all of the nozzles were fired simultaneously and continuously as the printhead was moved through the printzone above the media.
[0003] Typically, the print media is advanced under the inkjet printhead and held stationary while the printhead passes along the width of the media, firing its nozzles as determined by a controller to form a desired image on an individual swath, or pass. The print media is usually advanced between passes of the reciprocating inkjet printhead in order to avoid uncertainty in the placement of the fired ink droplets. If the entire printable data for a given swath is printed in one pass of the printhead, and the media is advanced a distance equal to the maximum swath height in-between printhead passes, then the printing mechanism may achieve its maximum throughput.
[0004] Often, however, it is desirable to print only a portion of the data for a given swath, utilizing a fraction of the available nozzles and advancing the media a distance smaller than the maximum swath height so that the same or a different fraction of nozzles may fill in the gaps in the desired printed image which were intentionally left on the first pass. This process of separating the printable data into multiple passes utilizing subsets of the available nozzles is referred to by those skilled in the art as “shingling,” “masking,” or using “print masks.” While the use of print masks does lower the throughput of a printing system, it can provide offsetting benefits when image quality needs to be balanced against speed. For example, the use of print masks allows large solid color areas to be filled in gradually, on multiple passes, allowing the ink to dry in parts and avoiding the large-area soaking and resulting ripples, or “cockle,” in the print media that a single pass swath would cause.
[0005] A printing mechanism may have one or more inkjet printheads, corresponding to one or more colors, or “process colors” as they are referred to in the art. For example, a typical inkjet printing system may have a single printhead with only black ink; or the system may have four printheads, one each with black, cyan, magenta, and yellow inks; or the system may have three printheads, one each with cyan, magenta, and yellow inks. Of course, there are many more combinations and quantities of possible printheads in inkjet printing systems, including seven and eight ink/printhead systems.
[0006] Each process color ink is ejected onto the print media in such a way that the drop size, relative position of the ink drops, and color of a small, discreet number of process inks are integrated by the naturally occurring visual response of the human eye to produce the effect of a large colorspace with millions of discernable colors and the effect of a nearly continuous tone. In fact, when these imaging techniques are performed properly by those skilled in the art, near-photographic quality images can be obtained on a variety of print media using only three to eight colors of ink. This high level of image quality depends on many factors, several of which include: consistent and small ink drop size, consistent ink drop trajectory from the printhead nozzle to the print media, and extremely reliable inkjet printhead nozzles which do not clog.
[0007] Unfortunately, however, there are many factors at work within the typical inkjet printing mechanism which may clog the inkjet nozzles, and inkjet nozzle failures may occur. For example, paper dust may collect on the nozzles and eventually clog them. Ink residue from ink aerosol or partially clogged nozzles may be spread by service station printhead scrapers into open nozzles, causing them to be clogged. Accumulated precipitates from the ink inside of the printhead may also occlude the ink channels and the nozzles. Additionally, the heater elements in a thermal inkjet printhead may fail to energize, despite the lack of an associated clogged nozzle, thereby causing the nozzle to fail.
[0008] Clogged or failed printhead nozzles result in objectionable and easily noticeable print quality defects such as banding (visible bands of different hues or colors in what would otherwise be a uniformly colored area) or voids in the image. In fact, inkjet printing systems are so sensitive to clogged nozzles, that a single clogged nozzle out of hundreds of nozzles is often noticeable and objectionable in the printed output.
[0009] It is possible, however, for an inkjet printing system to compensate for a missing nozzle by removing it from the printing mask and replacing it with an unused nozzle or a used nozzle on a later, overlapping pass, provided the inkjet system has a way to tell when a particular nozzle is not functioning. In order to detect whether an inkjet printhead nozzle is firing, a printing mechanism may be equipped with a low cost ink drop detection system, such as the one described in U.S. Pat. No. 6,086,190 assigned to the present assignee, Hewlett-Packard Company. The nozzle plate of a printhead is inherently near ground potential due to the power supply connections on the printhead. A conductive target may be placed a few millimeters below the nozzle plate, and a biasing voltage may be applied to the target, forming an electric field between the nozzle plate and the target. Upon firing an ink drop, as the ink drop begins to exit the nozzle, a charge accumulates on the protruding tip of the drop, due to the influence of the nozzle-plate-to-target electric field. When drop breakoff occurs, the drop retains this charge. When the drop contacts the target, a small current, in relation to the charge on the drop, is induced from the target to ground. The periodic flow of current from drops striking the target may be converted to a signal voltage by an amplifier which is AC-coupled to the target, and then an analog-to-digital converter may digitize the output signal for processing to determine if a nozzle or group of nozzles are working properly.
[0010] In practical implementation, however, this drop detection system has some limitations. Successive drops of ink, drying on top of one another quickly form stalagmites of dried ink which may grow toward the printhead. Since it is preferable to have the electrostatic sensing element very close to the printhead for more accurate readings, these stalagmites may eventually interfere with or permanently damage the printhead, adversely affecting print quality. Therefore, it is desirable to have a low cost and efficient method and mechanism for ink drop detection which is less susceptible to waste ink residue build-up.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a fragmented perspective view of one form of an inkjet printing mechanism illustrated with one embodiment of an absorbent conductive drop detector.
[0012] FIGS. 2 - 3 are an enlarged, side elevational views illustrating separate embodiments of a drop detector coupled with a paper path support.
[0013] [0013]FIG. 4 is an enlarged, side elevational view of illustrating an embodiment of a drop detector integral with a paper path support.
[0014] FIGS. 5 - 12 are enlarged, partially fragmented perspective views illustrating separate embodiments of non-contact drop detectors.
[0015] FIGS. 13 - 20 are enlarged, partially fragmented perspective views illustrating separate embodiments of non-contact charger drop detectors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] [0016]FIG. 1 illustrates an embodiment of a printing mechanism, here shown as an inkjet printer 20 , constructed in accordance with the present invention, which may be used for printing on a variety of media, such as paper, transparencies, coated media, cardstock, photo quality papers, and envelopes in an industrial, office, home or other environment. A variety of inkjet printing mechanisms are commercially available. For instance, some of the printing mechanisms that may embody the concepts described herein include desk top printers, portable printing units, wide-format printers, hybrid electrophotographic-inkjet printers, copiers, cameras, video printers, and facsimile machines, to name a few. For convenience the concepts introduced herein are described in the environment of an inkjet printer 20 .
[0017] While it is apparent that the printer components may vary from model to model, the typical inkjet printer 20 includes a chassis 22 surrounded by a frame or casing enclosure 24 , typically of a plastic material. The printer 20 also has a printer controller, illustrated schematically as a microprocessor 26 , that receives instructions from a host device, such as a computer, print server, or personal data assistant (PDA) (not shown). A screen coupled to the host device may also be used to display visual information to an operator, such as the printer status or a particular program being run on the host device. Printer host devices, such as computers and PDA's, their input devices, such as a keyboards, mouse devices, stylus devices, and output devices such as liquid crystal display screens and monitors are all well known to those skilled in the art.
[0018] A conventional print media handling system (not shown) may be used to advance a sheet of print media (not shown) from the media input tray 28 through a printzone 30 and to an output tray 31 . A carriage guide rod 32 is mounted to the chassis 22 to define a scanning axis 34 , with the guide rod 32 slideably supporting an inkjet carriage 36 for travel back and forth, reciprocally, across the printzone 30 . A conventional carriage drive motor (not shown) may be used to propel the carriage 36 in response to a control signal received from the controller 26 . To provide carriage positional feedback information to controller 26 , a conventional encoder strip (not shown) may be extended along the length of the printzone 30 and over a servicing region 38 . A conventional optical encoder reader may be mounted on the back surface of printhead carriage 36 to read positional information provided by the encoder strip, for example, as described in U.S. Pat. No. 5,276,970, also assigned to the Hewlett-Packard Company, the present assignee. The manner of providing positional feedback information via the encoder strip reader, may also be accomplished in a variety of ways known to those skilled in the art.
[0019] In the printzone 30 , the media sheet is supported by paper path ribs 39 and receives ink from an inkjet cartridge, such as a black ink cartridge 40 and a color inkjet cartridge 42 . The cartridges 40 and 42 are also often called “pens” by those in the art. The black ink pen 40 is illustrated herein as containing a pigment-based ink. For the purposes of illustration, color pen 42 is described as containing three separate dye-based inks which are colored cyan, magenta, and yellow, although it is apparent that the color pen 42 may also contain pigment-based inks in some implementations. It is apparent that other types of inks may also be used in the pens 40 and 42 , such as paraffin-based inks, as well as hybrid or composite inks having both dye and pigment characteristics. The illustrated printer 20 uses replaceable printhead cartridges where each pen has a reservoir that carries the entire ink supply as the printhead reciprocates over the printzone 30 . As used herein, the term “pen” or “cartridge” may also refer to an “off-axis” ink delivery system, having main stationary reservoirs (not shown) for each ink (black, cyan, magenta, yellow, or other colors depending on the number of inks in the system) located in an ink supply region. In an off-axis system, the pens may be replenished by ink conveyed through a conventional flexible tubing system from the stationary main reservoirs which are located “off-axis” from the path of printhead travel, so only a small ink supply is propelled by carriage 36 across the printzone 30 . Other ink delivery or fluid delivery systems may also employ the systems described herein, such as “snapper” cartridges which have ink reservoirs that snap onto permanent or semi-permanent print heads.
[0020] The illustrated black pen 40 has a printhead 44 , and color pen 42 has a tri-color printhead 46 which ejects cyan, magenta, and yellow inks. The printheads 44 , 46 selectively eject ink to form an image on a sheet of media when in the printzone 30 . The printheads 44 , 46 each have an orifice plate with a plurality of nozzles formed therethrough in a manner well known to those skilled in the art. The nozzles of each printhead 44 , 46 are typically formed in at least one, but typically a plurality of linear arrays along the orifice plate. Thus, the term “linear” as used herein may be interpreted as “nearly linear” or substantially linear, and may include nozzle arrangements slightly offset from one another, for example, in a zigzag arrangement. Each linear array is typically aligned in a longitudinal direction perpendicular to the scanning axis 34 , with the length of each array determining the maximum image swath for a single pass of the printhead. The printheads 44 , 46 are thermal inkjet printheads, although other types of printheads may be used, such as piezoelectric printheads. The thermal printheads 44 , 46 typically include a plurality of resistors which are associated with the nozzles. Upon energizing a selected resistor, a bubble of gas is formed which ejects a droplet of ink from the nozzle and onto the print media when in the printzone 30 under the nozzle. The printhead resistors are selectively energized in response to firing command control signals delivered from the controller 26 to the printhead carriage 36 . It is also possible to implement a page-wide printhead array which does not need to be reciprocated across the printzone 30 .
[0021] Between print jobs, the inkjet carriage 36 moves along the carriage guide rod 32 to the servicing region 38 where a service station 48 may perform various servicing functions known to those in the art, such as, priming, scraping, and capping for storage during periods of non-use to prevent ink from drying and clogging the inkjet printhead nozzles.
[0022] The printer chassis 22 is illustrated as supporting an electrically biased absorbent electrostatic sensing element, or “electrically biased absorbent target” 50 , in the printer's “inboard” region 52 located on the side of service station 48 near the printzone 30 . The print carriage 36 may be moved along carriage guide rod 32 until printheads 44 , 46 are positioned over the electrically biased absorbent target 50 . Ink droplets may be fired onto the upper surface of electrically biased absorbent target 50 and detected according to the method described in U.S. Pat. No. 6,086,190, assigned to the Hewlett-Packard Company, the present assignee. Target 50 may be constructed by using a foam pad which is pretreated with a conductive solvent such as glycerol or polyethylene glycol (PEG). Other absorbent materials may similarly be selected depending on design or cost restraints, for example, the electrically biased absorbent target 50 could be constructed of polyurethane or a rigid and porous sintered plastic. Electrically biased sensing conductor 54 applies a biasing voltage to the target 50 while also connecting the target 50 to an electrostatic drop detect printed circuit board assembly (PCA) 56 . The PCA 56 contains various electronics (not shown) for filtering and amplification of drop detection signals received from the target 50 via electrically biased sensing conductor 54 . An additional electrical conductor 58 links the PCA 56 to controller 26 for drop detection signal processing. PCA 56 may be located in various locations inside of the printer 20 to accommodate design goals such as sharing PCA real estate with other circuitry, locating in the proximity of the target 50 to reduce signal noise effects, or to remove the PCA 56 from the vicinity of conductive ink residue and ink aerosol.
[0023] Electrically biased absorbent target 50 does not need a cleaning mechanism, so it is simple to construct and economical, and should prevent the build-up of ink residue stalagmites as ink droplets are fired onto the target 50 because the droplets can be absorbed into the target 50 and preferably kept in solution by the optional ink solvent present in the target 50 . Electrically biased absorbent target 50 may be constructed in varying sizes to accommodate a portion of a printhead's 44 , 46 nozzles, an entire printhead's 44 , 46 nozzles, or even all of the nozzles for multiple printheads 44 , 46 . Additionally, electrically biased absorbent target 50 may be located in other locations below the plane defined by printheads 44 , 46 as they are propelled by the printhead carriage 36 back and forth on carriage guide rod 32 along scanning axis 34 . Examples of alternate locations for electrically biased absorbent target 50 include, for example, the “outboard region” 60 which is on the opposite side of printzone 30 from the service station 48 , the servicing region 38 , and “outside service station region” 62 .
[0024] FIGS. 2 - 4 illustrate embodiments of a non-contact electrically biased sensing target for use with a drop detector system. The printzone paper path ribs 39 support a sheet of printable media 64 as it is moved through the print zone 30 . For clarity of illustration, the printable media 64 is not shown in contact with the paper path ribs 39 , however, is actual practice, the printable media 64 is in contact with and supported by the paper path ribs 39 in the printzone 30 . As FIG. 2 illustrates, a non-contact electrically biased target 66 may be attached to the printzone paper path ribs 39 such that the target 66 rides below, yet does not interfere with, the printable media 64 as it passes over the paper path ribs 39 through the printzone. An electrically biased sensing conductor 54 may connect the non-contact electrically biased sensing target to the drop detector PCA 56 as illustrated in FIG. 1 for signal filtering and amplification. Electrically biased sensing conductor 54 also provides a biasing voltage to the target 66 . The reciprocating printhead carriage 36 may be moved along carriage guide rod 32 until either of the printheads 44 , 46 or a selected portion of each one is positioned over the non-contact electrically biased target 66 . The biasing voltage present on the target 66 creates an electric field between the target 66 and the ground plane present at the nozzle plate of the printheads 44 , 46 . Selected printhead 44 , 46 nozzles may then be fired in response to commands from controller 26 to eject ink droplets 68 onto the print media 64 over the non-contact electrically biased target 66 . As each droplet 68 begins to exit the printhead 44 , 46 nozzle, a charge accumulates on the protruding tip of the drop, due to the influence of the printhead 44 , 46 nozzle-plate-to-target 66 electric field. When drop breakoff occurs, the drop retains this charge. When the drop contacts the print media 64 , a small capacitive current, in relation to the charge on the ink droplet 68 , is created from the target 66 to ground. The periodic flow of capacitive current, from ink droplets 68 striking the print media 64 over target 66 , may be converted to a digitized signal voltage by PCA 56 which is coupled to the target 66 via electrically biased sensing conductor 54 . Processor 26 may then receive the digital signal from PCA 56 via conductor 58 for processing to determine if a nozzle or group of nozzles are working properly.
[0025] [0025]FIG. 3 illustrates another embodiment of a non-contact electrically biased sensing target for use with a drop detector system. Similar to the target 66 in FIG. 2, the embodiment of FIG. 3 has a non-contact electrically biased target 70 , however the target 70 of FIG. 3 may be coated or attached over the entire length of the paper path ribs 39 in the printzone 30 . The printable media 64 passes over target 70 , supported by target 70 and paper path ribs 39 as the print media 64 is moved through the print zone. Since the target 70 is full-width with respect to the printzone 30 , drop detection measurements may be taken at any location ink droplets 68 are fired onto the print media 64 , by examining the digital signal created by the capacitive current as done for the embodiment in FIG. 2. The embodiment illustrated in FIG. 3 may be used with reciprocating printheads 44 , 46 , or with a full-width printhead array 72 .
[0026] [0026]FIG. 4 illustrates another embodiment of a non-contact electrically biased sensing target for use with a drop detector system. Similar to the target 70 in FIG. 3, the embodiment of FIG. 4 has a full-width non-contact electrically biased target 74 , however the target 74 of FIG. 4 is integrally constructed with the paper path ribs 39 as opposed to the coated or attached target 70 . A conductive material such as, for example, copper, gold, palladium, stainless steel, or conductive plastic may be used to form the target 74 as illustrated in FIG. 4. Since the target 74 also performs the functions of paper path ribs 39 in FIG. 2, the target 74 naturally rides below, and does not interfere with, the printable media 64 as it passes over the target 74 through the printzone. Since the target 74 is full-width with respect to the printzone 30 , drop detection measurements may be taken at any location ink droplets 68 are fired onto the print media 64 , by examining the digital signal created by the capacitive current as done for the embodiment in FIG. 2. The embodiment illustrated in FIG. 4 may be used with reciprocating printheads 44 , 46 , or with a full-width printhead array 72 . Additionally, drop detection measurements taken using the sensors illustrated in FIGS. 2 - 4 may be taken while printing a calibration or test page, or even while printing any print job.
[0027] FIGS. 5 - 10 illustrate embodiments of a non-contact electrically biased sensing target for use with a drop detector system. In each of the embodiments illustrated in FIGS. 5 - 10 , a pen, such as black pen 40 , may be positioned such that the printhead 44 nozzles are aligned over the opening defined by the target loop 76 . It is intended that target loop 76 not be limited to the sizes and shapes shown in FIGS. 5 - 10 . Rather, the intent of illustrating various possible designs for the target loop 76 is to show that many shapes may be good candidates to select for a given application, such as, for example, circles, ovals, squares, rectangles, triangles, trapezoids, and other multi-sided or curved shapes, based on factors such as the size of the printheads, the electric field desired, and manufacturing concerns. The target loop 76 may be constructed by stamping it from a sheet of metal, forming it out of a conductive plastic, coating a plastic of the desired shape with a conductive material, bending a wire, or using a printed circuit board. Other methods of construction will be readily apparent to those skilled in the art, and are intended to be covered within the scope of this description.
[0028] An electrically biased sensing conductor 54 may connect the non-contact target loop 76 to the drop detector PCA 56 as illustrated in FIG. 1 for signal filtering and amplification. Electrically biased sensing conductor 54 provides a biasing voltage to the target loop 76 . The biasing voltage present on the target loop 76 creates an electric field between the target loop 76 and the ground plane present at the nozzle plate of the printhead 44 . Selected printhead 44 nozzles may then be fired in response to commands from controller 26 to eject ink droplets 68 through the opening defined by target loop 76 . As each droplet 68 begins to exit the printhead 44 nozzle, a charge accumulates on the protruding tip of the drop, due to the influence of the printhead 44 nozzle-plate-to-target loop 76 electric field. When drop breakoff occurs, the droplet 68 retains this charge. When the droplet 68 approaches and passes through the opening defined by the target loop 76 , a small current is induced from the target loop 76 , in relation to the charge on the ink droplet 68 , to ground. The periodic flow of this induced current from ink droplets 68 passing through the target loop 76 may be converted to a digitized signal voltage by PCA 56 which is coupled to the target 56 via electrically biased sensing conductor 54 . Processor 26 may then receive the digital signal from PCA 56 via conductor 58 for processing to determine if a nozzle or group of nozzles are working properly. Despite ink aerosol which may be present, target loop 76 does not substantially come into contact with the ink droplets 68 , so it should not need to be cleaned. A spittoon 78 may be provided below the target loop 76 to collect the ink droplets 68 which are fired through the target loop 76 . The spittoon 78 may be appropriately sized to have capacity to hold enough ink droplets 68 for the intended life of the printing mechanism which employs the target loop 76 . The ink droplets 68 may form stalagmites, but the surface of the spittoon where the ink droplets 68 impact can be designed to be far enough away from the printhead 44 to avoid most concerns for stalagmite crashes with the printhead 44 . If stalagmites are still a concern, an absorbent pad 80 , made from such materials as foam or felt, may be fitted into the bottom of spittoon 78 and optionally pretreated with a solvent such as glycerol or polyethylene glycol (PEG). The solvent tends to dissolve the ink droplets 68 , and the absorbent pad 80 tends to absorb the dissolved ink, thereby decreasing the likelihood of stalagmites.
[0029] FIGS. 11 - 12 illustrate embodiments of a non-contact electrically biased sensing plate 82 for use with a drop detector system. In each of the embodiments illustrated in FIGS. 11 - 12 , a pen, such as black pen 40 , may be positioned such that the printhead 44 nozzles may be energized causing ink droplets 68 to pass through an electric field created between the electrically biased sensing plate 82 and the ground plane defined by the printhead 44 nozzles. As FIG. 12 illustrates, multiple electrically biased sensing plates 82 may be used. It is intended that electrically biased sensing plates not be limited to the configurations shown in FIGS. 11 - 12 . Rather, the intent of illustrating possible designs for the electrically biased sensing plates 82 is to show that many plate orientations may be good candidates to select for a given application. The electrically biased sensing plates 82 may be constructed from metal, from conductive plastic, by coating a plastic of the desired shape with a conductive material, or by using a printed circuit board. Other methods of construction will be readily apparent to those skilled in the art, and are intended to be covered within the scope of this embodiment.
[0030] An electrically biased sensing conductor 54 may connect the non-contact electrically biased sensing plates 82 to the drop detector PCA 56 as illustrated in FIG. 1 for signal filtering and amplification. Electrically biased sensing conductor 54 provides a biasing voltage to the electrically biased sensing plates 82 . The voltage present on the electrically biased sensing plates 82 creates an electric field between the sensing plates 82 and the ground plane present at the nozzle plate of the printhead 44 . Selected printhead 44 nozzles may then be fired in response to commands from controller 26 to eject ink droplets 68 through the electric field. As each droplet 68 begins to exit the printhead 44 nozzle, a charge accumulates on the protruding tip of the drop, due to the influence of the printhead 44 nozzle plate-to-electrically biased sensing plates 82 electric field. When drop breakoff occurs, the droplet 68 retains this charge. As the droplet 68 approaches and passes by the electrically biased sensing plates 82 , a small current is induced from the sensing plates 82 , in relation to the charge on the ink droplet 68 , to ground. The periodic flow of this induced current from ink droplets 68 passing by the sensing plates 82 may be converted to a digitized signal voltage by PCA 56 which is coupled to the target 56 via electrically biased sensing conductor 54 . Processor 26 may then receive the digital signal from PCA 56 via conductor 58 for processing to determine if a nozzle or group of nozzles are working properly. Despite ink aerosol which may be present, electrically biased sensing plate 82 does not substantially come into contact with the ink droplets 68 , so it should not need to be cleaned. A spittoon 78 may be provided below the sensing plates 82 , inline with the droplets spit from printhead 44 , to collect the ink droplets 68 which are fired past the sensing plate 82 . The spittoon 78 may be appropriately sized to have capacity to hold enough ink droplets 68 for the intended life of the printing mechanism which employs the biased sensing plate 82 . The ink droplets 68 may form stalagmites, but the surface of the spittoon where the ink droplets 68 impact can be designed to be far enough away from the printhead 44 to avoid most concerns for stalagmite crashes with the printhead 44 . If stalagmites are still a concern, an absorbent pad 80 , made from such materials as foam or felt, may fitted into the bottom of spittoon 78 and optionally pretreated with a solvent such as glycerol or polyethylene glycol (PEG). The solvent tends to dissolve the ink droplets 68 , and the absorbent pad 80 tends to absorb the dissolved ink, thereby decreasing the likelihood of stalagmites.
[0031] FIGS. 13 - 18 illustrate embodiments of a non-contact electrically biased loop in conjunction with a contact sensing target for use with a drop detector system. In each of the embodiments illustrated in FIGS. 13 - 18 , a pen, such as black pen 40 , may be positioned such that the printhead 44 nozzles are aligned over the opening defined by the electrically biased loop 84 . It is intended that electrically biased loop 84 not be limited to the sizes and shapes shown in FIGS. 13 - 18 . Rather, the intent of illustrating various possible designs for the electrically biased loop 76 is to show that many shapes may be good candidates to select for a given application, such as, for example, circles, ovals, squares, rectangles, triangles, trapezoids, and other multi-sided or curved shapes. The electrically biased loop 84 may be constructed by stamping it from a sheet of metal, forming it out of a conductive plastic, coating a plastic of the desired shape with a conductive material, bending a wire, or using a printed circuit board. Other methods of construction will be readily apparent to those skilled in the art, and are intended to be covered within the scope of this embodiment.
[0032] Electrically biased conductor 86 provides a biasing voltage to the electrically biased loop 84 . The voltage present on the electrically biased loop 84 creates an electric field between the electrically biased loop 84 and the ground plane present at the nozzle plate of the printhead 44 . Selected printhead 44 nozzles may then be fired in response to commands from controller 26 to eject ink droplets 68 through the opening defined by electrically biased loop 84 . As each droplet 68 begins to exit the printhead 44 nozzle, a charge accumulates on the protruding tip of the drop, due to the influence of the printhead 44 nozzle-plate-to-electrically biased loop 84 electric field. When drop breakoff occurs, the droplet 68 retains this charge. Droplet 68 passes through the opening defined by the electrically biased loop 84 and contacts conductive target 88 . A sensing conductor 90 connects the target 88 to the drop detector PCA 56 as illustrated in FIG. 1 for signal filtering and amplification. When the droplet 68 contacts the conductive target 88 , a small current is created from the target 88 , in relation to the charge on the ink droplet 68 , to ground. The periodic flow of the current from ink droplets 68 contacting the target 88 may be converted to a digitized signal voltage by PCA 56 . Processor 26 may then receive the digital signal from PCA 56 via conductor 58 for processing to determine if a nozzle or group of nozzles are working properly. Despite ink aerosol which may be present, electrically biased loop 84 does not substantially come into contact with the ink droplets 68 , so it should not need to be cleaned. The target 88 may be placed relatively far from the printhead 44 when compared to the electrically biased loop 84 , reducing the likelihood that stalagmites from the ink droplets 68 may be a problem for the printhead 44 . A spittoon 78 may be provided around target 88 to contain the ink residue incident on the target 88 . Additionally, the conductive target 88 may be constructed of an absorbent pad which is pretreated with a conductive solvent such as glycerol or polyethylene glycol (PEG). Other absorbent materials may similarly be selected depending on design or cost restraints, for example, the conductive target 88 could be constructed of polyurethane or a rigid and porous sintered plastic. The solvent tends to dissolve the ink droplets 68 . The absorbent pad version of conductive target 88 tends to absorb the dissolved ink, thereby decreasing the likelihood of stalagmites.
[0033] FIGS. 19 - 20 illustrate embodiments of a non-contact electrically biased plate 92 in conjunction with a contact sensing target 88 for use with a drop detector system. In each of the embodiments illustrated in FIGS. 19 - 20 , a pen, such as black pen 40 , may be positioned such that the printhead 44 nozzles may be energized causing ink droplets 68 to pass through an electric field created between the electrically biased plate 92 and the ground plane defined by the printhead 44 nozzles. As FIG. 20 illustrates, multiple electrically biased plates 92 may be used. It is intended that electrically biased plates 92 not be limited to the configurations shown in FIGS. 19 - 20 . Rather, the intent of illustrating possible designs for the electrically biased plates 92 is to show that many plate orientations may be good candidates to select for a given application. The electrically biased plates 92 may be constructed from metal, molded of a conductive plastic, coated on a plastic of the desired shape with a conductive material, or fabricated by using a printed circuit board. Other methods of construction will be readily apparent to those skilled in the art, and are intended to be covered within the scope of this embodiment.
[0034] Electrically biased conductor 86 provides a biasing voltage to the electrically biased plates 92 . The voltage present on the electrically biased plates 92 creates an electric field between the electrically biased plates 92 and the ground plane present at the nozzle plate of the printhead 44 . Selected printhead 44 nozzles may then be fired in response to commands from controller 26 to eject ink droplets 68 through the electric field. As each droplet 68 begins to exit the printhead 44 nozzle, a charge accumulates on the protruding tip of the drop, due to the influence of the printhead 44 nozzle-plate-to-electrically biased plates 92 electric field. When drop breakoff occurs, the droplet 68 retains this charge. A sensing conductor 90 connects the target 88 to the drop detector PCA 56 as illustrated in FIG. 1 for signal filtering and amplification. When the droplet 68 contacts the conductive target 88 , a small current is created from the target 88 , in relation to the charge on the ink droplet 68 , to ground. The periodic flow of the current from ink droplets 68 contacting the target 88 may be converted to a digitized signal voltage by PCA 56 . Processor 26 may then receive the digital signal from PCA 56 via conductor 58 for processing to determine if a nozzle or group of nozzles are working properly. Despite ink aerosol which may be present, electrically biased plates 92 do not substantially come into contact with the ink droplets 68 , so the plates 92 should not need to be cleaned. The target 88 may be placed relatively far from the printhead 44 when compared to the electrically biased plates 92 , reducing the likelihood that possible stalagmites from the ink droplets 68 may be a problem for the printhead 44 . A spittoon 78 may be provided around target 88 to contain the ink residue incident on the target 88 . Additionally, the conductive target 88 may be constructed of an absorbent pad which is pretreated with a conductive solvent such as glycerol or polyethylene glycol (PEG). Other absorbent materials may similarly be selected depending on design or cost restraints, for example, the conductive target 88 could be constructed of polyurethane or a rigid and porous sintered plastic. The solvent tends to dissolve the ink droplets 68 . The absorbent pad version of conductive target 88 tends to absorb the dissolved ink, thereby decreasing the likelihood of stalagmites.
[0035] In each of the embodiments illustrated in FIGS. 13 - 20 , the non-contact loops 84 and the non-contact plates 92 have been described as supplied with a biasing voltage by conductor 86 . Additionally, the targets 88 in FIGS. 13 - 20 have been described as connected to the drop detector PCA 56 by conductor 90 . It is also possible, however, to switch the connectors 86 and 90 so that the loops 84 and plates 92 are used exclusively as non-contact sensing elements for ink drop detection and the targets 88 are used exclusively for electrically biasing. In this set of embodiments, As each droplet 68 begins to exit the printhead 44 nozzle, a charge accumulates on the protruding tip of the drop, due to the influence of the printhead 44 nozzle-plate-to-target 88 electric field. When drop breakoff occurs, the droplet 68 retains this charge. When the droplet 68 passes by the loop 84 or plates 92 , a small current is induced from the loop 84 or the plates 92 , in relation to the charge on the ink droplet 68 , to ground. The periodic flow of this induced current may be converted to a digitized signal voltage by PCA 56 . Processor 26 may then receive the digital signal from PCA 56 via conductor 58 for processing to determine if a nozzle or group of nozzles are working properly.
[0036] Various non-contact electrically biasing and sensing electrostatic drop detect target configurations, as well as absorbent target configurations have been illustrated with example embodiments to enable a low cost and efficient method and mechanism for ink drop detection which is less susceptible to waste ink residue build-up. Each of the target and electrically biasing element embodiments illustrated in FIGS. 1 - 20 may be constructed in varying sizes to accommodate a portion of a printhead's 44 , 46 nozzles, an entire printhead's 44 , 46 nozzles, or even all of the nozzles for multiple printheads 44 , 46 . Additionally, target and electrically biasing element embodiments illustrated in FIG. 1 and FIGS. 5 - 20 may be located in many locations below the plane defined by printheads 44 , 46 . Examples of locations for the target and electrically biasing element embodiments illustrated in FIG. 1 and FIGS. 5 - 20 include, for example, the “inboard region” 52 between the printzone and the service station, the “outboard region” 60 which is on the opposite side of printzone 30 from the service station 48 , the servicing region 38 , and “outside service station region” 62 .
[0037] Non-contact electrically biasing and sensing electrostatic drop detect target configurations, as well as absorbent target configurations enable a printing mechanism to reliably and economically gather ink drop detection readings, without the need for a cleaning mechanism to clean the target surface, in order to provide users with consistent, high-quality, and economical inkjet output despite printheads 44 , 46 which may clog over time. In discussing various components of the non-contact electrically biasing and sensing electrostatic drop detect target configurations, as well as absorbent target configurations, various benefits have been noted above.
[0038] It is apparent that a variety of other structurally equivalent modifications and substitutions may be made to construct non-contact electrically biasing and sensing electrostatic drop detect target configurations, as well as absorbent target configurations, according to the concepts covered herein depending upon the particular implementation, while still falling within the scope of the claims below. | A sensor configuration for use in detecting ink droplets ejected from an ink drop generator is provided. The sensor configuration includes a sensing element configured to receive a biasing voltage which creates an electric field from the sensing element to the ink drop generator. The sensor configuration also includes a sensing amplifier coupled to the sensing element, whereby the sensing element in imparted with an electrical stimulus when at least one ink droplet is ejected in the presence of the electric field, and thereafter passes in close proximity to the sensing element without substantially contacting the sensing element. Sensor configurations with a separate electrically biasing element which may or may not contact the ink droplets are also provided. Additionally, a printing mechanism having such sensor configurations and a method of making ink drop detection measurements are also provided. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the cleaning in turbulent flow regime of wellbore wall or tubing or casing. The present invention particularly relates to a process for the cleaning in turbulent flow regime of wellbore wall or tubing or casing using aqueous surfactant compositions.
2. Background of the Invention
An effective cleanout operation is important during drilling or workover of an oil or gas well, or for an acidizing treatment of a geological formation, or to secure the establishment of an effective bond between a cement composition and a wellbore wall or tubing or casing, in order to avoid undesirable results in oil and gas well operations. This is because, by way of example, an ineffective cleanout operation during drilling or workover of an oil well can result in damage where contamination and even plugging occurs at the formation from which there is intention to produce fluids.
Similarly, where an acidizing treatment of a formation is intended to increase the productivity of the formation, in the case that oil based contaminants are not removed from the wellbore zone adjacent to the formation interval, there can be a reduction in the effectiveness of the acidizing treatment. Moreover, poor cleaning of the wellbore wall, casing, liner or tubing string, can reduce the quality of the cement bonding during cementing operations, and therefore permit undesirable flow of fluids along the wellbore, or undesirable interconnection between separate formations zones, or undesirable fluid flow around the casing, or a failure to stabilize the casing in the wellbore. Remedial action for any of the above-mentioned problems, or resulting contamination of a formation interval, can incur substantial costs in both onshore and offshore well operations.
Foxenberg et al., describe in Hart's Petroleum Engineer International, October 1998, p23-28, that for cleaning regimes where a cleaning agent flows over a surface to be cleaned such as the displacement of a drilling fluid with a spacer fluid, turbulent flow usually has the advantage of increasing the cleaning efficiency. To promote a turbulent flow regime, those skilled in the art normally use commercially available cleaning agents, diluted with locally available water, which is viscosified by addition of suitable polysaccharide-based, or other, viscosifiers.
In recent years alkylpolyglycoside-based surfactants have increased in importance because they are made from renewable raw materials, they have an excellent environmental profile and their excellent surfactant properties. They have become especially important in detergent compositions, primarily for household cleaning products. Anionic derivatives of alkylpolyglycosides are known in literature, e.g. from EP 510564 and EP 510565. The advantages of alkylpolyglycoside-based surfactants have led to their use in other fields; WO 0069261, e.g., describes their application in compositions for agrochemical preparations. Synergism between the alkylpolyglycosides and the anionic surfactants is commonly exploited in the personal care and detergent sectors.
In practice, some weight ratios of binary mixtures of alkylpolyglycosides with anionic surfactants show synergic behavior for some fundamental surfactant properties, such as lowering critical micelle concentration, interfacial tension, and the like, for some important applicative parameters including increases in foaming, wetting, dishwashing performance, and the like. The use of combinations of alkylpolyglycosides with traditional (non alkylpolyglycoside-based) anionic surfactants are widely described, as reviewed by Fabry, et al., in Happi (August 1994 p, 111-115). It is possible to find descriptions of many compositions and processes related to the use of alkylpolyglycoside-based surfactants for well bore cleaning. For example, the following U.S. Pat. Nos. 5,977,032, 5,996,692, and 6,112,814 all disclose such applications.
Solutions of alkylpolyglycoside based synergic surfactant mixtures are effective in removing water and oil based drilling fluids, thread sealant and lubricating materials and oil based contaminants commonly found in wellbores; these include diesel oil, mineral oil, synthetic oils and crude oil and naturally occurring hydrocarbon substances. Alkylpolyglycoside based surfactant mixtures can be used as wetting, dispersing and/or emulsifying agents in caustic environments, such as in contact with cement slurries, remaining surface active at relatively high pH.
Chan, in U.S. Pat. No. 5,458,197, suggested the use of traditional anionics as cosurfactants in alkylpolyglycoside cleaning compositions for oil and gas well operations, but does not mention the use of the anionic derivatives of alkylpolyglycosides.
Notwithstanding the improvements in well cleanout operations described in these patents, there continues to be a need to provide a cleanout composition which maintains or improves on the characteristics needed for cleaning and that has improved toxicological and environmental properties, in line with legislation governing the use of chemicals in the oil and gas industry, and especially for offshore operations.
SUMMARY OF THE INVENTION
In one aspect, the present invention is a process for cleaning a wellbore wall, tubing or casing using a turbulent flow regime characterized by: (a) preparing an aqueous surfactant composition containing from about 10% to 60% by weight of a mixture of surfactants, the mixture comprising from 10% to 50% by weight of an anionic derivative of an alkylpolyglycoside, from 35% to 80% by weight of an alkylpolyglycoside and from 5% to 25% by weight of an anionic derivative of a fatty alcohol, their balance being 100%; (b) diluting the aqueous surfactant composition in water to form a diluted aqueous surfactant composition and injecting the diluted aqueous surfactant composition into a wellbore containing drilling mud, oily residues or other undesirable deposits; (c) extracting from the wellbore the diluted aqueous surfactant composition containing the drilling mud, oily residues or other undesirable deposits; (d) removing the drilling mud, oily residues or other undesirable deposits from the diluted aqueous surfactant composition; and (e) optionally, re-using the diluted aqueous surfactant composition.
In another aspect, the present invention is an aqueous surfactant composition for use in cleaning wellbore walls, tubing or casings comprising (a) from about 10% to 60% by weight of a mixture of surfactants, the mixture comprising from 10% to 50% by weight of an anionic derivative of an alkylpolyglycoside, (b) from 35% to 80% by weight of an alkylpolyglycoside and (c) from 5% to 25% by weight of an anionic derivative of a fatty alcohol, their balance being 100%.
In still another aspect, the present invention is a process for the preparation of these aqueous surfactant compositions characterized by: (a) reacting at 110-130° C. for about 2-3 hours a reducing saccharide with a fatty alcohol, the alcohol being in a 2 to 5 fold molar excess, forming a reaction mixture; (b) distilling off from the reaction mixture part of the unreacted fatty alcohol thus obtaining a mixture of alkylpolyglycoside and fatty alcohol containing from 3% to 15% of fatty alcohol; (c) esterifying the mixture of alkylpolyglycoside and fatty alcohol by adding to the mixture of alkylpolyglycoside and fatty alcohol at 110-130° C. over a period of 15-240 minutes a bi- or tri-carboxylic acid selected from the group consisting of citric acid, tartaric acid, malic acid, maleic acid, and mixtures thereof, forming an esterified mixture of alkylpolyglycoside and fatty alcohol; (d) diluting the esterified mixture of alkylpolyglycoside and fatty alcohol with water; and (e) neutralizing the resulting product.
In another aspect, the present invention is a process for the preparation of these aqueous surfactant compostions, characterized by to (a) reacting at 110-130° C. for about 2-3 hours a reducing saccharide with a fatty alcohol, the fatty alcohol being in a 2 to 5 fold molar excess, forming a reaction mixture; (b) distilling off from the reaction mixture part of the unreacted fatty alcohol thus obtaining a mixture of alkylpolyglycoside and fatty alcohol containing from 3% to 15% of fatty alcohol; (c) esterifying the mixture of alkylpolyglycoside and fatty alcohol by adding maleic anhydride to the mixture of alkylpolyglycoside and fatty alcohol at 110-130° C. over a period of 15-240 minutes; (d) diluting the esterified mixture of alkylpolyglycoside and fatty alcohol with water; and (e) sulfonating the resulting mixture.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the preferred embodiment of the present invention the total concentration of surfactants in the aqueous surfactant composition is about 20% to 50% by weight and the mixture of surfactants comprises from 15% to 45% by weight of an anionic derivative of an alkylpolyglycoside, from 40% to 75% by weight of an alkylpolyglycoside and from 8% to 15% by weight of an anionic derivative of a fatty alcohol, their balance being 100%. Respectively, the anionic derivative of an alkylpolyglycoside, the alkylpolyglycoside and the anionic derivative of fatty alcohol of the present invention are compounds represented by the formulae I, II and III:
I.
[R-O-(G) x ] n -(D) y
II.
R-O-(G) x
III.
R-O-D
where:
R is an aliphatic group, saturated or unsaturated, linear or branched,
having from 6 to 20 atoms of carbon, preferably from 8 to 16 atoms of carbon;
G is a residue of a reducing saccharide, preferably of glucose, connected to R—O by means of an ethereal O-glycosidical bond;
O is an oxygen atom;
D is an acyl residue of sulfosuccinic acid or of a carboxylic acid selected from the group consisting of citric, tartaric, maleic and malic acid.
n is a number between 1 and m−1, where m is the number of carboxylic groups in the acid that originates D;
x is a number from 1 to 10, representing the average degree of oligomerization of G;
y is a number from 1 to 10 representing the degree of average esterification of (G) x .
According to a fundamental aspect of the present invention, the aqueous surfactant composition containing from about 10% to 60% by weight of a mixture of surfactants is directly prepared by
a) reacting at 110-130° C. for about 2-3 hours a reducing saccharide, preferably glucose, with a fatty alcohol, the alcohol being in a molar excess of from 2 to 5 folds;
b) distilling off from the reaction mixture part of the unreacted fatty alcohol thus obtaining a mixture of alkylpolyglycoside and fatty alcohol containing from 3% to 15% by weight of fatty alcohol;
c) esterifying the mixture of alkylpolyglycoside and fatty alcohol thus obtained by adding to the reaction mixture at 110-130° C. over a period of 15-240 minutes maleic anhydride or a bi- or tri-carboxylic acid selected in the group consisting of citric acid, tartaric acid, maleic acid and malic acid;
d) diluting with water the cooled reaction mixture;
e) if maleic anhydride is used in step c), sulfonating the resulting mixture; or, if citric, tartaric, maleic or malic acid is used in step c), neutralizing the resulting mixture.
The aqueous surfactant composition of the present invention may advantageously comprise glycols, polyglycols or oligoglycols. Examples of glycols, polyglycols and oligoglycols include polyethylene glycol, polypropylene glycol, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, polyethylene glycol monomethylether, polypropylene glycol monomethylether, ethylene glycol monomethylether, propylene glycol monomethylether, diethylene glycol monomethylether, dipropylene glycol monomethylether, polyethylene glycol dimethylether, polypropylene glycol dimethylether, ethylene glycol dimethylether, propylene glycol dimethylether, diethylene glycol dimethylether, dipropylene glycol dimethylether. Preferred glycols according to the present invention are ethylene glycol, diethylene glycol or dipropylene glycol.
When considering surfactant compositions used in wellbore cleaning operations, particularly important is their toxicity to aquatic organisms, especially those low in the food chain, because of the possibility of accidental or willful discharge into the marine environment of the cleaning compositions, or of fluids contaminated with the cleaning compositions. For this reason, diagnostic toxicity testing of the aqueous surfactant compositions of the present invention were performed on the salt water crustacean, Artemia Salina . The aqueous surfactant compositions of the present invention exhibit an excellent cleaning performance while showing a clear eco-toxicological advantage over conventional compositions.
Cleaning agents, for oil and gas well use, are generally commercially supplied as relatively concentrated products and are normally diluted with locally available water before use. In the preferred embodiments of the invention, the aqueous surfactant compositions are diluted at from 1 to 10% by weight in viscosified water. The water may be hard or soft, or may very rarely be sea water when the supply of fresh water is severely limited.
Cleaning agents must meet specific performance requirements, specifically in terms of cleaning ability, compatibility with other substances used in the cleaning system and compliance with environmental legislation. The compositions of the present invention may also be applied in pipeline cleaning or pigging operations, for gravel pack or fracture cleaning fluids for wells, in spacer fluids, corrosion inhibitor fluids, wetting agents for cement slurries, as well as foaming agents and in other cleaning operations which are associated with hydrocarbon production and transport. These compositions are most useful for wellbore cleanout operations when the salinity and temperature involved with cleanout will not result in degradation of the composition or loss of its effectiveness.
The fluid remaining in a wellbore after completion of the drilling and casing process may well contain a significant amount of brine. Thus any cleaning solution used should be stable over a relatively wide range of temperatures, be tolerant of both caustic and acidic fluid compositions, and be tolerant over a relatively wide range of fluid salinity. The aqueous surfactant compositions in accordance with the present invention exhibit these properties in the conditions used in field applications.
It is known to those skilled in the art that cleaning regimes where a cleaning agent flows over a surface to be cleaned can be divided into laminar flow or turbulent flow regimes, where turbulent flow usually has an advantage of increasing the cleaning efficiency. To promote a turbulent flow regime, those skilled in the art often will use the cleaning agents, which are commercially supplied as concentrated products, and dilute them with locally available fresh water, which is viscosified by addition of commercial grades of suitable polysaccharide-based, or other, viscosifiers.
In a particular embodiment of the invention, it is generally preferred to add the present surfactant mixture to water viscosified with a natural polysaccharide, such as xanthan gum, in order to obtain a viscous aqueous composition suitable for cleaning under turbulent flow conditions.
The following examples are provided to illustrate the present invention. The examples are not intended to limit the scope of the present invention and they should not be so interpreted. Amounts are in weight parts or weight percentages unless otherwise indicated.
EXAMPLE 1
1a) Preparation of Composition 1
In a reaction vessel equipped with heating, cooling, stirrer, thermometer, a system of introduction of the reagents, such reaction vessel being connected both to a cooler provided of collector of water of reaction, and to a vacuum pump, the following components are added, under stirring: 930 g (5 mol) of a mixture of decyl alcohol, dodecyl alcohol, tetradecyl alcohol and hexadecyl alcohol with ratio 26:50:23,5:0,5, and 1.4 g of p-toluenesulphonic acid monohydrate. The temperature is set at 120° C. while the vacuum pump applies a pressure of 50-60 mm Hg. At a temperature of 120° C., 180 g (1 mol) of anhydrous glucose are added in portions in about 120 minutes. At the end of the last addition, the temperature of 120° C. is maintained for another 30 minutes, then the temperature is decreased to 50-60° C. and the neutralization is carried out with 1 g of a 30% solution of sodium hydroxide. The obtained product is an alkyl (C10-C12-C14-C16) polyglucoside containing about 75% of free fatty alcohol. By means of distillation on thin layer at 150° C. and at a pressure of 2 mmHg, the main part of unreacted fatty alcohol is distilled off, thus yielding an alkyl (C10-C12-C14-C16) polyglucoside containing about 12% of free fatty alcohol. The degree of glucose oligomerization is about 1.2.
In a reactor analogous to that described above, 148.4 g of the alkyl (C10-C12-C14-C16) polyglucoside containing about 12% of free fatty alcohol are introduced. The temperature is adjusted to 120° C. under stirring. At this temperature 22.6 g of maleic anhydride are added over a period of about 15 minutes. The reaction mixture is maintained at 120° C. until the acidity number reaches 76 (+/−3) mg/g of KOH. Then the reaction mixture is cooled down to 110-115° C. and a dilution is made with 244.4 g of water. The temperature is then adjusted to 80° C. and 29 g of sodium sulfite are added over a period of about 30 minutes.
The reaction mixture is mantained at 80° C. under stirring for 3 hours and then cooled down to room temperature (20° C.), thus obtaining about 444 g of an of an aqueous solution, where the dry fraction is 45% by weight and consists of about 40% of alkylpolyglucoside sulfosuccinic ester sodium salt, about 40% of alkylpolyglucoside and about 20% of fatty alcohol sulfosuccinic ester sodium salt (Composition 1)
1b) Evaluation of the Cleaning Efficiency of Composition 1
The Composition 1, diluted at 4% in water, is tested, in an essentially laminar flow cleaning situation, using the following method, performed at room temperature.
A rotating vertical steel cylinder about 4 cm in diameter is used to emulate drilling equipment and is immersed to a depth of about 4 cm into the test drilling fluid while rotating the cylinder at 600 rpm for one minute. The rotation is stopped and the cylinder removed from the drilling fluid and left stationary for another 30 seconds. The cylinder is then immersed to a depth of about 4 cm into a solution of the cleaning composition being tested while continuously rotating the cylinder at 200 rpm. At intervals of one minute after immersion the cylinder is inspected visually by the operator and the appearance of the cylinder is recorded using the following numerical scale:
5—no effect
4—some drilling fluid has been removed
3—more drilling fluid has been removed but the cylinder is still substantially covered with drilling fluid
2—the drilling fluid is partly removed from the cylinder
1—almost all the drilling fluid has been removed from the cylinder
0—the cylinder is free of drilling fluid and is now clean.
The test oil-based drilling fluid consists of a water-in-oil emulsion, where the oil is mineral oil, with the addition of barite as weighting agent, and chemical emulsifier, organophilic bentonite as viscosifier, and lime for pH control.
The same method is used to evaluate the cleaning efficiency of Composition 1 in turbulent flow regime by diluting it at 4% in water containing 0.8% of xanthan. The results of the tests are reported in Table 1 as the appearance of the cylinder.
TABLE 1
Appearance of the cylinder
Dilution of
After
After
After
After
After
Composition 1
1
2
3
4
5
in:
minute
minutes
minutes
minutes
minutes
Water
5
5
4
4
3
Thickened Water
2
1
0
0
0
1c) Toxicity Test on Composition 1
The LC 50 of Composition 1 is 14 mg/l, according to an Acute Toxicity Testing on Artemia S . performed on the salt water crustacean, Artemia Salina following the procedures devised by the Laboratory of Biological Research in Aquatic Pollution of Ghent University.
EXAMPLE 2
2a) Preparation of Composition 2
In a reaction vessel equipped with heating, cooling, stirrer, thermometer, a system of introduction of the reagents, such reaction vessel being connected both to a cooler and to a vacuum pump, the following components are added, under stirring: 930 g (5 mol) of a mixture of decyl alcohol, dodecyl alcohol, tetradecyl alcohol and hexadecyl alcohol with ratio 26:50:23,5:0,5, and 1.4 g of p-toluenesulphonic acid monohydrate. The temperature is set at 120° C. while the vacuum pump applies a pressure of 50-60 mm Hg. At a temperature of 120° C., 180 g (1 mol) of anhydrous glucose are added in portions in about 120 minutes. At the end of the last addition the temperature of 120° C. is maintained for another 30 minutes, then the temperature is decreased to 50-60° C. and the neutralization is carried out with 1 g of a 30% solution of sodium hydroxide. The obtained product is an alkyl (C10-C12-C14-C16) polyglucoside containing about 75% of free fatty alcohol. By means of distillation on thin layer at 150° C. and at a pressure of 2 mmHg, the main part of unreacted fatty alcohol is distilled off, thus yielding an alkyl (C10-C12-C14-C16) polyglucoside containing about 4% of free fatty alcohol. The degree of glucose oligomerization is about 1.2.
In a reactor analogous to that described above, 178.6 g of the alkyl (C10-C12-C14-C16) polyglucoside containing about 4% of free fatty alcohol are introduced. The temperature is adjusted to 120° C. under stirring; at this temperature 9.4 g of maleic anhydride are added over a period of about 15 minutes. The reaction mixture is maintained at 120° C. until the acidity number reaches 29 (+/−3) mg/g of KOH. Then the reaction mixture is cooled down to 110-115° C. and a dilution is made with 942.8 g of water. The temperature is than adjusted to 80° C. and 12 g of sodium sulfite, are added, over a period of about 30 minutes.
The reaction mixture is mantained at 80° C. under stirring for 3 hours and then cooled down to room temperature (20° C.), thus obtaining about 1143 g of an of an aqueous solution, where the dry fraction is 17.5% by weight and consists of about 17% of alkylpolyglucoside sulfosuccinic ester sodium salt, about 75% of alkylpolyglucoside and about 8% of fatty alcohol sulfosuccinic ester sodium salt (Composition 2).
2b) Evaluation of the Cleaning Efficiency of Composition 2
Composition 2 is diluted at 4% in water and tested, in an essentially laminar flow cleaning situation, by the method described in Example 1. The same method is used to evaluate the cleaning efficiency of Composition 2 in turbulent flow regime by diluting it at 4% in water containing 0.8% of xanthan. The results of the tests are reported in Table 2 as the appearance of the cylinder.
TABLE 2
Appearance of the cylinder
Dilution of
After
After
After
After
After
Composition 2
1
2
3
4
5
in
minute
minutes
minutes
minutes
minutes
Water
4
4
4
4
4
Thickened Water
2
2
1
0
0
2c) Toxicity Test on Composition 2
The LC 50 of Composition 2 is 69 mg/l, according to an Acute Toxicity Testing on Artemia S . performed on the salt water crustacean, Artemia Salina following the procedures devised by the Laboratory of Biological Research in Aquatic Pollution of Ghent University.
EXAMPLE 3
3a) Preparation of Composition 3
In a reaction vessel equipped with heating, cooling, stirrer, thermometer, a system of introduction of the reagents, such reaction vessel being connected both to a cooler and to a vacuum pump, the following components are added, under stirring: 930 g (5 mol) of a mixture of decyl alcohol, dodecyl alcohol, tetradecyl alcohol and hexadecyl alcohol with ratio 26:50:23,5:0,5, and 1.4 g of p-toluenesulphonic acid monohydrate. The temperature is set at 120° C. while the vacuum pump applies a pressure of 50-60 mm Hg. At a temperature of 120° C., 180 g (1 mol) of anhydrous glucose are added in portions in about 120 minutes. At the end of the last addition the temperature of 120° C. is maintained for another 30 minutes, then the temperature is decreased to 50-60° C. and the neutralization is carried out with 1 g of a 30% solution of sodium hydroxide. The obtained product is an alkyl (C10-C12-C14-C16) polyglucoside containing about 75% of free fatty alcohol. By means of distillation on thin layer at 150° C. and at a pressure of 2 mmHg, the main part of unreacted fatty alcohol is distilled off, thus yielding an alkyl (C10-C12-C14-C16) polyglucoside containing about 4% of free fatty alcohol. The degree of glucose oligomerization is about 1.2.
In a reactor analogous to that described above, 178.6 g of the alkyl (C10-C12-C14-C16) polyglucoside containing about 4% of free fatty alcohol are introduced. The temperature is adjusted to 120° C. under stirring; at this temperature 9.4 g of maleic anhydride are added over a period of about 15 minutes. The reaction mixture is maintained at 120° C. until the acidity number reaches 29 (+/−3) mg/g of KOH. Then the reaction mixture is cooled down to 110-115° C. and a dilution is made with 942.8 g of water. The temperature is then adjusted to 80° C. and 12 g of sodium sulfite, are added, over a period of about 30 minutes.
The reaction mixture is mantained at 80° C. under stirring for 3 hours and then cooled down to room temperature (20° C.). 170 g of diethyleneglycol are then added, always under stirring, thus obtaining about 1313 g of an of an aqueous solution, where the dry fraction is about 28% by weight and consists of 9% by weight of alkylpolyglucoside sulfosuccinic ester sodium salt, of 40% of alkylpolyglucoside, of 5% of fatty alcohol sulfosucccinic ester sodium salt and of 46% of diethyleneglycol (Composition 3).
3b) Evaluation of the Cleaning Efficiency of Composition 3
Composition 3 is diluted at 4% in water and tested, in an essentially laminar flow cleaning situation, by the method described in Example 1. The test on the Composition 3 in water is performed in an essentially laminar flow cleaning situation. The same method is used to evaluate the cleaning efficiency of Composition 3 in turbulent flow regime by diluting it at 4% in water containing 0.8% of xanthan. The results of the tests are reported in Table 3 as the appearance of the cylinder.
TABLE 3
Appearance of the cylinder
Dilution of
After
After
After
After
After
Composition 3
1
2
3
4
5
in
minute
minutes
minutes
minutes
minutes
Water
4
4
4
4
4
Thickened
2
1
0
0
0
Distilled Water
3c) Toxicity Test on Composition 3
The LC 50 of Composition 3 is 79 mg/l, according to an Acute Toxicity Testing on Artemia S . performed on the salt water crustacean, Artemia Salina following the procedures devised by the Laboratory of Biological Research in Aquatic Pollution of Ghent University.
COMPARATIVE EXAMPLE 4
An aqueous surfactant composition, where the dry fraction is 38% by weight and consists of 24% by weight of alkyl (C10-C12-C14-C16) polyglucoside sulfosuccinic ester sodium salt with a degree of glucose oligomerization of 1.2, of 64% of alkyl (C10-C12-C14-C16) polyglucoside with a degree of glucose oligomerization 1.2, and of 12% of fatty alcohol sulfosucccinic ester sodium salt (Composition 4) was diluted at 1% in water and in artificial sea water and tested, in an essentially laminar flow cleaning situation, by the method described in Example 1. The results of the tests are reported in Table 4 as the appearance of the cylinder.
TABLE 4
Appearance of the cylinder
Dilution of
After
After
After
After
After
Composition 4
1
2
3
4
5
in
minute
minutes
minutes
minutes
minutes
Water
4
3
3
2
2
Sea Water
4
3
3
3
3
The LC 50 of Composition 4 is 21 mg/l, according to an Acute Toxicity Testing on Artemia S . performed on the salt water crustacean, Artemia Salina following the procedures devised by the Laboratory of Biological Research in Aquatic Pollution of Ghent University.
COMPARATIVE EXAMPLE 5
The commercial product USL WASH W, from Lamberti USA Inc., diluted at 4% in water and in artificial sea water, is tested, in an essentially laminar flow cleaning situation, by the method described in Example 1. The same method is used to evaluate the cleaning efficiency USL Wash W in turbulent flow regime by diluting it at 4% in water containing 0.8% of xanthan. The results of the tests are reported in Table 5 as the appearance of the cylinder.
TABLE 5
Appearance of the cylinder
After
After
After
After
After
Dilution of USL Wash W
1
2
3
4
5
in
minute
minutes
minutes
minutes
minutes
Water
5
5
5
4
4
Thickened Water
2
2
2
2
2
The LC 50 of USL Wash W is 29 mg/l, according to an Acute Toxicity Testing on Artemia S . performed on the salt water crustacean, Artemia Salina following the procedures devised by the Laboratory of Biological Research in Aquatic Pollution of Ghent University.
As it appears from the above examples, with turbulent flow, the Compositions 1, 2 and 3 give a dramatic increase in cleaning ability and are significantly improved with respect to the commercially available product of Example 5. These three compositions (Composition 1, 2 and 3) give the unique results of completely cleaning the test cylinder over all of the tests performed in thickened distilled water and are therefore to be considered as giving exceptional cleaning performance in their application to turbulent flow cleaning systems. Furthermore, Composition 2 and Composition 3 are clearly much less toxic than the commercially available product of Example 5. This demonstrates a clear eco-toxicological advantage for the compositions described herein, which combines with the advantages in cleaning performance.
Although preferred embodiments of the invention have been described in detail herein, those skilled in the art will realize that certain modifications may be made without departing from the scope and spirit of the invention as recited in appended claims. | Disclosed is a process for cleaning wellbore walls, tubing or casings. The process is characterized by (a) preparing an aqueous surfactant composition containing from about 10% to 60% by weight of a mixture of surfactants, the mixture comprising from 10% to 50% by weight of an anionic derivative of an alkylpolyglycoside, from 35% to 80% by weight of an alkylpolyglycoside and from 5% to 25% by weight of an anionic derivative of a fatty alcohol, their balance being 100%; (b) diluting the aqueous surfactant composition in water to form a diluted aqueous surfactant composition and injecting the diluted aqueous surfactant composition into a wellbore containing drilling mud, oily residues or other undesirable deposits; (c) extracting from the wellbore the diluted aqueous surfactant composition containing the drilling mud, oily residues or other undesirable deposits; (d) removing the drilling mud, oily residues or other undesirable deposits from the diluted aqueous surfactant composition; and (e) optionally, re-using the diluted aqueous surfactant composition. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
FIELD OF INVENTION
[0003] This invention relates to methods and devices for treatment and/or collection of solid excrement deposited by a pet or other animal on a surface, and particularly to the use of a robotic device for detecting and carrying out the treatment and/or collection functions.
BACKGROUND OF INVENTION
[0004] A major concern of the owner of a pet or other animal, as well as the public in general, is the disposition of solid or semi-solid excrement of pets. This concern extends to lawns, public parks and other grassy areas and to the structures where the animal is housed on a permanent or semi-permanent basis, such as kennels, barns, stalls and the like.
[0005] Removal of a pet's waste is a primary concern for many pet owners. It can be linked to unsanitary conditions, damage to landscaping and unsightly conditions. Known practical solutions for removal of such waste require a human to search for, identify, and remove the waste if the owner does not want the waste to remain on the premises. Excrement disposition associated with housing structures for dogs and horses, and/or other animals require routine cleaning and/or other treatment on a regular basis to avoid matters such as offensive odors and/or the spread of infectious diseases.
[0006] “Walking” of pets, in particular, for purposes of permitting the animal to relieve their kidneys or bowels is commonplace and can be the source of serious objections by neighbors or members of the public. Prohibition of the “walking” of an animal except within designated areas, provides localization of the problem of waste removal, but still requires human intervention to maintain sanitary conditions.
[0007] It is therefore desirable that there be provided a method and/or device which is capable of autonomously detecting, treating and/or collecting of solid or semi-solid animal excrement disposed on a surface, particularly a grassy surface.
BRIEF DESCRIPTION OF FIGURES
[0008] FIG. 1 is a flow diagram of one embodiment of the method of the present invention;
[0009] FIG. 2 is a schematic representation of one embodiment of a device for detecting and/or treatment of animal excrement disposed on a surface and embodying various of the features of the present invention;
[0010] FIG. 3 is a skeletal schematic diagram of one embodiment of a navigation and control system of an apparatus of the present invention;
[0011] FIG. 4 is a top plan view representation of the embodiment of the present invention depicted in FIG. 2 with the chassis cover removed; and
[0012] FIG. 5 is a front view of the device depicted in FIG. 2 .
SUMMARY OF THE INVENTION
[0013] In one aspect of the present invention there is provided a method for the detection and treatment or collection of a quantity of solid or semi-solid animal excrement from a surface, particularly a grassy surface, including the steps of autonomously or semi-autonomously detecting the presence of the excrement on the surface, moving a collection/treatment device into position over the detected excrement, and, thereupon, subjecting the detected excrement to one or more of deodorization, disinfection, enhancement of deterioration, dispersal and/or collection.
[0014] The device of the present invention operates without the immediate or continued intervention of a human. Preferably, the device is robotic in nature, is readily portable, and preferably includes a rechargeable power source.
DETAILED DESCRIPTION OF INVENTION
[0015] With reference to the several Figures, in one embodiment of the present system, an autonomous or semi-autonomously operating robotic vehicle 12 is adapted to be disposed within, and moveable over, an area which contains or potentially will contain solid or semi-solid pet waste. The area may be the floor of a pen or other structure where animals reside or over which they may move. Particularly, the area may be a grass-covered lawn. Once the apparatus is positioned within the selected area, the apparatus is switched ON as illustrated in FIG. 1 . Optionally, the robotic apparatus may be programmed to maneuver over the selected area autonomously or semi-autonomously, being guided via various sensor devices adapted to detect the presence and location of a quantity of solid or semi-solid waste deposited on the surface of the selected area by a pet or other animal.
[0016] Detection of the waste deposit may be by means of odor sensors 16 , 18 , camera 20 , infrared sensors 22 , 24 or a combination of these and/or other known types of sensors.
[0017] Once a deposit is detected, a central control unit 26 for the robotic vehicle is activated to navigate the vehicle to a position adjacent to or hovering over, the detected waste deposit. Thereupon, the apparatus is further activated to perform at least one of treating the deposit to enhance its decomposition (applying an enzyme to the deposit, for example), application of a deodorant to the waste deposit, application of a disinfectant onto the waste deposit, dispersal of the waste deposit thereby enhancing its early decomposition, or collection of the waste deposit for disposal.
[0018] Implementation of the present invention may comprise any of various forms of robotic vehicles. One embodiment of a useful robotic vehicle for the present invention, as depicted in FIGS. 2-5 includes a Navigation assembly which serves to navigate the vehicle over a selected area of the surface. This assembly includes a vehicle chassis 28 adapted to be rollably supported and navigated over a selected area by a plurality of wheels 30 , 32 , 34 ,and 36 . The number and locations of the wheels is substantially optional so long as the wheels support the vehicle chassis substantially parallel to the surface over which the vehicle is to travel and are controllable for navigation of the vehicle.
[0019] Referring specifically to FIGS. 2-5 , power for navigation of the vehicle over the selected area may be provided by one or more electric motors 40 and 42 powered by one or more on-board rechargeable batteries 44 as shown in FIG. 3 or a conventional internal combustion engine (not depicted). In the embodiment of FIG. 2 , each of the wheels is connected to a respective one of the output shafts of the electric motors 40 , 42 . The right hand side (as viewed in FIG. 2 ) of the vehicle chassis is supported by a wheel pair having first and second wheels 32 and 34 . Similarly, the opposite side of the vehicle chassis is supported by a second wheel pair having wheels 36 and 38 .
[0020] More specifically, the wheels 32 and 34 are connected through pulleys 50 and 52 respectively, as shown in FIGS. 2 and 3 mounted on the output shaft 46 . This output shaft 46 is drivingly connected through pulleys 54 and 56 respectively. It will be noted that pulley 54 is mounted on axle 58 and that pulley 56 in mounted on axle 60 which drive wheels 32 and 34 , respectively. Each drive belt overwraps the pulleys and provides for transmission of drive power to the operatively associated wheel. As needed, reversing electric clutches or like devices can be incorporated in the drive system of the depicted robotic vehicle for speed selection, rotation direction, etc. of the wheels.
[0021] In a like manner, the left hand side of the depicted vehicle chassis is driven through drive shaft 48 and its operatively associated pulleys 81 and 82 as shown in FIG. 3 . Pulleys 80 and 81 are drivingly connected through drive belts 68 and 66 , respectively, which overwrap the operatively associated pulleys 72 and 70 respectively mounted on the respective axles 80 and 78 . It will be noted that the left hand wheel pair 38 and 36 are mounted on the axles 80 and 78 , respectively. Control of the direction and speed of rotation of the left hand wheels independently of the direction and speed of rotation of the right hand wheels provides for selection of the direction of forward, rearward and/or turning of the vehicle in response to the operation of the first and second motors as controlled by the central control unit 26 .
[0022] FIG. 4 schematically depicts one embodiment of apparatus useful in the operation of a robotic vehicle of the present invention. Specifically, in the embodiment depicted in FIG. 4 , each of the wheels of the vehicle is drivingly connected to a respective electric drive which in turn is independently controllably connected to a central controller unit 26 . Power for each motor is provided as by one or more rechargeable batteries. Preferably, the robotic vehicle is adapted to be stored in position to enable engaging the onboard battery to a source of electrical energy suitable for recharging of the battery when the vehicle is not in use.
[0023] Navigation of the present robotic vehicle is a function of the detection of a quantity of pet waste deposited within the selected area over which the vehicle is to travel. Specifically, employing one or more of infrared (heat detectors) sensors 22 , 24 , physical presence (camera 20 capable of comparing objects in the path of the vehicle to stored possible pet waste deposits), and/or odor sensors, and/or triangulation principles known in the art, signals from one or more of these sensors are input to a central controller unit 26 . Within the central controller unit 26 , which preferably includes a programmable computer, the signals are processed and output signals are issued to each of the drive motors for the wheels to cause the vehicle to be moved into a position adjacent to or preferably hovering over, a detected waste deposit. Thereupon, the central controller unit 26 issues one or more selected commands to effect actuation of one or more of (a) dispensing of disinfectant from a storage container 90 (see FIG. 3 ) carried on the chassis of the vehicle onto and/or around the waste deposit, (b) dispensing a deodorizer from a storage container 92 onto and/or around the waste deposit, (c) activation of a rotary sweeper 94 adapted to sweep the waste deposit from the area surface and into a receptacle 96 carried by the chassis of the vehicle.
[0024] In the preferred embodiment, the receptacle 96 shown in FIG. 3 is removably mounted on the chassis of the vehicle for ready withdrawal and transfer of collected waste to a proper disposal site. After cleaning of the emptied receptacle, it is returned to the vehicle for future use.
[0025] Collection of the waste deposit may take the form of employing a rotating sweeper 94 in the nature of a bristled brush or combing implement oriented to sweep the waste deposit into a receptacle 96 carried by the robotic vehicle. In one embodiment, the rotary sweeper 94 may take the form of a stiff bristled elongated brush rotatably supported on the chassis of the vehicle and having its bristles exposed to the surface over which the vehicle is to travel. As desired, rotation of this brush may be continuous or be intermittently activated through the central controller 26 , such as when the vehicle is hovering over a detected waste deposit. If desired or needed by reason of the terrain over which the vehicle is to travel, metal combing teeth 98 may be substituted for the bristles of the rotating brush. In either event, the rotation of the sweeper may be effected by means of a pulley 100 mounted on the spindle 102 of the sweeper which is, in turn, drivingly connected to the output shaft of the electric motor 42 by means of a drive belt 104 or the like. Activation of the electric motor is controlled through the central controller unit, as noted.
[0026] With reference to FIG. 2 , one of more sensors are mounted on the front end 108 of the vehicle, each directionally aimed forwardly of the vehicle. In FIG. 2 , there are depicted first and second infrared sensors 22 , 24 mounted adjacent opposite side margins 110 and 112 of the front end of the vehicle chassis. These sensors are oriented such that the beams 114 and 116 from each of these infrared sensors intersect one another at a selected distance ahead of the vehicle and in alignment with the centerline 108 of travel of the chassis of the vehicle. As desired, these beams optionally may be designed to “sweep” the surface area over which the vehicle is traveling and when one beam detects a perceived waste deposit, the other of the beams “homes” in on the same perceived waste deposit to develop triangulation information which is fed to the central controller 26 . Within the central controller unit 26 , output signals are directed to respective ones of the driven wheels of the vehicle to adjust the direction of travel of the vehicle along a path which will cause the vehicle to move into position contiguous to and preferably hovering over, the perceived waste deposit substantially in register with the centerline 106 of the vehicle 12 and directly in line with the rotating sweeper 94 . Thereby, the perceived waste deposit is positioned for treatment and/or collection by the present robotic vehicle.
[0027] Whereas infrared sensing of waste deposits may only occur with respect to “fresh” waste deposits emanating heat, the present invention contemplates the use of object detection employing a camera 20 or the like as a further or alternative mode for detecting a perceived waste deposit. In this instance, the image from the camera is directed to the central controller 26 where such image is compared to known or sample images of waste deposits and, as in order, provides an output which confirms the presence of a perceived waste deposit and/or results in the issuance of an action signal(s) from the central controller unit to one or more of the action elements of the vehicle 12 , such as navigation, collection, or treatment of the perceived waste deposit.
[0028] Still further, it is within the purview of the present invention to include odor sensors 16 , 18 whose detection beams function in like manner as the detection beams of the infrared sensors. Such odor sensors may be employed in combination and complementary fashion with the infrared sensors, or they may function independently of the infrared sensors to provide triangulation information to the central controller of a perceived waste deposit.
[0029] Whereas the vehicle of the present invention may move forward in a continuous fashion, treating and/or collecting waste deposits as it moves forwardly, preferably, the vehicle detects a perceived waste deposit, moves into a position generally over the perceived waste deposit and then hovers over the perceived wasted deposit for a period of time within which the perceived waste deposit is treated and/or collected as selected by the controller unit 26 . Following the expiration of such hover time period, the central controller unit activates the vehicle to again commence scanning the area over which the vehicle is to travel.
[0030] Selection of the area over which the present robotic vehicle is to travel may involve random forward movement of the vehicle 12 over the selected area, with the sensors serving to scan the surface of the area and providing guidance as to the forward movement of the vehicle. In this mode of operation, the camera may be provided with stored data which, when compared to the image transmitted by the camera to the central controller unit, detects objects in the path of the vehicle 12 which clearly are not waste deposits. Thereupon the central controller unit 26 may issue a signal(s) to the drive units for the wheels to alter the direction of forward movement of the vehicle around such non-waste deposit object. Numerous suitable modes of detecting objects in the path of the forwardly moving vehicle, and the guidance of the vehicle around such objects, are known in the art. Moreover, the vehicle may be programmed to reverse and change direction if an obstacle is encountered.
[0031] Alternatively, the vehicle 12 of the present invention may be programmed to move over the selected area in a grid pattern which results in the vehicle moving over the entire selected area over a period of time of operation of the vehicle. The prior art also includes numerous suitable means for such grid pattern type movement of a robotic vehicle. In this latter instance, upon the detection of a waste deposit, the central controller 26 of the present invention activates the operation of the treatment and/or collection functions of the present invention in the manner described hereinabove. In any event, the central controller 26 may be programmed to ensure that the vehicle has covered the entire selected area over a selected time period, if desired.
[0032] Also known in the prior art are various robotic vehicles. One particular prior art robotic vehicle is that known as the ExplorBot® ERSP® robotic development platform offered by Evolution Robotics, Inc. This particular platform may serve as the basis for the addition of those elements of the present invention which provide for the navigation of the present vehicle, detection and/or treatment of detected waste deposits, and/or other functions of the vehicle of the present invention are described herein. Among other things, this platform permits travel over irregular terrain.
[0033] While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific detail, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept. | A method and apparatus for the detection, treatment or collection of a quantity of solid animal excrement from a surface, particularly a grassy surface. The method includes the steps of autonomously or semi-autonomously detecting the presence of the excrement on the surface, moving a collection/treatment device into position over the detected excrement, and, thereupon, subjecting the detected excrement to one or more of deodorization, disinfection, enhancement of deterioration, dispersal and/or collection of the detected excrement. The apparatus of the present invention operates without the immediate or continued intervention of a human. Preferably, the device us robotic in nature, is readily portable, and preferably includes a rechargeable power source. | 0 |
RELATED APPLICATION
This is a continuation in part of application Ser. No. 08/684,004 filed Jul. 19, 1996, now abandoned and application No. 08/850,726 filed May 2, 1997.
INTRODUCTION TO THE INVENTION
This invention relates to the installation of decorative coverings. It has been shown in the present inventor's first patent U.S. Pat. No. 4,822,658 that carpets having a looped backing can be conveniently installed on a floor by the use of complementary hooked tape. One of the primary ways disclosed in that patent is attaching the tape to the floor at the perimeter and seams (hereinafter “perimeter and seam” installation). The present inventor has also developed an anchor sheet which is described in U.S. patent application Ser. No. 08/685,004 filed Jul. 19, 1996 and continuation-in-part application Ser. No. 08/850,726 filed May 2, 1997 (the specifications of which are herein incorporated by reference). Rather thin attaching the carpet directly to a hooked tape attached to the floor, an intermediate thin flexible relatively rigid anchor sheet is provided which gives rigidity and integrity and mass to the overlying pieces of carpet covering. The anchor sheet can be covered in hooks. The carpet has an underlying looped backing for attachment to the hooks. The carpet can be in pieces which overlap the anchor sheet pieces to provide rigidity and strength to the total unit.
The perimeter and seam method and the anchor sheet structure and method can both be used and will both work. However in some circumstances it may be advisable to use a combination of both methods in which a form of anchor sheet provides a stable framework into which either a cushion or a covering material or both can be inserted either attached to the floor by a hook and loop attachment method or as a “free float” within the framework. In these circumstances, the anchor sheet can be a support for a covering unit attached to the anchor sheet by hook and loop as shown in the earlier related cases. Carpet within the framework can then be installed with hook and loop or in a conventional manner, i.e., without hook and loop, by glue down or even by free floating.
In some circumstances the hook tape of a perimeter and scam installation can be the “framework” within which an anchor sheet installation can be made. In this case the anchor sheet may float within the framework created by hook tape attached to a floor. Additional methods of attaching a tape framework and a tape framework construction are disclosed as well as other methods of installing an anchor sheet as a framework, including the use of a form or jig.
BACKGROUND OF THE INVENTION
The need for flexibility in installing floor coverings is well known. Most floor coverings must be cut and fit on site and therefore must be flexible to provide for different physical limitations In addition subflooring and supporting substrates differ widely in both quality and type, even in new construction In old construction existing flooring may reman and present problems.
The background to the invention is substantially shown in the present inventor's prior issued patents U.S. Pat. No. 4,822,658 (Apr. 18, 1989, Pacione); U.S. Pat. No. 5,191,692 (Mar. 9, 1993, Pacione); U.S. Pat. No. 5,382,462 (Jan. 17, 1995, Pacione); and U.S. Pat. No. 5,479,755 (Jan. 2, 1996, Pacione). In addition attempts to make structural semi-permanent flooring and wall material incorporating a hook surface is also disclosed in the present inventor's earlier anchor board system U.S. Pat. No. 5,060,443 (Oct. 29, 1991, Pacione); U.S. Pat. No. 5,259,163 (Nov. Pat. No. 9, 1993, Pacione); and U.S. Pat. No. 5,144,786 (Sep. 8, 1992, Pacione).
SUMMARY OF THE INVENTION
A thin rigid but flexible anchor sheet has advantages to stabilize the overlying carpet to provide a relatively rigid subfloor for installation of an overlying carpet. When a resilient backing of cushioning material is attached to or supplied under such anchor sheet, the anchor sheet provides a novel subfloor which has significant advantages over existing underpads.
We have described the anchor sheet as both “flexible” and “rigid”. It is flexible in the sense that over a reasonable length it can bend and in most circumstances can even be rolled with a radius of curvature for example of perhaps 1 or 4 inches unlike for example plywood. It is rigid in the sense that if held at one end it can support itself for instance over a distance of 12-24 inches without drooping unlike a cloth or fabric tape.
It is not commonly appreciated that an underpad, while it provides resiliency, can lead to degradation in the overlying decorative textile surface. This is because the resiliency allows for the carpet to deform when walked upon or when furniture or other items are placed on the carpet. This deformation can, if it is not properly supported from below, result in crushing and eventual deterioration of the carpet structure.
The anchor sheet of this invention has a relatively rigid yet flexible thin sheet material, preferably a plastic or of a polymer material such as a polyester, polycarbonate, polypropylene or even a graphite or other advanced polymer material overlying a resilient cushion. This structure provides a surprising amount of resiliency and cushioning to the carpet. However because the overlying anchor sheet is relatively rigid, the carpet fibres are protected from crushing and therefore the life of the carpet is significantly extended while still appearing to have a sufficient degree of resiliency.
In order to provide the proper degree of resilience in the hooks and the proper degree of rigidity to the sheet, the hooks and sheets may need to be made from, for example, different plastic materials by lamination or coextrusion.
To the inventor's knowledge no person, until disclosed in this and the earlier related applications, has had the relatively unconventional idea of covering a resilient material with a thin flexible relatively rigid sheet material.
Thus the invention comprises in, one aspect, an anchor sheet subfloor comprising a laminate having an upper layer of a relatively thin and flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material.
While not as pronounced, the advantages of a relatively rigid but flexible anchor sheet to create a smooth subfloor and to tie overlying carpet pieces together into a stable mass can to some extent be achieved even without a resilient undercushioning. Thus the invention comprises in another aspect a relatively thin flexible rigid sheet material preferably of plastic or polymer which can be cut and fit on site to fit the contours of a room or other area to be covered to form by itself or in combination with other anchor sheets a free floating smooth subfloor on which can be laid decorative covering pieces.
In another aspect the invention comprises a carpet and subfloor comprising a first layer of relatively resilient cushioning material overlaying the floor. A second layer of a thin flexible rigid polymer material overlaying the first layer and hooks covering at least a portion of the top surface of the second layer and a carpet having an undersurface covered in loops and detachably attached to the hooks covering the second layer to form a coherent stable carpet structure.
In another aspect, the subfloor and structure created by the first resilient layer and the second layer of anchor sheet, can be covered across its surface by perimeter and seam hooked tape so as to allow for installation of a carpet on the subfloor in accordance with the method described in U.S. Pat. No. 4,822,658. In this case the subfloor is actually not attached to the floor directly but is normally “floating” but this may be sufficient, in many installations, to stabilize the carpet.
As previously described, in some circumstances, the anchor sheet can act as g framework for either a carpet or an underpad or both, Thus, in another aspect, the invention covers an anchor sheet, carpet and an underpad combination for installing a carpet or underpad onto a floor comprising an anchor sheet installed along the perimeter of an area to be covered, describing and bounding that area, hook tape attached to the sheet along the perimeter of the upper face of the anchor sheet and a resilient underpad of a height matching the height of the anchor sheet sized to fit within the area bounded by the anchor sheet. A carpet having an underside covered in loops can then be overlaid. The anchor sheet perimeter and the resilient underpad may be either free floating or installed in a conventional manner within the anchor sheet framework.
A more complex anchor sheet framework can also be formed consisting of modular covering units made as disclosed in related application Ser. No. 08/850,726. Thus in another aspect the invention comprises a modular framework for carpet installation comprising a plurality of covering modules having decorative coverings attached to a thin flexible rigid anchor sheet so as to leave exposed overlapping areas of anchor sheet or covering for detachable attachment and interlocking relationship to an adjoining module as disclosed in related application Ser. No. 08/850,726. In this aspect of the invention, the modules are then detachably interlocked to define and enclose an area. Carpet or underpad or carpet and underpad depending upon the height of the framework created, is then cut and fit within the area defined by the covering modules,
As previously mentioned, an anchor sheet subfloor can also be installed within a perimeter bounded by hooked tape, in effect creating a hooked tape framework. In this aspect of the invention, a perimeter of hooked tape is attached to the floor. The tape may be of a form disclosed in, for instance, U.S. Pat. No. 5,382,462 or having a tape with a cushioned backing or a tape with a foundation sheet as disclosed in the present application.
In this aspect of the invention, a thin rind flexible anchor sheet having an upper surface having a plurality of hooks in which the anchor sheet or anchor sheet and cushion is substantially the same height as the tape can then be cut and fit within the area bounded by the hooked tape to provide for a surface underlayment over which a carpet or other decorative covering having a looped backing can be installed.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, reference being had to the accompanying drawings, wherein:
FIG. 1 shows covering modules and a jig for installation.
FIG. 2 shows the covering modules and jig in the process of installation to a floor.
FIG. 3 shows the next step in installation of the covering module and jig.
FIG. 4 shows the finished covering module framework.
FIG. 5 shows the covering module framework at the commencement of the installation of an inserted cushion or carpet.
FIG. 6 shows the completed covering.
FIG. 7 shows the anchor sheet perimeter arrangement.
FIG. 7A shows another form of anchor sheet perimeter arrangement similar to that shown in FIG. 7 .
FIG. 8 shows another form of anchor sheet perimeter arrangement in which the anchor sheet carries a decorative covering which contains a border pattern.
FIG. 8A shows a completed anchor sheet perimeter arrangement.
FIG. 9 shows a form of anchor sheet upon which is installed a perimeter and seam hook and loop tape arrangement.
FIG. 10 shows a form of tape suitable for use in a perimeter arrangement.
FIG. 11 shows a cross-section of a perimeter arrangement having a hooked tape bounding an area of anchor sheet and an overlying decorative covering.
FIG. 12 shows an arrangement of anchor sheet providing a border.
FIG. 13 shows another border arrangement with anchor sheet and cushion.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 is shown a variety of covering modules 2 and 4 . These are similar to the type of covering modules disclosed in related case Ser. No. 08/850,726. In the case of covering module 2 there is an anchor sheet 6 larger than the decorative covering piece 8 . In the case of covering module 4 there is a decorative covering piece 10 which overlaps the anchor sheet 12 .
Normally the anchor sheet areas would be substantially covered in hooks 14 as shown in only representative detail. The overlapping pieces 10 will have on their undersurface loops (not shown) for attachment to the exposed hooks 14 of anchor sheet, for instance, 6 .
A jig or pattern 16 is also shown in FIG. 1 . Its use will become apparent.
The jig at 16 has corners for instance 18 and 19 which serve to locate the corresponding comers of decorative covering piece 8 at each of the four corners of the jig. Thus the covering modules are separated and appropriately spaced in the desired location. Covering module 4 cam then be inserted along the sides of the jig abutting the jig as shown. Loops on the undersurface of covering piece 10 (not shown) will enable the covering piece to be installed in detachable attachment in a manner shown in related case Ser. No. 08/850,726 preferably by the use of a smooth slip cover as disclosed in related U.S. patent application Ser. No. 08/850,726. The slip cover can be a hard smooth piece temporarily insert. It can then be removed and the covering modules will form a framework as shown in FIG. 3, in which pieces 4 and pieces 2 have combined to create a structure. Jig 16 is then removed as shown in FIG. 4 so that the anchor sheet framework now lies upon and circumscribes an area of floor 21 and also an area of hooked anchor sheet 20 which is at a different level than the surface of decorative covering 22 .
As shown in FIG. 5 a decorative covering unit 24 can be inserted into the framework 26 . The unit may be carpet having a looped backing (not shown) in which case the carpet would be detachably attached to hooks 28 in the area shown. Normally the complete area would be covered in hooks but only representative samples are shown.
If desired the floor area 21 could be made level with the hooked area 28 by the use of an anchor sheet of suitable thickness, also covered with hooks or smooth, or by the installation of a pad. The area of floor 21 could be left empty because of the low profile of the hooked area 20 .
FIG. 6 shows the unfinished subunit which is ready to be attached by hooks 30 to other adjoining anchor sheet units or covering modules.
In FIG. 7 is shown another form of anchor sheet perimeter installation in which an anchor sheet 32 is formed having a thin rigid flexible covering 34 preferably formed of a plastic or polymer material as described in related application Ser. No. 08/850,726 preferably of a polypropylene, polycarbonate or polyester material and laminated and bonded thereto is a resilient cushion 36 of polyurehane foam or other similar carpet underpad material. Similar anchor sheet units 32 A and 32 B are placed on the floor in abutting relation and the units may be joined together by a pressure sensitive adhesive hooked tape 38 overlying the seams of the anchor sheets or by plain single-sided pressure sensitive tape. Additional hooked tape 40 is added to the perimeter of the anchor sheet installation to provide for a regular perimeter and seam installation as shown in U,S. Pat. No. 4,922,659. It would be convenient if the tape covering joins 41 line up with carpet seams but if they do not, additional tape can be installed on the anchor sheet 32 to provide for at least seam coverage.
Of course if plain tape is used, then hooked tape will normally have to be installed at the carpet seams. Such tape is normally covered prior to installation. Full coverage could also be provided either by adding more hooked tape or by providing anchor sheet 32 with a flexible sheet pre-manufactured with a complete hook covering.
In FIG. 7A is shown an additional similar form of arrangement which combines a hooked tape 42 to be described later at the perimeter of the room, an underpad or anchor sheet with underpad 44 , an additional anchor sheet with underpad 46 , conventional underpads 48 and 50 and anchor sheets 52 and 54 with resilient cushioning and then tape 56 . Thus a complete resilient underlayment is created which is partly a framework made by tape 42 and anchor sheets 44 , 46 , 52 and 54 within which are contained conventional underpads 48 and 50 . A carpet can then be installed over top of this by perimeter and seam tape using tape 42 and 56 at the perimeter and tape 53 at the seams or by the use of an additional anchor sheet (not shown) to provide for decorative surface covering pieces. As shown in FIG. 8 an additional foundation sheet 58 of a similar material to the anchor sheet can have pre-attached permanently or detachably an anchor sheet 60 having a resilient undercushion 62 . The anchor sheet 60 could be one as shown in related application Ser. No. 08/850,726 having its upper surface substantially covered in hooks 64 , Decorative cover pieces, in this case carpet units 65 , can then be installed in any pattern over the anchor sheet. In the example given in FIG. 8 they are installed in a border pattern. When fully assembled as shown in FIG. 8A such a unit can create a framework within which carpet can be installed in a conventional way, or using hook and loop or perimeter and seam or in a small enough area free floated within the area bounded by the decorative border 66 as shown in FIG. 8 A.
FIG. 9 shows an arrangement similar to FIG. 7 in which there is an anchor sheet and resilient cushion framework 68 on either side of conventional carpet pads 70 . The conventional carpet pads may be free floating or attached to the floor in a conventional manner. Normally if the anchor sheets 68 are on the perimeter of the room and abut, for instance, wall 71 on one side and wall 72 on the other side, the whole structure can be “free floating” in the sense that it is not attached to the floor. Hook tape 74 can be installed at the perimeter. Suspended tape 76 at the seams provides a form of perimeter and seam installation over top of a conventional cushion or a partial anchor sheet and conventional cushion. The carpet or other decorative surface covering has loops on its undersurface at 80 (not shown) for detachable attachment to hooks 81 on pieces 74 and 76 .
FIG. 10 shows a form of hook tape that can be used to create a perimeter for the installation of a conventional underpad 87 . This tape has a foundation layer 8 to which is attached the tape 84 having a resilient cushion layer 86 . The tape is hook tape and contains across its surface resilient hooks 88 . It normally would be supplied with a tape covering 90 . The foundation sheet 82 allows for a lip or area so that the hook tape may be stapled or nailed through the sheet 82 or through tape 84 to the floor or it ran be installed using double-sided adhesive tape 92 or by hook and loop or by a conventional method.
Another form of tape 94 is also shown having foundation sheets 96 and 98 on both sides of the tape. The tape could be stapled to a floor and within the framework bounded by the tape could be inserted an appropriate underpad which could either be installed in a conventional manner or free floating between the tape gad an overlying anchor sheet or an anchor sheet having hooked covering (not shown) could also be installed within the area bounded by the tape.
In FIG. 11 is shown a cross-section of hooked tape 100 having cushion 102 attached to the floor.
If the tape is as shown in FIG. 10 it could have foundation sheet 82 for installation. Anchor sheet 104 with (as shown) or without an attached resilient cushion can then be inserted within the area bounded by hooked tape 100 and a decorative covering 106 having an undersurface covered in loops 107 could be installed across the area created by the hooked tape and anchor sheet.
FIG. 12 shows an arrangement in which an anchor sheet 108 is provided with hooks at least over the exposed area 110 shown and also under carpet pieces 112 and border pieces 114 , 116 and 118 . Border pieces 114 , 116 and 118 may be detachably attached to anchor sheet 108 in a pattern anchor sheet and 108 with such pieces could be sold as a preassembled unit. Such piece could be attached to a floor by pressure sensitive adhesive, with hook and loop or by nailing through sheet 108 . Carpet 112 having a loop backing and a pile surface 120 could then be installed and attached to hooks on anchor sheet 110 .
FIG. 13 shows another arrangement, in which anchor sheet 122 , has a resilient cushion 124 and a carpet covering piece 126 detachably attached to the anchor sheet. A conventional cushion 128 can abut the anchor sheet and cushion and a carpet 130 having a loop backing 132 can be installed over the anchor sheet 122 and cushion 128 .
It will be recognized that within the description of this present case and the related earlier pending cases many variations and permutations and combinations are possible of anchor sheet and tape with or without cushion and with or without installation directly to the floor all of which come within the spirit of the described invention as defined in the attached claims. | An anchor sheet subfloor that includes a laminate having an upper layer of relatively thin flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material. The upper sheet layer can be formed of a plastic or polymer material. In one arrangement, the sheet can be cut and fit within the boundaries of a room and the sheet has sufficient rigidity and mass to remain without distortion or buckling within the room by free floating on the existing floor without substantial attachment to the floor. It can be possible for a sheet to be cut and fit on site to fit the contours of a room to form by itself or in combination wit other anchor sheets a free floating smooth subfloor on which can be overlaid decorative covering pieces. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. patent application Ser. No. 61/388,056, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of Technology
[0003] The present disclosure relates generally to tissue graft fixation and, specifically, to components for use in tissue graft fixation.
[0004] 2. Related Art
[0005] In ligament reconstruction surgery, if the graft used is harvested from the quad tendon, the choice to use a particular type of fixation device, namely an Endobutton®, requires the use of a suture and a whip type of stitch, which requires the need to tie a knot. The use of knots involves a certain amount of variation in stiffness from knot to knot. The Endobutton® CL uses a continuous loop of suture, which has no knot and has demonstrated superior strength and stiffness. Methods of fixating an Endobutton® CL to a graft, especially a quad tendon, and devices for use therewith are needed.
SUMMARY
[0006] In an aspect, the present disclosure relates to a needle for attaching a fixator to a soft tissue graft. The needle includes a pointed distal end and a proximal end, the proximal end including a suture coupler, the suture coupler including a hook and a pocket formed by the hook, wherein the needle is curved along an entire length of the needle.
[0007] In an embodiment, the proximal end further includes a passage and an opening to the passage. In an embodiment, the proximal end further includes a groove on each side of the proximal end. In another embodiment, the needle includes a channel along the length of the needle. In yet another embodiment, the grooves intersect with the pocket. In a further embodiment, the needle further includes a fixator coupled to the needle, the fixator including a flexible member coupled to the fixator, the flexible member coupling the fixator to the needle.
[0008] In yet a further embodiment, a portion of the flexible member is housed within the pocket. In an embodiment, portions of the flexible member extending from the pocket are housed within the grooves. In another embodiment, the flexible member is in the form of a continuous loop, the loop including a first end housed within the pocket and a second end coupled to the fixator. In yet another embodiment, the fixator includes at least one hole, the second end of the suture coupled to the fixator via use of the hole. In a further embodiment, the fixator includes two holes, the second end of the suture coupled to the fixator via use of the two holes. In yet a further embodiment, the fixator includes four holes, the second end of the suture couped to the fixator via use of two of the holes, a trailing suture coupled to the third hole, and a leading suture coupled to the fourth hole.
[0009] In another aspect, the present disclosure relates to a method of fixating a soft tissue graft to bone. The method including coupling a fixator to the soft tissue graft via use of a needle, the needle including a pointed distal end, and a proximal end, the proximal end including a suture coupler, the suture coupler including a hook and a pocket formed by the hook, wherein the needle is curved along an entire length of the needle; and coupling the soft tissue graft to the bone via use of the fixator.
[0010] In an embodiment, the method further includes passing the soft tissue graft through a tunnel within the bone, the bone including a femur. In another embodiment, the fixator includes a flexible member coupled to the fixator, the flexible member coupling the fixator to the needle. In yet another embodiment, a portion of the flexible member is housed within the pocket. In a further embodiment, the flexible member is in the form of a continuous loop, the loop including a first end housed within the pocket and a second end coupled to the fixator.
[0011] In yet a further embodiment, the fixator includes at least one hole, the second end of the suture coupled to the fixator via use of the hole. In an embodiment, the fixator includes two holes, the second end of the suture coupled to the fixator via use of the two holes. In another embodiment, the fixator includes four holes, the second end of the suture coupled to the fixator via use of two of the holes, a trailing suture coupled to a third hole, and a leading suture coupled to a fourth hole.
[0012] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present disclosure and together with the written description serve to explain the principles, characteristics, and features of the disclosure. In the drawings:
[0014] FIG. 1 shows a side view of the needle of the present disclosure.
[0015] FIG. 2 shows an isometric view of the needle of FIG. 1 .
[0016] FIG. 3 shows an isometric view of the needle of FIG. 1 coupled to a fixator of the present disclosure.
[0017] FIGS. 4-12 show the method of fixating a soft tissue graft to bone of the present disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0018] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses.
[0019] FIGS. 1 and 2 show the needle 10 of the present disclosure. The needle 10 includes a distal end 11 and a proximal end 12 . For the purposes of this disclosure, the distal end 11 is pointed. However, it is within the scope of this disclosure for the distal end 11 to not be pointed. The proximal end 12 includes a suture coupler 12 a having a passage 12 b and an opening 12 b′ to the passage 12 b, a hook 12 c, and a pocket 12 d formed by the hook 12 c . Additionally, the suture coupler 12 a includes grooves 12 e on each side of the coupler 12 a , which intersect with the pocket 12 d. For the purposes of this disclosure, the needle 10 is curved along its entire length. However, it is within the scope of this disclosure for the needle 10 to not be curved. Furthermore, the needle 10 includes channels 13 along a length of the needle 10 . It is within the scope of this disclosure for the needle to have less than two channels 13 or no channels 13 . The purposes of the pocket 12 d and the grooves 12 e are for housing of a portion or portions of suture, as will be further described below. The needle 10 is made from a biocompatible metal material and via a process known to one of skill in the art. However, other material that would allow the needle 10 to be strong enough to be used for its intended purpose may be used.
[0020] FIG. 3 shows the needle 10 with a fixator 20 coupled to the needle 10 . The fixator 20 is an Endobutton®CL, manufactured and sold by Smith & Nephew, Inc. The fixator 20 includes a fixation device 21 and a closed loop suture 22 coupled to the fixation device 21 . A first end 22 a of the suture 22 is coupled to the suture coupler 12 a by placing the end 22 a through the opening 12 b ′ of the passage 12 b, through, the passage 12 b, and into the pocket 12 d. The hook 12 c substantially reduces the possibility of the end 22 a from escaping the pocket 12 d and thereby de-coupling from the needle 10 . The fixation device 21 includes four holes 21 a, 21 b with a second end 22 b of the suture 22 coupled to two of the holes 21 a. It is within the scope of this disclosure for the fixation device 21 to include one hole 21 a and for the end 22 a of suture 22 to be coupled to the fixation device 21 via the one hole 21 a. Additionally, the fixation device 21 includes two additional holes 21 b. These holes 21 b are for housing of trailing and leading sutures, as is further described in U.S. Pat. Nos. 5,306,301, 5,645,588, 6,533,802, and 7,530,990, the disclosures of which are incorporated herein by reference in their entireties.
[0021] FIGS. 4-12 show a method of coupling a soft tissue graft 30 to bone. FIG. 4 shows a soft tissue graft 30 . For the purposes of this disclosure, the graft 30 is a quad tendon. However, the graft 30 could be another human or animal soft tissue or a synthetic tissue. The graft 30 includes a first end 31 and a second end 32 . While not shown in FIGS. 4-12 , the first end 31 includes bone. The second end 32 , which doesn't include bone, is the end that the fixator 20 is coupled to. As shown in FIGS. 4 and 5 , the needle 10 is placed through a first location 32 a of end 32 and pulled through the graft 30 . As shown in FIGS. 6-8 , the needle 10 is subsequently brought back around the graft 30 , placed through a second location 32 b of end 32 , and pulled through the graft 30 . As shown in FIGS. 9-11 , the needle 10 is brought back around the end 32 such that suture end 22 a is looped around end 32 . The needle 10 may then be removed from the suture 22 by removing needle 10 from end 22 a. As shown in FIG. 12 , the final step is to pull on the fixation device 21 to tension suture 22 around end 32 . For the purposes of this disclosure, the needle 10 is placed through the graft 30 twice. However, it is within the scope of this disclosure to place the needle 10 through the graft 30 more or less than two times.
[0022] Once the fixator 20 has been coupled to the graft 30 , the graft 30 can be pulled through bone tunnels located in the tibia and femur and the graft 30 may be affixed to the femur by resting the fixation device 21 on the outer surface of the femur, as more fully explained in the '301, '588, '802, and '990 patents. For the purposes of this disclosure, the method involves the use of the needle 10 and fixator 20 with a soft tissue graft in ligament reconstruction surgery on the knee. However, the needle 10 and fixator 20 may be used with a soft tissue graft in connection with another type of surgery.
[0023] As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the disclosure, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. | The present disclosure relates to a needle for attaching a fixator to a soft tissue graft. The needle includes a pointed distal end and a proximal end, the proximal end including a suture coupler, the suture coupler including a hook and a pocket formed by the hook, wherein the needle is curved along an entire length of the needle. A fixator for use with the needle and method of fixating a soft tissue graft to a bone is also disclosed. | 0 |
This is a division of application Ser. No. 09/972,384, filed Oct. 5, 2001, now U.S. Pat. No. 7,342,601 which is entitled to the priority filing date of Japanese application 2000-313125, filed in Japan on 6 Oct. 2000, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to communication systems in which communications are performed among three or more communication devices, the communication devices which constitute the communication systems, and seating-order determination devices. The present invention further relates to group-determination-table generation devices for generating a group determination table used in the seating-order determination devices and the communication methods.
2. Description of the Related Art
In conventional teleconference systems, images and sound generated at a plurality of conference rooms distant from each other are transferred among the conference rooms through a network, and the images and sound sent from the other conference rooms are reproduced at each conference room. This allows a conference to be held as if all participants sat around one table.
In these conventional teleconference systems, conference participants are allowed to talk at the same time in each conference room.
In an actual conference, in some cases, some conversation groups are made among participants according to the situation of a progress in the conference, and topics are different in the groups. Each group is made tentatively by a part of conference participants for a certain topic, and the group is flexible. More specifically, a conversation group may be made according to a progress in the conference; persons constituting a group may be changed; and one group may be further divided into a plurality of groups. The structures of groups are always being changed.
In the conventional teleconference systems, each participant sees the other participants on monitor devices. Each monitor device corresponds to one participant, and their relationship is fixed. In a conference having six participants, for example, each participant sees the other five participants on five monitor devices. Each monitor device displays an assigned participant. In other words, in a teleconference terminal used by one participant, five monitor devices MDa, MDb, MDc, MDd, and MDe display the other participants HMa, HMb, HMc, HMd, and HMe in an always fixed manner.
Assuming that each monitor device is handled as the seat of the participant corresponding to the monitor device, it can be considered that the order of seats (seating order) can be made changeable to some extent.
In other words, the five monitor devices MDa, MDb, MDc, MDd, and MDe arranged in this order do not display the participants HMa, HMb, HMc, HMd, and HMe in a fixed manner, and the relationship between the monitor devices and the participants is made changeable.
With this feature, when a group is formed among participants, the seating order can be changed according to the formed group. When the user of the terminal and the participants HMb and HMd form a group, for example, if the seating order is changed such that the monitor device MDa displays the participants HMb and the monitor device MDb displays the participants HMd, the group is made to have a convenient condition for their conversation.
The seating order is changed, for example, by the seating-order-changing operations of the user. It is not realistic that the user performs a seating-order changing operation according to a group formed or released during a conference. This means that the user needs to perform a very troublesome operation. In addition, especially during a conference, the user wants to concentrate on the conference without performing any operations. Furthermore, a terminal user is not necessarily familiar with operations.
It can be considered that a system operator is assigned to seating-order-changing operations. It is also unrealistic, however, because extra man-power is required, and an operator usually cannot correctly understand conversation groups which always change their participants.
With the above-described reasons, even in a system which allows a seating order to be changed, the feature is usually not utilized.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the foregoing points. It is an object of the present invention to provide a communication system, such as a teleconference system, a communication device, a seating-order determination device, a communication method, a recording medium, a group-determination-table generating method, and a group-determination-table generating device, in which a seating order can be appropriately changed according to conversations which flexibly progress among participants to provide a more suitable communication-conversation environment.
The foregoing object is achieved in one aspect of the present invention through the provision of a communication system including at least three communication devices, and a seating-order determination device for generating seating-order information at each point of time for information sent from each communication device and for transmitting the seating-order information to each communication device.
Each communication device may control the output position of the information sent from other communication devices, according to the seating-order information to output the information sent from the other communication devices in a seating order corresponding to the seating-order information.
In this case, the seating order is always automatically changed to the most appropriate condition according to the progress of a conference and the state of conversations to provide the user with a suitable conference environment and a suitable communication environment.
The seating-order determination device may generate the seating-order information for the information sent from each communication device according to the degree of attention which the user of each communication device pays to the information sent from each communication device. In this case, the most appropriate seating order is implemented.
The seating-order determination device may group the information sent from each communication device according to the degree of attention which each user pays to the information sent from each communication device, and generate the seating-order information according to the result of grouping. In this case, the seating order is automatically changed with conversation groups being taken into account and a suitable teleconference system is implemented.
The seating-order information may be generated such that information belonging to the same group is arranged. In this case, the seating order is changed so as to collect the members of groups.
The seating-order information may also be generated such that information belonging to the same group is dispersed almost uniformly. In this case, the user is provided with an easy-to-converse environment.
When the seating order is changed according to the seating-order information, each communication device may output indication information indicating a change in the seating order to the user, for example, by image information or audio information. In this case, the user can understand that the seating order is to be changed, and the user is prevented from confusing with a change in the seating order.
When the seating order is changed according to grouping, each communication device may output indication information indicating the state of grouping to the user. In this case, the user successfully understands the states of conversation groups. This indication information also helps the user understand the current condition. As the indication information, a background image color may be used, which is one of the most easy-to-understand indications.
The degree of attention may be determined according to user-behavior detection information or information specified by the user. In this case, the degree of attention is suited as a reference for a change in the seating order. More specifically, when the user-behavior detection information includes the lines of sight or a face direction of the user, most suitable control is implemented by the use of a natural operation of the user.
The grouping may be performed according to the statistical relationship between a group structure and the degree of attention which the user of each communication device pays to the information sent from the other communication devices. In this case, the grouping is suited to generate the seating-order information.
Therefore, when a group-determination-table generating method and a group-determination-table generating device according to the present invention hold the statistical relationship, a suitable operation is implemented for changing the seating order.
The foregoing object is achieved in another aspect of the present invention through the provision of a seating-order determination device provided for a communication system having at least three communication devices, including seating-order-information generating means for generating seating-order information at each point of time for information sent from each communication device; and transmitting means for sequentially transmitting the seating-order information generated by the seating-order-information generating means to each communication device.
The foregoing object is achieved in still another aspect of the present invention through the provision of a communication device in a communication system including at least three communication devices communicating with each other, including receiving means for receiving information and seating-order information sent from other communication devices; attention-degree-information generating means for detecting the degree of attention which the user pays to the information sent from the other communication devices to generate attention-degree information; transmitting means for transmitting the attention-degree information generated by the attention-degree-information generating means; presenting means for presenting the information sent from the other communication devices; and information manipulation and distribution means for controlling the output positions of the information sent from the other communication devices according to the seating-order information received by the receiving means to output the information sent from the other communication devices in a seating order corresponding to the seating-order information.
The foregoing object is achieved in yet another aspect of the present invention through the provision of a group-determination-table generating device for generating a group determination table used for grouping information sent from each communication device according to the degree of attention of the user of each communication device in a communication system having at least three communication devices, including statistics means for reading attention-degree patterns indicating the degree of attention which the user of each communication device pays to information sent from other communication devices and group structure patterns indicating the group state of each user, and for collecting statistics on the attention-degree patterns and the group structure patterns; determination means for determining the correspondence between each attention-degree pattern and one of the group structure patterns from the statistics obtained by the statistics means; and determination-table generating means for generating a group determination table indicating attention-degree patterns and group structure patterns for which the correspondence is determined by the determination means.
The foregoing object is achieved in yet still another aspect of the present invention through the provision of a communication method for a communication system having at least three communication devices, including a seating-order generating step of generating seating-order information at each point of time for information sent from each communication device; and a transmitting step of sequentially transmitting the seating-order information generated in the seating-order generating step to each communication device.
The foregoing object is achieved in a further aspect of the present invention through the provision of a seating-order determination method for a seating-order determination device provided for a communication system having at least three communication devices, including a seating-order-information generating step of generating seating-order information at each point of time for information sent from each communication device; and a transmitting step of sequentially transmitting the seating-order information generated in the seating-order-information generating step to each communication device.
The foregoing object is achieved in a still further aspect of the present invention through the provision of a communication method for a communication device in a communication system including at least three communication devices communicating with each other, including a receiving step of receiving information and seating-order information sent from other communication devices; an attention-degree-information generating step of detecting the degree of attention which the user pays to the information sent from the other communication devices to generate attention-degree information; a transmitting step of transmitting the attention-degree information generated in the attention-degree-information generating step; a presenting step of presenting the information sent from the other communication devices; and an information manipulation and distribution step of controlling the output positions of the information sent from the other communication devices according to the seating-order information received in the receiving step to output the information sent from the other communication devices in a seating order corresponding to the seating-order information.
The foregoing object is achieved in a yet further aspect of the present invention through the provision of a group-determination-table generating method for a group-determination-table generating device for generating a group determination table used for grouping information sent from each communication device according to the degree of attention of the user of each communication device in a communication system having at least three communication devices, including a statistics step of reading attention-degree patterns indicating the degree of attention which the user of each communication device pays to information sent from other communication devices and group structure patterns indicating the group state of each user, and of collecting statistics on the attention-degree patterns and the group structure patterns; a determination step of determining the correspondence between each attention-degree pattern and one of the group structure patterns from the statistics obtained in the statistics step; and a determination-table generating step of generating a group determination table indicating attention-degree patterns and group structure patterns for which the correspondence is determined in the determination step.
The foregoing object is achieved in a yet still further aspect of the present invention through the provision of a recording medium for storing a processing program related to seating information for information sent from each communication device in a communication system having at least three communication devices, the processing program including a seating-order generating step of generating seating-order information at each point of time for information sent from each communication device; and a transmitting step of sequentially transmitting the seating-order information generated in the seating-order generating step to each communication device.
The foregoing object is achieved in an additional aspect of the present invention through the provision of a recording medium for storing a processing program related to seating-order determination in a seating-order determination device provided for a communication system having at least three communication devices, the processing program including a seating-order-information generating step of generating seating-order information at each point of time for information sent from each communication device; and a transmitting step of sequentially transmitting the seating-order information generated in the seating-order-information generating step to each communication device.
The foregoing object is achieved in a still additional aspect of the present invention through the provision of a recording medium for storing a processing program related to communication in a communication device of a communication system including at least three communication devices communicating with each other, the processing program including a receiving step of receiving information and seating-order information sent from other communication devices; an attention-degree-information generating step of detecting the degree of attention which the user pays to the information sent from the other communication devices to generate attention-degree information; a transmitting step of transmitting the attention-degree information generated in the attention-degree-information generating step; a presenting step of presenting the information sent from the other communication devices; and an information manipulation and distribution step of controlling the output positions of the information sent from the other communication devices according to the seating-order information received in the receiving step to output the information sent from the other communication devices in a seating order corresponding to the seating-order information.
The foregoing object is achieved in a yet additional aspect of the present invention through the provision of a recording medium for storing a processing program related to group-determination-table generation in a group-determination-table generating device for generating a group determination table used for grouping information sent from each communication device according to the degree of attention of the user of each communication device in a communication system having at least three communication devices, the processing program including a statistics step of reading attention-degree patterns indicating the degree of attention which the user of each communication device pays to information sent from other communication devices and group structure patterns indicating the group state of each user, and of collecting statistics on the attention-degree patterns and the group structure patterns; a determination step of determining the correspondence between each attention-degree pattern and one of the group structure patterns from the statistics obtained in the statistics step; and a determination-table generating step of generating a group determination table indicating attention-degree patterns and group structure patterns for which the correspondence is determined in the determination step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a teleconference system according to an embodiment of the present invention.
FIG. 2 is a block diagram of a teleconference device according to the embodiment.
FIG. 3 is a view showing a method for generating attention-degree information according to the embodiment.
FIG. 4 is a view showing another method for generating attention-degree information according to the embodiment.
FIG. 5 is a block diagram of a seating-order determination device according to the embodiment.
FIG. 6 is a view showing the initial state of an attention-destination table according to the embodiment.
FIG. 7 is a view showing the initial state of a group table according to the embodiment.
FIG. 8 is a flowchart of initialization processing applied to the attention-destination table and the group table according to the embodiment.
FIG. 9 is a flowchart of processing to be performed when attention-degree information is generated according to the embodiment.
FIG. 10 is a view showing an attention-destination table to which attention-degree information has been input according to the embodiment.
FIG. 11 is a flowchart of processing for inputting the contents of the attention-destination table to the group table according to the embodiment.
FIG. 12 is a view showing a group table obtained during the processing according to the embodiment.
FIG. 13 is a view showing an attention-destination table obtained during the processing according to the embodiment.
FIG. 14 is a view showing a group table obtained during the processing according to the embodiment.
FIG. 15 is a view showing an attention-destination table obtained during the processing according to the embodiment.
FIG. 16 is a view showing a group table obtained during the processing according to the embodiment.
FIG. 17 is a view showing an attention-destination table obtained during the processing according to the embodiment.
FIG. 18 is a view showing a group table obtained during the processing according to the embodiment.
FIG. 19 is a view showing an attention-destination table obtained during the processing according to the embodiment.
FIG. 20 is a view showing a group table obtained during the processing according to the embodiment.
FIG. 21 is a view showing an attention-destination table obtained during the processing according to the embodiment.
FIG. 22 is a view showing a group table obtained during the processing according to the embodiment.
FIG. 23 is a view showing an attention-destination table obtained during the processing according to the embodiment.
FIG. 24 is a view showing a group table obtained during the processing according to the embodiment.
FIG. 25 is a view showing an attention-destination table obtained during the processing according to the embodiment.
FIG. 26 is a flowchart of seating-order determination processing according to the embodiment.
FIG. 27A and FIG. 27B are views showing example seating-order determination according to the embodiment.
FIG. 28A , FIG. 28B , and FIG. 28C are views showing another example seating-order determination according to the embodiment.
FIG. 29 is a view showing example distributed-seating-order determination according to the embodiment.
FIG. 30 is a block diagram of an information manipulation and distribution section according to the embodiment.
FIG. 31 is a block diagram of an image manipulation section according to the embodiment.
FIG. 32 is a block diagram of an audio manipulation section according to the embodiment.
FIG. 33 is a block diagram of an information distribution section according to the embodiment.
FIG. 34A and FIG. 34B are views showing example image processing applied when the seating order is changed according to the embodiment.
FIG. 35A , FIG. 35B , FIG. 35C , and FIG. 35D are views showing another example image processing applied when the seating order is changed according to the embodiment.
FIG. 36A , FIG. 36B , and FIG. 36C are views showing still another example image processing applied when the seating order is changed according to the embodiment.
FIG. 37A and FIG. 37B are views showing example image processing for indicating groups according to the embodiment.
FIG. 38 is a view showing group patterns according to the embodiment.
FIG. 39 is a view showing the frequency table of group patterns for attention patterns according to the embodiment.
FIG. 40 is a view showing a group determination table according to the embodiment.
FIG. 41 is a view showing an attention-pattern conversion table according to the embodiment.
FIG. 42 is a view showing a group conversion table according to the embodiment.
FIG. 43 is a view showing a representative frequency table according to the embodiment.
FIG. 44 is a view showing a representative-group determination table according to the embodiment.
FIG. 45 is a view showing a group inverted-conversion table according to the embodiment.
FIG. 46A and FIG. 46B are views showing group conversion methods according to the embodiment.
FIG. 47 is a functional block diagram of a group-determination-table generating device according to the embodiment.
FIG. 48 is a flowchart of processing for generating the representative frequency table according to the embodiment.
FIG. 49 is a flowchart of processing for generating the representative-group determination table according to the embodiment.
FIG. 50 is a flowchart of processing for generating the group determination table according to the embodiment.
FIG. 51 is a view showing a satisfaction-degree weight table according to the embodiment.
FIG. 52 is a view showing example degrees of attentions paid to participants according to the embodiment.
FIG. 53 is a view showing the names of seats according to the embodiment.
FIG. 54 is a view showing an example seating order according to the embodiment.
FIG. 55 is a flowchart of sight-line detection processing according to the embodiment.
FIG. 56 is a view showing detection of both-end positions of an eye according to the embodiment.
FIG. 57 is a view showing a nostril-position detection area according to the embodiment.
FIG. 58 is a view showing the both-end positions of eyes, nostril positions, and eyeball-center positions according to the embodiment.
FIG. 59 is a view showing detection of a sight-line direction according to the embodiment.
FIG. 60 is a view showing a method for obtaining a line which makes the secondary moment of a predetermined set of pixels minimum, according to the embodiment.
FIG. 61 is a flowchart of processing for detecting a face direction according to the embodiment.
FIG. 62A and FIG. 62B are views showing original images used for detecting a face direction according to the embodiment.
FIG. 63A and FIG. 63B are views showing hair areas and skin areas used for detecting a face direction according to the embodiment.
FIG. 64A and FIG. 64B are views showing the centers of gravity of the hair areas and of the skin areas according to the embodiment.
FIG. 65 is a view showing an example relationship between a difference and an angle during face-direction detection according to the embodiment.
FIG. 66 is an outlined internal view of a specific monitor device, viewed from a side thereof, according to the embodiment.
FIG. 67 is an outlined elevation of the specific monitor device according to the embodiment.
FIG. 68 is a block diagram of an actual structure implementing a signal processing device and a seating-order determination device in each teleconference device in the teleconference system according to the embodiment.
FIG. 69 is a view showing an outlined structure of another teleconference device which displays conference participants on a screen and disposes sound images by speakers according to the embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A teleconference system according to an embodiment of the present invention will be described below in the following order.
1. Structure of communication system
2. Structure of teleconference device
3. Structure of seating-order determination device
4. Grouping processing in the seating-order determination device
5. Seating-order determination operation through grouping in the seating-order determination device
6. Seating-order changing processing performed according to seating-order information in a teleconference device
7. First example of grouping processing which uses a statistical relationship in the seating-order determination device
8. Second example of grouping process which uses a statistical relationship in the seating-order determination device
9. Seating-order determination operation not through grouping in the seating-order determination device
10. Attention-degree-information generating operation in a teleconference device
11. Structure of monitor device
12. Example structure of each device
1. Structure of Communication System
FIG. 1 shows an outlined structure of a teleconference system according to an embodiment of the present invention. In the present specification, a system refers to the whole structure formed of a plurality of devices and sections.
In the teleconference system shown in FIG. 1 , teleconference devices TCD 1 to TCDn are assigned to conference participants HM 1 to HMn located at a plurality of (one to n) positions. The teleconference devices TCD 1 to TCDn are connected through a communication network NT formed, for example, of an integrated services digital network (ISDN).
When the conference participants HM 1 to HMn do not need to be distinguished from each other, they are hereinafter collectively called conference participants HM. In the same way, when the teleconference devices TCD 1 to TCDn do not need to be distinguished from each other, they are hereinafter collectively called teleconference devices TCD. In FIG. 1 , an IDSN is taken as an example of the communication network NT. Instead of an ISDN, other transfer media, such as cable television networks, the Internet, and digital satellite communication, can be used.
Each teleconference device TCD captures the image data and audio data of the corresponding conference participant HM; performs mutual communication with other teleconference devices TCD through the communication network NT; and can reproduce the image data and audio data (can monitor the images and sound) of the other conference participants HM sent from the other teleconference devices TCD.
2. Structure of Teleconference Device
Each teleconference device TCD constituting the teleconference system has a structure shown in FIG. 2 .
The teleconference devices TCD 1 to TCDn have the same structure. FIG. 2 shows a detailed example structure of the teleconference device TCD 1 as a representative of the plurality of teleconference devices TCD 1 to TCDn.
The teleconference device TCD 1 includes at least a signal processing device SPD 1 connected to the communication network NT, for transmitting and receiving signals to and from the other teleconference devices TCD 2 to TCDn which constitute the teleconference system and for applying signal processing described later to signals transmitted and received; and monitor devices MD 2 to MDn in which the image data and audio data of the conference participants HM 2 to HMn transmitted from the other teleconference devices TCD 2 to TCDn constituting the teleconference system can be monitored correspondingly to the teleconference devices TCD 2 to TCDn.
When the monitor devices MD 2 to MDn do not need to be distinguished from each other, they are hereinafter collectively called monitor devices MD.
The users of the teleconference devices TCD 1 to TCDn are fixed to the conference participants HM 1 to HMn. The relationships between the monitor devices MD in the teleconference devices and the information of conference participants HM displayed thereon are not fixed but dynamically changed according to seating-order information described later.
For simplicity, until a change of a seating order is described, a description will be given under the assumption that the monitor devices MD 1 to MDn correspond to the conference participants HM 1 to HMn located in the teleconference devices TCD 1 to TCDn, respectively.
The signal processing device SPD 1 of the teleconference device TCD 1 includes a network connection terminal TN 1 for connecting to the communication network NT; an information transmitting and receiving section TRB 1 for transmitting and receiving information to and from the communication network NT; an information manipulation and distribution section PB 1 for applying information manipulation and distribution processing described later to signals to be sent to monitor device MD 2 to MDn; an attention-degree-information generating section JB 1 for generating attention-degree-information used for dynamically changing a seating order during a conference, as described later; output terminals TO 2 to TOn for outputting signals separately to the monitor devices MD 2 to MDn; input terminals TI 2 to TIn for receiving signals separately from the monitor devices MD 2 to MDn; and an input terminal TS for receiving a signal from a switch SW, which generates switch-pressing information described later, used for generating the attention-degree information.
A detailed structure of each of the monitor devices MD 2 to MDn will be described later. Each monitor device MD includes, as main components, at least a speaker provided at the front side of the body of the monitor device, and a display section disposed such that its screen G is directed in a predetermined direction (such as a direction towards the participant HM 1 ).
At least one monitor device MD among the monitor devices MD 2 to MDn is provided with a microphone for capturing sound around the teleconference device TCD 1 and the sound of what the conference participant HM 1 says, and a camera (such as a video camera) for capturing an image of the conference participant HM 1 .
It is preferable that a monitor device provided with a microphone and a camera be disposed at the position of a monitor device (monitor device MDm in the case shown in FIG. 2 ) which directly faces the conference participant HM 1 . It is also possible that all the monitor devices MD 2 to MDn are provided with microphones and cameras.
Image data captured by the camera and audio data captured by the microphone in the monitor device MD are transmitted to the other teleconference devices TCD 2 to TCDn through the signal processing device SPD 1 and the communication network NT.
Images based on image data sent from the teleconference devices TCD 2 to TCDn are displayed on the display sections of the monitor devices MD 2 to MDn, and sound based on audio data sent from the teleconference devices TCD 2 to TCDn is output from the speakers of the monitor devices.
In other words, the monitor devices MD 2 to MDn correspond to the teleconference devices TCD 2 to TCDn with one-to-one correspondence. For example, images based on image data (image data of the conference participant HM 2 and the surrounding thereof) captured by the camera of the teleconference device TCD 2 and sent through the communication network NT are displayed on the screen G of the display section of the monitor device MD 2 , and sound based on audio data (audio data of what the conference participant HM 2 says) captured by the microphone of the teleconference device TCD 2 and sent through the communication network NT is output from the speaker of the monitor device MD 2 .
In the same way, images based on image data captured by the camera of the teleconference device TCD 3 and transmitted are displayed on the screen of the display section of the monitor device MD 3 , and sound based on audio data captured by the microphone of the teleconference device TCD 3 and transmitted is output from the speaker of the monitor device. The other monitor devices MD work in the same way. Images sent from teleconference devices TCD are displayed and sound is output.
As described above, however, the relationships between the monitor devices MD 2 to MDn and the teleconference devices TCD 2 to TCDn are not fixed but is dynamically changed as a so-called seating-order change. Therefore, the above-described one-to-one correspondence relationship is a tentative correspondence relationship such as that used in a system initial condition.
It can be considered that image data transmitted and received through the communication network NT among the teleconference devices TCD 1 to TCDn includes still-picture data as well as motion-picture data.
The monitor devices MD 2 to MDn are disposed as shown in FIG. 2 as if the conference participant HM 1 , who is in a conference room having the teleconference device TCD 1 , and the other conference participants HM 2 to HMn (those displayed on the display sections of the monitor devices MD 2 to MDn) were around one table to have a conference. Assuming that six teleconference devices TCD are used in the teleconference system and each teleconference device TCD is provided with five monitor devices, the five monitor devices can be disposed as shown in the figure such that a conference participant HM and the five monitor devices MD form, for example, a regular hexagon.
The attention-degree-information generating section JB of the signal processing device SPD in each teleconference device TCD generates attention-degree information used when a seating order is dynamically changed during a conference, as described below.
The attention-degree-information generating section JB 1 of the signal processing device SPD 1 in the teleconference device TCD 1 is taken as an example among the attention-degree-information generating sections JB 1 to JBn corresponding to the teleconference devices TCD 1 to TCDn, and its operation will be described below.
The attention-degree-information generating section JB 1 detects the degrees of attention which the conference participant HM 1 pays to the other conference participants according to image data sent from the camera, for example, of the monitor device MDm disposed in the front of the conference participant HM 1 , and generates attention-degree information used for dynamically changing the seating order, as described later, according to the result of detection.
The degrees of attention which the conference participant HM 1 pays to the other conference participants include how much (more specifically, analog values or stepped values indicating the state in which) the conference participant HM 1 pays attention to each of the monitor devices MD 2 to MDn as well as whether (more specifically, digital “0” or “1” indicating whether) the conference participant HM 1 pays attention in a direction toward each of the monitor devices MD 2 to MDn or in another direction.
The attention-degree-information generating section JB 1 analyzes the image data of the conference participant HM 1 , sent from the camera of the monitor device MDm to detect the direction in which the conference participant HM 1 faces, every unit periods. Details thereof will be described later.
More specifically, the attention-degree-information generating section JB 1 detects a period Ij as shown in FIG. 3( a ) as information indicating the direction in which the conference participant HM 1 faces and a period for which the conference participant HM 1 continues to face in the direction. In this case, Ij is one of values 2 to n, which correspond to the other conference participants HM 2 to HMn, or 0, which indicates none of the conference participants HM 2 to HMn. The attention-degree-information generating section JB 1 detects a period I 2 in which the conference participant HM 1 faces the monitor device MD 2 on which an image of the conference participant HM 2 is displayed, a period I 3 in which the conference participant HM 1 faces the monitor device MD 3 on which an image of the conference participant HM 3 is displayed, a period Im in which the conference participant HM 1 faces the monitor device MDm on which an image of the conference participant HMm is displayed, a period In−1 in which the conference participant HM 1 faces the monitor device MDn−1 on which an image of the conference participant HMn−1 is displayed, a period In in which the conference participant HM 1 faces the monitor device MDn on which an image of the conference participant HMn is displayed, or a period I 0 in which the conference participant HM 1 faces none of the monitor devices MD 2 to MDn.
Then, the attention-degree-information generating section JB 1 detects a period longer than a time Tcont among detected periods, some of I 2 to In and I 0 . When the attention-degree-information generating section JB 1 detects a period longer than the time Tcont, it generates information (Hi:Aj) indicating that the conference participant HM 1 pays attention to the conference participant corresponding to the detected period, such as those shown in FIG. 3( b ).
In the information (Hi:Aj), “i” corresponds to a conference participant HMi (for example, “1” for HM 1 ), and “j” corresponds to one of the other conference participants HMj (i≠j) (2 to n corresponding to the other conference participants HM 2 to HMn when “i” is 1) or 0, which corresponds to none of the conference participants.
More specifically, a description is made in the case shown in FIG. 3 . When the attention-degree-information generating section JB 1 detects periods I 3 , I 0 , and I 2 as periods longer than the time Tcont among detected periods, some of I 2 to In and I 0 , shown in FIG. 3( a ), the attention-degree-information generating section JB 1 generates, as attention-degree information, information (H 1 :A 3 ) indicating that the conference participant HM 1 pays attention to the conference participant HM 3 corresponding to the detected period I 3 ; information (H 1 :A 0 ) indicating that the conference participant HM 1 pays attention to none of the monitor devices MD or pay attention to something other than the monitor devices MD, corresponding to the detected period I 0 ; and information (H 1 :A 2 ) indicating that the conference participant HM 1 pays attention to the conference participant HM 2 corresponding to the detected period I 2 , as shown in FIG. 3( b ).
The attention-degree-information generating section JB 1 may generate attention-degree information according to the detection of a period Ij and switch-pressing information sent from the switch SW. More specifically, when the attention-degree-information generating section JB 1 detects periods Ij serving as information indicating the direction in which the conference participant HM 1 faces and a period in which the conference participant HM 1 faces in the direction, as shown in FIG. 4( a ), and receives switch-pressing ON signals, such as those shown in FIG. 4( b ), obtained when the conference participant HM 1 presses the switch SW during the detected periods, some of I 2 to In and I 0 , the attention-degree-information generating section JB 1 generates information (H 1 :Aj), such as those shown in FIG. 4( c ), indicating that, during a period when the switch-pressing signal is ON, the conference participant HM 1 pays attention to the conference participant corresponding to the signal. In the case shown in FIG. 4 , when the attention-degree-information generating section JB 1 detects I 3 and I 4 as periods when the switch-pressing signal is ON, among the detected periods, some of I 2 to In and I 0 , the attention-degree-information generating section JB 1 generates, as attention-degree information, information (H 1 :A 3 ) indicating that the conference participant HM 1 pays attention to the conference participant HM 3 corresponding to the detected period I 3 , and information (H 1 :A 4 ) indicating that the conference participant HM 1 pays attention to the conference participant HM 4 corresponding to the detected period I 4 , as shown in FIG. 4( c ).
In addition to the above cases, it is also possible that the conference participant HM 1 explicitly specifies the direction in which the conference participant HM 1 pays attention. For example, pushbuttons corresponding to the other conference participants HM 2 to HMn and a pushbutton corresponding to a case in which the conference participant HM 1 pays attention to none of those participants are prepared, and the conference participant HM 1 specifies the direction in which the conference participant HM 1 pays attention by pressing the corresponding pushbutton. In this case, pushbutton-pressing information serves as the attention-degree information.
3. Structure of Seating-Order Determination Device
Attention-degree information generated by the attention-degree-information generating section JB 1 by determining whom the conference participant HM 1 pays attention among the conference participants HM 2 to HMn according to a behavior or a designation of the conference participant HM 1 as described above is transmitted to the information transmitting and receiving section TRB 1 in the signal processing device SPD 1 , and then to a seating-order determination device GJD via the network connection terminal TN 1 through the communication network NT.
The seating-order determination device GJD is structured as shown in FIG. 5 .
In FIG. 5 , the seating-order determination device GJD is provided with a network connection terminal 72 for connecting to the communication network NT; an information transmitting and receiving section 70 for transmitting and receiving information to and from the communication network NT; and a seating-order determiner 71 for determining a seating order according to attention-degree information sent from the teleconference devices TCD 1 to TCDn, for generating seating-order information indicating the seating order, and for sending the seating-order information to the information manipulation and distribution sections PB of the teleconference devices TCD 1 to TCDn.
More specifically, in the seating-order determination device GJD, the information transmitting and receiving section 70 picks up the attention-degree information sent from the teleconference devices TCD 1 to TCDn among signals passing through the communication network NT, and sends the attention-degree information to the seating-order determiner 71 . The seating-order determiner 71 determines the seating order of the conference participants HM 1 to HMn attending the conference through the teleconference devices TCD 1 to TCDn, and generates seating-order information indicating the determined seating order.
The information transmitting and receiving section 70 transmits the generated seating-order information to the communication network NT to send it to the teleconference devices TCD 1 to TCDn.
Although details will be described later, the teleconference devices TCD 1 to TCDn receive the seating-order information sent from the seating-order determination device GJD at the information manipulation and distribution sections PB; and the information manipulation and distribution sections PB determine the correspondences between conference participants HM and monitor devices MD according to the seating-order information as described later, applies video and audio manipulation such that, for example, a change in seating order is easy to understand, and sends images and sound related to the conference participants HM corresponding to the monitor devices MD 2 to MDn to implement the determined seating order.
4. Grouping Processing in the Seating-Order Determination Device
Various methods for determining a seating order can be considered for the seating-order determination device GJD. A method can be considered as an example, in which a conversation group to which conference participants HM 1 to HMn belong is determined and then a seating order is determined according to the result of group determination such that participants belonging to the same group are set close to each other.
A process for determining a conversation group in the seating-order determination device GJD will be described below before seating-order determination processing performed according to a group is described.
Various group-determination rules used in the seating-order determination device GJD can be considered. In the following description, a rule in which a link is made between a person who pays attention to another person and the another person, who attracts attention, and one group is formed of persons who are coupled directly or indirectly by links is used as an example. Details of a group determination and update process performed by the rule according to attention-degree information in the seating-order determiner 71 of the seating-order determination device GJD will be described below. In this rule, one group is formed of persons who directly or indirectly pay attention to others, and the others, who attract attention directly or indirectly.
A condition in which a person directly or indirectly pays attention to another person, and the another person attracts attention directly or indirectly will be described with the following example. It is assumed, as an example, that a person A pays attention to a person B, and the person B pays attention to a person C. In this example, it is considered that the person A pays attention to the person B “directly” (the person B also pays attention to the person C “directly”) and the person B attracts attention “directly;” and the person A pays attention to the person C “indirectly (through the person B)” and the person C attracts the attention of the person A “indirectly (through the person B).” In this example, there is only one person, the person B, between the person A and the person C. But, there may be a plurality of persons between the person A and the person C.
The seating-order determiner 71 holds an attention-destination table formed of an “individual number” column indicating numbers assigning to conference participants attending a conference held with this teleconference system; an “attention-destination number” column indicating the numbers of conference participants whom the conference participants HM 1 to HMn using the teleconference devices TCD 1 to TCDn pay attention; and a “whether registration has been made to group table” column indicating whether registration has been made to a group table, as shown in FIG. 6 .
The seating-order determiner 71 also holds a group table formed of a “group number” column indicating numbers assigned to groups formed in the teleconference system; a “number of members” column indicating the number of members belonging to each group among the conference participants; and a “member” column indicating conference participants belonging to the groups, as shown in FIG. 7 .
The seating-order determiner 71 performs initialization at the start of communication prior to receiving attention-degree information, as shown in FIG. 8 .
More specifically, the seating-order determiner 71 generates the attention-destination table shown in FIG. 6 and performs initialization in the process of step S 31 shown in FIG. 8 .
In the initialization, the seating-order determiner 71 sets the “individual number” column to the numbers (H 1 to Hn in a case shown in FIG. 6 ) corresponding to conference participants attending a conference held with the teleconference system in the attention-destination table shown in FIG. 6 ; sets the “attention-destination number” column all to a number A 0 which indicates that the conference participants HM 1 to HMn who use the teleconference devices TCD 1 to TCDn pay attention to none of them; and sets the “whether registration has been made to group table” column to all “x” which indicates that registration has not yet been made to any group.
The seating-order determiner 71 generates a group table and performs initialization in the process of step S 32 as shown in FIG. 7 .
In the initialization, the seating-order determiner 71 sets the “group number” column to G 1 to Gn which indicate that each of the teleconference devices TCD 1 to TCDn forms one group, in the group table shown in FIG. 7 ; sets the “number of members” column to all 0, which indicates that none attends any group; and sets the “member” column to all null, which indicates that any group has no member.
When the seating-order determiner 71 receives attention-degree information, it starts a process to be performed when attention-degree information is generated, as shown in FIG. 9 .
In FIG. 9 , when the seating-order determiner 71 receives attention-degree information, it sets the attention-destination table according to the attention-degree information in the process of step S 41 as shown in FIG. 10 .
Actually, the seating-order determiner 71 specifies the “attention-destination number” column such that, when information (Hi:Aj) is received, which indicates that the conference participant HMi indicated by Hi pays attention to the conference participant HMj corresponding to Aj, the “attention-destination number” cell corresponding to an individual number of Hi is set to Aj.
The “whether registration has been made to group table” column is all initialized to “x.”
In a case shown in FIG. 10 , the “attention-destination number” cell corresponding to an “individual number” of H 1 is set to A 3 corresponding to the conference participant HM 3 as the attention destination of the conference participant HM 1 indicated by an “individual number” of H 1 ; the “attention-destination number” cell corresponding to an “individual number” of H 2 is set to A 0 , which indicates that none attracts attention, as the attention destination of the conference participant HM 2 indicated by an “individual number” of H 2 ; the “attention-destination number” cell corresponding to an “individual number” of H 3 is set to A 5 corresponding to the conference participant HM 3 as the attention destination of the conference participant HM 3 indicated by an “individual number” of H 3 ; and the “attention-destination number” cell corresponding to an “individual number” of H 4 is set to A 2 corresponding to the conference participant HM 2 as the attention destination of the conference participant HM 4 indicated by an “individual number” of H 4 . A description for conference participants HM 5 to HMn will be omitted. The “attention-destination numbers” column is specified for HMi in this way.
The seating-order determiner 71 sets the “numbers of members” column all to 0 and the “member” column all to null as shown in FIG. 7 in the group table in the process of step S 42 .
After steps S 42 and S 43 , the seating-order determiner 71 sets the group table according to the contents of the attention-destination table for each of “individual numbers” H 1 to Hn in the process of step S 43 .
FIG. 11 is a detailed flowchart of processing for setting the group table according to the contents of the attention-destination table in step S 43 of the flowchart of FIG. 9 . In FIG. 11 , “registration” means registration to the group table; a “self entry” means a self entry in the attention-destination table; an “attention destination” means an attention destination in a self entry; an “attention-destination entry” means the entry of an attention destination in the attention-destination table; a “self group” means a group to which the self belongs as a member; and an “attention-destination group” means a group to which an attention destination belongs as a member. An actual registration operation means that the number of members is incremented by one in a group table; a corresponding number is added as a member in the group table; and the corresponding “whether registration has been made to group table” cell in the attention-destination table is changed to “◯.”
A requirement concerning the setting of the entry of a conference participant HMi in the attention-destination table will be first described. A requirement (hereinafter called a first requirement in each teleconference device) concerning the setting of the entry of the conference participant HMi having an individual number of Hi in the attention-destination table includes the registration of the individual number Hi to the group table, and a change of the “whether registration has been made to group table” cell in the entry of the individual number Hi in the attention-destination table to “◯.” When the attention-destination number corresponding to the individual number Hi is A 0 (which means the conference participant pays attention to none of the other conference participants), only this requirement applies.
When the attention-destination number corresponding to the individual number Hi is not A 0 , a requirement (hereinafter called a second requirement in each teleconference device) includes the registration of the attention-destination number to the group table, a change of the “whether registration has been made to group table” cell in the entry of the attention destination in the attention-destination table to “◯,” and the registration of the individual number Hi and the attention destination to the same group in the group table.
By following the flowchart shown in FIG. 11 , whether these requirements are satisfied is checked.
In the process of step S 51 , the seating-order determiner 71 determines whether the “whether registration has been made to group table” cell in the self entry of the individual number Hi in the attention-destination table is “◯.” When the “registration” in the self entry has already been set to “◯” in step S 51 , since it is ensured that registration to the group table has already been performed, the first requirement is already satisfied. Therefore, when it is determined in step S 51 that YES is obtained, the seating-order determiner 71 does not perform work related to registration of the individual number Hi to the group table, and the processing proceeds to step S 53 . When it is determined in step S 51 that NO is obtained, since the “registration” is “x” in the self entry, the processing proceeds to step S 52 .
In the process of step S 52 , the seating-order determiner 71 registers the self (individual number) to a group having no member and the smallest number in the group table, and the processing proceeds to step S 53 .
As the results of steps S 51 and S 52 , the first requirement is satisfied before the process of the next step S 53 .
In the process of step S 53 , the seating-order determiner 71 determines whether the attention-destination number is not A 0 . When the attention-destination number is A 0 , in other words, it is determined in step S 53 that NO is obtained, since all requirements have already been satisfied, the seating-order determiner 71 finished the processing. When the attention-destination number is not A 0 , in other words, when it is determined in step S 53 that YES is obtained, the processing proceeds to step S 54 to satisfy the second requirement.
In the process of step S 54 , the seating-order determiner 71 determines whether the “whether registration has been made to group table” cell in the attention-destination entry is “◯.”
When the “registration” is “x” in the attention-destination entry, in other words, it is determined in step S 54 that NO is obtained, since it is sure that the attention-destination entry has not been registered to the group table, the processing proceeds to step S 58 , and the seating-order determiner 71 registers the attention destination to the group (self group) to which the self belongs, and sets the “whether registration has been made to group table” cell in the attention-destination entry in the attention-destination table to “◯.” Since the second requirement is surely satisfied with the process of step S 58 , the seating-order determiner 71 finishes the processing.
When it is determined in step S 54 that the “registration” is “◯” in the attention-destination entry, which means that the attention destination has already been registered, only the last item of the second requirement needs to be satisfied, which indicates that the individual number Hi and the attention destination belong to the same group. When it is determined in step S 54 that YES is obtained, the seating-order determiner 71 refers to the group table in the next step S 55 and checks whether the individual number Hi and the attention destination belong to the same group in step S 56 .
When it is confirmed in step S 56 that they belong to the same group, in other words, when it is determined in step S 56 that YES is obtained, since the second requirement has already been satisfied, the seating-order determiner 71 finishes the processing.
When it is determined in step S 56 that No is obtained, since the individual number Hi and the attention destination need to belong to the same group, the seating-order determiner 71 merges the two groups to which the individual number Hi and the attention destination belong in the process of step S 57 . More specifically, the seating-order determiner 71 merges (adds the number of members in the group having a larger number to that in the group having a smaller number, adds the members of the group having the larger number to those of the group having the smaller number, sets the number of members in the group having the larger number to zero, and sets the members of the group having the larger number to null) the group having a larger number into the group having a smaller number among the two groups. As a result, the second requirement is satisfied. Since all the requirements have been satisfied, the seating-order determiner 71 finishes the processing.
The confirmation of the requirements related to the settings of the entry of the conference participant HMi in the attention-destination table has been finished.
When the entry corresponding to the individual number Hi has been set in the attention-destination table, it is necessary that both the entry corresponding to the individual number Hi and those corresponding to the individual numbers up to Hi−1 be set in the attention-destination table. As for the setting of the entry corresponding to the individual number H 1 , since the other entries have not yet set so far, it is required that only the entry corresponding to the individual number H 1 be set.
Operations which may be performed when the entry corresponding to the individual number Hi is input include a new registration to the group table, the merger of two groups in the group table, and a change in the “whether registration has been made to group table” cell in the attention-destination table to “◯.” With these operations, neither numbers registered according to the entries corresponding to individual numbers up to Hi−1, followed by Hi, are deleted, nor the “whether registration has been made to group table” cells are set to “x.” In addition, two numbers belonging to the same group are not separated, either. Therefore, the process for setting the entry corresponding to the individual number Hi into the tables does not break the requirements satisfied by the processes for the individual numbers up to Hi−1, followed by Hi. Consequently, it is inductively understood that, when the processes related to the entries of all individual numbers Hi, shown in FIG. 11 , have been finished, the requirements for the entries of all individual numbers H 1 to Hi are satisfied.
Changes in the attention-destination table and in the group table, made in the processing shown by the flowchart of FIG. 11 will be described below by examples. It is assumed here that the group table has a state shown in FIG. 7 as initial states, and the attention-destination table has a state shown in FIG. 10 when group-determination information has been input. Changes in the attention-destination table and the group table will be explained.
The setting of the entry of the conference participant HM 1 (having an individual number of H 1 ) will be described first.
Since the “whether registration has been made to group table” cell is “x,” it is determined in step S 51 of FIG. 11 that NO is obtained, and the entry corresponding to the individual number H 1 is input to the group table in the next step S 52 . As a result of the process of step S 52 , the “number of members” for a group number G 1 having the smallest number is set to one, and the individual number H 1 is input to the “member” column, as shown in FIG. 12 . The “whether registration has been made to group table” cell for the individual number H 1 is changed to “◯” in the attention-destination table as shown in FIG. 13 .
Then, it is determined in step S 53 that YES is obtained. Since the attention destination is A 3 indicating the conference participant HM 3 , and the “whether registration has been made to group table” cell for the entry of the individual number H 3 is “x,” as shown in FIG. 13 , it is determined in step S 54 that NO is obtained. As a result, in step S 58 , the individual number H 3 of the attention destination is input to the group G 1 , which is the “self group.” In the group table, the “number of members” in the group G 1 is set to two and its members are H 1 and H 3 in the group table as shown in FIG. 14 . In the attention-destination table, the “whether registration has been made to group table” cells for the individual numbers H 1 and H 3 are set to “◯” as shown in FIG. 15 .
The setting of the entry of the conference participant HM 1 (having an individual number of H 1 ) has been finished.
The setting of the entry of the conference participant HM 2 (having an individual number of H 2 ) will be described next.
Since the “whether registration has been made to group table” cell is “x” when the entry corresponding to the individual number H 2 is input to the tables, it is determined in step S 51 of FIG. 11 that NO is obtained, and the entry corresponding to the individual number H 2 is input to the group table in the next step S 52 . As a result of the process of step S 52 , the number of members for a group number G 2 having the next smallest number is set to one, and the individual number H 2 is input to the member column, as shown in FIG. 16 . The “whether registration has been made to group table” cell for the individual number H 2 is changed to “◯” in the attention-destination table as shown in FIG. 17 . Since the attention-destination number of the individual number H 2 is A 0 as shown in the case of FIG. 17 , the setting of the entry of the conference participant HM 2 has been finished at this point.
The setting of the entry of the conference participant HM 3 (having an individual number of H 3 ) will be described next.
Since the “whether registration has been made to group table” cell is “◯” as shown in FIG. 15 when the entry corresponding to the individual number H 3 is input to the tables, because the entry corresponding to the individual number H 1 has been set. Therefore, it is determined in step S 51 of FIG. 11 that YES is obtained. Since the conference participant HM 3 having the individual number H 3 pays attention to the conference participant HM 5 , it is determined in step S 53 that YES is obtained. Since the “whether registration has been made to group table” cell for the individual number H 5 , indicating the attention destination, is “x,” as shown in FIG. 17 , it is determined in step S 54 of FIG. 11 that NO is obtained.
As a result, in step S 58 , the individual number H 5 of the attention destination is input to the group G 1 , which is the “self group” of the individual number H 3 . In the group table, the number of members in the group G 1 is updated to three and its members are updated to H 1 , H 3 , and H 5 in the group table as shown in FIG. 18 . In the attention-destination table, the “whether registration has been made to group table” cell for the individual number H 5 is set to “◯” as shown in FIG. 19 .
The setting of the entry of the conference participant HM 3 (having an individual number of H 3 ) has been finished.
The setting of the entry of the conference participant HM 4 (having an individual number of H 4 ) will be described next.
Since the “whether registration has been made to group table” cell is “x” when the entry corresponding to the individual number H 4 is input to the tables, it is determined in step S 51 of FIG. 11 that NO is obtained, and the entry corresponding to the individual number H 4 is input to the group table in the next step S 52 . As a result of the process of step S 52 , the number of members for a group number G 3 which is the group following the groups G 1 and G 2 is set to one, and the individual number H 4 is input to the member column, as shown in FIG. 20 . The “whether registration has been made to group table” cell for the individual number H 4 is changed to “◯” in the attention-destination table as shown in FIG. 21 .
Then, it is determined in step S 53 that YES is obtained. Since the attention destination is A 2 indicating the conference participant HM 2 , and the “whether registration has been made to group table” cell for the entry of the individual number H 2 is “◯,” as shown in FIG. 21 , it is determined in step S 54 that YES is obtained.
In step S 55 , a group number is searched for the individual number H 2 of the attention destination to obtain the group number G 2 to which the individual number H 2 serving as the attention destination belongs. In the next step S 56 , it is determined that NO is obtained because the group number to which the individual number H 4 belongs is G 3 and the group number to which the individual number H 2 serving as the attention destination belongs is G 2 . In the next step S 57 , the group number G 3 to which the individual number H 4 belongs is merged into the group G 2 , which has a smaller number, to which the individual number H 2 belongs.
Therefore, in the group table, the number of members in the group G 2 is updated to two, and its members are updated to H 2 and H 4 , as shown in FIG. 22 . The attention-destination table is updated (the same as that shown in FIG. 21 ) as shown in FIG. 23 .
The setting of the entry of the conference participant HM 4 (having an individual number of H 4 ) has been finished.
The setting of the entry of the conference participant HM 5 (having an individual number of H 5 ) will be described last.
Since the “whether registration has been made to group table” cell is “◯” as shown in FIG. 23 when the entry corresponding to the individual number H 5 is input to the tables. Therefore, it is determined in step S 51 of FIG. 11 that YES is obtained. Since the conference participant HM 5 having the individual number H 5 pays attention to the conference participant HM 3 , it is determined in step S 53 that YES is obtained. Since the “whether registration has been made to group table” cell for the individual number H 3 , indicating the attention destination, is “◯” as shown in FIG. 23 , it is determined in step S 54 of FIG. 11 that YES is obtained.
In step S 55 , a group number is searched for the individual number H 3 of the attention destination to obtain the group number G 1 to which the individual number H 3 serving as the attention destination belongs. In the next step S 56 , it is determined that YES is obtained because the group number to which the individual number H 3 serving as the attention destination belongs is G 1 , and the individual number H 5 has already been registered to the group G 1 . The processing is finished.
The group table is updated (is the same as that shown in FIG. 22 ) as shown in FIG. 24 , and the attention-destination table is updated (is the same as that shown in FIG. 23 ) as shown in FIG. 25 .
With the processing described above, when information related to all individual numbers are input to the attention-destination table, the “registration to group table” column is set to all “◯” in the attention-destination table. All individual numbers have already been registered to any one of groups as members in the group table.
5. Seating-Order Determination Operation Through Grouping in the Seating-Order Determination Device
When group determination is finished in the processing described above, the seating-order determination device GJD determines a seating order such that persons belonging to the same group are collectively arranged.
To this end, the seating-order determination device GJD holds seating-order information as well as group information.
When a group is changed, the seating-order determination device GJD refers to the held seating-order information and changes it by processing shown in a flowchart of FIG. 26 to determine a new seating order. This processing will be described below.
In step S 101 , it is determined whether there is a group (hereinafter called a divided group) in which its members are separated.
When no group is divided at the seating order used before a change, in other words, when members are collectively arranged in all groups, since the target condition is satisfied, the seating order used before a change is used as is. The processing shown in FIG. 26 is finished.
When it is determined in step S 101 that there is a divided group, a group having the largest number of members is determined among divided groups in step S 102 . When there are a plurality of divided groups, a group having the minimum group number is regarded as the largest group. Since the largest group is divided, if a set of one person or more collectively arranged is called a sub group, the largest group is formed of a plurality of sub groups.
When the largest divided group is determined, the largest sub group is determined in the largest divided group and a sub group located closest to the largest sub group is determined in step S 103 . When there are a plurality of groups having the largest number of members among sub groups, a group to which a person having the minimum individual number belongs is regarded, for example, as the largest sub group. When separate sub groups are located at the same distance from the largest sub group clockwise and counterclockwise, the sub group located at the distance counterclockwise is regarded, for example, as the sub group closest to the largest group.
When the sub group closest to the largest sub group is determined, the determined sub group is connected to the largest sub group in step S 104 . This connection process will be described below.
The determined sub group closest to the largest sub group counterclockwise from the largest sub group is shifted clockwise to connect to the largest sub group. The determined sub group closest to the largest sub group clockwise from the largest sub group is shifted counterclockwise to connect to the largest sub group. When the determined sub group is located at the same distance from the largest sub group clockwise and counterclockwise, the determined sub group is, for example, shifted clockwise to connect to the largest sub group. Persons located between the largest sub group and the sub group closest thereto are shifted by the number of members belonging to the sub group closest to the largest sub group in the direction opposite that in which the sub group closest to the largest sub group is shifted.
Details of the connection process have been described.
Since the number of sub groups in the largest divided group is reduced by one by the above-described connection process, the largest divided group is collectively arranged by the repetition of the process shown in the flowchart of FIG. 26 .
When the process for one divided group is finished, the same process can be applied to the next largest group by the repetition of the process shown in the flowchart. Therefore, each of all groups is collectively arranged by the repetitions of the process shown in the flowchart, and the seating-order determination processing is finished with the target condition being obtained.
Two example seating-order changes in the seating-order determination processing will be described below.
FIG. 27 shows a first example. In a state shown in FIG. 27( a ), only a group G 1 indicated by black circles is divided into sub groups SG 1 and SG 2 . The sub group SG 2 closest to the largest sub group SG 1 is located in the counterclockwise direction.
In this case, the connection process performs shifting indicated by arrows in FIG. 27( a ) to change a seating order to that shown in FIG. 27( b ), and the seating-order determination processing is completed.
FIG. 28 shows a second example. In a state shown in FIG. 28( a ), two groups, a group G 1 indicated by black circles and a group G 2 indicated by white circles, are divided. The largest divided group is the group G 1 . The group G 1 is divided into three sub groups SG 1 , SG 2 , and SG 3 . The sub groups SG 2 and SG 3 are located at the same distance from the largest sub group SG 1 clockwise and counterclockwise. In this case, according to the above-described rule, shifting is performed first so as to connect the sub group SG 3 , located in the counterclockwise direction from the largest sub group.
Then, as shown in FIG. 28( b ), two sub groups SG 11 and SG 2 are disposed. The sub group closest to the largest sub group SG 11 is SG 2 , and located in the clockwise direction from the largest sub group SG 11 .
The connection process is applied to the sub group SG 2 to obtain a state shown in FIG. 28( c ), in which the group G 1 is collectively arranged.
As a result of the process, another divided group G 2 is collectively arranged. A total to two repetitions of the connection process completes the seating-order determination processing.
When the seating-order determination processing is completed as described above, for example, the seating-order determiner 71 generates seating-order information showing the determined seating order and sends it to each teleconference device TCD. Together with the seating-order information, the seating-order determiner 71 sends group information indicating the state of grouping.
In the above-described case, the seating-order determiner 71 determines the seating order according to the result of group determination such that conference participants belonging to the same groups are collectively arranged. To make a viewing range small when watching members belonging to the same group, members belonging to the same groups may be arranged so as to be uniformly dispersed.
As shown in FIG. 29 , for example, a seating order may be determined such that conference participants belonging to groups G 1 and G 2 are uniformly dispersed.
6. Seating-Order Changing Processing Performed According to Seating-Order Information in a Teleconference Device
Operations of a teleconference device TCD, performed when image data and audio data sent from each teleconference device TCD, and the above-described seating-order information sent from the seating-order determination device GJD are received in the teleconference system according to the present embodiment will be described below. The teleconference device TCD 1 will be taken as an example among the teleconference devices TCD 1 to TCDn and its operations will be described.
When the information transmitting and receiving section TRB 1 of the teleconference device TCD 1 receives a signal sent through the communication network NT, the information transmitting and receiving section TRB 1 separates the image data and the audio data corresponding to the teleconference devices TCD 2 to TCDn from the signal; picks up the above-described seating-order information (including the group information); and sends the picked-up seating-order information as well as the separated image data and audio data to the information manipulation and distribution section PB 1 .
The information manipulation and distribution section PB 1 distributes input images and/or sound to the corresponding monitor devices MD according to the seating-order information. The information manipulation and distribution section PB 1 may manipulate images and/or sound to be distributed, so that, for example, a seating-order change is made easy to understand intuitively.
A specific process to be performed in the information manipulation and distribution section PB 1 will be described below by taking a case as an example, in which manipulation is applied to images and sound so as to make a seating-order change easy to understand intuitively, and images and sound are sent to the corresponding monitor devices MD according to the seating-order information.
FIG. 30 shows the structure of the information manipulation and distribution section PB 1 . It includes an input terminal 201 for receiving images and sound received by the information transmitting and receiving section TRB 1 shown in FIG. 2 ; an input terminal 202 for receiving seating-order information received by the information transmitting and receiving section TRB 1 ; a motion determination section 203 for performing motion determination related to the seating-order information; a connection determination section 204 for determining a connection state according to the seating-order information; an image manipulation device 205 and an audio manipulation device 206 for manipulating input images and sound; and an information distribution section 207 for distributing manipulated images and sound to each monitor device MD.
The output terminals TO 2 to TOn connected to the information distribution section 207 are those used for sending images and sound to the monitor devices MD 2 to MDn as shown in FIG. 2 .
The motion determination section 203 determines the directions and amounts of the relative motions of conference participants HM located at remote places against the conference participant HM 1 located on site according to the input seating-order information, namely, determines the directions and amounts of motions related to changes in a seating order, and sends the results as motion information to the image manipulation section 205 and to the audio manipulation section 206 .
FIG. 31 shows the structure of the image manipulation device 205 . The image manipulation device 205 includes image manipulators 250 - 2 , 250 - 3 , . . . , and 250 - n for manipulating the input images corresponding to conference participants HM.
The images of conference participants HM are sent from an input terminal 251 to the image manipulators 250 - 2 , 250 - 3 , . . . , and 250 - n , and the motion information is sent from the motion determination section 203 through an input terminal 252 to the image manipulators 250 - 2 , 250 - 3 , and 250 - n.
Each of the image manipulators 250 - 2 , 250 - 3 , . . . , and 250 - n extracts a motion related to the corresponding conference participant HM from the motion information, and manipulates the input image of the corresponding conference participant HM that the movement of the conference participant HM is intuitively easy to understand, as required, according to the extracted motion.
The manipulated images are output from an output terminal 253 to the information distribution section 207 .
In an example manipulation performed in each of the image manipulators 250 - 2 , 250 - 3 , . . . , and 250 - n , arrows indicating the directions of the relative motions of conference participants HM located at remote places against the conference participant HM 1 located on site are superposed on input images.
FIG. 34 ( a ) shows an input image, and FIG. 34( b ) shows a manipulated image obtained when a motion direction is left.
When a relative motion is not found, a method in which an arrow is not superposed may be used. An arrow is superposed until the time immediately before a connection is changed by the information distribution section 207 , described later.
In another example manipulation performed in each of the image manipulators 250 - 2 , 250 - 3 , . . . , and 250 - n , input images are moved on screens in the directions of the relative motions of conference participants HM located at remote places against the conference participant HM 1 located on site.
FIG. 35( a ) shows an input image, and FIG. 35( b ), ( c ), and ( d ) shows manipulated images obtained every time when a predetermined time elapses, if the motion direction is left. Input images are moved until the time immediately before a connection is changed by the information distribution section 207 .
In still another example manipulation performed in each of the image manipulators 250 - 2 , 250 - 3 , . . . , and 250 - n , input images are moved on screens as described above with the background being fixed and only the portion of the conference participants HM in the input images being moved.
To implement the above-described manipulation, there is a method in which backgrounds viewed from the cameras corresponding to conference participants HM located at remote places are set to blue backgrounds (BB); portions other than the blue backgrounds are extracted as conference participants from input images by the image manipulators 250 - 2 , 250 - 3 , . . . , and 250 - n ; the portions are shifted according to the corresponding motions and then attached back to the images; and a fixed background is attached to the parts other than the portions attached in the images.
FIG. 36( a ) shows an example input image, obtained before movement, FIG. 36( b ) shows a manipulated image obtained when a predetermined time elapses, and FIG. 36( c ) shows a manipulated image obtained when a predetermined time further elapses, if a motion direction is left. As shown in the figure, the image of the conference participant is shifted, for example, in the left direction according to the direction in which a seating order is changed with a blue background (BB) being used as a background. The image is shifted according to the corresponding motion, for example, until the time immediately before a connection is changed by the information distribution section 207 , described later.
When the seating order of conference participants displayed on the monitor devices MD 2 to MDn is changed, these image manipulation processes make the change and a direction in which the change is performed easy to understand for the conference participant HM 1 .
FIG. 32 shows the structure of the audio manipulation device 206 . The audio manipulation device 206 includes audio manipulators 260 - 2 , 260 - 3 , . . . , and 260 - n for manipulating the input sound corresponding to conference participants HM.
The sound of conference participants HM are sent from an input terminal 261 to the audio manipulators 260 - 2 , 260 - 3 , . . . , and 260 - n , and the motion information is sent from the motion determination section 203 through an input terminal 262 to the image manipulators 260 - 2 , 260 - 3 , and 260 - n.
Each of the audio manipulators 260 - 2 , 260 - 3 , . . . , and 260 - n extracts a motion related to the corresponding conference participant HM from the motion information, and manipulates the input sound of the corresponding conference participant HM so that the movement of the conference participant HM is intuitively easy to understand, as required, according to the extracted motion.
The manipulated sound is output from an output terminal 263 to the information distribution section 207 .
In an example manipulation performed in each of the audio manipulators 260 - 2 , 260 - 3 , . . . , and 260 - n , a message such as “the seating order is being changed” and/or sound indicating a change of the seating order is superposed on sound when a conference participant HM located at a remote place relatively moves against the conference participant HM 1 located on site. The message and/or sound is superposed, for example, until the time immediately before or immediately after a connection is changed by the information distribution section 207 , described later.
In another example manipulation, a message such as “the seating order is being changed” and/or sound indicating a change of the seating order is superposed on sound irrespective of the motion of a conference participant HM located at a remote place. The message and/or sound is superposed, for example, until the time immediately before or immediately after a connection is changed by the information distribution section 207 , described later.
The connection determination section 204 , shown in FIG. 30 , determines a method for connecting images and sound to each monitor device MD according to the seating order information input from the input terminal 202 , and sends it to the information distribution section 207 as connection information.
FIG. 33 shows the structure of the information distribution section 207 . Images sent from the image manipulation device 205 through an input terminal 271 , and sound input from the sound manipulation device 206 through an input terminal 272 are sent to a matrix switcher 270 . The images and sound are sent to each monitor device MD so as to conform to the seating-order information, according to the connection information sent from the connection determination section 204 through an input terminal 273 to the matrix switcher 270 . In other words, the matrix switcher 270 switches the images and sound to the output terminals TO 2 to TOn according to the connection information.
Since the information manipulation and distribution section PB has the above-described structure in the signal processing device SPD of each teleconference device TCD, a dynamic seating-order change is performed in the monitor devices MD 2 to MDn according to the seating-order information generated by the seating-order determination device GJD.
The relationships (seating order) between the monitor devices MD 2 to MDn and conference participants HM 2 to HMn shown thereon are flexibly changed according to conversation groups made and released during a conference such that a suitable condition is made for the conference participant HM 1 to do conversation.
In the foregoing description, both images and sound are handled as information related to conference participants HM located at remote places. One of them may be handled as the information.
In the foregoing description, images and sound are manipulated. Input images and/or sound may be directly sent to the information distribution section 207 without being manipulated.
When a seating-order is frequently changed, a confusion may occur as to which conversation each conference participant is doing.
To avoid such a condition, when the seating-order determination device GJD determines a seating order according to group determination as described above, a process for making the background of each conference participant HM in the corresponding image have similarity in units of groups can be applied in image processing performed by the information manipulation and distribution section PB.
More specifically, for example, backgrounds viewed from the cameras corresponding to conference participants HM located at remote places are set to blue backgrounds; the information manipulation and distribution section PB extracts these blue backgrounds as backgrounds; and changes them to backgrounds having the same colors in units of groups. The information manipulation and distribution section PB sets the background color of each image and performs image processing according to the group information. A method for setting the backgrounds of conference participants who belong to the same group as the self (conference participant HM 1 ) to, for example, a fixed color (such as blue) can be considered so as to understand the conference participants belonging to the same group as the conference participant HM 1 .
FIG. 37A and FIG. 37B show example background colors used before and after conversion. In the figure, G 1 to G 3 indicate the numbers of groups to which conference participants belong. In this case, in a state obtained after the conversion shown in FIG. 37B , the conference participants belonging to the group G 2 understand that the conference participant having the blue background belongs to the same group, and easily understands that the group G 1 having a red background and the group G 3 having a green background are formed.
7. First Example of Grouping Processing which Uses a Statistical Relationship, in the Seating-Order Determination Device
In the foregoing case, the seating-order determination device GJD uses a group determination method based on the rule in which a link is made between a person who pays attention to another person and the another person, who attracts attention, and one group is formed of persons who are coupled directly or indirectly by links. In another case, a group can be determined by statistical relationships between attention patterns which indicate combinations of the attention destinations of conference participants, and group patterns.
In such a case, a process can be used in which the seating-order determination device GJD prepares a group determination table like that shown in FIG. 40 , and converts an attention pattern to a group pattern according to the table.
A method for preparing such a group determination table in advance according to statistics will be described below. A case in which the number of conference participants is three will be taken as an example.
To make a group determination table, an experiment is performed to have actual conversation states, and time-sequential samples formed of combinations of attention patterns and group patterns are prepared, for example, at a predetermined interval.
It is possible, for example, that attention patterns are automatically obtained and group patterns are determined by a person.
Two methods for generating a group determination table according to the samples can be considered. A first method will be described first.
In this method, the most frequently generated group pattern is found for each attention pattern, and the group pattern is registered as the group pattern corresponding to the attention pattern.
An experiment is first performed in this method to record a pattern of the attention destinations of conference participants and a group pattern formed at that time at a predetermined interval to generate a frequency table between attention patterns and group patterns, like that shown in FIG. 39 .
In FIG. 39 , numbers (zero indicates that a conference participant pays attention to nobody) indicated below conference participants HM 1 to HM 3 are those of the attention destinations of the conference participants, and GP 1 to GP 5 indicate the numbers of group patterns.
FIG. 38 shows example definitions of group patterns.
Various group forms are defined as group patterns GP 1 to GP 5 as shown in FIG. 38 , in which a group pattern GP 1 indicates that three conference participants HM 1 to HM 3 have no group, a group pattern GP 2 indicates a state in which conference participants HM 1 and HM 2 form a group, . . . .
The frequency table shown in FIG. 39 indicates that, as a result of the experiment, when the attention destinations of the conference participants HM 1 to HM 3 are all zero, the group pattern GP 1 is formed 10034 times, the group pattern GP 2 is formed 130 times, . . . , and the group pattern GP 5 is formed 3024 times.
A group pattern is determined in the experiment, for example, by a person who sees the state.
According to such a frequency table, the group pattern corresponding to an attention pattern of the conference participants HM 1 to HM 3 is selected so as to have the highest probability, and the group determination table shown in FIG. 40 is made from the selected correspondences.
In the frequency table shown in FIG. 39 , when the attention destinations of the conference participants HM 1 to HM 3 are all zero, the group pattern GP 1 has the highest frequency. Therefore, when the conference participants HM 1 to HM 3 have an attention destination of 0, which is shown by (0, 0, 0), the group pattern is set to GP 1 .
When the conference participant HM 3 has an attention destination of 1 and the other conference participants HM 1 and HM 2 have an attention destination of 0, which is shown by (0, 0, 1), the group pattern is set to GP 4 according to the frequency table shown in FIG. 39 .
A group pattern having the highest frequency is determined for each of all attention-destination patterns to make the relationships between attention-destination patterns and group patterns shown in FIG. 40 .
The seating-order determination device GJD holds a group determination table generated in advance, like that described above, to determine the group corresponding to an attention pattern of the conference participants HM 1 to HM 3 by referring to the group determination table when it receives attention-degree information from the teleconference devices TCD, and generates seating-order information according to the group determination.
8. Second Example of Grouping Processing which Uses a Statistical Relationship, in the Seating-Order Determination Device
In the foregoing case, all attention patterns are independently handled when the frequency table between attention patterns and group patters is generated. In a second case, attention patterns similar to each other are collectively handled to generate a frequency table, and a group determination table is formed according the frequency table.
When attention-destination patterns of the conference participants HM 1 to HM 3 are (0, 0, 2), (0, 1, 0), (0, 3, 0), (2, 0, 0), and (3, 0, 0), for example, their mutual attention-destination relationships are substantially the same as attention destinations obtained by rotating and/or inverting those of (0, 0, 1). Therefore, for example, the group patterns GP 1 , GP 2 , GP 3 , GP 4 , and GP 5 corresponding to an attention pattern of (0, 0, 2) are regarded as the same as the group patterns GP 1 , GP 2 , GP 3 , GP 4 , and GP 5 corresponding to an attention pattern of (0, 0, 1), obtained by inverting (applying inversion for a segment drawn from the conference participant HM 3 to the middle of the conference participants HM 1 and HM 2 to) the group patterns of the attention pattern of (0, 0, 2), similar attention patterns are collectively handled as an attention pattern of (0, 0, 1), and then statistics is obtained.
In this case, when an attention pattern of (0, 0, 1) corresponds to determination group patterns GP 1 , GP 2 , GP 3 , GP 4 , and GP 5 in a group determination table, an attention pattern of (0, 0, 2) corresponds to the determination group patterns GP 1 GP 2 , GP 3 , GP 4 , and GP 5 .
In other words, in the second case, each set of attention patterns which are made the same by rotation or inversion is represented by a representative attention pattern, statistics is obtained for representative attention patterns, a group-pattern determination table is generated from the statistics for the representative attention patterns, and finally, a group determination table is generated for all attention patterns.
With the use of such a method, it is expected that individuality is avoided and highly reliable determination is made with a relatively small number of samples.
A detailed procedure for generating a group determination table in the second case will be described below.
Prior to the generation of a group determination table based on statistics, a conversion table for converting actual attention patterns and actual group patterns to representative attention patterns and representative group patterns is generated in advance.
In the same way as in the first case, a condition in which the number of conference participants is three is taken as an example. An attention-pattern conversion table shown in FIG. 41 , a group conversion table shown in FIG. 42 , and a group inverted-conversion table shown in FIG. 45 need to be prepared in advance.
The attention-pattern conversion table shown in FIG. 41 shows which representative pattern serves as a representative of an attention pattern, and which conversion method is used for converting an attention pattern to a representative attention pattern.
As a representative attention pattern, an attention pattern having the smallest number is selected when the attention-destination numbers of the conference participants HM 1 , HM 2 , and HM 3 are regarded as a third digit, a second digit, and a first digit, respectively, to form a decimal number.
Conversions are expressed by whether inversion is performed and the number of rotations under a rule in which inversion is performed first and then rotation is performed. FIG. 46A and FIG. 46B show the axis of inversion and the direction of rotation. Examples of inversion and rotation are shown in FIG. 46A and FIG. 46B .
In the attention-pattern conversion table shown in FIG. 41 , whether inversion is performed is indicated by “0,” which shows no inversion, and “1,” which shows that inversion is performed.
The number of rotations means the number of rotations performed in the direction shown in FIG. 46B .
The group conversion table shown in FIG. 42 indicates that each group pattern is converted to which group pattern when the above-described inversion and rotation are performed.
More specifically, group patterns obtained when neither inversion nor rotation is applied to each group pattern, when rotation is applied once, when rotation is applied twice, when only inversion is applied, when inversion is applied and then rotation is applied once, and when inversion is applied and then rotation is applied twice are shown in the table.
When attention patterns in samples are converted to representative attention patterns, this table is used for obtaining group patterns corresponding to group patterns in samples which match the conversion. Details will be described later.
The group-pattern inverted-conversion table shown in FIG. 45 indicates a group pattern obtained when the inverted conversion of a specified conversion is applied to each group pattern, and is used for generating the group determination table shown in FIG. 40 from a representative-group determination table shown in FIG. 44 , described later.
A device structure and a generation procedure for generating the group determination table shown in FIG. 40 from these tables will be described next.
FIG. 47 shows functional blocks of a device for generating the group determination table shown in FIG. 40 .
Each block can be implemented by either software or hardware. A group-determination-table generating device having the functional blocks shown in FIG. 47 may be built, for example, in the seating-order determination device GJD, or may be implemented, for example, by a personal computer which is a separate device from the seating-order determination device GJD. In either case, when the seating-order determination device GJD is finally made to hold a generated group determination table, if it receives attention-degree information from the teleconference devices TCD, it determines the group corresponding to an attention pattern of the conference participants HM 1 to HM 3 by referring to the group determination table and generates seating-order information according to the group determination.
The group-determination-table generating device includes, as shown in FIG. 47 , information obtaining means 301 , information conversion means 302 , representative-frequency-table generating means 303 , representative-group-determination-table generating means 304 , representative-group determination means 305 , group inverted-conversion means 306 , and group-determination-table generating means 307 .
The information obtaining means 301 obtains attention patterns and group patterns as samples obtained in an experiment.
The information conversion means 302 uses the pattern conversion table shown in FIG. 41 and the group conversion table shown in FIG. 42 to convert the attention patterns and the group patterns obtained by the information obtaining means 301 .
The representative-frequency-table generating means 303 generates a representative frequency table like that shown in FIG. 43 according to representative attention patterns and representative group patterns.
The representative-group-determination-table generating means 304 generates a representative group determination table like that shown in FIG. 44 according to the representative frequency table.
The representative-group determination means 305 searches the representative-group determination table shown in FIG. 44 to determine the representative group pattern corresponding to a representative attention pattern.
The group inverted-conversion means 306 inverted-converts representative group patterns to group patterns.
The group-determination-table generating means 307 generates the group determination table shown in FIG. 40 from group patterns and attention patterns.
In FIG. 47 , solid lines with arrows indicate a flow of generating the representative-group determination table shown in FIG. 44 , and dotted lines with arrows indicate a flow of generating the group determination table shown in FIG. 40 from the representative-group determination table.
The group-determination-table generating device having such a structure first generates a representative frequency table such as that shown in FIG. 43 .
All attention patterns and group patterns in samples are first converted to representative attention patterns and to group patterns (hereinafter, for convenience, called representative group patterns) to which conversion matching the conversion from the attention patterns to the representative attention patterns is applied, and the frequencies of the representative group patterns for each representative attention pattern are indicated in a representative frequency table.
FIG. 48 shows processing for generating the representative frequency table.
In FIG. 48 , “registration to representative frequency table” means that the frequency of a representative attention pattern and a corresponding representative group pattern is incremented by one.
In step S 110 , the information obtaining means 301 obtains a first sample of an attention pattern and a group pattern. Then, in the next step S 111 , the information conversion means 302 uses the attention-pattern conversion table to search for the representative attention pattern corresponding to the attention pattern obtained as the sample and a conversion method to the representative attention pattern.
In the next step S 112 , the information conversion means 302 uses the group conversion table shown in FIG. 42 to convert the group pattern to a representative group pattern according to the conversion method searched for in step S 111 .
With these steps S 111 and S 112 , the representative attention pattern and the representative group pattern are obtained for the one obtained sample.
In the next step S 113 , the representative-frequency-table generating means 303 registers the obtained representative attention pattern and the obtained representative group pattern into the representative frequency table shown in FIG. 43 . In other words, the cell corresponding to the current sample is incremented by one.
In step S 114 , it is determined whether the processing has been finished for all samples. When the processing has not yet been finished, the information obtaining means 301 obtains the next sample of an attention pattern and a group pattern in step S 115 , the processing returns to step S 111 , and the same processes as described above are performed.
Therefore, when the processes of steps S 111 , S 112 , and S 113 have been finished for all samples, the representative frequency table shown in FIG. 43 has been completed.
Next, the representative-group determination table shown in FIG. 44 is generated from the representative frequency table generated as described above.
The representative-group determination table indicates the representative group pattern corresponding to each representative attention pattern. A representative attention pattern in each entry (row) is the same as that shown in the representative frequency table.
The representative-group determination table is generated by registering, as the representative group pattern corresponding to each representative attention pattern, the representative group pattern having the highest frequency for each representative attention pattern among representative group patterns. FIG. 49 shows the specific procedure of generating the table.
The representative-group-determination-table generating means 304 obtains a first entry of the representative frequency table generated by the representative-frequency-table generating means 303 in step S 120 . In step S 121 , the representative-group-determination-table generating means 304 determines the representative-group pattern having the highest frequency for the representative attention group in the obtained entry, and registers it to the representative-group determination table.
In the representative frequency table shown in FIG. 43 , for example, the frequencies of representative group patterns are indicated for a representative attention pattern of (0, 0, 0) in a first entry. The representative group pattern GP 1 has the highest frequency. Therefore, as shown in a first row of the representative-group determination table shown in FIG. 44 , the representative group pattern GP 1 is registered correspondingly to a representative attention pattern of (0, 0, 0).
In step S 122 , it is determined whether the processing has been finished for all entries in the representative frequency table. When the processing has not yet been finished, the next entry is obtained in step S 123 and the processing returns to step S 121 .
When the process of step S 121 is finished for all entries, the processing is finished at step S 122 .
With the above-described processing, the representative-group determination table shown in FIG. 44 is generated from the representative frequency table shown in FIG. 43 . The processing performed so far corresponds to the flow indicated by the solid lines in FIG. 47 .
The group determination table shown in FIG. 40 is finally generated from the representative frequency table.
The group determination table includes all attention patterns. To generate the group determination table, the group pattern having the “relationship between the representative attention pattern and the representative group pattern registered therefor” corresponding to each attention pattern in the representative-group determination table, which relationship matches the “relationship between the attention pattern and the group pattern registered therefor,” is registered.
FIG. 50 shows a specific procedure for generating the group determination table. (The procedure corresponds to the flow indicated by the dotted lines in FIG. 47 ).
After the representative-group determination table is generated as described above, in step S 130 shown in FIG. 50 , the information obtaining means 301 obtains a first attention pattern. In step S 131 , the information conversion means 302 uses the attention-pattern conversion table to search for a representative attention group and a conversion method to the representative attention pattern for the obtained attention pattern. The result of searching is passed to the representative-pattern determination means 305 .
In the next step S 132 , the representative-group determination means 305 uses the representative-group determination table to search for the representative group pattern corresponding to the representative attention pattern passed from the information conversion means 302 . The result of searching is passed to the group inverted-conversion means 306 as the representative group pattern.
In step S 133 , the group inverted-conversion means 306 uses the group inverted-conversion table shown in FIG. 43 to inverted-converts the representative group pattern passed from the representative-group determination means 305 to a group pattern.
In step S 134 , the group-determination-table generating means 307 registers an entry formed of the attention pattern obtained by the information obtaining means 301 as described above, and the group pattern sent from the group inverted-conversion means 306 into the group determination table.
In step S 135 , it is determined whether the processing has been finished for all attention patterns. When the processing has not yet been finished, the next attention pattern is obtained in step S 136 , and the processing returns to step S 131 .
When registration has been made to the group determination table for all attention patterns, the processing is finished at step S 135 .
With the above-described processing, the group determination table shown in FIG. 40 is generated.
A group determination table used for group determination is generated as described above. The seating-order determination device GJD performs grouping with the use of a group determination table to generate seating-order information.
9. Seating-Order Determination Operation not Through Grouping in the Seating-Order Determination Device
So far, a case has been described in which the seating-order determination device GJD first performs group determination and then determines a seating order according to the result of group determination. A seating order can be determined without performing group determination. An example case will be described below.
The seating-order determination device GJD holds an information request degree Rij indicating a degree at which each conference participant HMi wants the information of another conference participant HMj. It is considered, for example, that the information request degree is high for an attention destination at a point of time close to the current time. When a conference participant HMi paid attention to conference participants HM 2 and HM 5 in the past and currently pays attention a conference participant HM 3 , for example, the information request degrees of the conference participant HMi for these conference participants are set to areas Ri 2 , Ri 5 , and Ri 3 located under a curve shown in FIG. 52 . The curve shown in the figure is based on an exponential function for a constant K larger than zero and smaller than one.
More specifically, the seating-order determination device GJD checks whether each conference participant HMi pays attention to another conference participant HMj at a constant interval, and sets a variable Aij indicating whether attention is paid to “1” when the conference participant HMi pays attention to the conference participant HMj, and sets it to “0” when the conference participant HMi does not pay attention to the conference participant HMj.
When attention checking is finished, the seating-order determination device GJD calculates the information request degree of the conference participant HMi for the conference participant HMj at a time “t” by the following expression (1).
Rij ( t )= KRij ( t− 1)+ Aij ( t ) (1)
where, K is an attenuating coefficient.
Then, the seating-order determination device GJD calculates an overall satisfaction degree Sm of the entire conference participants for each of all possible seating-order candidates (seating-order number m). The following expression (2) is used.
S m = ∑ i ∑ j Wmij · Rij ( 2 )
where, Wmij is a satisfaction-degree weighting coefficient determined in advance for each information request degree in each seating order, and held, for example, in a satisfaction-degree weighting table shown in FIG. 51 .
The table shown in FIG. 51 shows a case in which the number of conference participants is six. Characters A to F correspond to seat numbers, and numerals 1 to 6 shown therebelow correspond to conference participants HM 1 to HM 6 .
Since the relative positional relationships among conference participants are meaningful in a seating order, when it is specified, for example, that a conference participant HM 1 is always assigned to a seat A, the number of seating orders is equal to the number of the permutations of five things, which is 120, and a seating-order number ranges from 1 to 120.
FIG. 53 shows an example arrangement of seats A to F.
The satisfaction-degree weight Wmij shown in FIG. 51 is set, for example, larger when the distance between HMi and HMj is closer in a seating order “m.” More specifically, for example, the reciprocal 1/Dij — 1 of the number Dij — 1 indicating that HMj is located at the Dij — 1-th position from HMi, or the reciprocal 1/Dij — 2 of a number Dij — 2 indicating the distance between HMi and HMj when the distance between adjacent seats is set to “1” can be used as the satisfaction-degree weight.
In a seating order shown in FIG. 54 , D 16 _ 1 is 2, and D 16 _ 2 is √{square root over (3)}.
The seating-order determination device GJD determines the seating order corresponding to the maximum satisfaction degree Sm as a result of calculation. When there is a plurality of the maximum satisfaction degrees Sm, the seating order which makes the sum of the distances of movements required for the other conference participants, viewed from each conference participant smallest, or the seating order which has the smallest seating-order number can be selected.
10. Attention-Degree-Information Generating Operation in a Teleconference Device
Various operations for dynamically changing a seating order according to the attention degrees of conference participants have been described. A specific processing for detecting a direction (direction toward any of the monitor devices MD 2 to MDn or another direction) in which a conference participant HM 1 pays attention, according to image data sent, for example, from the camera of the monitor device MDm disposed at the front of the conference participant HM 1 in the attention-degree-information generating section JB 1 shown in FIG. 2 will be described.
As a first example of the processing for detecting a direction in which the conference participant HM 1 pays attention, to be performed in the attention-degree-information generating section JB 1 of the teleconference device TCD 1 according to the present embodiment, the detection (sight-line detection) of the lines of sight of the conference participant HM 1 can be taken.
FIG. 55 is a flowchart of sight-line detection processing in the attention-degree-information generating section JB 1 .
In FIG. 55 , the attention-degree-information generating section JB 1 receives image data captured by the camera provided, for example, for the monitor device MDm disposed at the front of the conference participant HM 1 in step S 11 . In the next step S 12 , the attention-degree-information generating section JB 1 uses the color information of the sent image to detect the outlines of both eyes of the conference participant HM 1 in a facial image. More specifically, the attention-degree-information generating section JB 1 extracts color areas, such as skin, whites, and irises, by using the color information of the sent image, and obtains, for example, the boundaries of the extracted color areas to detect the outline E of the right eye and that of the left eye as shown in FIG. 56 . FIG. 56 indicates only one eye.
Then, in step S 13 , the attention-degree-information generating section JB 1 obtains the positions of the leftmost point F 1 and the rightmost point F 2 of the right eye and those of the left eye according to the outlines E of both eyes obtained in step S 12 , determines a search area NE for searching for the nostrils, as shown in FIG. 57 , with the positions of the rightmost and leftmost points F 2 and F 1 of the right and left eyes being used as references, and detects the positions of the nostrils NH in the search area NE. More specifically, the attention-degree-information generating section JB 1 obtains a line M which makes the center Q of gravity of the sets of pixels constituting the outlines E of the right and left eyes and the secondary moment (inertia for the line) of the sets of pixels constituting the outlines E smallest; obtains pixels one each in the right and left directions, located at the largest distances L 1 and L 2 from the center Q of gravity in the directions of line M; and obtains the pixels as the rightmost and leftmost points F 2 and F 1 , as shown in FIG. 56 .
Next, the attention-degree-information generating section JB 1 uses the positions of the rightmost and leftmost points F 2 and F 1 of the right and left eyes, obtained as described above, as references and determines the search area NE for searching for the nostrils in the lower direction from the rightmost and leftmost points F 2 and F 1 , as shown in FIG. 57 . Since the images of the nostrils NH are darker than that of the other parts, the attention-degree-information generating section JB 1 detects low-luminance image areas as the positions of the nostrils NH in the search area NE.
Then, in step S 14 , the attention-degree-information generating section JB 1 assumes the central positions ECs of the eyeballs EBs and the radius “r” of the eyeballs EBs according to the geometrical positional relationships among the positions of the rightmost and leftmost points F 2 and F 1 of the right eye, those of the rightmost and leftmost points F 2 and F 1 of the left eye, and those of the nostrils NH, as shown in FIG. 58 .
In step S 15 , the attention-degree-information generating section JB 1 uses the luminance information of the image in the outline E of the right eye and that in the outline E of the left eye to detect the central positions EAC of the pupils EA.
In step S 16 , the attention-degree-information generating section JB 1 calculate vectors EV connecting between the central positions EC of the eyeballs EB detected in step S 14 and the central positions EAC of the pupils EA detected in step S 15 , regards the obtained vectors EVs as the lines of sight, and determines the directions in which the vectors EVs are directed, namely, determines the monitor to which the vectors EVs are directed among the monitor devices MD 2 to MDn.
With the foregoing flow, the attention-degree-information generating section JB 1 detects the lines of sight of the conference participant HM 1 .
A line M which makes the secondary moment of the set of pixels, such as that of pixels constituting the outline E can be obtained, for example, by the following calculation.
A straight line M indicated by an expression (3), as shown in FIG. 60 , will be taken as an example.
x sin θ− y cos θ+ρ=0 (3)
The secondary moment for the straight line M can be indicated by an expression (4) where Ri indicates the distance between the straight line M and each point (xi, yi) of the set of pixels constituting the outline E.
m
=
∑
i
Ri
2
=
∑
i
(
x
i
sin
θ
-
y
i
cos
θ
+
ρ
)
2
(
4
)
The straight line M which makes the secondary moment smallest is the straight line M which makes “m” in the expression (4) minimum. To make “m” in the expression (4) minimum, θ and ρ satisfying the following conditions (5) and (6) are used as those in the expression (4).
θ: sin 2θ= b /( b 2 +( a−c ) 2 ) 1/2 , cos 2θ=( a−c )/( b 2 +( a−c ) 2 ) 1/2 (5)
ρ: ρ=− x 0 sin θ+ y 0 cos θ (6)
The expression (6) (x 0 sin θ+y 0 cos θ+ρ=0) indicates that the line passes through the center of gravity of the set of pixels.
In the expressions (5) and (6), “a,” “b,” and “c” are indicated by expressions (7), (8), and (9), respectively. (x 0 , y 0 ) indicates the coordinates of the center of gravity of the set of pixels.
a
=
∑
i
(
x
i
-
x
0
)
2
(
7
)
b
=
2
∑
i
(
x
i
-
x
0
)
(
y
i
-
y
0
)
(
8
)
c
=
∑
i
(
y
i
-
y
0
)
2
(
9
)
As a second example of the processing for detecting a direction in which the conference participant HM 1 pays attention, to be performed in the attention-degree-information generating section JB 1 of the teleconference device TCD 1 according to the present embodiment, the detection of the face direction of the conference participant HM 1 can be taken, which will be described below.
FIG. 61 shows a flowchart of processing for detecting a face direction in the attention-degree-information generating section JB 1 .
In FIG. 61 , the attention-degree-information generating section JB 1 receives original image data, such as that shown in FIG. 62A and FIG. 62B , of the face of the conference participant HM 1 from the monitor device MDm disposed at the front of the conference participant HM 1 in step S 21 . In the next step S 22 , the attention-degree-information generating section JB 1 uses the color information of the received face images to detect a skin area and a hair area. More specifically, the attention-degree-information generating section JB 1 extracts skin-color and hair-color areas by using the color information of the received face images, and detects a skin area “se” and a hair area “he” by the extracted color areas, as shown in FIG. 63A and FIG. 63B .
In the next step S 23 , the attention-degree-information generating section JB 1 specifies frames for detecting the center “fg” of gravity of the total area “fe (=“se”+“he”)” of the skin area “se” and the hair area “he” and the center “sq” of gravity of the skin area “se,” as shown in FIG. 64A and FIG. 64B . The frames are specified, for example, by setting zones in the vertical direction in the images. More specifically, for example, the upper end “re” of the total area “fe” of the hair area “he” and the skin area “se” is used as a reference, and a zone is specified between a point a length “const_a” below the upper end “re” and a point a length “const_a”+“const_b” below the upper end “re.”
Then, in step S 24 , the attention-degree-information generating section JB 1 obtains the center “fg” of gravity of the total area “fe” of the skin area “se” and the hair area “he” and the center “sq” of gravity of the skin area “se” within the frames specified in step s 23 . In a subsequent process, both the horizontal components and vertical components of these centers of gravity can be used, or either the horizontal components or the vertical components of the centers of gravity can be used. As an example, a case in which only the horizontal components of the centers of gravity are used is taken, and will be described below.
In step S 24 , the attention-degree-information generating section JB 1 obtains the center “fg” of gravity of the total area “fe” of the skin area “se” and the hair area “he” and the center “sq” of gravity of the skin area “se.” In step S 25 , the attention-degree-information generating section JB 1 calculates the difference obtained by subtracting the center “fg” of gravity of the total area “fe” of the skin area “se” and the hair area “he” from the center “sq” of gravity of the skin area “se.”
Then, in step S 26 , the attention-degree-information generating section JB 1 detects a face direction by using the difference obtained in step S 25 . More specifically, either of the following two methods are, for example, used to detect a face direction by using the difference. It is assumed that X indicates a difference, Y indicates a face-direction angle, and the angle of the face of the conference participant HM 1 is set to 0 degrees when the conference participant HM 1 is directed to the camera of the monitor device MDm. In one method used in step S 26 , prior to face-direction detection processing, data for the difference X and the face-direction angle Y is obtained in advance; the face-direction angle Y corresponding to the difference X is obtained, for example, as the average; their relationship is obtained as shown in FIG. 65 ; and the face-direction angle Y is obtained from the difference X obtained in step S 25 , according to the relationship shown in FIG. 65 . In another method used in step S 26 , the face-direction angle Y is obtained from the following expression (10) by using the difference X obtained in step S 25 .
Y =α sin( X ) (10)
With the above flow, the attention-degree-information generating section JB 1 detects the face direction of the conference participant HM 1 .
In still another method for detecting the direction in which the conference participant HM 1 is directed, for example, an infrared ray is emitted to the face of the conference participant HM 1 ; an infrared ray reflected from the face of the conference participant HM 1 is received to form an image; and the face direction is detected from the image.
11. Structure of Monitor Device
An example specific structure of each of the monitor devices MD 2 to MDn in the structure shown in FIG. 2 will be described next by referring to FIG. 66 and FIG. 67 . FIG. 66 is an outlined internal view of a monitor device MD, viewed from a side. FIG. 67 is an outlined elevation of the monitor device MD.
In the following description, for simplicity, a case is taken as an example, in which information related to conference participants HM 1 to HMn is displayed on monitor devices MD 1 to MDn in teleconference devices TCD 1 to TCDn.
In the present embodiment, each of the monitor devices MD 2 to MDn is provided, as shown in FIG. 66 and FIG. 67 , with a cabinet 10 ; a speaker 13 disposed at the front (front of the monitor device MD) of the cabinet 10 ; a display section 15 disposed such that a screen 14 is directed in a predetermined direction (upper direction in the case shown in FIG. 66 ); a half mirror 12 for reflecting light emitted from the screen 14 of the display section 15 towards the front of the monitor device MD along a one-dot chain line BO in the figure and for passing light incident from the front of the monitor device MD along a two-dot chain line BI in the figure; and a camera 16 (such as a video camera) supported by a supporting section 18 behind the half mirror 12 . On the upper surface of the cabinet 10 in the monitor device MD, for example, a microphone 11 supported by a supporting section 17 is also provided.
The microphone 11 may be provided, for example, only for the monitor device (monitor device MDm in the case shown in FIG. 2 ) disposed at the front of the conference participant HM 1 among the monitor devices MD 2 to MDn.
The camera 16 of each of the monitor devices MD 2 to MDn receives incident light (such as an optical image of the conference participant HM 1 ) passing through the half mirror 12 along the two-dot chain line BI in FIG. 66 , and converts it to image data. The image data output from the camera 16 is sent to the information transmitting and receiving section TRB 1 of the signal processing device SPD 1 , and then sent to the teleconference devices TCD 2 to TCDn through the communication network NT. The image data output from the camera 16 , for example, of the monitor device MDm disposed at the front of the conference participant HM 1 among the monitor devices MD 2 to MDn is also sent to the attention-degree-information generating section JB 1 of the signal processing device SPD 1 and is used for detecting lines of sight or a face direction when attention-degree information is generated, as described above.
The microphone 11 of each of the monitor devices MD 2 to MDn converts sound, such as surrounding sound of the teleconference device TCD 1 and what the conference participant HM 1 says, to audio data. The audio data output from the microphone 11 is sent to the information transmitting and receiving section TRB 1 of the signal processing device SPD 1 , and then, sent to the teleconference device TCD 2 to TCDn through the communication network NT.
On the screen 14 of the display section 15 in the monitor device MD 2 among the monitor devices MD 2 to MDn, an image based on image data (that of the conference participant HM 2 and the surroundings) captured by the camera 16 of the monitor device. MD 1 provided correspondingly to the conference participant HM 1 in the teleconference device TCD 2 and sent through the communication network NT is displayed. From the speaker 13 of the monitor device MD 2 , sound based on audio data (that of what the conference participant HM 2 says) captured by the microphone 11 of the monitor device MD 1 provided correspondingly to the conference participant HM 1 in the teleconference device TCD 2 and sent through the communication network NT is reproduced. In the same way, on the screen 14 of the display section 15 in the monitor device MD 3 , an image based on image data captured by the camera 16 of the monitor device MD 1 provided correspondingly to the conference participant HM 1 in the teleconference device TCD 3 and sent through the communication network NT is displayed. From the speaker 13 of the monitor device MD 3 , sound based on audio data captured by the microphone 11 of the monitor device MD 1 provided correspondingly to the conference participant HM 1 in the teleconference device TCD 3 and sent through the communication network NT is emitted. The situation is the same for the other monitor devices MD. An image sent from the corresponding teleconference device is displayed and sound is emitted.
In each of the monitor devices MD 2 to MDn in the present embodiment, as shown in FIG. 66 , since light emitted from the screen 14 of the display section 15 is reflected by the half mirror 12 in the direction indicated by the one-dot chain line BO towards the conference participant HM 1 , a face image and the like of the conference participant HM located at the other side is displayed on the screen 14 of the display section 15 as a mirror image, which is reflected by the half mirror 12 to be in a correct state. In FIG. 67 , RV indicates an image (a virtual image of the conference participant HM at the other side) obtained when a mirror image of the conference participant HM located at the other side, displayed on the screen 14 of the display section 15 is reflected by the half mirror 12 .
When a mirror image of the conference participant at the other side is displayed on the screen 14 of the display section 15 in a monitor device MD in the present embodiment, the positions of the eyes in the virtual image, which are optically conjugate with those of the eyes in the mirror image are displayed so as to almost match the principal point of the lens of the camera 16 through the half mirror 12 . Therefore, the lines of sight of the conference participant HM 1 and those of the conference participant at the other side match.
More specifically, a case in which the conference participant HM 1 sees the monitor MDm (an image of the conference participant HMm) in the teleconference device TCD 1 and the conference participant HMm sees the monitor device MD 1 (an image of the conference participant HM 1 ) in the teleconference device TCDm is taken as an example and will be described. In this case, a mirror image of the face or the like of the conference participant HMM is displayed on the screen 14 of the display section 15 in the monitor device MDm in the teleconference device TCD 1 ; and the camera 16 of the monitor device MDm captures an image of the conference participant HM 1 who is directed to the monitor device MDm and sends image data to the teleconference device TCDm and others. A mirror image of the face or the like of the conference participant HM 1 is displayed on the screen 14 of the display section 15 in the monitor device MD 1 in the teleconference device TCDm; and the camera 16 of the monitor device MD 1 captures an image of the conference participant HMm who is directed to the monitor device MD 1 and sends image data to the teleconference device TCD 1 and others.
In this condition, at the teleconference device TCD 1 , when a mirror image of the conference participant HMm at the other side is displayed on the screen 14 of the display section 15 in the monitor device MDm, the positions of the eyes in the virtual image, which are optically conjugate with those of the eyes in the mirror image are displayed so as to almost match the principal point of the lens of the camera 16 . At the same time, at the teleconference device TCDm, when a mirror image of the conference participant HM 1 at the other side is displayed on the screen 14 of the display section 15 in the monitor device MD 1 , the positions of the eyes in the virtual image, which are optically conjugate with those of the eyes in the mirror image are displayed so as to almost match the principal point of the lens of the camera 16 . Therefore, at the teleconference device TCD 1 , the lines of sight of the conference participant HM 1 match those of the virtual image of the conference participant HMm at the other side. At the teleconference device TCDm, the lines of sight of the conference participant HMm match those of the virtual image of the conference participant HM 1 at the other side.
In general conventional teleconference systems, conference participants do not see virtual images made by half mirrors but directly see images (real images) displayed on the screens of display sections. In addition, cameras are disposed above or below, or at the right or left of the screens of the display sections in their vicinities. Therefore, in general conventional teleconference systems, the lines of sight of conference participants are directed to images (real images) displayed on the screens of the display sections, and are not directed to the lenses of the cameras. Consequently, the lines of sight of the conference participant at the other side, displayed on the screen of a display section does not seem to be directed to you. Unlike the present embodiment, it is impossible to perform conversation while the lines of your sight match those of the conference participant at the other side.
In contrast, in the teleconference system according to the present embodiment, when the monitor device of each teleconference device TCD has the structure shown in FIG. 66 and FIG. 67 , a conference participant can perform conversation with the conference participant at the other side while they see their eyes each other, namely, the lines of their sight match.
In the present embodiment, when a plurality of monitor devices MD in a teleconference device TCD are disposed, as shown in FIG. 2 , as if the conference participants HM 2 to HMn located at the teleconference devices TCD 2 to TCDn and the conference participant HM 1 sat around a table, namely, when the plurality of monitor devices are disposed such that the relative positional relationships among the conference participants HM 2 to HMn at the places where the teleconference devices TCD 2 to TCDn are disposed are maintained, not only the lines of sight match between the conference participant HM 1 and the conference participant at the other side, but also the conference participant HM 1 understands whom the other conference participants HM are directed to.
12. Example Structure of Each Device
FIG. 68 shows an actual example device structure which can be used for the signal processing device SPD of each teleconference device TCD or the seating-order determination device GJD, in a teleconference system according to an embodiment of the present invention. These devices can be implemented, for example, by personal computers. The group-determination-table generating device like that shown in FIG. 47 can also be implemented by the following device structure.
The structure shown in FIG. 68 includes a CPU 100 for controlling each section; a ROM 101 for storing basic input and output systems (BIOS) and various initial values; a RAM 102 for tentatively storing various programs, data, and data obtained during calculation; a hard-disk drive (HDD) 104 for driving a hard disk for storing an operating system (OS), various application programs (computer programs), and other data; a removable-medium drive 105 for driving a removable medium 106 , such as a CD-ROM, a CD-R, a CD-RW, a DVD-ROM, a DVD-RAM, a DVD-R, a DVD-RW, a removable hard disk, and a semiconductor memory; and a communication interface section 103 for connecting to an external communication network (the communication network NT), such as an ISDN, a commercial telephone line, a cable-TV line, and a digital communication-satellite line, and for connecting to an external bus, such as that conforming to the IEEE-1394 standard or a USB, and to various external connection terminals.
The structure shown in FIG. 68 can further include, for example, an input operation device, such as a mouse or a keyboard, operated by the user and a monitor for displaying information, although they are not shown.
An application program for implementing the functions of the signal processing device SPD in the teleconference system according to the present embodiment described above, especially the attention-degree-information generating function in the attention-degree-information generating section JB 1 and the information manipulation and distribution function in the information manipulation and distribution section PB, or the group determination processing, the seating-order determination processing, and the seating-order-information generating function is provided by the removable medium 106 or by communication through the communication interface section 103 .
The application program provided by the removable medium 106 or by the communication interface section 103 is stored in the hard disk of the HDD 104 , is read from the hard disk of the HDD 104 , and tentatively stored in the RAM 102 . The CPU 100 executes various operations in the teleconference system according to the present embodiment according to the application program tentatively stored in the RAM 102 .
FIG. 69 shows another example structure of the teleconference device TCD 1 .
In the example structure shown in FIG. 69 , as display means for displaying images of conference participants HM 2 to HMn in teleconference devices TCD 2 to TCDn, the monitor devices MD 2 to MDn, such as those shown in FIG. 2 , corresponding to the teleconference devices TCD 2 to TCDn (the conference participants HM 2 to HMn) are not provided, but, for example, one bent screen 31 is provided and images are displayed on the screen 31 , for example, by a projector.
In the example structure shown in FIG. 69 , images of the conference participants HM 2 to HMn are displayed on the screen 31 as if the conference participant HM 1 and the other conference participants HM 2 to HMn sat around a table for a conference.
A camera 34 and a microphone 35 are disposed, for example, at the front of the conference participant HM 1 . Image data of the conference participant HM 1 , captured by the camera 34 and audio data of the conference participant HM 1 , captured by the microphone 35 are sent to the other teleconference devices TCD 2 to TCDn through the communication network NT. In the example structure shown in FIG. 69 , the image data of the conference participant HM 1 , captured by the camera 34 is also sent to the attention-degree-information generating section JB 1 of the signal processing device SPD 1 .
Audio data of conference participants HM 2 to HMn, sent from the other teleconference devices TCD 2 to TCDn are controlled such that individual sound images are formed in the vicinities of images of the conference participants HM 2 to HMn, displayed on the screen 31 , and are sent to speakers 32 and 33 disposed at the right and left of the screen 31 and emitted. With this control, the positions of images of the conference participants HM 2 to HMn, displayed on the screen 31 almost match those of locations where the voices (sound) of the conference participants HM 2 to HMn are heard.
In the present embodiment, the attention-degree-information generating section JB is disposed in each of the signal processing devices SPD 1 to SPDn of the teleconference devices TCD 1 to TCDn. On attention-degree-information generating section JB may be independently provided on the communication network NT.
In the present embodiment, as shown in FIG. 2 , the monitor devices MD 2 to MDn are separated from the signal processing device SPD 1 . Each or one of the monitor devices MD 2 to MDn can have the function of the signal processing device.
In the present embodiment, as shown in FIG. 1 , the seating-order determination device GJD is independently connected to the communication network NT. Each or one of the teleconference devices TCD 1 to TCDn can have the function of the seating-order determination device.
In the present embodiment, as examples for detecting a direction, the lines of sight and a face direction are separately detected. They can be detected at the same time.
In the present embodiment, one conference participant belongs to only one group at each point of time. It is also possible that a plurality of groups is defined, such as a group to which a conference participant mainly belongs and a group in which a conference participant does not give opinions but from which the conference participant wants to obtain information; each conference participant is allowed to belong to a plurality of groups; and a seating order is determined according to which group each of the conference participants at the other sides belongs to.
As described above, according to the teleconference system of the present embodiment, even when a plurality of conference participants say at the same time, it is easier for a conference participant to listen to a speech in a group which the conference participant belongs to, and it is also easier to see images. Therefore, the teleconference system provides each conference participant with comfort and satisfaction with information. | In a communication system having at least three communication devices communicating with each other, a seating-order determination device for generating seating-order information for information sent from each communication device and for transmitting the seating-order information to each communication device is provided. Each communication device controls the output position of each information according to the seating-order information to output the information sent from the other communication devices in a seating order corresponding to the seating-order information. The seating order is always automatically changed to the most appropriate condition according to the progress of a conference and the state of conversations to provide the user with a comfortable conference environment and a comfortable communication environment. | 8 |
This application claims priority under 35 U.S.C. §119 from U.S. Provisional Application Ser. No. 60/902,591 (filed Feb. 21, 2007), the disclosure of which is incorporated by reference herein for all purposes as if fully set forth.
BACKGROUND OF THE INVENTION
The present invention pertains to a yellow ink for inkjet printing and, in particular, to a yellow ink comprising a combination of specific yellow colorants. The present invention further pertains to an ink set comprising this yellow ink.
Inkjet printing is a non-impact printing process in which droplets of ink are deposited on a substrate, such as paper, to form the desired image. The droplets are ejected from a printhead in response to electrical signals generated by a microprocessor. Inkjet printers offer low cost, high quality printing and have become a popular alternative to other types of printers.
An ink jet ink set for color printing will generally comprise a cyan, magenta and yellow (CMY) ink, which are referred to as the primary colors. An ink set will also commonly comprise a black ink (CMYK).
A suitable ink should generally exhibit good crusting resistance, good stability, proper viscosity, proper surface tension, good color-to-color bleed alleviation, rapid dry time, consumer-safety and low strike-through.
In addition, the ink set should provide printed images having good color characteristics, such as correct hue and high chroma. Preferably, the ink set will achieve these favorable characteristics on a range of media including plain paper as well as specialty media such as transparency film and coated paper. Also, preferably, the hard copy output is reasonably lightfast.
While some of these conditions may be met by ink vehicle design, other conditions must be met by the proper selection and combination of the colorants. The selection of the colorants becomes especially important when additional limitations are placed on the choice of the colorants because of other system requirements, such as the color-to-color bleed control mechanism.
The term “bleed” means the invasion of one color into another, once the ink is deposited on the print medium. It can be seen as a ragged border between two adjacent colors. The occurrence of bleed is especially problematic between a black ink and color ink because it is all the more visible. Preferably bleed is minimized or eliminated so that borders between colors are clean and sharp.
U.S. Pat. No. 5,488,402 discloses a method for preventing color bleed between two different color ink compositions wherein the first ink is anionic and comprises a coloring agent which includes one or more carboxyl and/or carboxylate groups, and the second ink includes a precipitating agent which is designed to ionically crosslink with the coloring agent in the first ink to form a solid precipitate in order to prevent bleed between the two ink compositions. Multivalent metal salts are disclosed as being useful as the precipitating agent.
U.S. Pat. No. 5,518,534 discloses an ink set for alleviating bleed in multicolor printed elements employing a first ink and a second ink, each containing an aqueous carrier medium and a colorant; the colorant in the first ink being a pigment dispersion and the second ink containing a salt of an organic acid or mineral acid having a solubility of at least 10 parts in 100 parts of water at 25° C., wherein the salt is present in an amount effective to alleviate bleed between the first and second inks.
To take advantage of a bleed control mechanism involving salts, it is necessary to have a set of inks that can provide suitable performance characteristics while maintaining reliability in the presence of those salts. U.S. Pat. No. 6,053,969, for example, discloses an ink set with salt compatibility that addresses these needs. A key aspect of this art is the selection of yellow colorant for the yellow ink in this ink set. The difficulties of selecting the yellow colorant are described. For example, DY132 has favorable hue angle, chroma and lightfastness, but is incompatible with precipitating agents (inorganic salts). DY86 has favorable, chroma and lightfastness, but a lower than desired hue angle and no compatibility with precipitating agents. AY23 has favorable hue angle, chroma and compatibility with precipitating agents, but poor lightfastness. AY17 has favorable chroma, lightfastness and compatibility with precipitating agents, but higher than desired hue angle. IIford Y104 (CAS Number 187674-70-0) has favorable chroma, lightfastness and compatibility with precipitating agents, but lower than desired hue angle. However, a yellow ink with a combination of yellow colorants, namely AY17 and IIford Y104 achieves all the target attributes, namely a hue angle of 90-95, plain paper chroma of at least 70, good lightfastness and compatibility with inorganic salts.
Co-owned and co-pending application U.S. application Ser. No. 11/472,710 discloses other yellow colorant combinations, namely Acid Yellow 17 with Acid Orange 33 and/or Reactive Yellow 181, that achieve target attributes similar to the AY17/IIford Y104 combination in U.S. Pat. No. 6,053,969.
However, the aforementioned salt stable yellow inks, and ink sets containing same, have some performance deficiencies on specialty paper. In particular, the regions of the CYM composite black (combination of cyan, magenta and yellow inks) printed on photo quality microporous glossy paper have undesirable haze and hue shift.
A need still exists for improved inks, particularly yellow inks, and ink sets that provide appropriate color, lightfastness and bleed control on both plain paper and specialty paper, such as photoglossy paper, and that exhibit little or no haze or hue shift.
SUMMARY OF THE INVENTION
In one aspect, this invention pertains to a yellow inkjet ink comprising an aqueous vehicle and colorant soluble in the aqueous vehicle, wherein the colorant comprises Direct Yellow 169 (DY169) and Acid Yellow 79 (AY79). In one embodiment, the colorant consists essentially of DY169 and AY79. In yet another embodiment, the colorant consists only of DY169 and AY79.
In another aspect, the present invention pertains to an inkjet ink set comprising the yellow ink set forth above, and at least one or more of inks a-c as follows:
(a) a magenta inkjet ink comprising Acid Red 52 and a second dye selected from the group consisting of AR249, AR289, RR180, RR23, CAS Number 182061-89-8 and mixtures thereof; (b) a cyan inkjet ink comprising a dye selected from the group consisting of Direct Blue 199, Acid Blue 9 and mixtures thereof; and/or (c) a black inkjet ink comprising carbon black pigment.
Colorants are referred to by their “C.I.” designation established by Society Dyers and Colourists, Bradford, Yorkshire, UK and published in The Color Index , Third Edition, 1971, unless otherwise indicated.
Preferably, all inks in the ink set are aqueous inks comprising aqueous vehicle. The aqueous vehicle of each ink is selected independently and may be the same as or different from the aqueous vehicle of any other ink in the set.
In preferred embodiment, the yellow ink comprises a bleed control additive, most preferably a metal salt, which inhibits bleed from a black pigment when the inks are printed adjacently.
In yet another aspect the present invention pertains to a method for ink jet printing onto a substrate, comprising the steps of:
(a) providing an ink jet printer that is responsive to digital data signals; (b) loading the printer with a substrate to be printed; (c) loading the printer with an inkjet ink or inkjet ink set forth above and as described in further detail below; and (d) printing onto the substrate using the inkjet ink set in response to the digital data signals.
Preferred substrates include plain paper and photo glossy paper.
These and other features and advantages of the present invention will be more readily understood by those of ordinary skill in the art from a reading of the following detailed description. It is to be appreciated that certain features of the invention which are, for clarity, described above and below in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. In addition, references in the singular may also include the plural (for example, “a” and “an” may refer to one, or one or more) unless the context specifically states otherwise. Further, reference to values stated in ranges include each and every value within that range.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a graph of reflectance measurements over the range of 425 to 625 nm for three composite black samples.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Yellow Ink
In selecting the colorant for the yellow ink and, in general, for the inks of the ink sets of the present invention, numerous factors need to be considered including, but not limited to, appropriate hue angle and color performance, particularly on plain paper; good lightfastness; and compatibility (stability) in formulations having relatively high inorganic salt.
The yellow colorant should provide a yellow ink having a hue angle on plain paper of from about 83 to about 97, and preferably between about 86 and about 94. It is desirable that the yellow ink exhibit a chroma of at least about 70 (on plain paper). As evidenced by the examples hereinafter, yellow ink in accordance with the present invention comprising a mixture of DY169 and AY79 exhibits the desired hue angle and chroma. It is also compatible with typical levels of metal salts useful for bleed control and has adequate lightfastness.
To achieve the desired yellow hue, the weight ratio of DY169 to AY79 is preferably between about 9:1 to about 1:9, and more preferably between about 1:5 and 5:1.
The hue angle is determined by standard spectrophotometric measurement of printed samples. The hue angle of a specific ink when printed on different papers may vary slightly, so the ratio of dyes can be adjusted within the above ranges by routine optimization so as to achieve the hue value within the desired range.
Vehicle
The ink vehicle is the carrier (or medium) for the colorant. An “aqueous vehicle” refers to a vehicle comprised of water or a mixture of water and at least one water-soluble organic solvent (co-solvent) or humectant. Selection of a suitable mixture depends on requirements of the specific application, such as desired surface tension and viscosity, the selected colorant, and compatibility with substrate onto which the ink will be printed.
Examples of water-soluble organic solvents and humectants include: alcohols, ketones, keto-alcohols, ethers and others, such as thiodiglycol, sulfolane, 2-pyrrolidone, 1,3-dimethyl-2-imidazolidinone and caprolactam; glycols such as ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, trimethylene glycol, butylene glycol and hexylene glycol; addition polymers of oxyethylene or oxypropylene such as polyethylene glycol, polypropylene glycol and the like; triols such as glycerol and 1,2,6-hexanetriol; lower alkyl ethers of polyhydric alcohols, such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, diethylene glycol monomethyl, diethylene glycol monoethyl ether; lower dialkyl ethers of polyhydric alcohols, such as diethylene glycol dimethyl or diethyl ether; urea and substituted ureas.
An aqueous vehicle will typically contain about 30% to about 95% water with the balance (i.e., about 70% to about 5%) being the water-soluble solvent. Ink compositions typically contain about 60% to about 95% water, based on the total weight of the aqueous vehicle.
Metal Salt
A metal salt can be incorporated in an ink formulation to help control bleed, and may provide other benefits as well. Use of metal salts in this way has been described, for example, in previously mentioned U.S. Pat. Nos. 5,488,402 and 5,518,534 (the disclosures of which are incorporated by reference herein for all purposes as if fully set forth). The salts are referred to in some art as precipitating agents because they are believed to operate by reacting with the anionic groups (such as carboxyl or sulfonate) associated with a colorant (such as a dye, or a self-stabilized pigment, or the anionic group on a dispersant associated with a dispersed pigment) of another ink in the ink set to form an insoluble complex. However, the present invention is not bound by any particular theory of operation.
The metal salt is substantially soluble in the ink vehicle and the metal can be a monovalent or multivalent cation. Suitable metal cations include, for example:
Group IA metals Na +1 , Li +1 , K +1 , Rb +1 and Cs +1 ;
Group IIA metals Mg +2 , Ca +2 , Sr +2 and Ba +2 ;
Group IIIA metals Al +3 , Ga +3 and In +3 ;
transition metals Cr +3 , Mn +2 , Fe +2 , Fe +3 , Co +3 , Ni +2 , Cu +2 , Zn +2 , Y +3 and Cd +2 ; and
Lanthanide metals La +3 , Pr +3 , Nd +3 , Sm +3 , Eu +3 , Gd +2 , Tb +3 , Dy +2 , Ho +3 , Er +3 , Tm +3 , Yb +3 and Lu +3 .
Preferred monovalent metal cations include, but are not limited to, Na +1 and K +1 , and preferred multivalent metal cations include, but are not limited to, Zn +2 , Mg +2 , Ca +2 , Cu +2 , Ni +2 and Fe +2 .
Mixtures of any two or more of metals and metal salts is also suitable.
In the context of the present invention, the amount of metal salt present is expressed on a metal cation (M +n ) basis in parts per million (ppm), that is parts by weight of M +n per million weight of ink. The amount of M +n present (total) is generally the range of from about 1000 ppm to about 30,000 ppm and, more typically, from about 2000 ppm to about 20,000 ppm.
Suitable metal salts can be the salt of a mineral or organic acid, the appropriate selection of which is readily achieved through routine experimentation. The mineral acid may be hydrochloric acid, phosphoric acid, sulfuric acid, hydrobromic acid, nitric acid, hydriodic acid, hydrofluoric acid. The organic acids may be carboxylic acids, particularly those carboxylic acids substituted with electron withdrawing groups, and organic sulfonic acids. Some examples of such acids include chloroacetic acid, p-toluene sulfonic acid, sulfanilic acid, benzene sulfonic acid, and so forth.
Additives
Other ingredients (additives) may be formulated into the inkjet ink, to the extent that such other ingredients do not interfere with the stability and jetablity of the finished ink, which may be readily determined by routine experimentation. Such other ingredients are in a general sense well known in the art.
Commonly, surfactants are added to the ink to adjust surface tension and wetting properties. Suitable surfactants include ethoxylated acetylene diols (e.g. Surfynols® series from Air Products), ethoxylated primary (e.g. Tomadol® series from Tomah Products) and secondary (e.g. Tergitol® series from Union Carbide) alcohols, sulfosuccinates (e.g. Aerosol® series from Cytec), organosilicones (e.g. Silwet® series from GE Silicons) and fluoro surfactants (e.g. Zonyl® series from DuPont). Surfactants are typically used in the amount of about 0.01 to about 5% and preferably about 0.2 to about 2%, based on the total weight of the ink.
Polymers may be added to the ink to improve durability. The polymers can be soluble in the vehicle or dispersed (e.g. “emulsion polymer” or “latex”), and can be ionic or nonionic. Useful classes of polymers include acrylics, styrene-acrylics and polyurethanes.
Biocides may be used to inhibit growth of microorganisms. Buffers may be used to maintain pH. Buffers include, for example, tris(hydroxymethyl)-aminomethane (“Trizma” or “Tris”).
Inclusion of sequestering (or chelating) agents such as ethylenediaminetetraacetic acid (EDTA), iminodiacetic acid (IDA), ethylenediamine-di(o-hydroxyphenylacetic acid) (EDDHA), nitrilotriacetic acid (NTA), dihydroxyethylglycine (DHEG), trans-1,2-cyclohexanediaminetetraacetic acid (CyDTA), diethylenetriamine-N,N,N′,N″, N″-pentaacetic acid (DTPA), and glycoletherdiamine-N,N,N′,N′-tetraacetic acid (GEDTA), and salts thereof, may be advantageous, for example, to eliminate deleterious effects of heavy metal impurities.
Proportions of Ingredients
The components described above can be combined to make an ink in various proportions and combinations in order to achieve desired ink properties, as generally described above, and as generally recognized by those of ordinary skill in the art. Some experimentation may be necessary to optimize inks for a particular end use, but such optimization is generally within the ordinary skill in the art.
The amount of vehicle in an ink is typically in the range of from about 70% to about 99.8%, and more typically from about 80% to about 99%. Colorant is generally present in amounts up to about 10%. Percentages are weight percent of the total weight of ink.
Other ingredients (additives), when present, generally comprise less than about 15% by weight, based on the total weight of the ink. Surfactants, when added, are generally in the range of about 0.2 to about 3% by weight based on the total weight of the ink. Polymers can be added as needed, but will generally be less than about 15% by weight based on the total weight of the ink.
Ink Properties
Drop velocity, separation length of the droplets, drop size and stream stability are greatly affected by the surface tension and the viscosity of the ink. Ink jet inks typically have a surface tension in the range of about 20 dyne/cm to about 70 dyne/cm at 25° C. Viscosity can be as high as 30 cP at 25° C., but is typically somewhat lower. The ink has physical properties are adjusted to the ejecting conditions and printhead design. The inks should have excellent storage stability for long periods so as not clog to a significant extent in an ink jet apparatus. Further, the ink should not corrode parts of the ink jet printing device it comes in contact with, and it should be essentially odorless and non-toxic. Preferred pH for the ink is in the range of from about 6.5 to about 8.
Inkjet Ink Set
The yellow ink of the present invention is advantageously used in an ink set with other dye-based colored inks, such as a magenta and a cyan dye-based ink, wherein the other inks have similar beneficial attributes such as chroma, lightfastness and tolerance to bleed control agents.
A magenta ink preferred for use with the prescribed yellow ink comprises mixture of AR 52 and a second magenta dye selected from the group consisting of AR249, AR289, RR180, RR23, CAS Number 182061-89-8 and mixtures thereof. Most preferred as the second magenta dye are AR249 and CAS Number 182061-89-8. A dye with CAS Number 182061-89-8 is commercially available from IIford Imaging Group (IIford M377). The structure of CAS Number 182061-89-8 can be seen from Magenta Formula II in previously incorporated U.S. Pat. No. 6,053,969. The weight ratio of AR52 to the second magenta dye required to achieve a desirable magenta hue is generally from about 1:3 to about 1:8, respectively, when the second dye is either AR249 or CAS Number 182061-89-8.
A cyan ink preferred for use with the prescribed yellow ink comprises a cyan dye selected from the group consisting of DB199, AB9 and mixtures thereof.
The other dye-based inks in the set preferably comprise an aqueous vehicle in which the colorant is soluble. The aqueous vehicle, optional other components and ink properties are similar to, but selected independently of, the yellow ink as described above.
Dye-based inks, including the yellow ink of the present invention, typically have a colorant (dye) content from about 0.1 wt % to about 8 wt % and, more typically, from about 0.5 wt % to about 6 wt %, based on the total weight of the ink. The “dye content” in a given ink refers the total dye present in that ink, whether a single dye species or a combination of two or more dye species.
The dyes are usually in their salt form, such as an alkali metal (Na, K, or Li) or quaternary ammonium salt. Most commonly, the commercially available salt form is sodium. Other salt forms can be made using well-known techniques.
Ink sets may further comprise one or more “gamut-expanding” inks, including different colored inks such as an orange ink, a green ink, a red ink and/or a blue ink, and combinations of full strength and light strengths inks such as light cyan and light magenta.
The yellow ink of the present invention, and any of the preferred magenta and/or cyan dye-based inks just described, are advantageously used in an ink set that further includes a pigmented black ink. It is especially advantageous for the dye-based ink(s) to comprise bleed control agents, such as metal salts, and for the pigment in the black ink to be an anionically-stabilized pigment dispersion that will “crash” or be immobilized on contact with the metal salts in the dye-based colored inks and thereby resist bleeding into the colored areas of a printed image.
The aqueous anionic pigment ink comprises an aqueous vehicle and optionally ingredients (additives) as described above for the yellow ink, and a black pigment stably dispersed in the aqueous vehicle. The black pigment is preferably carbon black.
Pigments, traditionally, are stabilized to dispersion in a vehicle by dispersing agents, such as polymeric dispersants or surfactants. More recently though, so-called “self-dispersible” or “self-dispersing” pigments (hereafter “SDP(s)”) have been developed. As the name would imply, SDPs are dispersible in water, or aqueous vehicle, without dispersants. Thus, pigment may be stabilized to dispersion by surface treatment to be self-dispersing (see, for example, U.S. Pat. No. 6,852,156, the disclosure of which is incorporated by reference herein for all purposes as if fully set forth), by treatment with dispersant in the traditional way, or by some combination of surface treatment and dispersant.
Preferably, when dispersant is employed, the dispersant(s) is a random or structured polymeric dispersant. Preferred random polymers include acrylic polymer and styrene-acrylic polymers. Most preferred are structured dispersants which include AB, BAB and ABC block copolymers, branched polymers and graft polymers. Some useful structured polymers are disclosed in U.S. Pat. No. 5,085,698, EP-A-0556649 and U.S. Pat. No. 5,231,131 (the disclosures of which are incorporated by reference herein for all purposes as if fully set forth).
The dispersant or surface treatment applied to the pigment creates an anionic surface charge (“anionic pigment dispersion”). Preferably, that surface charge is imparted predominately by ionizable carboxylic acid (carboxylate) groups.
Useful pigment particle size is typically in the range of from about 0.005 micron to about 15 micron. Preferably, the pigment particle size should range from about 0.005 to about 5 micron, more preferably from about 0.005 to about 1 micron, and most preferably from about 0.005 to about 0.3 micron.
Sources of colorants used in inkjet inks are generally well know to those skilled in the art.
Method of Printing
The method of printing prescribed herein can be accomplished with any suitable inkjet printer. The substrate can be any suitable substrate, but the instant invention is particularly useful for printing on paper, especially “plain” paper and specialty paper such as photo glossy paper.
EXAMPLES
Inks were prepared by mixing the indicated ingredients together and filtering the resulting solution. Water was deionized unless otherwise stated. The dyes used were “inkjet grade” meaning that they were relatively pure and free of extraneous salts. Aerosol OT is a surfactant from Cytec Industries. Byk 348 is a surfactant from Byk Chemie.
Color measurements were made with a commercially available spectrophotometer, in this case a Spectroeye from Gretag-MacBeth. Hue (h ab ) and chroma (C* ab ) values are read directly from the instrument but are based on CIELAB colorspace L*, a* and b* terms according to the following equations: h ab =tan −1 (b*/a*) where the angle is adjusted for the appropriate quadrant and C* ab =(a* 2 +b* 2 ) 1/2 . The measurements and definitions are well known in the art, see for example ASTM Standard E308 and Principles of Color Technology , Billmeyer and Saltzman, 3rd Ed., Roy Berns editor, John Wiley & Sons, Inc. (2000).
Reflectance values of the CYM composite black were measured at several wavelengths using a Gregtag densitometer. Dark and black images are associated with low reflectance values.
Inks Y1, Y2, C1 and M1 were prepared according to the formulations in the following tables. Ink referred to as “HP 57” was the Hewlett Packard commercial ink supplied with the HP 57 print cartridge. Inventive ink Y1 was compatible with salts but was not formulated with salt for these examples.
Ink Y1
Ink Y2
Ingredient
(Inventive)
(comparative)
DY169
1.0
—
AY79
2.0
—
AY17
—
4.20
AO33
—
0.22
2-pryrolidone
5.0
5.0
Isopropanol
2.0
2.0
Aerosol OT
0.25
0.25
Byk 348
0.2
0.2
Water (to 100%)
Balance
Balance
Ingredients
Ink C1
Ink M1
DB199
4.3
—
AR249
—
4.5
2-pryrolidone
5.0
5.0
Isopropanol
2.0
2.0
Aerosol OT
0.25
0.25
Byk 348
0.2
0.2
Water (to 100%)
Balance
Balance
Inks were loaded into and printed from a HP 57 cartridge with a Hewlett Packard Photosmart 7760 inkjet printer. Images consisting of blocks of the primary colors and CYM composite black were printed on Staples “Photo Supreme High Gloss” microporous media selecting “HP Photo Glossy” and “Best” as paper type and print quality respectively. The temperature was about 22° C. and relative humidity was about 41%. The chroma and hue angles are summarized in the following table.
Microporous Paper
Plain Paper
Ink
C* ab
h ab
C* ab
h ab
Ink Y1
108.5
89.0
72.9
87
Ink Y2
89.3
89.0
62.1
89
HP 57 yellow
96.3
89.0
65.1
90
Ink M1
74.5
356
—
—
HP 57 magenta
71.0
345
—
—
Ink C1
66.1
235
—
—
HP 57 cyan
67.1
225
—
—
The reflectance measurements of the CYM composite black prints are summarized in FIG. 1 . Referring to FIG. 1 , the “HP 57” is a composite of commercial HP 57 cyan, magenta and yellow inks; the “Ink Y1” is a composite of inks Y1, C1 and M1; the “Ink Y2” is a composite of inks Y1, C1 and M1. It can be seen that the inventive Ink Y1 composite black has low reflectance throughout the entire range of wavelengths 425 nm to 625 nm. This quantifies what can be visually, which is, the ink set with the inventive yellow ink gives a clear (non-hazy), “true” black color. By contrast, the HP 57 composite black has high reflectance at all wavelengths (hazy appearance) and the reflectance is unequal over the 425 nm to 625 nm range resulting in a bluish, rather than black, hue. Likewise, the comparative Ink Y2 composite black is also hazy and has a bluish hue shift.
The results demonstrate that the inventive ink and ink set has good color on both plain paper and specialty paper, and that an advantageous composite black is obtained on microporous paper. | The present invention pertains to a yellow ink for inkjet printing and, in particular, to a yellow ink containing a combination of specific yellow colorants, namely Direct yellow 169 and Acid Yellow 79 . The present invention further pertains to ink set having this yellow ink. The ink and ink set are particularly advantageous for printing on plain and photo glossy paper. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application, titled “Wavefront Multiplexing in Passive Optical Network with Remote Digital Beam Forming” (or K-Muxing in PON with RDBF), is related to
1. U.S. Pat. Appl. Pub. No. 20130223840; “Resource Allocation in PON Networks via Wave-front Multiplexing and De-multiplexing,” published on Aug. 29, 2013, 2. U.S. Pat. No. 8,111,646; “Communication System For Dynamically Combining Power From A Plurality Of Propagation Channels In Order To Improve Power Levels Of Transmitted Signals Without Affecting Receiver And Propagation Segment,” Issued on Feb. 7, 2012. 3. U.S. Pat. No. 8,098,612; “Apparatus And The Method For Remote Beam Forming For Satellite Broadcasting Systems,” Issued on Jan. 17, 2012. 4. U.S. Pat. Appl. Pub. No. 20110197740; “Novel Karaoke and Multi-Channel Data Recording/Transmission Techniques via Wavefront Multiplexing and Demultiplexing,” published on Aug. 18, 2011. 5. U.S. Pat. Appl. Pub. No. 20140081989; “Wavefront Muxing and Demuxing for Cloud Data Storage and Transport,” published on Mar. 20, 2014.
[0007] All of the above are incorporated herein by reference in their entireties.
BACKGROUND
[0008] 1. Field of the Disclosure
[0009] Four independent technologies are incorporated in this invention to efficiently and cost effectively implement dynamic last mile connectivity. The four technologies are passive optical networks (PON), Small cell, wavefront multiplexing (or K-muxing), and digital beam forming (DBF). We have filed US patents for communications architectures featuring K-muxing overlaid over low cost of PON. Those inventions relate particularly to resource allocation in passive optical networks (PON) via wavefront multiplexing (WF-muxing or K-muxing) and wavefront demultiplexing (WF-demuxing or K-demuxing). The “WF-muxing in PON” can be configured for performing remote digital beam forming (RDBF) over a service area covered by multiple small cells. The RDBF may generate multiple shaped beams with enhanced connectivity and better isolations over a same frequency slot concurrently to serve multiple users over the coverage area.
[0010] 2. Brief Description of the Related Art
[0011] Wavefront multiplexing/demultiplexing (WF muxing/demuxing) process embodies an architecture that utilizes multi-dimensional waveforms in various applications. Multiple data sets are preprocessed by WF muxing before stored/transported. WF muxed data is aggregated data from multiple data sets that have been “customized/processed” and disassembled into any scalable number of sets of processed data, with each set being stored on a storage site or being transported via a propagation channel. The original data is reassembled via WF demuxing after retrieving a lesser but scalable number of WF muxed data sets. The WF muxing/demuxing solution enhances data security and data redundancy in some applications, and facilitates dynamic resource (power and bandwidth, etc.) in others. In addition, WF muxing/demuxing methods enable a monitoring capability on the integrity of stored/transported waveforms.
[0012] K-space is a well understood term in solid state physics and imaging processing. The k-space can refer to:
[0013] a. Another name for the frequency domain but referring to a spatial rather than temporal frequency
b. Reciprocal space for the Fourier transform of a spatial function c. Momentum space for the vector space of possible values of momentum for a particle d. According to Wikipedia (September 2015), the k-space in magnetic resonance imaging (MRI)
i. a formalism of k-space widely used in magnetic resonance imaging (MRI) introduced in 1979 by Likes and in 1983 by Ljunggren and Twieg. ii. In MRI physics, k-space is the 2D or 3D Fourier transform of the MR image measured.
[0019] We shall introduce the terms K-mux, Kmux, or KMx for representing the Wavefront multiplex; and K-muxing, Kmuxing, or KMxing for the Wavefront multiplexing. We may also use “K-Muxing in PON” for “WF-Muxing in PON”, “K-muxer” for “WF muxer”, and so on. In Electromagnetic (EM) theory, the letter K is often used to represent a directional vector and is a wave number in a propagation direction. The term (ωt−K·R) has been used extensively for propagation phase. K represents a directional (moving) surface and R a directional propagation displacement. Both are vectors. Therefore a vector K is a “wavefront” mathematically. We will be using k-space as wavefront domain or wavefront space.
[0020] The present invention relates to methods and architectures for dynamic allocations of time slots or equivalent bandwidths of Passive Optical Networks (PON) via wavefront multiplexing (WF muxing or K-muxing) and wavefront de-multiplexing (WF-demuxing or K-demuxing) techniques to generate multi-dimensional waveforms propagating through existing time slots of PON network concurrently, enabling usage exceeding the bandwidth limits set by time slots or subchannels bandwidths for a subscriber. The architectures support dynamic bandwidth allocations as well as configurable bandwidth allocations. They also support dynamic “power resources” allocations as well as configurable power resources allocations of optical lasers to different signals of various subscribers.
[0021] It is also related to Digital beam forming (DBF) over a region for subscriber operation. Wireless network via the DBF shall optimize connectivity and minimize interference among multiple concurrent users. It may form a shaped beam, or multiple dynamic beams with orthogonal beam (OB) patterns. DBF can be implemented locally within the perimeter of a subscriber. It may also be implemented remotely via a remote beam forming (RBF) technique. DBF is a digital technique for implementing a beam-forming network (BFN). Similarly a remote beam-forming network (RBFN) may also be implemented digitally via remote DBF techniques.
[0022] Cellphone industry has responded to the increasing data transmission demands from smartphones, tablets, and similar devices by the introduction of 3G and 4G cellular networks. As demand continues to increase, it becomes increasingly difficult to satisfy this requirement, particularly in densely populated areas and remote rural areas. An essential component of the 4G strategy for satisfying demand is the use of picocells and femtocells. Together, these are classified as small cells. The term small cell is an umbrella term for low-powered radio access nodes that operate in licensed and unlicensed spectrum that have a range of 10 in to several hundred meters. Small cells now outnumber macro-cells and microcells combined, and the proportion of small cells in 4G networks is expected to rise.
[0023] A small cell is defined by a low-power, short range, self-contained base station. Initially used to describe consumer units intended for residential homes, the term has expanded to encompass higher capacity units for enterprise, rural and metropolitan areas. Key attributes include IP backhaul, self-optimization, low power consumption, and ease of deployment.
[0024] The small cell access point is a small base station, much like a Wi-Fi hot spot base station, placed in a residential, business, or public setting. It operates in the same frequency band and with the same protocols as an ordinary cellular network base station. Thus, a 4G smartphone or tablet can connect wirelessly with a 4G small cell with no change. The small cell connects to the Internet, typically over a DSL, fiber, or cable landline. Packetized traffic to and from the small cell connects to the cellular operator's core packet network via a small cell gateway.
[0025] There are several differences between picocells and femtocells. Typically, picocells cover a larger area than a femtocell and are installed and operated by the carrier. A femtocell on the other hand, is designed to be installed by the network customer. An example of the use of the femtocell is to provide coverage in the home or in a small office setting. Typically, a femtocell can serve only somewhere between 4 and 16 simultaneous users, whereas a picocell may be able to handle up to 100 users.
[0026] Small cells have been proposed as solutions for 5G, allowing frequency reuse efficiently but also moving the network complexity from base-stations to backbone network controls. PON can be used as the backhaul of small cell deployments.
[0027] According to the paper “Cost Optimization of Fiber Deployment for Small-cell Backhaul” by C. S. Ranaweera; et al. on Optical Fiber Communication Conference and Exposition and the National Fiber Optic Engineers Conference ( OFC/NFOEC ), 2013, many optimized PON deployments for various scenarios have been studied. However, cost-efficient deployments of PONs for small cell backhauling using existing infrastructure adds complexity because the existing resources must be taken into account. It has been shown in the paper, cost-efficient PON deployments using existing fiber resources for the purpose of small cell backhauling by determining the fiber routes, the best locations for splitters, and the most favorable number of PONs for a range of split ratios. For a test case, the resulting cost-optimized PON can save up to 56% of the deployment cost associated with small cell backhauling, in comparison to typical Ethernet based PTP fiber backhauling approaches.
[0028] In addition, DBF over multiple small cells via a remote digital beam forming (RDBN) network at a head-end of a PON will make frequency reuse more efficient than conventional optimizations of small cell radiations.
[0029] Remote beam forming (RBF) has been implemented in all TDRSS satellites in 1980s using FDM muxing among back-channels in feeder-links. Their RBF were implemented by analogue means. Remote digital beam forming (RDBF) was used in many mobile satellite systems (MSS) in early 2000s via techniques of ground base beam-forming (GBBF) using FDM muxing among back-channels in feeder-links. Most of the concerns and difficulties in implementation of RBF or RDBF are related to dynamic calibrations, and equalization of multiple channels in a feederlink, maintaining coherent operation among multiple array elements on board satellites.
[0030] A US patent with the U.S. Pat. No. 5,903,549 by Von der Embse et al in 1999 proposed a CDM muxing scheme in feeder links for mobile satellite applications. Since CDM muxing covering entire bandwidth of feeder-links, variations on amplitude and phase delays over multiple CDM channels are minimum. Thus dynamic calibration and equalizations among propagation channels in feederlink become less an issue.
[0031] In this patent application we are proposing a K-muxing scheme, over a TDM in PON format, with capability for continuous and dynamic calibration and equalization among multiple backchannels in feeder-links for terrestrial wireless communication applications. The feeder-links for the PONs are the time slots via fibers. Thus dynamic calibration and equalizations among propagation channels in feederlink may become an issue. Similar K-muxing scheme can be overlaid over FDM or CDM channels for many wireless communications applications; including those via satellites and via terrestrial hubs. They also are applicable to cable networks.
[0032] 3. Background in PON.
[0033] Most of the Fiber-to-the-Home deployments in recent years have been based on industry standard technologies such as Gigabit Ethernet Passive Optical Networks (GEPON) and Gigabit PON (GPON). Passive Optical Network (PON) is a point-to multipoint network. A PON consists of optical line terminal at the service provider's central office and many number of optical network units near end users. The goal of PON is to reduce the amount of fiber. There are two standards of the Passive Optical Network available, the GPON and the GEPON. GPON (Gigabit PON) is the evolution of broadband PON (BPON) standard. The protocols used by GPON are ATM, GEM, and Ethernet. It supports higher rates and has more security.
[0034] GEPON or EPON (Ethernet PON) is an IEEE standard that uses Ethernet for sending data packets. By 2010, there were over 15 million EPON ports installed. GEPON uses 1 gigabit per second upstream and downstream rates. EPON/GEPON is a fast Ethernet over passive optical networks which are point to multipoint to the premises (FTTP) or fiber to the home (FTTH) architecture in which single optical fiber is used to serve multiple premises or users.
[0035] The success of these deployments has led to significant innovation in both system architecture and the components that are used to build these systems, and the next generation of passive optical networks will inevitably be far more advanced than what is typically deployed today.
[0036] Traditional PON architectures feature one optical feed shared among 32 or more users, as depicted in FIG. 1 . In a GPON or GEPON system all subscribers use a common optical wavelength. They share the fiber infrastructure, which is done through time division multiplexing (TDM). Each of those 32 homes transmits over the same fiber, but the time in which they are allowed to “occupy” the fiber is allocated by the Optical Line Terminal (OLT) at the central office. While the equipment in each home is capable of transmitting at over 1,250 Mbps, it can only do so during its allotted time on the fiber, and therefore it is not uncommon for each subscriber in a legacy PON system to only achieve sustained data rates of around 30 Mbps. This concept of many users sharing a common fiber helps minimize the fiber infrastructure required in an FTTH deployment.
[0037] An Optical Line Terminal (OLT) provides a direct optical interface to the Ethernet/IP network core. Together with Optical Network Unit (ONU), it completes the end-to-end optical last mile with up to 1 Gbps of bandwidth to residential and business customers.
[0038] An OLT may consist of 4 PON cards, each card with 2 PON links, total up to 8 PON links. Each PON link delivers 1 Gbps of shared bandwidth between up to 32 subscribers within 20 Km reach. An OLT may serve a maximum of 256 subscribers from a 19″ 2RU chassis. With layer 2 switching capability, OLT has up to 8 optical or electrical gigabit uplink ports.
[0039] According to Wikipedia, there are also many variations in PONs such as:
[0040] 1. TDM-PON
APON/BPON, EPON and GPON have been widely deployed. By 2015, EPON has approximately 40 million deployed ports and ranks first in deployments. GPON growth has been steady, but fewer than 2 million installed ports. For TDM-PON, a passive optical splitter is used in the optical distribution network. In the upstream direction, each ONU (optical network units) or ONT (optical network terminal) burst transmits for an assigned time-slot (multiplexed in the time domain). In the downstream direction, the OLT (usually) continuously transmits (or may burst transmit).
[0043] 2. DOCSIS Provisioning of EPON or DPoE
Data over Cable Service Interface Specification (DOCSIS) Provisioning of Ethernet Passive Optical Network, or DPoE, is a set of Cable Television Laboratory specifications that implement the DOCSIS service layer interface on existing Ethernet PON (EPON, GEPON or 10G-EPON) Media Access Control (MAC) and Physical layer (PHY) standards. It makes the EPON OLT look and act like a DOCSIS Cable Modem
[0046] Termination Systems (CMTS) platform (which is called a DPoE System in DPoE terminology).
[0047] 3. Radio frequency over glass
Radio frequency over glass (RFoG) is a type of passive optical network that transports RF signals that were formerly transported over copper (principally over a hybrid fibre-coaxial cable) over PON. RFoG offers backwards compatibility with existing RF modulation technology, but offers no additional bandwidth for RF based services. Although not yet completed, the RFoG standard is actually a collection of standardized options which are not compatible with each other (they cannot be mixed on the same PON). Some of the standards may interoperate with other PONs, others may not.
[0051] 4. WDM-PON
Wavelength Division Multiplexing PON, or WDM-PON, is a non-standard type of passive optical networking, being developed by some companies. The multiple wavelengths of a WDM-PON can be used to separate Optical Network Units (ONUs) into several virtual PONs co-existing on the same physical infrastructure. There is no common standard for WDM-PON nor any unanimously agreed upon definition of the term.
[0055] 5. Long-Reach Optical Access Networks
The concept of the Long-Reach Optical Access Network (LROAN) is to replace the optical/electrical/optical conversion that takes place at the local exchange with a continuous optical path that extends from the customer to the core of the network.
[0057] In this application, we will present examples using TDM PON for implementing incoherent K-muxing on information digital data sets, and RFoG for examples using coherent K-muxing on waveform or signal digital data set. In transmit, an information digital data set is converted into a waveform or signal digital data set through modulators. Similarly, a set of received waveform or signal digital data may also be converted to a set of received information data via demodulators.
[0058] In short, K-muxing for incoherent operation in data transport and storage are for enhancing data privacy via a superposition formatting on data and improved survivability via data redundancy. On the other hand, K-muxing for coherent operation in signal transmission via multiple channels are for coherent power combining to achieve enhanced signal-to-noise ratio (SNR) in a receiver, and dynamical resource allocations for communications applications. The resources include both power and bandwidth.
SUMMARY
[0059] The present invention relates to orthogonal modes propagations in a multi-dimensional communications channel via multidimensional waveforms The architecture will enable operator to allocate existing asset (e.g. bandwidth) to various subscribers dynamically. It also relates to Passive Optical Networks (PON), Small cell, Wavefront Multiplexing or K-muxing, and digital beam forming (DBF) and remote digital beam forming (RDBF). The K-muxing may be implemented to function in incoherent modes to enhance privacy and survivability in data transport. The same K-muxing may also be implemented for operations in coherent modes for power combining and resource allocations.
[0060] However, this sharing of fiber is one of the main factors limiting higher data rates to subscribers. Wavefront multiplexing (WF muxing) techniques shown in FIG. 3 allow the same fiber infrastructure to be used more effectively, while enabling a subscriber to dynamically access the PON network faster with re-configurable high data rate, up to the full 1,250 Mbps, available to them when needed. There are no requirements to replace existing infrastructures, but with additional pre- and post-processes at both OLT and ONTs.
[0061] The upgraded PONs can support
Subscribers with different but fixed needs in data rates; and Subscribers with different and dynamic needs in data rates; and Subscribers with different needs in optical powers in a PON network; enhancing coverage quality of the PON network Subscribers (ONTs) at longer distances from an OLT getting more shares of a (laser) power to boost their signals; Subscribers (ONTs) at shorter distances from an OLT getting less shares of a (laser) power to boost their signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0067] The drawings disclose illustrative embodiments of the present disclosure. They do not set forth all embodiments. Other embodiments may be used in addition or instead. Details that may be apparent or unnecessary may be omitted to save space or for more effective illustration. Conversely, some embodiments may be practiced without all of the details that are disclosed. When the same reference number or reference indicator appears in different drawings, it may refer to the same or like components or steps.
[0068] Aspects of the disclosure may be more fully understood from the following description when read together with the accompanying drawings, which are to be regarded as illustrative in nature, and not as limiting. The drawings are not necessarily to scale, emphasis instead being placed on the principles of the disclosure. In the drawings:
[0069] FIG. 1 shows a data communication system via a PON in a forward direction according to an embodiment of the present disclosure.
[0070] FIG. 1A shows functional blocks of ONUs in the data communication system in FIG. 1 according to embodiments of the present disclosure.
[0071] FIG. 1B shows a data communication system via a PON in a return direction according to an embodiment of the present disclosure.
[0072] FIG. 2 shows a forward link architecture of a PON connected to a small-cell hub (or Picocell hub) and a WI-FI hub according to embodiments of the present disclosure.
[0073] FIG. 3 shows a K-muxing forward link architecture over a data communication system via PON connected to a small-cell hub (or Picocell hub) and a WI-FI hub according to embodiments of the present disclosure.
[0074] FIG. 3A shows functional blocks of ONUs in the data communication system in FIG. 3 including the functions of K-demuxing according to an embodiment of the present disclosure.
[0075] FIG. 3B shows a configuration of a pre-processing including a K-muxing in forward link over a data communication system via PON according to embodiments of the present disclosure.
[0076] FIG. 3C shows configurations of a 4-to-4 K-muxing in forward link via PON according to embodiments of the present disclosure.
[0077] FIG. 3D shows configurations of updated ONUs including 4-to-4 K-demuxing in forward link via PON according to embodiments of the present disclosure.
[0078] FIG. 3E shows configurations of a 4-to-4 K-demuxing in forward link via PON according to embodiments of the present disclosure.
[0079] FIG. 4 shows an architecture of a PON connected to a small-cell hub (or Picocell hub) with a first digital beam forming (DBF) network and a WI-FI hub with a second DBF network according to embodiments of the present disclosure.
[0080] FIG. 4A shows forward direction routing networks for a user at headend of a PON connected to a small-cell hub (or Picocell hub) with a first digital beam forming (DBF) network and a WI-FI hub with a second DBF network according to embodiments of the present disclosure.
[0081] FIG. 5 shows a K-muxing architecture over a data communication system via PON connected to a small-cell hub (or Picocell hub) with a first digital beam forming (DBF) network and a WI-FI hub with a second DBF network according to embodiments of the present disclosure.
[0082] FIG. 5A show shows functional blocks of ONUs in the data communication system in FIG. 5 including the functions of K-demuxing according to an embodiment of the present disclosure.
[0083] FIG. 6 shows a K-muxing architecture for a forward link over a signal communication system via a PON connected to a small-cell hub (or Picocell hub) and a WI-FI hub with remote digital beam forming (RDBF) networks according to embodiments of the present disclosure. The PON may operate in one of RFoG modes.
[0084] FIG. 6A shows functional blocks of ONUs including K-demuxing and optimization according to an embodiment of the present disclosure.
[0085] FIG. 7 shows a forward link architecture via a PON connected to multiple small-cell hub (or Picocell hub) to function as a multibeam array with remote digital beam forming (RDBF) networks according to embodiments of the present disclosure. The PON may operate in one of RFoG modes.
[0086] While certain embodiments are depicted in the drawings, one skilled in the art will appreciate that the embodiments depicted are illustrative and that variations of those shown, as well as other embodiments described herein, may be envisioned and practiced within the scope of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0087] Illustrative embodiments are now described. Other embodiments may be used in addition or instead. Details that may be apparent or unnecessary may be omitted to save space or for a more effective presentation. Conversely, some embodiments may be practiced without all of the details that are disclosed.
[0088] Before describing embodiments of the present invention, a definition has been included for these various terms. These definitions are provided to assist in teaching a general understanding of the present invention.
[0089] All figures illustrate forward direction implementations and key functions. Most of return direction implementations and key functions are similar and not shown.
[0090] For conventional TDM-PON, a passive optical splitter is used in the optical distribution network. In the upstream or return direction, each ONU (optical network units) or ONT (optical network terminal) burst transmits for an assigned time-slot (multiplexed in the time domain). In this way, the OLT is receiving signals from only one ONU or ONT at any point in time. For K-muxing over a TDM PON, each ONU (optical network units) or ONT (optical network terminal) in the upstream or return direction continuously transmits K-muxed signals with unique WF vectors at low power level for all time-slots (multiplexed in the time domain).
[0091] Structure of Passive Optical Network (PON):
[0092] FIG. 1 is a forward link schematic diagram showing a passive optical network (PON) for multiple user processors according to an embodiment of the present invention. The passive optical network 1100 includes an optical line terminal 1200 (OLT), optical transferring devices or optical dividers 1150 , the number n of optical network units 1300 (ONUs), and multiple optical fibers 1160 , 1162 and 1164 , wherein the number n may be a positive integer greater than 2, such as 4, 8 or 12. The optical fiber 1160 connects the optical line terminal 1200 (OLT) and the optical transferring devices or optical dividers 1150 and each of the optical fibers 1162 connects the optical dividers 1150 and a corresponding one of the optical network units 1300 (ONUs). The optical fibers 1164 are used for interconnecting the optical dividers 1150 .
[0093] An OLT 1200 further comprises three major function: a conventional multiplexing, an optical modulating or frequency converting, and an optical source. Referring to FIG. 1 for a downstream operation, the depicted OLT 1200 for a TDM PON comprises a function of 32-to-1 TDM muxing 1210 , and a function of optical modulating 1220 . The function for the 32-to-1 TDM muxing 1210 converts 32 lower speed data streams (D 1 , D 2 . . . D 32 ) into one TDM muxed output stream with high flow rate. The TDM muxed output shall feature digital symbols as a bit stream with two levels representing “1” or “zero” only. They are information data to be used in the function of optical modulating 1220 as the direct modulating input. The second input for the optical modulating 1220 is an optical laser 1230 serving as the optical carrier source for an optical modulator with the optical modulating function. The optical modulator with functions of the optical modulating 1220 converts a bit stream of information data to a stream of optical waveform stream which is sent to the rest of the PON.
[0094] The purpose for the PON depicted is to deliver D 1 data stream to a first user with a first of 32 ONUs 1300 , ONU 1 ; to deliver D 2 data stream to a second user with ONU 2 , and so on. The total throughput of the PON 1100 will then be shared among the 32 users usually uniformly. For a total throughput capacity of 1 or 2.5 Gbps, each user shall get a maximum capacity of 31.25 or 78.125 Mbps, respectively.
[0095] Referring to FIG. 1 , the optical dividers 1150 may serve as an optical coupler and an optical splitter. For example, in a downstream direction, the optical divider 1150 can serve as an optical splitter for splitting an input optical signal, passing from the optical line terminal 1200 and through the optical fiber 1160 , into multiple output optical signals, some being sent to other optical dividers through the respective optical fibers 1164 , and others passing to the respective optical network units 1300 through the respective optical fibers 1162 , wherein data carried by each of the output optical signals are substantially equivalent to those carried by the input optical signal.
[0096] In an upstream direction (not indicated in FIG. 1 ), the optical dividers 1150 can serve as an optical coupler for combining optical signals, passing from the respective optical network units 1300 and through the respective optical fibers 1162 and other optical dividers 1150 via associated fibers 1164 , into an optical signal, passing to the optical line terminal 1200 through the optical fiber 1160 .
[0097] The optical line terminal 1200 (OLT) is arranged between a central office (CO) processor and the optical dividers 1150 . In the downstream direction, the OLT 1200 can transform electronic data, output from the central office processor, into optical data sent to one of the optical dividers 1150 through the optical fiber 1160 . The data bit streams, D 1 to D 32 are part of the electronic data, output from the central office processor.
[0098] In the upstream direction (not shown), the OLT 1200 shall transform optical data, output from the fiber 1160 into electronic data sent to the central office processor. The opposite end of the fiber 1160 is connected to one of the optical dividers 1150 .
[0099] FIG. 1A depicts major functions of optical network units (ONUs) 1300 . There are 3 ONUs: ONU 1 for a first user, ONU 16 for a 16 th user and ONU 32 for a 32 nd user. Each of the ONUs shall convert a muxed optical signal stream to a TDM muxed data bit stream (not shown). Each ONU performs additional data manipulation comprising of two functions: (1) TDM demuxing 1310 converting an incoming TDM muxed data stream to 32 individual data bit streams (D 1 , D 2 . . . D 32 ), and (2) a 32-to-1 switching 1320 . As a result, the output from ONU 1 will be D 1 digital bit stream. Those for ONU 16 and ONU 32 shall be the bit data streams D 16 and D 32 , respectively. The above mentioned functions are features of a TDM demuxing switch.
[0100] FIG. 1B is a return link schematic diagram showing a passive optical network (PON) for multiple user processors according to an embodiment of the present invention. In the upstream direction (return link), each ONU burst-transmits for an assigned time-slot (multiplexed in the time domain). In this way, the OLT 1200 is receiving signals from only one of ONUs 1300 at any point in time.
[0101] The passive optical network 1100 includes an optical line terminal 1200 (OLT), optical transferring devices or optical dividers 1150 , the number n of optical network units 1300 (ONUs), and multiple optical fibers 1160 , 1162 and 1164 , wherein the number n may be a positive integer greater than 2, such as 4, 8 or 12. The optical fiber 1160 connects the optical line terminal 1200 (OLT) and the optical transferring devices or optical dividers 1150 and each of the optical fibers 1162 connects the optical dividers 1150 and a corresponding one of the optical network units 1300 (ONUs). The optical fibers 1164 are used for interconnecting the optical dividers 1150 .
[0102] Referring to FIG. 1B for an upstream operation, one of the depicted ONUs 1300 , say ONU 2 for a TDM PON comprises a function of 32-to-1 TDM muxing (not shown) and a function of optical modulating (not shown). Both are, respectively, similar to the TDM muxing 1210 and the modulating 1220 of the OLT 1200 in FIG. 1 . The function for the TDM muxing 1210 converts a lower speed data stream (D 2 ) into one TDM burst output stream with high flow rate in an assigned time slot. Other users at return links shall burst their data streams in other respectively assigned time slots. The 32-to-1 TDM muxed output in the fiber segment 1160 just before the OLT shall feature digital symbols in optical signals or waveforms as a bit stream with two levels representing “1” or “zero” only. They are information data used in the function of optical modulating 1220 as the direct modulating input in ONUs. The second inputs for optical modulating 1220 are embedded optical lasers (not shown) serving as the optical carrier sources for optical modulators with the optical modulating functions. The optical modulators (not shown) with functions of the optical modulating 1220 convert bit streams of information data to a stream of optical waveform stream which is sent to the rest of the PON.
[0103] An OLT 1200 in receiving further comprises two major receiving function: an optical demodulating 1224 and a TDM demuxing 1214 .
Embodiment 1
[0104] FIG. 2 depicts a PON 1100 connected to a user processor 2100 for a second user through one of the ONUs 1300 , the ONU 2 designated as for a second user with a designated data bit stream D 2 . The user processor 2100 comprises a router 2110 which is connected to a picocell hub 2120 for cell phone wireless connectivity via a picocell hub antenna 2232 . Cellphone 2236 can be operational within the antenna coverage or field-of-view (FOV) 2234 . Picocell is also referred as small-cell. The router 2110 may also be connected to WiFi hub 2130 for wireless connectivity via a WiFi hub antenna 2132 for many personal devices 2136 . A notebook as one of personal devices 2136 may connect to Internet when it is within the FOV 2134 of the WiFi hub antenna 2132 .
[0105] Referring to FIG. 2 , each of the optical network units 1300 (ONUs) is arranged between one of the optical dividers 1150 and a corresponding one of thirty-two user processors 2100 . In the downstream direction, each of the optical network units 1300 can transform optical data, output from one of the optical dividers 1150 , into electronic data sent to a corresponding one of the user processors 2100 .
[0106] In the upstream direction (not shown), each of the optical network units ONUs 1300 can transform electronic data, output from a corresponding one of the user processors 2100 , into optical data sent to one of the optical dividers 1150 through a corresponding one of the optical fibers 1162 .
Embodiment 2
[0107] FIG. 3 is a down link or a forward direction schematic diagram showing a passive optical network (PON) 1100 in combination with wave-front multiplexing (K-muxing 130 ) and WF demultiplexing (K-demuxing 140 ) techniques for dynamically allocating the resource of the passive optical network system for multiple user processors 2100 according to an embodiment of the present invention. We shall refer to the K-muxing 130 in a preprocessor and K-demuxing 140 in post-processors. They are new functions in conjunction with a PON 1100 in this patent application. In short the K-muxing 130 before OLT 1200 in a pre-processor 1800 and the K-demuxing 140 after ONUs 1300 in post-processors 1340 in forward direction may be referred as new or additional functions for the OLT 1200 and the ONUs 1300 . These new functions may be implemented by additional S/W and/or electronics boxes in the OLT and the ONUs. We referred this architecture, a PON in a combination of K-muxing 130 and K-demuxing 140 , as “K-muxing in a PON” 1900 .
[0108] The basic operation principles of “K-muxing in a PON” 1900 have been presented in U.S. Pat. Appl. Pub. No. 20130223840 “Resource Allocation in PON Networks via Wave-front Multiplexing and De-multiplexing,” published on Aug. 29, 2013.
[0109] FIG. 3 is modified from FIG. 2 ; a WF muxing/demuxing or K-muxing/demuxing are overlaid on a conventional PON distribution to provide dynamic resource allocation capability. The PON for forward link is for 32 subscribers. A preprocessor with the K-muxing 130 will be implemented prior to a function of TDM muxing 1210 in OLT 1200 . The function of K-muxing 130 may be implemented by an updated software in OLT. It illustrates that all of the 32 subscribers participate for a resource sharing program enabled by the functions of K-muxing 130 and K-demuxing 140 . The set-up of a user processor 2100 for a second user are identical to the one in FIG. 2 .
[0110] In the preprocessor 1800 , the D 1 data stream for a first subscriber is transformed to appear on all 32 outputs carried by all 32 time-slots in the PON 1100 with a unique weighting vector, called wavefront vector 1 or WFV 1 . So are the remaining 31 down-stream data D 2 to D 32 . More precisely, the 32 substreams (D 1 to D 32 ) of data samples after a K-muxing 130 can be expressed as
[0000]
MD
1
=
w
1
,
1
*
D
1
+
w
1
,
2
*
D
2
+
…
+
w
1
,
32
*
D
32
(
1
-
1
)
MD
1
=
w
2
,
1
*
D
1
+
w
2
,
2
*
D
2
+
…
+
w
2
,
32
*
D
32
…
…
(
1
-
2
)
MD
32
=
w
32
,
1
*
D
1
+
w
32
,
2
*
D
2
+
…
+
w
32
,
32
*
D
32
(
1
-
32
)
[0111] And equations (1-1) to (1-32) can be written in a matrix form;
[0000] [ MD]=[W][D] (2)
[0112] Furthermore, the column vector [w 1,1 , w 2,1 , w 3,1 , . . . , w 32,1 ] T is the wavefront vector 1 or WFV 1 , which “carrys” D 1 data stream through the 32 TDM channels through a fiber 1160 . So are the remaining 31 wavefront vectors for the 31 remaining down-stream data. We may state that D 2 data stream is sent to a destination via a second wavefront WFV 2 propagating in a fiber network with 32 channels, and that D 32 is riding on WFV 32 .
[0113] We shall note that the output of the TDM mux 1210 will convert a sequential stream of digital samples into a high speed serial bit stream so that the optical modulator 1220 shall convert the electrical bit symbols of 0's and 1's to optical signals with two intensity levels of lasers in fibers.
[0114] At destinations, the ONUs will convert the optical signals of TDM muxed digital streams and using K-demuxing to recover the digital streams D 1 to D 32 accordingly. The recovered D 2 data stream is connected to a router 2110 separating data sets for various applications, including those to be sent via a WiFi hub 2130 and those via a picocell hub 2120 .
[0115] Three post processors 1340 for user 1 , user 2 and user 32 , respectively are shown in FIG. 3A . Each post processor 1340 comprises an ONU and key functions of K-demuxing 140 . Optical waveforms or optical signals are received, and then demodulated by a demodulator (not shown) to become a bit stream of digital data, which is buffered, and then converted into 32 parallel substreams of digital samples (MD 1 to MD 32 ) by a device with function of TDM de-mux 1310 . The 32 substreams of received digital samples are sent to a processor for 32-to-32 K-demuxing 140 . The 32 output streams (D 1 to D 32 ) are the corresponding data streams in forward links for the 32 subscribers.
[0116] In another embodiment, a different version of preprocessor 1800 with functions of K-muxing 130 and an OLT 1200 when only 4 of 32 subscribers are participating on the “resource sharing” capability is illustrated in FIG. 3B ; while corresponding K-demuxing 140 with ONUs 1300 are shown in FIG. 3D . More details of the functions of K-muxing 130 , including input mapping, are depicted in FIG. 3C .
[0117] In a preprocessor 1800 shown in FIG. 3B , there are 4 subscribers (users 1 , 16 , 17 , and 32 ) decided to participate on a resource sharing program. For a forward direction data delivery, a K-muxing 130 is reconfigured for 4-inputs and 4 outputs. The four inputs are input data streams to be delivered to the four users at the other end of the PON 1100 as the one shown in FIG. 3 . The four outputs are connected to the four corresponding time slots of a 32-to-1 TDM mux 1210 . The TDM mux 1210 usually features a first input port for the data for user 1 , and a second input for input data for user 2 , and so on. Therefore, the four K-muxed outputs MD 1 , MD 16 , MD 17 , and MD 32 from the K-muxing 130 shall be sent to the first, the 16 th , the 17 th and the 32 nd inputs of the TDM mux 1210 respectively. The remaining 28 user input data streams from D 2 to D 15 and from D 18 to D 31 , shall be sent to the corresponding input ports of the TDM mux 1210 . These 28 users are non-participants of the resource sharing program, and they will get a fixed maximum rate of data flow at 32 Mbps. The maximum data flow rate is calculated based on 1.024 Gbps total bit flow rate on a fiber distributed among 32 subscribers. Each subscriber will get 32 Mbps throughput. The optical laser 1230 provides an optical carrier for downstream communications in a fiber 1160 , while the optical modulator 1220 converts a set of digital bit stream data into a continuous flow of optical signals or a stream of optical waveforms.
[0118] Details in one deeper layer of a version of the K-muxing 130 in FIG. 3B is illustrated in FIG. 3C . The selected version of the K-muxing 130 function comprises three major blocks: (1) 4 sets of input mapping 132 , (2) a set of K-transforming or K-Xing 138 performing a 16-to-16 wavefront transformation, and (3) 4 sets of 4-to-1 TDM muxing 134 . A 16-to-16 K-Xing 138 features 16 inputs and 16 outputs. Each input corresponds to 1/16 of a total available bandwidth from a PON fiber network. As a result among 4 concurrent users the total equivalent bandwidth or flow rate is 32 Mbps*4 or 128 Mbps. Estimated granularity for the resource allocation is ¼ of the maximum 32 Mbps flow-rate allowed for a subscriber, or 8 Mbps.
[0119] Each input mapping 132 features configurable functions of 1-to-N TDM demuxing with a constant output clocking rate of 8 Mbps, where N is an integer and 16≧N≧1. Its input rate may vary from 8 Mbps to 128 Mbps.
[0120] In addition a controller 136 is used to configure the 4 sets of input mapping function according to an embedded programmable algorithm. The program may decide bandwidth resources for individual users according to a priority list among the 4 users. As an example, a dynamic priority list reads as follows; (1) 1 st priority for user 1 , (2) 2 nd priority for user 17 , and (3) 3 rd priority for user 16 , and user 32 . A resource optimization algorithm allocates upper boundaries of 50% total bandwidth for the 1 st priority user, 25% for the 2 nd priority user, and 12.5% for each remaining two users.
[0121] The K-Xing 138 may perform a 16-to-16 Hadamard transform (HT) at a clock rate of 8 Mbps. Let us assume that 8-bit per sample as input samples then the Hadamard transform with 8-bit arithmetic operation will be clocked at 1 million clocks per second. As a result, the 16 outputs must also feature with 8-bit samples with a flow rate of 1 million samples per second. Every 4 of the 16 outputs are aggregated by a device performing 4-to-1 TDM muxing 134 at an output flow rate of 4 million samples per second. In addition, the device shall convert the muxed sample stream in the output to a bit stream at a flow rate of 32 Mbps. Thus, in the 4 bit-stream outputs corresponding to MD 1 , MD 16 , MD 17 , and MD 32, each sample shall feature a weighted sum of corresponding samples in D 1 , D 16 , D 17 , and D 32 . Similarly, a selected D 1 sample shall appear and contribute to the corresponding 4 contiguous output samples in each of all 4 output bit-streams (MD 1 , MD 16 , MD 17 , and MD 32 ). The weighting distribution of the selected D 1 sample in the 4 sets of 4 contiguous samples (total 16 samples) shall be one of the 16 wave-front vectors (WFVs) associated with the function of 16-to-16 K-Xing 138 implemented by a 16-to-16 Hadamard transform.
[0122] Among the 4 K-muxed data streams, MD 1 , MD 16 , MD 17 , and MD 32 , a total flow rate of 128 Mbps (32 Mbps*4) is reserved in forward links or a down-stream direction for a PON distribution. The data stream D 1 for the first user with a first priority will get an equivalent flow rate of 64 Mbps, and the data stream D 17 for the 17 th user with a second priority shall feature a flow rate of 32 Mbps. Similarly both the data streams D 16 for the 16 th user and the data streams D 32 for the 32 nd user feature a third priority. Each will get an equivalent flow rate of 16 Mbps.
[0123] Alternatively when we use 64 bit arithmetic operations in the HT, each of the 16 bit stream inputs features a flow rate of 8 Mbps which is considered as a flow of digital samples with a flow rate of 125 K samples per second, or 125 KSps, with 64 bits per sample or 8 bytes per sample. The corresponding K-demuxing 140 not shown in ONUs must feature the same versions of HTs.
[0124] FIG. 3D depicts the functions of K-demuxing 140 in conjunction of ONU 1300 for 4 users. Four post processors 1340 for user 1 , user 16 , user 17 , and user 32 , respectively are shown. Each post processor 1340 comprises an ONU and key functions of K-demuxing 140 . Optical waveforms or optical signals are received, and then demodulated by a demodulator (not shown) to become a bit stream of digital data, which is buffered, and then converted into 4 parallel substreams of digital samples (MD 1 , MD 16 , MD 17 , and MD 32 ) by a device with function of TDM de-mux 1310 with 1 input and 32 outputs. MD 1 , MD 16 , MD 17 , and MD 32 are the outputs from port 1 , port 16 , port 17 and port 32 , respectively. They are also the 4 inputs to a device with function of K-demuxing 140 . The functional diagram from K-demuxing 140 (shown in FIG. 3E ) features inversed flows of the signals in K-muxing 130 in FIG. 3C , dynamically converting and transforming 4 input substreams of [MD 1 , MD 16 , MD 17 , Md 32 ] with an equal data flow rate to 4 substreams of [D 1 , D 16 , D 17 , D 32 ] with various data flow rate. Each of the 4 input is processed by a 1 to 4 TDM demuxing to become 4 substreams.
[0125] For the 1 st user, the 4-to-1 output switch 1320 will be set by a controller to deliver D 1 stream, a right output stream from the 4 outputs of D 1 , D 16 , D 17 , or D 32 . D 1 is flowing at a rate of 64 Mbps. The controlling signals are sent by a central command for the advanced PON. All the calculations have not included the processing overhead.
[0126] Details in one more layer of the K-demuxing 140 in FIG. 3D is illustrated in FIG. 3E . The K-demuxing 140 function comprises three major blocks, (1) 4 sets of 1-4 TDM demuxing 144 , (2) a set of K-transforming or K-Xing 148 performing a 16-to-16 wavefront transformation, and (3) 4 sets of input mapping 132 . A 16-to-16 K-Xing 148 features 16 inputs and 16 outputs. Each input corresponds to 1/16 of a total available bandwidth from a PON fiber network. As a result among 4 concurrent users the total equivalent bandwidth or flow rate is 32 Mbps*4 or 128 Mbps. The granularity for the resource allocation is ¼ of the maximum 32 Mbps flowrate allowed for a subscriber, and is 8 Mbps.
[0127] Each output mapping 142 features configurable functions of N-to-1 TDM muxing with a constant input clocking rate of 8 Mbps, where N is an integer and 16≧N≧1. Its output rate may vary from 8 Mbps to 128 Mbps.
[0128] In addition a controller 146 is used to configure functions of the 4 sets of output mapping 142 according to an embedded programmable algorithm which shall be informed by a command center responsible for the dynamic PON configuration. The program may decide bandwidth resources for individual users according to a priority list among the 4 users for both the input mapping 132 in K-muxing 130 and the output mapping 142 in K-muxing 140 . As an example, a dynamic priority list reads as follows: (1) 1 st priority for user 1 , (2) 2 nd priority for user 17 , and (3) 3 rd priority for user 16 , and user 32 . A resource optimization algorithms allows 50% allocated for the 1 st priority user, 25% for the 2 nd priority user, and 12.5% for each of the two remaining users.
[0129] The 4 inputs to the K-demuxing 140 are MD 1 , MD 16 , MD 17 , and MD 32 . Each sample in the 4 inputs shall feature a weighted sum of corresponding samples in D 1 , D 16 , D 17 , and D 32 to be recovered. Each input is then connected by a device performing 1-to-4 TDM demuxing 144 at a output flow rate of 1 million samples per second, converting the muxed sample stream in a bit stream format at a flow rate of 32 Mbps to 4 outputs of bit stream each at a flow rate of 8 Mbps, or 1 million sample per second assuming 8 bits per sample. There shall be 16 inputs to a device with functions of K-Xing 148 , performing a 16-to-16 Hadamard transform (HT) at a clock rate of 1 M operations per second and converting 16 inputs to 16 outputs. Each of the inputs and outputs is flowing at 8 Mbps. We have assumed that 8-bit per sample as input samples then the Hadamard transform with 8-bit arithmetic operation will be clocked at 1 million clocks per second. As a result, the 16 outputs must also feature with 8-bit samples with a flow rate of 1 million samples per second. The outputs shall feature 16 substreams of separated flows of samples of D 1 , D 16 , D 17 , or D 32 .
[0130] Among the 4 K-muxed data streams, MD 1 , MD 16 , MD 17 , and MD 32 , a total flow rate of 128 Mbps (32 Mbps*4) is reserved in forward links or a down-stream direction for a PON distribution. The data stream D 1 for the first user with a first priority will get an equivalent flow rate of 64 Mbps, and the data stream D 17 for the 17 th user with a second priority shall feature a flow rate of 32 Mbps. Similarly both the data streams D 16 for the 16 th user and the data streams D 32 for the 32 nd user feature a third priority. Each will get an equivalent flow rate of 16 Mbps.
[0131] There are 16 total substreams after going through a Hadamard transform concurrently. There shall be 4 output mapping 142 functions in parallel. The first output mapping shall convert n 1 substreams to a D 1 stream, where n 1 =8 in this example. Similarly, the 2 nd , 3 rd , and 4 th output mapping shall respectively convert n 2 , n 3 , and n 4 substreams to D 16 , D 17 and D 32 data streams. In this example n 2 =4, n 3 =n 4 =2. The 4 sets of output mapping are controlled by a controller 146 .
Embodiment 3
[0132] FIG. 4 depicts the same functional blocks as those in FIG. 2 , except in the user side. The updated user processor 3100 comprises two smart array antennas; a first one for picocell hub 2110 and a second one for a WiFi hub 2130 . The picocells are also referred to as small cells. 4 antenna array elements 2232 for the picocell hub 2120 are connected to a device for function of digital beam forming (DBF) 3120 . A first smart array is formed by the 4 elements 2232 and a first one (DBF 1 ) of the DBF 3120 for the Picocell hub 2120 .
[0133] The first smart array shall operate on a cell phone band, connecting multiple cell phones 2236 to the picocell hub 2120 concurrently over a common fields of view 2234 . The smart array may form concurrent tracking beams with orthogonal beam patterns. For three cell phones 2236 , the smart array shall automatically form three concurrent beams. The first beam shall be dynamically optimized following current position of a first cellphone with a beam peak at a first user direction while steering a first and a second nulls, respectively, to the directions of the 2 nd and the 3 rd users. As a result, the transmitted signals intended for the first cellphone in forward direction is maximized in the first cellphone direction, and will not reach the second and the third cellphones. In receive, the received signals feature maximized sensitivity in the intended first cellphone direction, and minimized sensitivity (or zero response) at the directions of the second and the third cellphones.
[0134] By the same principles, a 2 nd beam shall be dynamically optimized following current position of the 2 nd cellphone with a beam peak at its direction while steering a first and a second nulls, respectively, to the directions of the 1 st and the 3 rd cellphones. As a result, the transmitted signals intended for the 2 nd cellphone in forward direction is maximized in its direction, and will not reach the 1 st and the 3 rd cellphones. In receive, the received signals feature maximized sensitivity in the intended 2 nd cellphone direction, and minimized sensitivity (or zero response) at the directions of the first and the third cellphones.
[0135] For the concurrent 3rd beam, it shall be dynamically optimized following current position of the 3 rd cellphone with a beam peak at its direction while steering a first and a second nulls, respectively, to the directions of the 1 st and the 2 nd cellphones. As a result, the transmitted signals intended for the 3 rd cellphone in forward direction is maximized in its direction, and will not reach the 1 st and the 2 nd cellphones. In receive, the received signals feature maximized sensitivity in the intended 3 rd cellphone direction, and minimized sensitivity (or zero response) at the directions of the first and the second cellphones.
[0136] As a result of the first of the DBF 3120 , DBF 1 , forming three tracking beams with OB patterns, the same frequency slot may be reused by three folds or 3× reused.
[0137] 4 array elements 2132 for the WiFi hub 2130 are connected to a device (DBF 2 ) for DBF functions. A second smart array is form by the 4 elements 2132 and a second one of the DBF 3120 for the WiFi hub 2130 . The 2 nd smart antenna shall operate on a WiFi band, connecting to multiple user devices such as notebooks 2136 concurrently over a second common fields of view 2134 . The 2 nd smart array may also form concurrent tracking beams with orthogonal beam patterns. For two notebooks, the smart array shall automatically form two concurrent beams. The first beam shall be dynamically optimized following current position of a first notebook with a beam peak at a first user direction while steering a first null, respectively, to the direction of the 2 nd notebook. As a result, the transmitted signals intended for the first notebook in forward direction is maximized in the first notebook direction, and will not reach the second notebook. In receive, the received signals feature maximized sensitivity in the intended first notebook direction, and minimized sensitivity (or zero response) at the direction of the second notebook.
[0138] By the same principles, a 2 nd beam shall be dynamically optimized following current position of the 2 nd notebook with a beam peak at its direction while steering a first null to the direction of the 1 st notebook. As a result, the transmitted signals intended for the 2 nd notebook in forward direction is maximized in its direction, and will not reach the 1 st notebook. In receive, the received signals feature maximized sensitivity in the intended 2 nd notebook direction, and minimized sensitivity (or zero response) at the directions of the first and the notebook.
[0139] FIG. 4A depicts three cellphone inputs (s p1 , s p2 , and s p3 ) and two other IP input streams (s w1 and s w2 ) as part of aggregated data input D 2 for the second user at the headend via a network 1182 of a set of routers 2110 before the OLT 1200 . D 2 data stream after the PON network 1100 is delivered to the updated user processor 3100 . We shall use the following formula to represent aggregated signals; s p , s w , and D 2
[0000] S p =[s p1 ,s p2 ,s p3 ] (3-1)
[0000] s w =[s w1 ,s w2 ] (3-2)
[0000] and D 2=[ s p ,s w , . . . ] (3-3)
[0140] An aggregated signal stream, s p , comprises three cell phone data streams, s p1 , s p2 , s p3 , where s p1 for a first cellphone, s p2 for a 2 nd cellphone, s p3 for a 3 rd cellphone. These signals are delivered to the cell phones via three shaped beams with OB patterns, which are continuously optimized by the DBF 1 tracking all cellphone positions with a first common field of view 2234 . They are re-radiated using cell phone bands.
[0141] For advanced applications in another embodiment, we may take advantages of 3× frequency reuse potential to concurrently deliver three independent information sets to three cell phones via the 3 shaped beams with OB patterns in a common frequency slot.
[0142] Similarly, another aggregated signal stream, s w , comprises two IP data streams, s w1 , s w2 , where s w1 for a first of the two notebooks 2136 , s w2 for a 2 nd of the notebooks 2136 within a second common field of view 2134 using same frequency slot in WiFi band. It can achieve a 2× frequency reuse. These signals are delivered to the notebooks 2136 via two shaped beams with OB patterns, which are continuously optimized by the DBF 2 tracking all notebooks.
[0143] In this configuration, the flow rate in PON 1100 features 1 Gbps throughput total for 32 potential users. The maximum flow rate of the D 2 stream for the second user is fixed at ˜32 Mbps. FIG. 5 will depict other embodiments which can operate PON for D 2 data stream associated with the same second user to exceed the maximum flow rate of ˜32 Mbps.
Embodiment 4
[0144] FIG. 5 depicts a PON with K-muxing configuration 1180 in conjunction with the DBF 3120 in a user processor 3100 . The PON with K-muxing configuration 1180 comprises of a PON 1100 and a K-muxing 130 which enables D 2 data stream associated with the same second user to exceed a maximum flow rate of ˜32 Mbps. A network 1182 for D 2 data stream for the second user identical to that as shown in FIG. 4A may comprise inputs (s p1 , s p2 , and s p3 ) for three cell phones 2236 , and those (s w1 and s w2 ) for the two notebooks 2136 before the k-muxing 130 . The functions of K-muxing 130 have been shown extensively in FIG. 3 and FIG. 3B . We will not repeat them in here again.
[0145] In short the K-muxing 130 enables the D 2 stream being delivered to the user processor 3100 via unused and available bandwidth asset in the PON 1100 . The delivery flow rate which may exceed an upper limit set by the time slots by the TDM mux 1210 in the OLT 1200 .
[0146] The functions of K-muxing 130 , in general, may be implemented by software in a hosting processor for better flexibility, by additional hardware for faster processing speed to the hosting processor, or by combinations of the above for compromised performance with flexibility and speed.
[0147] FIG. 5A depicts functions of updated ONUs 1340 , each of which comprises of a regular ONU 1300 and a K-demuxing 140 . The functions of K-demuxing 140 have been shown extensively in FIG. 3A and FIG. 3D . We will not repeat them in here again. In addition, updated ONUs 1340 feature same functions as those in FIG. 3A or those in FIG. 3D .
Embodiment 5
[0148] FIG. 6 depicts a configuration of PON in conjunctions of using remote digital beam forming. A first remote digital beam forming RDBF 6102 A is for cell phone signals (s p1 , s p2 , and s p3 ) to be delivered to three cellphones 2236 , respectively through three tracking beams which are radiated by the four array elements 2232 . The radiations feature dynamic OB beam patterns following the three slow moving cellphones over a first common field of view 2234 . The RDBF 1 6102 A shall feature three inputs and one muxed output, spe, which comprises 4 element signal components to be radiated by the four radiating element 2232 for the cellphone hub 2120 . Each element signals comprises of a sum of weighted signals for three cell phone signals (s p1 , s p2 , and s p3 ). s p′s stands for all three sets of s p signals.
[0149] Similarly, the RDBF 2 6102 B shall feature two inputs and one muxed output, swe, which comprises 4 element signal components to be radiated by the four radiating elements 2132 for a WiFi hub 2130 .
[0150] There are two input sample streams s w1 and s w2 for the DBF in RDBF 2 6102 A. Each is replicated 4 times and then weighted individually by a beam weight vector (BWV) with 4 components. The 4 outputs feature sums of the two weighted inputs.
[0000] E 1= w 11* s w1 +w 12* s w2 (3a)
[0000] E 2= w 21* s w1 +w 22* s w2 (3b)
[0000] E 3= w 31* s w1 +w 32* s w2 (3c)
[0000] E 4= w 41* s w1 +w 42* s w2 (3d)
[0151] The two BWV's for the two beams featuring dynamic tracking capability with OB radiation patterns are represented as follows:
[0000] BWV 1=[ w 11, w 21, w 31, w 41] T (4a)
[0000] BWV 2=[ w 12, w 22, w 32, w 42] T (4b)
[0152] The four element signal streams (E 1 to E 4 ) are then FDM muxed into a single output swe.
[0153] As indicated in equations (3), each element signals comprises of a sum of weighted signals for two notebook signals (s w1 , and s w2 ), which will be delivered to the two notebooks 2136 , respectively through two tracking beams. These tracking beams are radiated by the four WiFi array elements 2132 . The radiations feature dynamic OB beam patterns following the two re-locatable notebooks over a second common field of view 2134 . The first FOV 2234 and the second FOV 2134 may have very significant overlaps in coverage.
[0154] The two muxed outputs, spe from RDBF 1 6102 A and swe from RDBF 2 6102 B, along with others such as s 2 c depicted in the Figure are multiplexed again by a muxing device 6104 before sent to s 2 input of the K-muxing 130 .
[0155] It is notice that we have used (s 1 , s 2 , s 3 , . . . , s 32 ) in here instead of (D 1 , D 2 , D 3 , . . . , D 32 ) in previous figures to indicate the inputs of the K-muxing 130 are signal samples (in waveform domain or after modulation in transmission), and not data samples (in information domain or before modulation in transmission). The K-muxing 130 as a part of preprocessing in the OLT 1200 shall operate in a coherent mode processing samples of signal waveforms or signals in the TDM optical channels.
[0156] The PON 1180 shall be operating in a mode of Radio Frequency over Glass (RFoG). The TDM mux 1210 will convert 32 parallel signal sample streams into one muxed sample stream. The mixer 1220 will function as for a heterodyne up-converter to optical frequency band. The laser 1230 will provide an optical carrier.
[0157] Differential amplitude variations and phase delays among the optical channels shall be calibrated, and compensated dynamically. Calibration and compensations are part of equalization process which can be done continuously and iteratively optimized. It may also be implemented periodically via matrix inversion optimization. The optimization for dynamic equalization may be implemented in the headend 6100 or user ends as a part of upgraded ONU's 6300 . As a result, the equalized multiple channels can be used to transport element signals to be radiated coherently from a first remote digital beam forming 6102 A to a set of radiating element 2232 of an array for transmission of cell phone signals over a common field of view 2234 in a user facility via the user processor 3100 .
[0158] In the user processor 3100 , a demuxing device 2110 shall perform inverse functions of functions of the muxing device 6104 in the headend 6100 , separating the signal flows of spe, swe, and s 2 c . The picocell hub 2120 shall receive a first muxed 4-element signal stream, spe, which is connected to one of the two FDM demux 6510 and being converted to 4 element signal streams. These element signals streams are then sent to the 4 radiating elements 2232 respectively. Concurrently the WiFi hub 2130 shall receive a second muxed 4-element signal stream, swe, which is connected to one of the two FDM demux 6510 for conversion to 4 element signal streams. These element signals streams are then sent to the 4 radiating elements 2132 respectively.
[0159] The multiple beam coverage in the first common FOV 2234 for three cellphone 2236 and the second common FOV 2134 for the two notebooks 2136 have been discussed in previous FIG. 4 and FIG. 5 . We will not repeat the details in here again.
[0160] The K-muxing 130 is operating on signal samples over multiple TDM optical channels. Similarly the K-demuxing in updated ONUs 6300 shall also feature processing on signal samples among multiple optical TDM channels. FIG. 6A depicts the K-demuxing 140 for coherent operation in 3 updated ONU's 6300 : ONU 1 , ONU 16 , and ONU 32 . In one of the ONU's 6300 , say ONU 1 , k-muxed signal streams transported by multiple channels of a PON 1100 are recovered by a device performing TDM demux 1310 . The outputs are dynamically equalized by an equalization, calibrating and compensating differentials of amplitude variations and phase delays among propagating signals through the multiple TDM channels. Signals from the 32 equalized channels are then sent to a device performing K-demuxing 140 with 32 outputs. The first of the 32 output is selected by a switch 1320 and delivered as the output of ONU 1 .
[0161] The optimization techniques have been discussed extensively in the reference of U.S. Pat. Appl. Pub. No. 20130223840. Optimization inputs may be replications of some of normal outputs of the K-demuxing 140 . In addition, when s 1 , s 16 , and s 32 for the 3 users are uncorrelated at the headend, it is also possible to use correlations among these three received signals at a user end, detecting “leakages” thus indications of un-equalized propagation channels. These leakages may be used as performance “cost” in optimization schemes which features cost minimization to achieve fine tuning of equalizations of amplitude variations and phase delays among multiple dynamic propagation channels.
Embodiment 6
[0162] FIG. 7 depicts a down-stream, or a forward link, functional block diagram for small cells and remote DBF via PON for multiple house-holds using identical functional blocks as those in FIG. 6 . In the downstream direction, the OLT 1200 continuously transmits (or may burst transmit). ONUs see their own data through the address labels embedded in the signal. The block diagram is for delivering three digital cell phone data streams (s p1 , s p2 , and s p3 ), including digital voices, from a headend 6100 to three cellphones 2236 - 1 to 2236 - 3 , respectively over a coverage area 7234 .
[0163] The three cellphone data streams (s p1 , s p2 , and s p3 ) are sent to a remote digital beam forming processor, RDBF 1 6102 A, which calculates and implements weighted sums for three concurrent beams to be radiated by the radiating elements associated with the 4 post-processors, 7232 - 1 to 7232 - 4 , over households of 4 customers.
[0164] The associated element signals implemented by the RDBF 1 6102 A for the 4 radiating elements associated with the 4 post processors 7232 - 1 to 7232 - 4 are as followed;
[0000] Ep 1= w 11* s p1 +w 12* s p2 +w 13* s p3 (5a)
[0000] Ep 2= w 21* s p1 +w 22* s p2 +w 23* s p3 (5b)
[0000] Ep 3= w 31* s p1 +w 32* s p2 +w 33* s p3 (5c)
[0000] Ep 4= w 41* s p1 +w 42* s p2 +w 43* s p3 (5d)
[0165] The three BWV's for the three beams featuring dynamic tracking capability with OB radiation patterns are represented as follows;
[0000] BWV 1=[ w 11, w 21, w 31, w 41] T (6a)
[0000] BWV 2=[ w 12, w 22, w 32, w 42] T (6b)
[0000] BWV 3=[ w 13, w 23, w 33, w 43] T (6c)
[0166] Each element signal is sent to a corresponding input of a K-muxing 130 which features N-inputs and N-outputs where N=4. The K-muxing 130 features similar functional blocks as the ones in FIG. 3C . The 4 outputs are sent to 4 of the 32 inputs of a 32-to-1 TDM muxing in the OLT 1200 (please see FIG. 3B ). The element signals are embedded in an optical signal stream propagating trough the fiber 1160 .
[0167] A passive fiber network comprises (1) a first fiber segment 1160 connected between an OLT 1200 and a passive divider 1150 , (2) second fiber segments connected to a passive divider 1150 to a ONU, and (3) third fiber segments connected between passive dividers 1150 .
[0168] In the downstream direction, the OLT 1200 continuously transmits optical signal streams. Individual ONUs see their own data through the address labels embedded in the signal. Corresponding post processors 7232 - 1 to 7232 - 4 shall recover the element signal streams in RF, which will then be conditioned (amplified and filtered), converted to a desired frequency slot in cellphone band, power amplified, before being sent to respective antenna element for radiation.
[0169] These four elements are usually separated by a large distance (>10 m or in terms of 50's or even 500's of cell-band wavelengths) from one another, forming an array by the RDBF 1 6120 A for a clean connection to a first cellphone 2236 - 1 , that for a second cellphones 2236 - 2 , and that for a third cellphone 2236 - 3 over a coverage area 7234 in near fields. The coverage area 7234 shall include 4 field-of-views (FOVs) of the four individual elements: a first element FOV 2234 - 1 , a second element FOV 2234 - 2 , a third element FOV 2234 - 3 , and a fourth element FOV 2234 - 4 .
[0170] Each of the 4 post processors 7232 comprises an updated ONU 6300 , a picocell hub 2120 , and a cell antenna 2232 . These are identical to the ones shown in FIG. 6 .
[0171] A first dynamically shaped beam is for the 1st cellphone 2236 - 1 and shall feature a tracking beam peak at the location of the 1 st cellphone with two tracking nulls at the locations of the 2 nd and the 3 rd cellphones. Similarly, a 2 nd dynamically shaped beam shall feature a tracking beam peak at the location of the 2 nd cellphone 2236 - 2 with two tracking nulls at the locations of the 1 st and the 3 rd cellphones 2236 - 1 and 2236 - 3 . In addition, a 3 rd dynamically shaped beam shall feature a tracking beam peak at the location of the 3 rd cellphone 2236 - 3 with two tracking nulls at the locations of the 1 st and the 2 nd cellphones 2236 - 1 and 2236 - 2 . The three dynamic shaped beams operated in a same frequency slot, featuring 3× frequency reuse, shall have very little mutual interferences.
[0172] In the upstream direction (not shown), each ONU burst transmits for an assigned time-slot (multiplexed in the time domain). In this way, the OLT is receiving signals from only one ONU or ONT at any point in time. However, with a K-demuxing 140 , which features 4 inputs and 4 outputs, in place for the headend 6100 , the OLT shall be receiving signals from only one ONU at most point in time, but shall be capturing 4 muxed signals from 4 participating ONUs at assigned 4 time slots, assuming the lasers for the 4 ONUs emitting in an identical optical wavelength.
[0173] When the lasers for the 4 ONUs emitting in different optical wavelength, there shall have multiple optical spectrum lines in assigned received time slots. Each modulated optical line in the spectrum shall be associated to a specific ONU. Additional processing using advanced, filtering techniques are required to separate the modulating RF signals for individual optical wavelength. Thus RF signal streams from individual ONUs are captured separately for further processing. | Four independent technologies are incorporated in this invention to efficiently and cost effectively implement dynamic last mile connectivity. The four technologies are passive optical networks (PON), Small cell, wavefront multiplexing (or K-muxing), and digital beam forming (DBF). We have filed US patents for communications architectures featuring K-muxing overlaid over low cost of PON. Those inventions relate particularly to resource allocation in passive optical networks (PON) via wavefront multiplexing (WF-muxing or K-muxing) and wavefront demultiplexing (WF-demuxing or K-demuxing). The “WF-muxing in PON” can be configured for performing remote digital beam forming (RDBF) over a service area covered by multiple small cells. The RDBF may generate multiple shaped beams with enhanced connectivity and better isolations over a same frequency slot concurrently to serve multiple users over the coverage area. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit under 35 U.S.C. §119(a) of German Patent Application No. 10 2010 016 814.9, filed May 5, 2010, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method for introducing solder onto a workpiece, preferably onto a semiconductor device such as a solar cell, wherein solder is applied in the molten state onto the workpiece under ultrasonic action with the use of a solder wire. Further, the invention relates to a device for introducing solder onto a workpiece, in particular onto a semiconductor device such as a solar cell, comprising a solder-wire introduction means, a heating means for the solder wire, an ultrasonic sonotrode as well as a transport means for the transport of the workpiece relative to both the heating means as well as the ultrasonic sonotrode, wherein the solder wire is melted in a heating zone associated with the heating means.
[0004] 2. Description of Related Art
[0005] A method for introducing a connecting conductor onto a solar cell, in which a solder is applied onto the solar cell by means of ultrasonic soldering, is known from WO-A-2008/014900 (DE-A-10 2006 035 626). In this case, the solder in the form of a solder wire or solder preforms is soldered on at the soldering temperature by means of an ultrasonic sonotrode.
[0006] The soldering of solder onto solar cells, in particular by means of ultrasound has the advantage that a fluxing agent does not need to be used, whereby if it had to be used, the danger of damage to the solar cell would increase. Due to the ultrasonic action, oxide layers present on the solar cells are broken up, in order to assure a mechanically solid and electrically well-conducting joint between the solder and the corresponding metal layer of the solar cell. This is particular of advantage when the metal layer involves an aluminum layer such as a back-surface contact composed of aluminum.
[0007] Corresponding ultrasound soldering methods are also taken from, e.g., U.S. Pat. No. 6,357,649 or the reference Mardesich et al.: “A Low-Cost Photovoltaic Cell Process Based on Thick Film Techniques”; 14th IEEE PV, Sp. Conf. Proc., 1980, pp. 943-947.
BRIEF SUMMARY OF THE INVENTION
[0008] The problem of the present invention is to enhance a method and a device of the type named initially, so that the solder is introduced very precisely onto the workpiece without subjecting the workpiece to undesirably high temperatures.
[0009] In order to solve the problem, it is essentially proposed according to the method that the solder wire is introduced in a gap running between a heating means and a sonotrode producing ultrasonic vibrations, is melted in the gap, and flows through the gap onto the workpiece.
[0010] Unlike the prior art, the solder material is not guided through a heating means and then delivered through an opening in order to solder the workpiece via ultrasonic action, which can also be designated “soldering on”. Rather, the solder wire is introduced into a free gap on the side, whereby the width of the gap is predetermined by the distance between heating means and sonotrode. Here, the gap between the sonotrode and the heating means is preferably designed in such a way that it has a width B that is preferably approximately ½D≦B≦D with D=the diameter of the solder wire.
[0011] According to the invention, not only is the heating means heated to a temperature above the melting point of the solder wire, but the sonotrode is also, the temperature adjustment being made independently in each case.
[0012] Since the gap is bounded by the sonotrode excited to longitudinal vibration, despite the high surface tension that the molten solder possesses, the solder is pulled through the gap. In this respect, the gap exercises roughly a capillary effect.
[0013] Due to the provision provided in this respect, there particularly also results the advantage that conventional solder materials can be successfully used as the basis for the soldering of workpieces, in particular solar cells, materials such as those based on tin-zinc, tin-silver, or even of pure tin.
[0014] It is provided in an enhancement that operation is conducted at a low sonotrode frequency, preferably in the range between 10 kHz and 40 kHz, in order to avoid a shunting of the surface layer, such as an SiN x layer, running on the top surface of a solar cell. Further, it is particularly provided that the lengthwise axis of the sonotrode encloses an angle of <90° relative to the normal line proceeding from the surface of the workpiece such as a solar cell, so that a completely horizontal alignment, thus a horizontal coupling is possible.
[0015] Further, there exists the possibility of allowing the sonotrode vibration to deviate from the resonance frequency in a targeted manner. This can be carried out by off-tuning the sonotrode or by employing a sonotrode length that deviates from a whole-number λ/2, λ being the amplitude of the ultrasonic vibration.
[0016] The rate of application of the solder should lie in the range between 0.1 millimeter per second (mm/sec) and 200 mm/sec, in particular between 20 mm/sec and 80 mm/sec.
[0017] In addition, there is the possibility of introducing solder strips that exercise the function of busbars, which are commonly applied onto solar cells, by means of the method according to the invention. Thus, there is the possibility of introducing, e.g., two or more busbars, preferably of tin, onto the front side of a solar cell. The solder tracks exercising the function of busbars should thus have widths between 0.5 millimeters (mm) and 15 mm, preferably in the range of 2 mm.
[0018] In order to achieve a sufficient process stability, it is further provided that the ultrasound system used is continuously active, thus the sonotrode constantly vibrates, in order to avoid deviations in resonance that may occur in actuating the ultrasound system. A continuous vibrational excitation additionally has the advantage that solder-caused wetting properties are stabilized in the heating zone between the heating means and the sonotrode.
[0019] In addition, it is particularly advantageous that an encrustation can be eliminated without problem in the region where the molten solder is introduced by cleaning the gap by providing a blow-off pulse after soldering one workpiece or a predetermined number of workpieces. This cleaning is then carried out when the device comprising the heating means and the sonotrode is raised, so as to position a new workpiece in the region of the sonotrode.
[0020] The blowing off can be particularly carried out by employing a gas such as N 2 , air, argon or other suitable inert gases. However, a rinsing with a liquid may also be carried out.
[0021] Alternatively or in addition, a cleaning means can be provided, in order to free the gap between the sonotrode and the heating means from e.g., solder-caused encrustrations, for example, by employing rotating brushes or other suitable elements. There is also the possibility of setting up a suction means in order to remove contaminants.
[0022] In another embodiment of the invention, a block-shaped unit having a high heating capacity is used as the heating means, which assures that a desired, uniform temperature prevails in the region of the gap. In this case, the block-shaped or cuboid-shaped heating unit can be aligned relative to the sonotrode in such a way that the longitudinal axis of the heating unit encloses an acute angle of up to 20°, preferably in the range of 0° to 5°, relative to the surface of the workpiece, proceeding from the end near the sonotrode. In this way, it is assured that an undesired heating of the workpiece is absent, since the bottom of the heating unit is inclined relative to the surface of the workpiece, in order to achieve a sufficient distance.
[0023] The gap is preferably bounded by a heating-unit projection that is shaped like a cylinder segment, wherein the gap may have the same crosswise dimension over its height—crosswise to the direction of application of the solder—and in the direction of the workpiece may expand conically, thus in the direction of application of the solder. A constant width over half of the gap is likewise possible.
[0024] A device of the type named initially is characterized in that the heating zone comprises a gap that is bounded by the heating means and the ultrasonic sonotrode, the gap being the introduction for the solder to the workpiece. It is particularly provided that the gap between the sonotrode and the heating means preferably has a width B with ½D≦B≦D, wherein D=the diameter of the solder wire.
[0025] The gap may have a constant width over its height. There is also the possibility, however, that the gap can be conically expanded in the direction of the workpiece.
[0026] The heating means in particular involves a cuboid-shaped unit which can be equipped with heating cartridges and which has a sonotrode-side projection that particularly possesses a cylindrical as well as a semi-cylindrical geometry.
[0027] In addition, the block-shaped or cuboid-shaped heating unit is preferably aligned relative to the workpiece such that, proceeding from the sonotrode, the bottom of the heating means relative to the workpiece encloses an acute angle, which can amount to approximately 20°. Preferably, the angle should lie between 0° and 5°. In this way, there is a distancing between the heating means and the workpiece with the consequence that the latter is not heated in an undesired manner.
[0028] The sonotrode, which also is heated to a temperature above the melting point of the solder material, is additionally surrounded by a thermally insulating tube, such as a ceramic tube, above the heating means.
[0029] In addition, a cleaning means is provided, by means of which a blow-off pulse is provided for cleaning the heating zone, thus the gap region. Liquid or gas such as N 2 , air, argon or another inert gas can be utilized as the cleaning medium.
[0030] Alternatively or additionally, there is the possibility of assigning a cleaning means to the sonotrode and to the heating means in order to clean the gap or the heating zone. Thus, solder-caused encrustations between the heating means or the heating unit and the sonotrode can be removed without problem.
[0031] Solder-caused contaminations may also be removed by means of a suction device.
[0032] Other details, advantages and features of the invention result not only from the specific embodiments described herein, but also from the features to be derived therefrom—taken alone and/or in combination—but also from the following description of a preferred example of embodiment to be taken from the drawing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0033] FIG. 1 shows a section of a device for introducing a solder material onto a workpiece.
[0034] FIG. 2 shows the section of the device according to FIG. 1 rotated by 90°.
[0035] FIG. 3 shows the section of the device according to FIGS. 1 and 2 in a bottom view.
[0036] FIG. 4 shows an excerpt from FIG. 3 in an enlarged representation.
[0037] FIG. 5 shows representations of the principle in question with solder material of a wetted and a non-wetted gap.
DETAILED DESCRIPTION OF THE INVENTION
[0038] A section or details of a device by means of which a preferably strip-shaped solder strip is introduced onto a workpiece 10 can be taken from the figures. Workpiece 10 particularly involves a semiconductor device such as a solar cell, in order to solder electrical contacts, for example, onto it after introducing the solder material. In this case, cell connectors may be involved.
[0039] The solder material can be introduced in such a way that solder strips are formed, which exercise the function of busbars that are introduced onto the solar cell and are, in particular, connected to current collectors (grid fingers).
[0040] In order to introduce the solder onto workpiece 10 , solder wire 12 is introduced into a heating zone 14 by a solder-wire introduction means (not shown), the heating zone running between a heating means 16 and a sonotrode 18 of an ultrasound device.
[0041] In the figures, sonotrode 18 , which has a rod geometry, is surrounded by a ceramic tube 20 having a heating coil, above heating means 16 , in order to heat the sonotrode to a temperature above the melting point of the solder material. Sonotrode 18 further proceeds in the known way from an ultrasonic transducer 22 , by means of which sonotrode 18 is excited to ultrasonic vibrations in the range between 10 kHz and 80 kHz, particularly between 10 kHz and 40 kHz, just to name numbers by way of example.
[0042] In the example of embodiment, heating means 16 involves a cuboid or block-type heating unit 17 , which is equipped with heating cartridges. Thus, heating unit 17 has a high heat capacity in order to assure the desired constant temperatures in the region of heating zone 14 .
[0043] Solder wire 12 is introduced into heating zone 14 , and, in fact, is introduced obliquely from the side in the example of embodiment, as is illustrated in principle by comparing the figures. However, the teaching according to the invention will not be limited hereby.
[0044] According to the invention, heating zone 14 has a gap 24 , which is bounded on one side by sonotrode 18 and on the other side by a preferably semicylindrically-shaped projection 26 of heating means 16 or of heating unit 17 , as results from FIGS. 3 and 4 . Of course, it is not absolutely necessary that the heating unit 17 has a corresponding projection. Rather, on the sonotrode side, the heating unit 17 may have a flat surface, which likewise bounds a corresponding gap.
[0045] Preferably, however, projection 26 , which may also possess a geometry having a circular section that differs, however, from that derived from the drawing, extends from the surface of heating unit 17 facing sonotrode 18 .
[0046] As is illustrated in FIG. 4 , the gap width B, thus the clearance between sonotrode 18 and projection 26 is selected in such a way that it preferably lies between ½D and D with D=diameter of the solder wire. The width B extends in the direction of application of solder 10 onto the workpiece, thus in the plane of the drawing in FIG. 1 and parallel to the segment of workpiece 10 that is shown. The width B may be constant or may expand conically in the direction of the workpiece.
[0047] Both heating unit 17 as well as sonotrode 18 are adjusted to a temperature that lies above the melting point of solder wire 12 . Preferably, solder material is used which melts in the range between 100 degrees Celsius (° C.) and 350° C., although the temperature range may lie between 80° C. and 600° C. The temperature adjustment of heating unit 17 is thus made in the region of its projection 26 , independently of the adjustment of the temperature of sonotrode 18 .
[0048] According to the invention, solder wire 12 is introduced into gap 24 in heating zone 14 . The solder wire melts in this way. Despite the high surface tension, a wetting of the boundary of gap 24 is produced (see the representation on the right in FIG. 5 ) due to the sonotrode 18 excited to ultrasonic vibration, with the consequence that the molten solder flows through gap 24 onto the surface of workpiece 10 and then the solder introduced onto workpiece 10 is loaded with ultrasound [vibration] via the flat front surface 28 of sonotrode 18 , this surface facing workpiece 10 , in order to assure the soldering of workpiece 10 . The vibration antinode of the excited sonotrode 18 runs in the region of the front surface 28 .
[0049] The molten solder is shown for sonotrode 18 that is not placed in vibration in the representation on the left in FIG. 5 .
[0050] As results from FIGS. 1 and 2 , the cuboid-shaped or block-type heating unit 17 is aligned to the workpiece surface by its bottom 30 in such a way that, proceeding from sonotrode 18 , an acute angle α results, which should lie between 0° and 20°, in particular between 0° and 5°. In this way, it is additionally assured that workpiece 10 is not heated in an undesired manner via heating unit 17 .
[0051] The gap 24 may have a constant width over its height. There is also the possibility, however, that the gap is increased in the direction of workpiece 10 , in particular, if the region of gap 24 , which is bounded by heating unit 17 , extends perpendicular to bottom 30 of heating unit 17 .
[0052] In addition, it is provided according to the invention that with the use of a cleaning means (not shown), after removing the ultrasound device with heating means 16 , a blow-off pulse is delivered for cleaning the gap region. In this case, a gas or a liquid may be used, which loads the gap region in pulse-like manner, so that solder-caused encrustations are removed.
[0053] Alternatively or in addition, a mechanical cleaning means can be provided, in order to remove solder-caused encrustations. In this case, these involve rotating brushes or other equally acting elements that make possible a removal of encrustations.
[0054] Further, a suction device may be provided in order to be able to collect or suction off solder-caused contaminations.
[0055] In order to achieve process stability, the sonotrode may remain continuously excited, even when a solder wire is not introduced. In this way, it is assured that resonance deviations will be avoided. Also, solder-caused wetting properties are stabilized in the gap.
[0056] The rate of application of the solder onto workpiece 10 should lie in the range between 2 mm and 200 mm/sec, preferably between 20 mm and 80 mm/sec.
[0057] Although the longitudinal direction of the sonotrode is aligned along the normal line proceeding from workpiece 10 in the example of embodiment, other angles are also possible. In particular, an oblique coupling of the ultrasound is possible. This means that the longitudinal axis of sonotrode 18 relative to the normal line proceeding from workpiece 10 encloses an angle of >0°. In this case, an alignment parallel to the surface of workpiece 10 may result optionally. The sonotrode tip or the associated surface of heating unit 17 must be designed correspondingly, in order to make available the necessary gap for the solder wire.
[0058] The invention also includes the circumstance when a targeted deviation of the resonance frequency is provided, e.g., by off-tuning sonotrode 18 or by employing a sonotrode 18 of a length that deviates from a whole-number λ/2 with λ=amplitude.
[0059] In the region of the gap, sonotrode 18 should have a cylindrical geometry with a diameter that lies between 0.5 mm and 4 mm, preferably between 1 mm and 2 mm. | A method and a device for introducing solder onto a solar cell is provided. The method and device employ a solder wire introduced in the molten state onto the solar cell under the action of ultrasonic vibrations applied by a sonotrode. Solder is introduced very precisely onto the solar cell, without subjecting the solar cell to undesirably high temperatures, by introducing the solder wire into a gap running between a heating device and the sonotrode, which applies ultrasonic vibrations and melts and flows through the gap onto the solar cell. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
None.
TECHNICAL FIELD
The present invention relates to a system for cable attachment. More particularly, it relates to applications where an electrical cable, hose, or hydraulic line must be attached to a rigid member.
BACKGROUND
A tie wrap is a common way to attach an electrical cable, hose, or hydraulic line to a rigid member, such as a pipe or a structural beam. Most of the electrical cables, hoses, or hydraulic lines have a smooth finish. With a tie wrap alone, it must be fastened extremely tight to prevent movement and slippage of the cable, hose, or hydraulic line. Due to the tightness required to prevent slippage, the tie wrap can cause the cable, hose, or hydraulic line to be badly deformed and can actually damage the cable, hose, or hydraulic line. Many times the attachment is in a wet location or even under water, which increases the chance of slippage. The friction between the cable, hose, or hydraulic line and the rigid member is not great enough to prevent slippage.
Cable attachment devices in the prior art, such as a tie wrap, have another significant shortcoming. The prior art devices lack any vibration damping characteristics, and thus vibration from the rigid member is transferred to the cable, hose, or hydraulic line causing mechanical wear and damage.
There is a need in the art for a device that can increase the friction without over tightening of the fastener (e.g., the tie wrap). There is a need for a device to hold the cable, hose, or hydraulic line in position and provide a high-friction support to eliminate slippage. There is a further need in the art for a device that acts as a shock absorber to minimize vibration damage to the cable, hose, or hydraulic line during operation.
BRIEF SUMMARY
The present invention is a cable attachment method and device used with a fastener to secure a cable, hose, or hydraulic line to a rigid member to prevent slippage. In one embodiment, the device includes a soft, flexible, cylindrical body having a longitudinal bore configured to accept a fastener. The cylindrical body has at least one opening located near a longitudinal midpoint, which is configured to accept and support the cable.
While two embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, wherein is shown and described only the embodiments of the invention, by way of illustration, of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a side view of a cable attachment device according to a first embodiment of the present invention.
FIG. 1B is a perspective view of a cable attachment device according to a first embodiment of the present invention.
FIG. 2 is a perspective view of the cable attachment device of FIG. 1A with a cable and a fastener.
FIG. 3 is a perspective view of the cable attachment device of FIG. 1A, in operation.
FIG. 4 is a perspective view of a cable attachment device according to a second embodiment of the present invention.
FIG. 5 is a perspective view of the cable attachment device of FIG. 4, in operation.
DETAILED DESCRIPTION
FIG. 1A is a side view and FIG. 1B is a perspective view of a cable attachment device 10 according to a first embodiment of the present invention. As shown in FIGS. 1A and 1B, the cable attachment device 10 includes a body 12 with a proximal opening 14 a at a first end and a distal opening 14 b at a second end. The proximal opening 14 a and the distal opening 14 b are connected by a longitudinal bore. In one embodiment, the body 12 has a lateral cross-section that is cylindrical in shape. In another embodiment, the lateral cross-section is square-shaped. In another embodiment, the lateral cross-section is triangular-shaped. The body 12 includes a notch 16 formed between the proximal opening 14 a and the distal opening 14 b. In one embodiment, the opening is formed near a longitudinal center of the body 12 . In one embodiment, the notch 16 is generally cut in the shape of a “V,” and forms an opening in a wall of the body 12 . The edges of the notch 16 include a first side 18 a and a second side 18 b, which meet at an intersection 20 .
In one embodiment, the body 12 is made from a soft, rubber-like material. In one embodiment, the body 12 is made from rubber. In another embodiment, the body 12 is made from a polymeric material. In a further embodiment, the body 12 is made from any material, known to those of ordinary skill in the art, that has a coefficient of friction sufficiently great to minimize slippage between the body 12 and the rigid member.
FIG. 2 shows a perspective view of the cable attachment device 10 , along with a cable 22 and a fastener 24 . In various embodiments of the present invention, the cable 22 is a support cable, an electrical cable, a hose, or a hydraulic line. In one embodiment of the present invention, the fastener 24 is a tie wrap. The unique shape of the cable attachment device 10 provides several functions. The notch 16 keeps the cable 22 in line with a rigid member (as shown in FIG. 3) that the cable 22 is being mounted to. The notch 16 provides an open area in the body 12 where the fastener 24 can pass over a surface of the cable 22 facing away from the rigid member. The generally “V”shape of the notch 16 allows the fastener 24 to be readily manipulated through the openings 14 a, 14 b and around the cable 22 . This design also makes it possible to install the cable attachment device 10 to an existing cable 22 .
The size and design of the opening of the notch 16 is important as it holds the cable attachment device 10 in position on the cable 22 when the fastener 24 is inserted through the body 12 . The cable attachment device 10 is also held in place by the frictional forces between the body 12 , the cable 22 , and the rigid member. This allows the cable attachment device 10 to be installed at a pre-measured location on the cable 22 and to remain in that location even when the fastener 24 is not fastened.
A cable attachment method 30 is illustrated in FIG. 3 . As shown in FIG. 3, the cable attachment device 10 is used, with the fastener 24 , to secure the cable 22 to a rigid member 32 . As shown, the fastener 24 enters the proximal opening 14 a, exits the notch 16 , before the cable 22 , passes over the top of the cable 22 , enters the body 12 through the notch 16 , on the other side of the cable 22 , and exits the distal opening 14 b. The fastener 24 is then tightened. The body 12 of the cable attachment device 10 is made of a soft rubber-like material that will flex and bend to conform to the surface of the rigid member 32 . This will provide maximum surface are contact between the cable attachment device 10 and the rigid member 32 , and thus maximum friction to prevent slippage. The soft, rubber-like material of the body 12 will also conform to any irregularities in the shape of the cable 22 and thus will maintain maximum friction to prevent slippage. The physical characteristics of the body 12 will also act to dampen any vibration in the rigid member 32 , and prevent the vibration from reaching and damaging the cable 22 .
FIG. 4 is a perspective view of a cable attachment device 40 according to a second embodiment of the present invention. As shown in FIG. 4, the cable attachment device 10 includes a body 42 that is cylindrical in shape with a proximal opening 44 a at a first end and a distal opening 44 b at a second end. The body 42 includes a first cable opening 46 a and a second cable opening 46 b configured for insertion of the cable 22 . The body 42 further includes a first fastener opening 48 a and a second fastener opening 48 b configured for insertion of the fastener 24 . The body 12 is made from a soft, rubber-like material.
FIG. 5 is a perspective drawing of a cable attachment method 50 . As shown in FIG. 5, the cable attachment device 40 is used, with the fastener 24 , to secure the cable 22 to the rigid member 32 . As shown, the cable 22 is threaded through the cable openings 46 a, 46 b, such that it is in line with the rigid member 32 . The fastener 24 enters the proximal opening 44 a, exits the first fastener opening 48 a, passes over the top of the cable 22 , which is located inside the body 12 , reenters the body 12 through the second fastener opening 48 b, and exits the distal opening 44 b. The fastener 24 is then tightened. The body 42 of the cable attachment device 10 is made of a soft rubber-like material that will flex and bend to conform to the rigid member 32 . This will provide maximum surface are contact between the cable attachment device 40 and the rigid member 32 , and thus maximum friction to prevent slippage. The soft, rubber-like material of the body 12 will also conform to any irregularities in the shape of the cable 22 and thus will maintain maximum friction to prevent slippage. The physical characteristics of the body 12 will also act to dampen any vibration in the rigid member 32 , and prevent the vibration from reaching and damaging the cable 22 .
The cable attachment method 50 also addresses a technique for protecting the cable 22 from being damaged by fasteners 24 that have sharp edges. In this embodiment, the fastener 24 tightens against the body 42 of the cable attachment device 50 and thus eliminates direct contact between the fastener 24 and the cable 22 , which serves to protect the cable 22 from damage.
Although the present invention has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | The present invention is a cable attachment method and device used with a fastener to secure a cable, hose, or hydraulic line to a rigid member to prevent slippage. The device includes a soft, flexible, cylindrical body having a longitudinal bore configured to accept the fastener. The body has an opening adapted to accept the cable. The body operates to create a high level of friction between the cable and the rigid member and to protect the cable from vibration of the rigid member. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present disclosure is a continuation of U.S. patent application Ser. No. 12/903,055 (now U.S. Pat. No. 8,402,249) filed on Oct. 12, 2010. This application claims the benefit of U.S. Provisional Application No. 61/253,019 filed on Oct. 19, 2009. The entire disclosures of the applications referenced above are incorporated herein by reference.
FIELD
Aspects of the present disclosure relate generally to dynamically partitioning a physical memory device into non-overlapping regions, where each region corresponds to a particular application and the memory mapping mode used for each region is associated with the application.
BACKGROUND
In modern computer systems, system addresses must be mapped to physical memory addresses so that the system can access the memory. Generally, system addresses are linear while, for example, synchronous dynamic random access memory (SDRAM) addresses are three-dimensional. Various modes map a system address to an SDRAM device's physical memory address; these modes include row-bank-column and bank-row-column. Each mode has its own advantages and disadvantages. For example, mappings calculated according to row-bank-column may be useful for applications that need to cross page boundaries (e.g., video decoding), while mappings calculated according to bank-row-column may be most effective for applications that generally do not need to cross page boundaries (e.g., a general-purpose processor making short accesses of the memory). In current SDRAM-based systems, only one mode can be supported in a single SDRAM device at any one time.
Therefore, it may be desirable to provide a system and method that flexibly can access a single physical memory device according to at least two memory mapping modes simultaneously.
SUMMARY
A system is provided and includes a register and a controller. The register is configured to store a map relating distinct regions of a memory to respective mapping modes. Each of the mapping modes identifies a predetermined order of dimensions of a respective region of the memory. Each of the dimensions of the regions of the memory is identified as a row, a bank, or a column. The mapping modes include (i) a first mapping mode having a first predetermined order of dimensions, and (ii) a second mapping mode having a second predetermined order of dimensions that is different from the first predetermined order of dimensions associated with the first mapping mode. The controller is configured to control access to the distinct regions of the memory according to the map stored in the register, including controlling access to a first region of the memory according to the first mapping mode while controlling access to a second region of the memory according to the second mapping mode.
A method is provided and includes generating a map. The map relates distinct regions of a memory to respective mapping modes. Each of the mapping modes identifies a predetermined order of dimensions of a respective region of the memory. Each of the dimensions of the regions of the memory is identified as a row, a bank, or a column. The mapping modes include (i) a first mapping mode having a first predetermined order of dimensions, and (ii) a second mapping mode having a second predetermined order of dimensions that is different from the first predetermined order of dimensions associated with the first mapping mode. The map is stored in a register. Access to the distinct regions of the memory is controlled according to the map stored in the register including controlling accessing a first region of the memory according to the first mapping mode while controlling accessing a second region of the memory according to the second mapping mode.
Embodiments described herein provide systems and methods that enable the partitioning of physical memory into non-overlapping regions of contiguous physical memory addresses, such that each region may be programmed dynamically and independently according to different memory mapping modes, depending on real-time requirements of the system.
In accordance with one aspect of the disclosure, a system includes a physical memory device, a mapping register configured to maintain a memory mapping mode for each of multiple regions within the physical memory device (where each region is associated with a contiguous portion of physical memory addresses associated with the physical memory device that does not overlap with any other region) and a memory controller configured to control access to and from the physical memory device according to the mapping register.
The mapping register may be configured to maintain a memory mapping scheme for each region, where the memory mapping scheme is based at least on the memory mapping mode.
The physical memory device may be a synchronous dynamic random access (SDRAM) device, and the memory mapping mode may be based on a combination of bank, row and column values. In a further embodiment, the memory mapping mode may be one of either bank-row-column (BRC) or row-bank-column (RBC).
The mapping register may be configured to maintain a refresh status variable for each region to determine whether the region will be refreshed.
In accordance with another aspect of the disclosure, a method of mapping system addresses to physical addresses associated with a physical memory device is disclosed. For each of multiple applications, the method receives memory requirements associated with the application, allocates a region of the physical memory device to the application (where the region is a contiguous portion of the physical addresses that does not overlap with any other region and is associated with a memory mapping mode), determines a memory mapping scheme for the region (where the memory mapping scheme defines the mapping between system addresses and the region and is based at least on the memory mapping mode) and modifies a mapping register to reflect the region.
The mapping register may be modified to reflect the memory mapping scheme.
The memory requirements may include an application type, and the mapping mode may be determined based on the application type.
In an embodiment, the memory mapping mode may be based on a combination of bank, row and column values in a synchronous dynamic random access memory (SDRAM) device. In a further embodiment, the memory mapping mode may be one of either bank-row-column (BRC) or row-bank-column (RBC).
In an embodiment, the method may enable the refresh for each region.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a simplified high level functional block diagram of a generalized system according to an embodiment.
FIG. 2 is a simplified flow diagram illustrating operation of one embodiment of a method of dynamically controlling memory allocation and memory mapping mode.
FIG. 3 is a simplified high level functional block diagram of a video server system according to an embodiment.
FIGS. 4A-C are simplified high level illustrations of memory allocations and memory mapping modes for a memory device.
FIG. 5 is a simplified high-level illustration of a DDR device programmed for mixed BRC and RBC memory mapping modes.
FIG. 6 is a simplified high-level illustration of a DDR device programmed for mixed BRC and RBC memory mapping modes with unused banks.
FIG. 7 is a simplified high-level illustration of a DDR device programmed for mixed BRC and RBC memory mapping modes and half-bank granularity.
FIG. 8 is a simplified high level illustration of a DDR device programmed for segment RBC memory mapping mode.
FIG. 9 is a simplified high-level illustration of a DDR device programmed for mixed BRC and RBC memory mapping modes, with segment RBC, half-bank granularity and unused banks.
DESCRIPTION
Embodiments described herein allow multiple memory mapping modes to be used simultaneously and changed dynamically, thereby potentially resulting in faster access times, faster data transfer, lower latency and/or reduced power requirements (because, e.g., refreshing can be done more efficiently, and fewer accesses of the memory may be required for read/write operations). Generally, embodiments described herein may enable the partitioning of physical memory into non-overlapping regions of contiguous physical memory addresses. Each region may be programmed dynamically and independently according to different memory mapping modes, depending on real-time requirements of the system. Also, refresh of a particular region may be enabled/disabled independently, regardless of the memory mapping mode used. Refresh actions generally draw a lot of current in the system; by disabling refresh of one or more regions (when possible), the system's power requirements may be reduced.
Typically, a computer system's operating system (OS), applications executed by the computer system and data used by the applications are loaded partially or entirely into memory. It will be understood by those of skill in the art that “applications” or “programs” as used herein correspond generally to sequences of instructions executed by the computer system and are used to perform one or more specific tasks; examples include word processing software, video coding/decoding software, system utilities required by the OS, web browsers, email clients, etc. The memory generally is in the form of synchronous dynamic random-access memory (SDRAM) and is made accessible to the computer system via a memory mapping scheme that translates logical or system addresses referenced by the system's operating system into the physical addresses used by the memory controller, and vice versa.
An SDRAM device address is configured in banks (B), rows (R) and columns (C), generally treated as a three-dimensional array. System addresses usually are linear (one-dimensional). As a result, in order for the system to access and use the physical memory, it is necessary to provide a mapping scheme between the two addressing protocols. Accordingly, an SDRAM address generally can be thought of as a function of a system address (A); i.e., B=F 0 (A), R=F 1 (A) and C=F 2 (A).
Memory mapping modes include RBC (row-bank-column) and BRC (bank-row-column). With RBC, a number of most significant bits of a system address may be mapped to the row (R), a number of least significant bits may be mapped to the column (C) and the remaining bits in between may be mapped to the bank (B). With BRC, a number of most significant bits of a system address may be mapped to the bank (B), a number of least significant bits may be mapped to the column (C) and the remaining bits in between may be mapped to the row (R). It will be appreciated that the number of bits used to represent R, B and C may depend on the size of the memory, the size of the address space, etc., and that, in some instances, certain of the same bits may be used for both R and B (or any other combination). For example, it may be the case that the 10 most significant bits are used for both R and B, in which case the value represented by those bits may have a first function applied to it to determine R (e.g., value/7) and a second function to determine B (e.g., value mod 7).
Turning now to the drawings, FIG. 1 is a simplified high level functional block diagram of a generalized system according to an embodiment. System 100 may include processor 105 (including, for example, microprocessors, microcontrollers, digital signal processors, etc.) that may execute the instructions of a computer program, OS and one or more applications 125 , physical memory device 120 that may provide memory for system 100 , memory controller (MC) mapping register 110 that may hold configuration information for portions of memory device 120 , and memory controller 115 that may manage the flow of data going to and from memory device 120 . While shown in FIG. 1 as separate from memory controller 115 , MC mapping register 110 may be a part of memory controller 115 .
It will be appreciated that embodiments of the disclosure are not limited to systems with the layout illustrated in FIG. 1 , and generally may be practiced in any system that uses at least the elements listed above with respect to FIG. 1 , including system-on-a-chip (SoC) systems, which generally integrate most components of a computer or other electronic system into one or more integrated circuits on a chip.
A computer system usually has varying memory requirements, depending on the type of application(s) currently accessing the memory. For example, a central processing unit (CPU) generally accesses and uses physical memory in a manner that is different from the way, say, a high definition (HD) video decoder might—each application, etc. exhibits a different access pattern. If the memory mapping mode used to map system addresses to physical memory addresses is, for example, bank-row-column (BRC), then CPU(-type) accesses may be able to take advantage of the mapping, but HD decoding may suffer (because row-bank-column (RBC) may be more efficient for this type of application).
The pros and cons regarding BRC and RBC mapping modes are known in the art. BRC generally works well for partial bank operations, e.g., partial bank refresh/self-refresh, which can help to lower power consumption. (Refresh operations generally require a lot of power.) Similarly, BRC generally is preferable for linear accesses (e.g., a CPU making short accesses). BRC also may be preferred for segment operations, i.e., where different applications in the system can use independent physical banks without page open/close interference between them. Generally, it is preferable to use BRC for accesses that do not cross page boundaries.
Downsides of BRC can include unbalanced bank access whereby some banks may be busy while others may be almost idle, etc.; if there is heavy access on one portion of the memory and everything is mapped to that portion, then the system may experience increased congestion. Also, there generally is a large penalty for cross-page accesses, i.e., accesses to different rows within the same bank. Each time a page has to be crossed, the row has to switch, so the entire row must be closed and then opened again, thus there is a pre-charge penalty and an open penalty, which can result in a delay.
RBC generally provides more balanced access to all the banks, thus it usually can more efficiently use multi-bank techniques to improve page hit-rates and access performance (e.g., via better bus utilization and lower access latency). Also, there generally is less of a penalty for cross-page accesses (i.e., accessing different banks). Generally, RBC is preferable for accesses that may need to cross page boundaries.
Problems with RBC can include access being scattered across all banks, so when there is access across multiple pages, multiple banks need to be accessed, which may make partial bank refreshes/self-refreshes difficult.
It will be appreciated that while BRC and RBC memory mapping modes are discussed herein with respect to some embodiments, in certain embodiments other known memory mapping modes may be used, including, for example, variations of RBC and BRC.
Throughout this disclosure, the examples and figures discussed assume a single 128 megabyte (MB) double data-rate (DDR) SDRAM device with a 32-bit interface, though it will be understood by those of skill in the art that larger or smaller memory devices with varying specifications may be supported, including devices that use other SDRAM standards, such as DDR2, DDR3, etc. A DDR device with a 32-bit interface may have eight banks, 8192 rows (per bank) and 512 columns (per row). Given that the examples used throughout this disclosure assume a 128 MB DDR device, each of the 8192 rows corresponds to 2 kilobytes (KB) of memory (i.e., a 2 KB page size); thus, each of the eight banks corresponds to 16 MB of memory. Accordingly, in BRC memory mapping mode, there may be a latency penalty when crossing the 2 KB boundary, whereas with RBC there is no latency penalty when crossing the 2 KB boundary. Also, with BRC, 16 MB of memory may be accessed before a bank switch is required, but with RBC, just 2 KB of memory may be accessed before a bank switch is required.
Given the exemplary constraints outlined above (i.e., a 128 MB DDR device with eight banks, 8192 rows per bank and 512 columns per row), the memory may be partitioned into a maximum of 65,536 regions (8 banks×8192 rows); i.e., where each row is a region. The maximum value is noted simply to highlight the potential utility of multiple, configurable regions; a typical configuration may include 8 regions (with 1 bank per region).
In one aspect of the embodiments described herein, system addresses are linear and the address space of the memory spans 27 bits, so that the address space may be referred to as A[26:0]. In this case, given all of the previous assumptions, BRC mapping across the entire memory (as may be done with known systems) may be as follows: B[2:0]=A[26:24], R[12:0]=A[23:11] and C[8:0]=A[10:2]. Similarly, RBC mapping (across the entire memory) may be as follows: R[12:0]=A[26:14], B[2:0]=A[13:11] and C[8:0]=A[10:2]. Other mappings for linear system addresses and 27-bit memory address spaces also are possible. Likewise, the disclosure is applicable to other configurations of system addresses and address spaces, giving rise to other relationships.
FIG. 2 is a simplified flow diagram illustrating operation of one embodiment of a method of dynamically controlling memory allocation and memory mapping modes. At 200 , system 100 may implement a power on reset (PoR) process, whereby system 100 may be powered on and at which point various start-up routines may be executed. At 205 , system 100 may determine the size of DDR device 120 . A check then may be made of the maximum number of memory regions memory controller 115 can recognize and use. Generally, the size of MC mapping register 110 will correspond to the number of regions memory controller 115 can support. For example, if MC mapping register 110 has 8 registers, then memory controller 115 may be able to support 8 regions—one region per register.
Next during PoR, at 210 , the memory available at DDR device 120 may be set to a single type (e.g., BRC, RBC, etc.) and refresh may be disabled for all eight regions. At 215 a check of the memory requirements for boot, application and system software (including the OS), etc. may be performed, and the system may be booted at 220 . It will be appreciated that generally, in a SoC-type system, the values “determined” by the hardware/system initialization steps performed at 205 - 20 will be pre-defined (e.g., before the system is powered on, it may already be pre-determined that the OS, boot, etc. will need 16 MB, be set to BRC memory mapping mode and use bank 0).
At 225 , after system 100 boots, the operating system (OS) residing within system 100 may monitor application launches, exits and modified memory requirements. At this point the OS may be aware of the size of DDR device 120 and the number of regions MC mapping register 110 can support. The memory requirements of an application may be determined substantially concurrently with the application's launch, as illustrated at 230 , and the application may inform the OS of these requirements.
At 235 , the OS may call a memory management function to allocate the memory needed for the application. The memory management function may take certain arguments, including the amount of memory needed and either the type of application requesting the memory or the memory mapping mode desired by the application (e.g., an HD video coding application might request RBC mode). Generally, these values will be a part of the information that may be supplied by the application at 230 . If the application's type (e.g., video encoder, video decoder, network monitor, etc.) is being used to inform the memory management function (i.e., instead of the application specifying a particular memory mapping mode), then a table (or similar structure), accessible to the memory management function, that defines the type of memory mapping mode to be used for that particular application type, may be used to determine the memory mapping mode.
Next, the memory management function may allocate to the application a region corresponding to a contiguous block of physical memory addresses. A mapping scheme may be calculated to map system addresses to the physical addresses within the region. The memory management function may update MC mapping register 110 to reflect the new region, including the span of system addresses that map into the region (e.g., A[26:0]<16 MB), the mapping scheme calculated for the region (e.g., the BRC scheme discussed with respect to FIG. 5 ), the mode to be used for the region (e.g., BRC), and if warranted (see discussion of 240 below), the refresh status for the region. It will be appreciated that MC mapping register 110 may be updated in real-time as decisions are made regarding mapping information and refresh statuses. It will be further appreciated that in some embodiments, the mapping scheme need not be saved to MC mapping register 110 , but instead may be calculated in real-time as needed, saved separate from memory controller 115 and accessed by a device driver as needed, etc.
At 240 , refresh for the region to be used by the application may be enabled so that the data within the bank(s) of that region can be maintained during operation of the application. As discussed above, the purpose of controlling the refresh associated with a region is to save power; if a bank currently is unused, there may be no reason to continually refresh it. It will be appreciated that the refresh at 240 need not always occur; indeed, it may be skipped altogether (e.g., in the case where power usage is not a concern, etc.), and so the refresh at 240 is shown in phantom.
At 245 , the memory management function may report to the OS that the updating of MC mapping register 110 was successful, and the OS may update its memory allocation table to reflect the now-allocated memory. The OS then may report this information to the application that requested the memory; at this point the application will know the system addresses of the memory allocated for it and may begin to access this memory.
While an application is running it may recalculate its memory requirements at 265 , and may conclude, for example, when it switches from doing one type of task to another, that its memory requirements have changed. At 270 the application may inform the OS of the modified memory requirements, and the OS may call the memory management function to release the memory the application currently is using. At 275 , the memory management function may update MC mapping register 110 to reflect the new region. At 280 , refresh may be enabled for the new region (if it is not already enabled) and may be disabled for any portions of unused memory. At 285 , the memory management function may inform the OS that the updating of MC mapping register 110 was successful, and the memory allocation table may be updated to reflect the now-allocated memory. The OS then may report this information to the application requesting the memory; at this point the application will know the system addresses of the memory allocated for it and may begin to access it.
When an application exits and informs the OS at 225 , the OS, at 250 may call the memory management function to release the memory that was allocated by the application. At 255 , refresh may be disabled for the region corresponding to the now-unassigned memory. At 260 , the memory management function may inform the OS that its operations have completed, and the memory allocation table may be updated to reflect the now-available memory.
It will be appreciated that a device driver associated with memory controller 115 may be used to carry out some of the operations described above with respect to FIG. 2 . As is known in the art, a device driver generally is software that allows higher-level computer programs (e.g., an OS) to interact with a hardware device (e.g., DDR device 120 ). The device driver ultimately may decide the mapping between the system addresses and the physical memory (including the memory mapping mode if not provided by the application). Consequently, the device driver generally will be specific to DDR device 120 and the operating system used by system 100 .
FIG. 3 is a simplified high level functional block diagram of a video server system according to an embodiment. It will be appreciated that FIG. 3 is similar to FIG. 1 , except that applications 125 of system 100 have been specified as ingress/egress router 325 , video encoder/decoder 330 , video-in 335 and video-out 340 , and network interface 345 , camera 350 and display 355 have been added. Video server 300 may be capable of acting as both an input and output video server. When performing as a video-out server, raw video may be received through video-in 350 , encoded via video encoder/decoder 330 , packetized by ingress/egress router 325 and then served through network interface 345 . Conversely, when performing as a video-in server, packetized video may be received by network interface 345 and ingress/egress router 325 , decoded by video encoder/decoder 330 and sent to video-out 340 to be displayed by a display device 355 in communication with system 300 . Video server 300 may be capable of handling video-in and video-out functions independently and in parallel.
Using FIG. 2 as a general guide, the following is a simplified example of video server 300 operating according to an embodiment. For purposes of explanation only, and to tie in with earlier discussion, it is assumed that DDR device 320 is a single, 128 MB, 32-bit DDR device. At 200 , a PoR routine may begin for video server 300 . It is determined, at 205 , that the size of DDR device 320 is 128 MB, and that memory controller 315 can recognize and use up to 8 regions. Next, at 210 , all banks of DDR device 320 may be set to BRC mode. At 215 , it may be determined that 16 MB of memory is required for the boot-up sequence, application software, etc.; accordingly, region 0 (i.e., bank 0, 0 MB-16 MB) may be allocated for this purpose. Refresh for bank 0 may be enabled and refresh for banks 1-7 may remain disabled. FIG. 4A illustrates a sample memory allocation for DDR device 320 after functions 200 - 220 have been executed.
Once video server 300 completes its boot process at 220 , it may begin to monitor for application launches and exits, as shown at 225 . At 230 , a video server application may be launched, which may spawn four “sub”-applications (e.g., threads of the video server application, etc.): ingress and egress router 325 , video encoder/decoder 330 , video-in 335 and video-out 340 . For each of the four sub-applications, 230 - 245 may be executed, and memory controller 315 ultimately may be programmed as follows (and these values may be reflected in MC mapping register 310 ):
(1) 16 MB (e.g., region 0, bank 0, addresses 0 MB-16 MB) allocated for the operating system and application software, mapped using BRC memory mapping mode with refresh enabled for region 0; (2) 16 MB (e.g., region 1, bank 1, addresses 16 MB-32 MB) allocated for ingress and egress router 325 , mapped using BRC memory mapping mode with refresh enabled for region 1; (3) 48 MB (e.g., region 2, banks 2-4, addresses 32 MB-80 MB) allocated for video encoder/decoder 330 , mapped using RBC memory mapping mode with refresh enabled for region 2; and (4) 48 MB (e.g., region 3, banks 5-7, addresses 80 MB-128 MB) allocated for a video buffer to be used by video-in 335 and video-out 340 , mapped using RBC memory mapping mode with refresh enabled for region 3.
FIG. 4B illustrates a sample memory allocation for DDR device 320 after 230-245 have been executed for each of the four sub-applications.
According to an embodiment, as described previously with reference to 265 - 285 of FIG. 2 , an application may inform the OS of its memory requirements during its operation, and not just at launch/exit. During operation, the video server application may switch from HD mode with streaming, to dual-standard definition (SD) mode (with no router and no streaming), whereby video server 300 will process two independent video channels simultaneously.
When the video server application switches modes it may recalculate its memory requirements at 265 , and may conclude, for example, that each SD channel needs 16 MB for video encoder/decoder 330 and 16 MB to buffer video-in 335 and video-out 340 . At 270 the video server application may inform the OS of the updated memory requirements, and the OS may call the memory management function to release the memory the video server application currently is using (i.e., regions 1-3, banks 1-7, addresses 16 MB-128 MB). At 275 , the memory management function may update MC mapping register 110 to reflect the new region. Accordingly, per the example requirements discussed above, 32 MB of DDR device 320 may be allocated for the first SD channel (e.g., region 1, banks 1-2, addresses 16 MB-48 MB), mapped using the RBC memory mapping mode with refresh enabled for region 1; and 32 MB may be allocated for the second SD channel (e.g., region 2, banks 3-4, addresses 48 MB-80 MB), mapped using the RBC memory mapping mode with refresh enabled for region 2. Refresh for region 3 (i.e., banks 5-7) may be disabled because that memory (i.e., addresses 80 MB-128 MB) is not currently being used.
At 285 , the memory management function may inform the OS that the updating of MC mapping register 110 was successful, and the memory allocation table may be updated to reflect the now-allocated memory. The OS then may report this information to the sub-applications; at this point the sub-applications will know the system addresses of the memory allocated for each of them and may begin to access it. FIG. 4C illustrates a sample memory allocation for DDR device 320 after 265-285 have been executed.
When the video server application exits it may inform the OS of its closing at 225 . The OS, at 250 , may call the memory management function to release the memory that was allocated by the application (e.g., after the switch operation discussed above, banks 1-4, addresses 16 MB-80 MB). At 255 , the memory management function may disable refresh of the banks within the regions previously used by the video server application. At 260 the memory management function may inform the OS that the updating of MC mapping register 110 was successful, and the memory allocation table may be updated to reflect the now-available memory. After 250-260 have executed, the physical memory allocation may look as it did in FIG. 4A , namely region 0 (i.e., bank 0) is allocated to the OS, etc., and region 1 (i.e., banks 1-7) are unused.
FIGS. 5-9 are simplified high-level illustrations of a DDR device programmed according to various embodiments. It will be understood that these illustrations are just examples, and that there may be a practically limitless number of possible configurations, depending on the size of the memory, the number of regions supported and the current requirements of applications that are accessing the memory.
FIG. 5 is a simplified high-level illustration of a DDR device 500 programmed for mixed BRC and RBC memory mapping modes. In an example situation in which a user of video server 300 begins streaming video content via network interface 345 , according to the steps previously discussed with regard to FIG. 2 , the memory may be remapped to take advantage of the access nature of video decoding (e.g., RBC may be most efficient). In this case, for example, assume that 16 MB of memory needs to be allocated for general application and CPU access (in this example, the 16 MB of memory may correspond to A[26:0]<16 MB), while 112 MB is needed for the streaming video (in this example, the 112 MB may correspond to A[26:0]≧16 MB). Such a scenario limits the BRC mapping to its own bank (i.e., bank 0, region 0), and limits the RBC mapping to the next seven banks (i.e., banks 1-7, region 1). Accordingly, the BRC mapping scheme may be B=A[26:24], R=A[23:11] and C=A[10:2]; and the RBC mapping scheme may be B=(A[26:11]%7)+1, R=(A[26:11]/7) and C=A[10:2]. “7” may be used as the divisor and mod value in this particular example because the region to be used for RBC includes 7 banks (i.e., 112 MB). It will be appreciated that the mappings discussed above are just limited examples, and that, depending on the state and constraints of the system, the mappings may be different; for example, bank 0 may not always correspond to region 0, and instead may correspond to, for example, region 6. The same general caveat applies to the other embodiments described below.
FIG. 6 is a simplified high-level illustration of a DDR device 600 programmed for mixed BRC and RBC memory mapping modes with unused banks. Again, if a user of video server 300 begins streaming video content via network interface 345 , then according to the operations previously discussed with regard to FIG. 2 , the memory may be remapped to take advantage of the access nature of video decoding (e.g., RBC may be most efficient). In this case, for example, assume that 16 MB of memory needs to be allocated to general application and CPU access (in this example, the 16 MB of memory may correspond to A[26:0]<16 MB), while 32 MB (instead of 112 MB, as in the last example) is needed for the streaming video (in this example, the 32 MB of memory may correspond to 48 MB≧A[26:0]≧16 MB). Such a scenario limits the BRC mapping to its own bank (i.e., bank 0, region 0), and limits the RBC mapping to the next two banks (e.g., banks 1-2, region 1). Accordingly, the BRC mapping scheme may be B=A[26:24], R=A[23:11] and C=A[10:2]; and the RBC mapping scheme may be B=(A[26:11]%2)+1, R=(A[26:11]/2) and C=A[10:2]. “2” may be used as the divisor and mod value in this particular example because the region to be used for RBC includes 2 banks (i.e., 32 MB). The region not in use, i.e., region 2 (banks 3-7) can be mapped according to any memory mapping mode, and refresh for banks 3-7 may be disabled.
As illustrated by FIG. 6 , within the RBC region, when the page size is added to any system address, the resulting physical memory address will point to the next bank. For example, in the RBC region of FIG. 6 , page 0 is mapped into bank 1, page 1 is mapped into bank 2, page 2 is mapped into bank 1, page 3 is mapped into bank 2, etc.
FIG. 7 is a simplified high-level illustration of a DDR device 700 programmed for mixed BRC and RBC memory mapping modes with partial-bank granularity, such that a region's boundary can occur within a bank. In FIG. 7 , region 0 is BRC mapped to the first half of bank 0 (i.e., rows 0-4095), and the remainder of the physical memory is RBC mapped to region 1 (i.e., the second half of bank 0, and banks 1-7). Partial-bank mapping granularity may correspond to any value that is a multiple of rows.
FIG. 8 is a simplified high level illustration of a DDR device 800 programmed for segment RBC memory mapping mode. If a user of video server 300 is using two separate applications, each of which is streaming video content via network interface 345 , then according to the steps previously discussed with regard to FIG. 2 , the memory may be remapped to take advantage of the access nature of video decoding (e.g., RBC may be most efficient). In this case, for example, if it is assumed that 64 MB of memory is needed for each of the two video streaming applications, then two regions (each 4 banks; 64 MB)—one for each streaming application—may be created (in this example, the first 64 MB of memory may correspond to 0≦A[26:0]<64 MB, and the second 64 MB may correspond to 64 MB≦A[26:0]≦128 MB). Accordingly, the RBC mapping scheme may be B={A[26], A[12:11]}, R=A[25:13] and C=A[10:2], and the opened pages of one video streaming application will not be closed by the other.
As illustrated by FIG. 8 , within any RBC region, when the page size is added to any system address, the resulting physical memory address will point to the next bank. For example, in region 0 of FIG. 8 , page 0 is mapped into bank 0, page 1 is mapped into bank 1, page 2 is mapped into bank 2 and page 3 is mapped into bank 3. A similar pattern can be seen in region 1. It will be appreciated that in segment RBC mode there can be multiple RBC regions, and not just the two shown in FIG. 8 .
FIG. 9 is a simplified high-level illustration of a DDR device 900 programmed to incorporate versions of all of the memory mappings described with respect to FIGS. 5-8 , including mixed BRC and RBC, segment RBC, half-bank granularity and unused banks. The first half of bank 0 (region 0) uses BRC, the second half of bank 0 and banks 1-2 (region 1) use RBC, banks 3-6 (region 2) use RBC and banks 6-7 (region 3) are unused.
In accordance with the foregoing, the systems and methods described herein may be implemented in hardware, firmware, software or other instruction sets maintained in a non-transitory computer readable medium, or a combination of these. Generally, the systems and methods described herein may be integrated with or employed in conjunction with any system where multiple applications use the same physical memory device, especially where the multiple applications exhibit disparate access patterns.
Several features and aspects of the present disclosure have been illustrated and described in detail with reference to particular embodiments by way of example only, and not by way of limitation. Those of skill in the art will appreciate that alternative implementations and various modifications to the disclosed embodiments are within the scope and contemplation of the present disclosure. Therefore, it is intended that the disclosure be considered as limited only by the scope of the appended claims. | A system including a register and a controller. The register is configured to store a map relating distinct regions of a memory to respective mapping modes. Each of the mapping modes identifies a predetermined order of dimensions of a respective region of the memory. Each of the dimensions of the regions of the memory is identified as a row, a bank, or a column. The mapping modes include (i) a first mapping mode having a first predetermined order of dimensions, and (ii) a second mapping mode having a second predetermined order of dimensions that is different from the first predetermined order of dimensions associated with the first mapping mode. The controller is configured to control access to the distinct regions of the memory according to the map stored in the register, including controlling access to a first region of the memory according to the first mapping mode while controlling access to a second region of the memory according to the second mapping mode. | 8 |
RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 60/209,108, filed on Jun. 2, 2000, entitled Structure For Managing The Virtualization Of Block Storage, the disclosure of which is hereby incorporated by reference in its entirety. Additionally, the entire disclosures of the present assignee's following utility patent applications filed on the same date as the present application are both incorporated herein by reference in their entireties: Ser. No.: 09/872,921, to James Reuter, et al., entitled Structure And Process For Distributing SCSI LUN Semantics Across Parallel Distributed Component; and Ser. No.: 9/872,721, to James Reuter, et al., entitled Data Migration Using Parallel, Distributed Table Driven I/O Mapping.
FIELD OF THE INVENTION
The present invention relates to systems and methods for managing virtual disk storage provided to host computer systems.
BACKGROUND OF THE INVENTION
Virtual disk storage is relatively new. Typically, virtual disks are created, presented to host computer systems and their capacity is obtained from physical storage resources in, for example, a storage area network.
In storage area network management, for example, there are a number of challenges facing the industry. For example, in complex multi-vendor, multi-platform environments, storage network management is limited by the methods and capabilities of individual device managers. Without common application languages, customers are greatly limited in their ability to manage a variety of products from a common interface. For instance, a single enterprise may have NT, SOLARIS, AIX, HP-UX and/or other operating systems spread across a network. To that end, the Storage Networking Industry Association (SNIA) has created work groups to address storage management integration. There remains a significant need for improved management systems that can, among other things, facilitate storage area network management.
While various systems and methods for managing array controllers and other isolated storage subsystems are known, there remains a need for effective systems and methods for representing and managing virtual disks in various systems, such as for example, in storage area networks.
SUMMARY OF THE INVENTION
In response to these and other needs, the preferred embodiments of the present invention provide a system and method for the management of virtual storage. The system and method include an object-oriented computer hardware/software model that can be presented via a management interface (e.g., via graphical user interfaces, GUIs, command line interfaces, CLIs, application programming interfaces, APIs, etc.), via documents (e.g., customer documents, training documents or the like, including electronic documents, such as Word documents, PDF files, web pages, etc., or physical documents), or via other means.
In preferred embodiments, the model advantageously provides the separation of physical storage management from virtual disks presented to the hosts. This is preferably done using virtual disks in conjunction with a storage pool hierarchy. The virtual disk can be a logical “disk” that is visible to one or more host system(s). It is independent of physical storage and is preferably managed by setting attributes. On the other hand, the storage pool hierarchy provides a boundary between the virtual and physical parts of the model via “encapsulation” of physical storage such that physical components may change without affecting the virtual parts of the model.
Preferably, management can be automated such that the user (e.g., customer, manager and/or administrator) specifies goals rather than means—enhancing ease of use while maintaining flexible deployment of storage resources. The preferred embodiments of the invention may advantageously reduce the cost and/or complexity of managing storage—by simplifying the management of change. In preferred embodiments, one or more of the following and other advantages can be realized with the present invention.
Erased Boundaries
Typically, storage controller or subsystem boundaries can cause inefficient use of capacity, capacity to be in the wrong place, manual rebalancing to be required and/or problems with host access to capacity. The preferred embodiments of the present invention can enable, for example, a host-independent, controller-independent, storage area network (SAN)-wide pool of storage for virtual disks, effectively erasing these boundaries and the problems caused by these boundaries. Among other things, this can also simplify the acquisition and deployment of new storage because new storage can simply be more capacity in the pool.
Centralized Management
Typically, each storage subsystem in a SAN is managed separately, causing boundaries in the management model with resulting complexities and inefficiencies of management. The preferred embodiments of the present invention enable, among other things, a single, central management view of an entire SAN.
Uniform Capabilities
Typically, when a SAN has multiple storage subsystems, the subsystems may have different capabilities, adding complexity and confusion to the management of the storage and the hosts using the storage. The preferred embodiments of the present invention can provide, e.g., a virtual disk that has uniform management capabilities and that is independent of the capabilities offered by the subsystems providing the capacity. Among other things, this can reduce management complexity. With the preferred embodiments of the present invention, virtual disks can be managed with attributes that are independent of the physical storage, separating the virtual parts of the model from the physical parts of the model.
The preferred embodiments of the present invention can enable features such as: a) substantially no disruption of service to host systems and applications during management operations; b) easy to add/remove storage subsystems; c) more efficient use of space; d) less wasted space overhead; e) volume expansion; f snapshot copies; g) selective presentation of virtual disks only to desired hosts; h) attribute-based management of virtual disks; i) host systems de-coupled from storage management; and/or j) future extensions easily added without disruption to hosts or to storage subsystems.
The above and other embodiments, features and advantages will be further appreciated upon review of the following description of the preferred embodiments in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown by way of example and not limitation in the accompanying drawings in which like reference numbers represent like parts throughout and in which:
FIG. 1 is a schematic illustration of a distributed virtual storage network;
FIG. 2 is a schematic illustration of a preferred object-oriented model of the present invention;
FIG. 3 is a schematic illustration of a storage pool hierarchy bridging the virtual and physical realms in preferred embodiments of the present invention;
FIG. 4 is a schematic illustration of an illustrative storage pool hierarchy;
FIG. 5 is a schematic illustration of a management agent and corresponding management consoles that can be used in some preferred embodiments of the invention;
FIGS. 6 and 7 schematically illustrate management operations that can be employed in some preferred embodiments of the present invention;
FIGS. 8 to 15 illustrate graphical user interfaces that can be provided to facilitate management of virtual storage in relation to the creation of a virtual disk in some illustrative embodiments of the invention;
FIGS. 16 to 18 illustrate some exemplary navigational views that can be presented to a user to facilitate management of the storage system in some illustrative embodiments of the invention; and
FIGS. 19 to 29 illustrate some exemplary disk management and properties views that can be presented to a user to facilitate management and selection of disk properties in some illustrative embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Preferred Environments (e.g., Storage Area Networks)
The present invention can be applied in a wide range of systems, e.g., in storage area network (SAN) systems and in other environments. In some embodiments, the present invention can be applied in, e.g., heterogeneous SAN environments (e.g., at the storage level). In some other embodiments, the present invention can be applied in, e.g., open SAN environments (e.g., at the fabric level). In some other embodiments, the present invention can be applied in, e.g., non-SAN environments (e.g., at the server level). The present invention can also be applied in various systems shown in the above-identified patent applications incorporated herein-by-reference and in other systems as would be apparent to those in the art based on this disclosure.
In some non-limiting preferred embodiments, the present invention can be applied in a virtualized storage area network (SAN) system 100 using one or more distributed mapping tables, as needed to form one or more virtual disks for input/output (I/O) operations between hosts and storage containers 160 , as illustrated in FIG. 1 . In particular, the table contains a mapping that relates a position in a virtual disk 150 with an actual location on the storage containers 160 .
The system 100 principles of distributed, virtual table mapping can be applied to any known SAN. It should therefore be appreciated that the storage devices are known technologies and may refer to any type of present or future known programmable digital storage medium, including but not limited to disk and tape drives, writeable optical drives, etc. Similarly, the hosts 140 may be any devices, such as a computer, printer, etc., that connect to a network to access data from a storage device.
Likewise, the storage network is also intended to include any communication technology, either currently known or developed in the future, such as the various implementations of Small Computer Systems Interface (SCSI) or Fibre Channel. This distributed virtualization is most useful in environments where a large amount of storage is available and connected using some sort of “storage network” infrastructure. One preferred implementation uses Switched Fibre-Channel connected storage. However, nothing in the design of the system 100 precludes its use on other types of storage networks, including storage networks that are not yet invented.
The hosts access the table through multiple mapping agents 110 . The system 100 uses multiple agents 110 that are associated with the hosts 140 . Preferably, each host has a separate agent 110 , but the system 100 could be easily configured so that more than one host 140 connects to an agent 110 . If multiple hosts 140 connect to the same agent 110 , the hosts 140 may share that agent's mapping table (alternately, there may be independent tables per host). The agent 110 stores the mapping table in volatile memory such as DRAM. As a result, if one of the agents 110 loses power, that agent 110 loses its copy of the table. Such an event could take place if the mapping agent 110 is embedded in the host 140 , for example, a backplane card serving as the mapping agent 110 , and the host 140 system loses power.
By storing the mapping table in volatile memory, the table can be easily and rapidly accessed and modified on the agents 110 . Storing the mapping table in volatile memory has the further advantage of substantially reducing the cost and complexity of implementing the agents 110 as mapping agents. Overall, the agents 110 allow the performance-sensitive mapping process to be parallelized and distributed optimally for performance. The mapping agents 110 reside on a host 140 and are in communication with a virtual disk drive 150 .
The system 100 further comprises a controller 120 that is separate from the mapping agents 110 . The controller 120 administers and distributes the mapping table to the agents 110 . Control of the mapping table is centralized in the controller 120 for optimal cost, management, and other implementation practicalities. The controller 120 further stores the mapping table in a semi-permanent memory, such as a magnetic disk or an EPROM, so that the controller 120 retains the table even after a power loss. In this way, the responsibility for persistent storage of mapping tables lies in the controller 120 so that costs and complexity may be consolidated. Any controller 120 known in the art of digital information storage may be employed as needed to implement the present invention. Within this framework, each of the mapping agents 110 preferably interacts only with the controller 120 and not with the other agents 110 . Furthermore, the architecture allows for a controller 120 comprised of redundant, cooperating physical elements that are able to achieve very high availability. As a result, the system 100 is highly scaleable and tolerant of component failures.
The interactions of the controller 120 and the agents 110 are defined in terms of functions and return values. In a distributed system, this communication is implemented with messages on some sort of network transport such as a communication channel 130 . The communication channel 130 may employ any type of known data transfer protocol, such as TCP/IP. In one implementation, the communication channel 130 is the storage network itself. The communication channel 130 has access to non-virtual storage containers 160 . Any suitable technique may be used to translate commands, faults, and responses to network messages.
II. Preferred Management Model
FIG. 2 illustrates an object-oriented model employed in some preferred embodiments of the invention. The objects in the illustrated model are described in detail below. The objects include operations that either humans or automated policy can invoke—e.g., based on the model, a user (e.g., a system administrator) can assign storage resources via a system management interface.
As shown, the host folder, the virtual disk folder, and the storage pool objects can reference themselves. That is, multiple instances of these objects can be referenced under the same object type. This captures the notion of a tree-structured hierarchy. For example, the folder object representing the root of the tree always exists and sub-folders can be created as needed. This is generally analogous to a WINDOWS folder hierarchy, which is also a tree structure. A WINDOWS EXPLORER folder browser interface, for example, would be an illustrative graphical user interface representation of this kind of structure. Similarly, command line interfaces may support this concept with a notion such as “current directory.”
Host
The host object 140 ′ represents a host system (e.g., a computer, etc.) that consumes a virtual disk and supports one or more applications.
Host Agent
The host agent object 110 ′ is a component that provides virtualizing capability to the hosts (e.g., a “mapping agent”). A host has zero or more host agents through which virtual disks can be presented to that host. If a host has zero associated agents, presentation is not possible. The model preferably allows this because there may be temporary situations where a host does not have an agent (e.g., one has not been added or repaired). A host agent may serve multiple hosts or, alternatively, a host agent may attach to only a single host.
The presented unit, described below, references all host agents through which a host may be reached for a given virtual disk. A host agent may be used by zero or more presented units to present zero or more virtual disks to a host.
Virtual Disk
The virtual disk object 150 ′ represents a block-store disk as seen by a host system. It is independent of physical storage and is a logical object that contains the data that the system stores on behalf of host systems.
Virtual disk service operations are preferably similar to those of a locally attached physical disk. A virtual disk can include, for example, a compact (non-sparse) linear array of fixed-size data blocks indexed by nonnegative integers, which may be read or written. A read operation transfers the data from a set of consecutively indexed data blocks to the host system. A write operation transfers data from the host system to a set of consecutively indexed data blocks.
While a virtual disk can be seen by host systems as a compact linear array of blocks, an implementation may save space by not allocating physical storage to any block that has never been written. Read operations issued to blocks that have never been written can, for example, transfer a block of all zeros. In some embodiments, several virtual disks may share resources. Preferably, however, such virtual disks behave similarly to independent physical disks as seen through the service interface.
In contrast to typical service operations, virtual disk management operations can be unique. For example, the notion of performing a snapshot operation is foreign to today's physical disks. Many management operations can treat virtual disks like independent objects, which can be desirable because customers understand physical disks to be independent objects. However, other operations can either expose or control relationships between virtual disks. These relationships include temporal relationships, shared capacity relationships, performance interdependencies, data reliability co-dependencies, availability co-dependencies and/or other relationships.
Derived Unit
The derived unit object 250 adds protocol personality (e.g., SCSI, Fiber Channel, CI, etc.) to a block-store represented by the virtual disk—i.e., the derived unit supplies the I/O protocol behavior for the virtual disk. When a virtual disk is presented to a host, a derived unit is created to add semantics (e.g., SCSI) to the block storage provided by the virtual disk.
If desired, more than one derived unit can be allowed per virtual disk, such as for such cases where an administrator wants to treat these as independent disks that happen to have shared contents. However, this may be of limited use in some cases and products can be made that will only allow one derived unit per virtual disk. Preferably, a derived unit is always associated with only one virtual disk.
While some illustrative derived units involve SCSI protocols, the architecture allows for derived units for protocol types other than SCSI. The SCSI model can be selected, for example, where host driver stacks support the SCSI model. However, a host-attached mapping agent can provide any interconnect model desired to a host depending on circumstances.
Additionally, SCSI disks, for example, may have mode pages, reservation stacks and geometry information in addition to the information stored in their data blocks. In some illustrative and non-limiting examples, the derived unit may provide storage to capture persistent information related to a host-storage interconnect used to access the virtual disk—e.g., when a virtual disk is accessed via a SCSI interconnect, the derived unit can provide a place to store the SCSI mode pages associated with that virtual disk.
Presented Unit
The presented unit object 240 provides an association between a host or group of hosts and a derived unit. This association allows a host or a specific group of hosts to access a derived unit and its underlying virtual disk. In the system, there may be many hosts. Often, such hosts are non-cooperating. Accordingly, it is preferred that virtual disks be selectively presented to hosts. The derived unit of a virtual disk may be presented to several hosts and not presented to others. In some embodiments, individual hosts may be members of a host group. Hosts or host groups to which a derived unit is not presented have no knowledge of the derived unit and its underlying virtual disk and cannot use it.
The presented unit manages presentation of virtual disks with derived unit personality (e.g., SCSI) to individual hosts. Preferably, it can manage multiple agents in a single host and multiple paths to such agents. This object is related to a virtual disk through a derived unit and it makes the virtual disk accessible over the host-storage interconnect. The presented unit defines the way that the host addresses the virtual disk and controls which hosts are authorized to access the virtual disk.
The presented unit provides the association between the virtual disk's derived unit and the host and is primarily responsible for managing the connection to the host over all available paths to all available host agents. A host may have zero or more associated presented units. Each presented unit is associated with only one derived unit, but a derived unit may be associated with multiple presented units (e.g., one for each host to which the virtual disk is presented).
The derived and presented unit objects are indirectly exposed to the user interfaces and are seen as controls to present a virtual disk to one or more host.
Virtual Disk Replica
Preferably, each virtual disk contains one or more virtual disk replica 150 R. A virtual disk replica preferably contains a complete copy of the virtual disk block data. In some embodiments, only one virtual disk replica may be supported. In embodiments where only one virtual disk replica is provided per virtual disk, it may not likely be exposed in user-visible interfaces. Preferably, multiple virtual disk replicas per virtual disk are supported to enable disaster tolerant data replication.
Preferably, each virtual disk replica references a sub-pool in the storage pool hierarchy. That is, each virtual disk replica preferably has an attribute that references one sub-pool. Each sub-pool may be referenced by zero or more virtual disk replicas. The storage pool hierarchy becomes the focal point for the management flexibility, because a virtual disk replica sub-pool attribute can be changed, possibly causing the virtual disk replica storage to migrate. Similarly, the data containers and sub-pools under a sub-pool can change, possibly causing all affected virtual disk replicas to migrate.
Storage Pools
The storage pool object 210 represents a hierarchy of pools and sub-pools, forming a tree structure. The root is the entire storage pool. Preferably, any node in the tree can contain data containers. This hierarchy organizes the physical storage into a name space that is independent of physical storage but that still represents physical structure, such as storage in different rooms, buildings, sites, etc. This is useful, for example, for allocating independent storage for different virtual disk replicas of a virtual disk. As noted, one attribute of a virtual disk replica is the sub-pool from which the virtual disk replica should obtain its storage capacity. Any data containers in that sub-pool or its children is preferably eligible to provide capacity for that virtual disk replica.
With respect to the storage pool hierarchy, each sub-pool preferably references zero or more data containers (e.g., logical unit numbers (LUNs)) and each data container used for the virtual pool is preferably referenced by only one sub-pool. Data containers not used for virtual disk storage are preferably not referenced by any sub-pool.
The storage pool object is used to organize the storage available to the system. Pools contain the pools of space that are available to the system. Virtual disks are created and managed from space within storage pools. Storage pools can be organized into different categories based upon customer needs. These categories include but are not limited to reliability characteristics, business organization, physical location, and storage controller structure. Storage pools can also provide space management features. Storage pool space management can be used to determine total capacity, free space, used space, reliability characteristics and/or other things.
Storage Controller
The storage controller object 200 represents an array controller or some other type of storage subsystem that provides data containers to the storage pool. The storage controller contains the physical connections that are managed to access the storage. The storage controller contains all of the data containers presented by that storage controller. And, each data container preferably belongs to only one storage controller.
Data Container
The data container object 160 ′ represents, for example, physical LUNs presented by a storage controller. Storage containers 160 ′ may refer to any type of present or future known programmable digital storage medium, including but not limited to disk drives, tape drives and writeable optical drives.
Host Folder
The host folder object 230 can be used, if desired, to cope with scaling. To manage a large number of hosts, the hosts are preferably grouped into a folder hierarchy. This hierarchy helps to provide a partitioning of name spaces. As noted, host folders can contain hosts and host folders. The individual folders in the host folder hierarchy can contain zero or more host objects. Preferably, each host object is contained in only one host folder. This object can be omitted in other embodiments.
Virtual Disk Folder
Similar to the host folder object, the virtual disk folder object 220 can be used, if desired, to cope with scaling. To manage a large number of virtual disks, the virtual disks are preferably grouped into a folder hierarchy. This hierarchy helps to provide a partitioning of name spaces. This enables the arrangement of virtual disks into a hierarchical name space and is similar to a directory tree in a file system. Virtual disk folders can contain virtual disks and virtual disk folders.
This object is preferably defined by the administrator to organize and name groups of virtual disks. The name of the virtual disk folder preferably appears as an element in the virtual disk path name. The virtual disk folder allows the implementation of folder access control, default attribute values for new virtual disks created within the folder, and the ability to rename folders.
As with the host folder, each virtual disk folder can contain zero or more virtual disks, and each virtual disk is preferably contained in only one virtual disk folder. This object can also be omitted in other embodiments.
Other Aspects/Embodiments
In some preferred embodiments, a notable aspect of the above model includes the separation of physical storage management from virtual disks presented to hosts. The objects enabling this separation include the virtual disk and the storage pool hierarchy. The virtual disk is independent of physical storage and is manageable by setting attributes. The storage pool hierarchy provides the boundary between the virtual and the physical parts of the model and encapsulates the physical storage in a way that allows the physical components to change without affecting the virtual parts of the model. The physical parts of the model represent the physical components of the environment, including the storage subsystems and the storage they present. The use of hierarchical navigation provides a helpful management mechanism to traverse the group objects based upon the primary object; the system and method can, e.g., use folder objects to navigate the sub-folders and the objects within the folders.
FIG. 3 is a schematic diagram illustrating space management according to some preferred embodiments of the invention. In this figure, the two vertical columns represent the logical view and the physical view of the system. The storage-pool hierarchy provides a bridge between these two views.
In FIG. 3, “storage” is preferably used to refer to physical block storage consumed in the system. Various forms of redundancy such as RAID techniques and replication increase the amount of storage needed to contain user data.
In FIG. 3, “capacity” is preferably used to refer to the hosts'view of sizes. For example, a virtual disk is created to contain a certain capacity. The capacity of a virtual disk is only indirectly related to the amount of physical storage used to store that virtual disk.
In FIG. 3, “allocated space” is preferably space that occupies storage on the system. For example, a virtual disk that is fully allocated has sufficient blocks allocated to contain all of the user data and redundant information at the specified level of redundancy. Failures may cause allocated storage to become inaccessible or could cause the contents of allocated storage to be destroyed.
In FIG. 3, “reserved space” is preferably space that has been set aside on a system to prevent others from using it, but the specific blocks of physical stores might not yet be allocated. Preferably, when the system is operating normally, reserved space is guaranteed to be available, while failures of the underlying physical storage may cause reserved space to be unallocatable. Some differences between reserved and allocated storage can include: a) space can be reserved more quickly than it can be allocated, so this moves allocation cost from create time to first-write time; and b) if available physical storage drops below reserved storage levels, the system is more likely to continue providing virtual disk service than if physical storage drops below allocated storage levels.
In FIG. 3, “committed capacity” preferably represents the amount of capacity promised to hosts of virtual disks, whether or not it is reserved or allocated. Committed capacity is not guaranteed to be available when needed. A system that has committed more capacity than it can possibly store is said to have “over-committed” its capacity.
In FIG. 3, the uppermost object in the logical view is the virtual disk. It has a capacity and policies that decide how and when that capacity is to be allocated. Each virtual disk replica tracks allocated and reserved capacity and storage. A visible attribute is not needed, but its existence can be implied and used to track reserved storage. Preferably, volume occupancy and reserved storage is automatically adjusted any time a virtual disk is created, deleted or changes allocation.
Once again, bridging the gap between the logical and physical worlds is the storage-pool hierarchy, including, e.g., a root storage pool and child storage pools. Preferably, each storage pool computes the sum of the allocated, reserved, and available storage of its child storage pools. In addition, each storage pool preferably contains a settable attribute to track the storage committed against that storage pool. The total storage committed attribute preferably sums the storage committed attribute of a storage pool and its children. Therefore, anytime a virtual disk is created, deleted or changes allocation, the storage pool hierarchy preferably automatically reflects those changes.
FIG. 4 is a schematic diagram that shows an example of one storage pool hierarchy for illustrative purposes. In this non-limiting example, the storage pool hierarchy is selected based on physical location. As previously explained, however, the hierarchy could alternatively be based on other attributes. In this illustration, the virtual disks X, Y and Z reference a “root” pool, an “Americas” sub-pool (having NA and LA sub-pools) and a “Europe” sub-pool, respectively.
In preferred embodiments, the storage pool becomes the focal point of space management. Whenever new space is needed, the virtual disk replica that needs it preferably gets its space in the storage pool associated with that virtual disk replica. It does so by updating the storage committed attribute of the storage pool. It can also use the storage allocated total and storage reserved total to determine if sufficient space is available in the storage pool to satisfy the virtual disk's allocation policy.
In various embodiments, the model can be altered while still taking advantage of one or more benefit of the present invention and some objects can be eliminated in some embodiments. For example, while the virtual disk folder and the host folder hierarchies are helpful for managing the naming of a large number of objects and are helpful for scaling, a subset that leaves out one or more of these objects, but preserves the separation of virtual and physical through the use of, for example, the virtual disk, the virtual disk replica and the storage pool hierarchy can be employed in other embodiments. As another example, models may eliminate the virtual disk replica and move its pool attribute to the virtual disk—e.g., if there is no need to support disaster tolerant replication.
In addition, subsets of objects can be utilized in independent or separate models. As one example, the virtual disk, the virtual disk replica and the storage pool hierarchy are objects that support the separation of the virtual and the physical. Hence, these objects can be used in independent or separate models. As another example, the host, the host agent, the presented unit, the derived unit, and the virtual disk are objects that support the flexible presentation of virtual disks to hosts. Hence, these objects can also be used in independent or separate models. Accordingly, embodiments can be directed to these subsets of objects as well as to other subsets or variations as would be apparent based on this disclosure.
The object-oriented models of the present invention can be used in system implementation, customer documents, training documents, etc., and, most notably, in user interfaces, such as graphical user interfaces (GUIs), command line interfaces (CLIs) and application programming interfaces (APIs) involved in the management of the system.
III. Management Using The Preferred Models
According to some preferred embodiments of the invention, a controller 120 , such as that illustrated in the non-limiting examples of FIGS. 1 and 5, is connected to a general purpose network, such as for example a WAN, the Internet, etc., and provides a web-based management interface that can be provided to a client-computer host system with a suitable web browser. In this regard, the controller preferably operates as a server providing the web-based management interface. The hardware and software providing this management interface is referred to herein as a management agent MA. Because the management agent MA offers a web interface in these preferred embodiments, any appropriate computer system with a suitable web browser could potentially operate as a remote management console MC. In this case, a TCP/IP communication, for example, can be established. The interface provided at such a remote management console can include a graphical user interface, a command line interface and/or any other appropriate computer interface. The management console can thus enable a user (e.g., a storage administrator) to manage the virtual storage system. A storage administrator preferably includes one or more person that is responsible for the management and operation of the system.
The management agent MA preferably provides an interface to the manageable objects, provides an engine for executing extrinsic policies, and provides an interface for controlling extrinsic policies. In preferred embodiments, the various object models, discussed herein, describe capabilities of the management agent. In addition, the management agent may include a repository for storing historical management data, persistent state associated with extrinsic policies, etc. Preferably, the management agent also includes general-purpose services for scheduling, event generation, and logging.
In other embodiments, an application programming interface (API) can be provided to the management agent MA. For example, an API can be used in conjunction with various host-side applications or the like. However, a management console need not use the API; API is only one example out of many potential management interfaces.
In some embodiments, a management interface can be provided directly at a host computer system to provide a management interface for the host system. In some embodiments, one or more of the host systems receiving storage services from a system may be configured to issue management commands to the system. For example, a host system may want to make its database consistent and then request a snapshot of the virtual disks that store its database. In addition, once the snapshot is complete, it may want to resume its database.
While the management console MC preferably communicates with the management agent via an open network, the management console can include a computer that communicates via any appropriate communication channel.
As shown in FIG. 5, a management agent MA may have one or more of a variety of managing clients MC. These may include, for example, local and/or remote management consoles, SNMP agents, and/or host systems. For example, the system may include a Simple Network Management Protocol (SNMP) agent able to access the management agent through a local API. This can enable management through SNMP products like NETVIEW, etc.
The system may also include a local instantiation of the management console communicating via a low level local console interface. This might be useful during, for example, initial installation, network configuration, etc.
FIG. 6 schematically illustrates that with preferred embodiments of the present invention the workload can be more evenly distributed across all spindles, can greatly reduce throughput bottlenecks, and can avoid load-balancing procedures for applications and databases. FIG. 7 schematically shows that the virtual storage system can provide a single virtual storage pool for numerous host systems (e.g., application servers, etc.), that the preferred embodiments can facilitate on-line, demand driven, capacity redeployment and that the system can facilitate on-line addition of devices and virtual volumes. In preferred embodiments, a user (e.g., a storage administrator) can perform the above operations on-line at a management console MC or other computer interface.
The preferred embodiments of the present invention can create a system having: a single, large pool of storage resources in which virtual disks can be instantiated; any virtual disk that can be presented to any host attached to the system by a management command; and/or a single management domain.
FIGS. 8 to 15 show illustrative graphical user interfaces that can be provided (e.g., via management consoles MC or the like) to facilitate management of the virtual storage in relation to the creation of a virtual disk utilizing a model according to the preferred embodiments of the present invention. These figures merely show some illustrative examples of how a model according to preferred embodiments of the present invention can be presented. Various other graphical user interfaces and/or other interfaces, such as command line interfaces or application programming interfaces, could be used in other embodiments.
In the non-limiting example shown in FIG. 8, virtual disks can be created with a wizard that leads the customer through a series of steps. Using virtual disk navigation, a desired folder is initially selected and a virtual disk menu is brought down to present “new” under “virtual disk.”
FIG. 9 shows another user screen shot that can be provided with the wizard, requesting that the user enter a family name for the new virtual disk.
FIG. 10 shows another user screen shot that can be provided with the wizard, requesting that the user specify the RAID level and the write cache policy. In one example, the default can be parity RAID and mirrored write-back cache. The RAID level is preferably specified early in the process because it will affect the allocated storage. Preferably, the RAID level and cache policy are specified together because they both impact performance and reliability.
FIG. 11 shows another user screen shot that can be provided with the wizard, requesting that the user provide the capacity for the new virtual disk. In some preferred embodiments, this step would also allow the user to select a storage allocation policy. In some embodiments, all virtual disks can merely be fully allocated. At this point, the system can determine whether there is any storage pool in which a fully allocated virtual disk of the requested size can be created. If the user increases the capacity too high, a message can preferably describe the capacity limit and its relationship to the RAID level and the storage allocation policy.
FIG. 12 shows another user screen shot that can be provided with the wizard, requesting that the user specify the location for the new virtual disk. Preferably, a default would be an automatic storage pool or storage pool selection. An automatic storage pool selection will preferably select the largest storage pool that is compatible with the requirements of the virtual disk. Preferably, if the customer selects manual storage pool selection, any storage pools that have insufficient storage will be grayed out (i.e., as non-selectable).
FIG. 13 shows another user screen shot that can be provided with the wizard, requesting that the user specify a derived unit for the virtual disk. Preferably, the customer can optionally specify that the unit is to be read-only. This step preferably selects the derived unit architecture and allows the customer to supply a name.
FIG. 14 shows another user screen shot that can be provided with the wizard, requesting that the user specify a host to which the unit is presented. In some embodiments, the user can be allowed to specify a group of hosts cataloged in a like host folder.
FIG. 15 shows the result of creating a new virtual disk (in the illustrated example, a virtual disk family) with the new virtual disk in the virtual disk folder.
FIGS. 16 to 18 illustrate some exemplary navigational views that can be presented to a user (e.g., via the management station or other interface) to facilitate management of the storage system. In preferred embodiments, a basic user interface will offer multiple navigation views for addressing paradigm shifts (e.g., from physically organized to virtually organized) and for changing from host-centric views to storage-centric views and the like.
In the illustrative embodiment, six buttons B 1 to B 6 at the top of the navigation pane are provided that enable a user to easily switch between navigation views. Again, this is merely an illustrative case and other embodiments can have more or less views.
FIG. 16 shows an illustrative navigation view by virtual disk (i.e., button B 1 is clicked). In this illustrative example, two sub-systems fuweba and fuwebb are shown and the virtual disk directories under one is open. The open directory has three virtual disk families. The members of the selected family are shown in the right-hand pane.
FIG. 17 shows an illustrative navigation view by host (i.e., button B 5 is clicked). In this illustrative example, as shown, virtual disks presented to a host may be shown in a separate pane.
FIG. 18 shows an illustrative navigation view by logical location (i.e., button B 3 is clicked). Preferably, logical locations are defined by the customer. A logical location may, in some cases, span physical locations. As described above, logical locations are hierarchical and are called storage pools. An LUN is an exemplary primitive storage pool. This picture shows two systems, fuweba and fuwebb. Fuweba has two top-level storage pools defined, the first of which is made up of two second-level storage pools. At the lowest level, each LUN is a storage pool.
Although not illustrated, other navigational views can include storage resource navigational views (i.e., button B 2 ), fibre topology navigational views (i.e., button B 6 ), host navigational views (i.e., button 5 ) and/or navigation by physical devices (i.e., button 4 ).
FIGS. 19 to 29 illustrate some exemplary disk management and properties views that can be presented to a user (e.g., via the management station or other interface) to facilitate management and selection of disk properties.
With reference to FIG. 19, an illustrative graphical user interface for virtual disk navigation and management is shown. The right pane shows the contents of the virtual disk folder. Preferably, the virtual disk folder contains either virtual disk families or other virtual disk folders or both. The right pane shows some basic attributes of the objects within the virtual disk folder. In the illustrative embodiment, a menu bar is at the top of the right pane.
With reference to FIG. 20, this illustrative interface expands the virtual disk menu in the virtual disk folder pane. “New” allows the creation of new virtual disk families and folders (e.g., as described above). “Discard” allows an empty virtual disk folder or family to be eliminated. “Rename” allows a virtual disk folder or family to be renamed. “Properties” displays the virtual disk folder or family properties. Preferably, this can also be done by double-clicking on the icon.
With reference to FIG. 21, this illustrative interface expands the “edit” menu in the virtual disk folder pane. “Cut” and “paste” can preferably be used to move a virtual disk folder or family from its current folder or family to another. Alternatively, this could also be done with drag and drop. In this example, “cut” is grayed out because nothing is selected within the folder and “paste” is grayed out because nothing has been cut. Preferably, there will be no cut without a paste being done.
With reference to FIG. 22, this illustrative interface demonstrates operations that may be performed on virtual disks in some embodiments. At the top of the virtual disk detail pane is a menu bar that gives the customer access to virtual disk operations on the selected virtual disk. FIG. 23 shows a list of illustrative virtual disk functions. FIG. 24 shows a list of illustrative virtual disk edit functions. For example, cut and paste may be used to move a virtual disk to another folder. FIG. 25 shows a list of illustrative virtual disk configure functions.
Configure commands can be supplied for controlling, among other things, one or more of the following attributes: write protected; presented; capacity; RAID Level; caching policy; and/or consistency set membership. Preferably, most of these are virtual disk attributes that can be additionally or alternatively managed via a properties page.
FIG. 26 shows an illustrative virtual disk properties page. This particular page shows a graphical user interface that is a general properties page. FIG. 27 shows a virtual disk properties page for unit access. It allows one to create, modify and delete a virtual disk's access control entry (i.e., a presented unit). In this illustrative case, a different tab is used to manage the unit protocol (i.e., derived unit). That is, in this embodiment, derived units are created independently of presented units and hosts. Preferably, presented units are created by selecting a host system and a derived unit and then using the “add” button. In some cases, only the host need be selected. In this embodiment, host selection can be done with a host navigation hierarchy instead of a flat host namespace. In this embodiment, there are details of the presented unit that can advantageously be observed and controlled. In this embodiment, this can be done by highlighting an existing unit access entry and then clicking on “modify.” Although not shown, another interface can be displayed that allows the basic parameters of the presented unit to be modified, such as, for example, the host system, the access and/or the derived unit. In addition, it is preferably possible to disable a presented unit. Preferably, a requirement for presented units includes the ability to present a unit to all hosts within a group of hosts. In some embodiments, to effect this, a host folder may be specified as the host system in a presented unit. In that manner, each host system within the host folder could be given equal access.
FIG. 28 is an illustrative GUI screen showing a virtual disk properties page for “unit protocol.” This can be used to provide control over the derived unit. In some cases, a derived unit is an abstraction that most administrators can ignore. In this embodiment, operations enabled by this tab can include the creation of a new derived unit, the modification of the read-write/read-only state of an existing derived unit, and the deletion of an existing derived unit with a zero reference count. This page preferably also allows the user to give a derived unit a unit name. Preferably, as with the presented unit page, the derived unit can be modified by highlighting a specific derived unit and then pressing modify. Preferably, doing so can be used to reveal additional architecture-specific attributes of the derived unit.
FIG. 29 is an illustrative GUI screen named the “location tab” that enables the customer to manage the location of a virtual disk. In some embodiments, an independence constraint could be added when the pool or storage pool selection is automatic.
While preferred embodiments of the invention have been described, the present invention is not limited to these preferred embodiments, but includes everything encompassed within the scope of the appended claims and all alterations and modifications as would be apparent to those in the art based on this disclosure. | Preferred embodiments of the present invention provide a system and method for the management of virtual storage. The system and method include an object-oriented computer hardware/software model that can be presented, for example, via a management interface (e.g., via graphical user interfaces, command line interfaces, application programming interfaces, etc.). In some preferred embodiments, the model separates physical storage management from virtual disks presented to hosts and management can be automated such that the user (e.g., customer, manager and/or administrator) specifies goals rather than means—enhancing ease of use while maintaining flexible deployment of storage resources. | 8 |
FIELD
[0001] The present disclosure relates to window regulator systems.
BACKGROUND
[0002] Vehicle doors have windows that can be opened and closed. Within the door, there can be a window regulator assembly including a carrier panel, a motor, rails and window regulator lifter or carrier plate assembly which is driven along is respective rail by the motor with associated cabling. There are several problems, however, with these window regulator assemblies. For example, in situations where the window regulator lifter assemblies are driven by cables, pulleys can be are used to effect a change in direction for the cables within the regulator assembly. However, due to forces involved in operating and/or in installing the window regulator assembly, the joint between the pulleys and the carrier may be subject to premature failure.
[0003] It is recognized that window regulator systems can be fastened to the interior of the vehicle doors in a variety of different ways. It is advantageous for such fastening systems to be streamlined in design as well as to be strong enough to withstand cable tension forces during installation and/or operation.
SUMMARY
[0004] It is an object of the present invention to provide a pulley installation on a window regulator system component to obviate or mitigate at least some of the above-presented disadvantages.
[0005] An aspect provided is a component for a window regulator system of a vehicle closure panel including: a rail having a rail aperture extending between a first side of the rail and a second side opposite the first side, the rail aperture having a retaining surface associated with the rail aperture; a pulley for mounting adjacent to the first side, the pulley having a pulley aperture with a pulley surface opposite the first side; a pulley rivet having a rivet body including a retaining lip for engaging with the pulley surface and a retainer portion for engaging with the retaining surface, the rivet body configured for receipt in both the pulley aperture and the rail aperture when installed, the rivet body having a hole for receiving a fastener for fastening the rail to a panel via the pulley rivet; wherein, when installed, the rivet body is positioned within the pulley aperture and within the rail aperture, such that engagement between the retaining lip and the pulley surface inhibits separation of the pulley from the rail while engagement of the retainer portion with the retaining surface inhibits separation of the pulley rivet from the rail aperture.
[0006] A further aspect provided a pulley rivet having a rivet body including a retaining lip for engaging with a pulley surface and a retainer portion for engaging with a retaining surface, the rivet body configured for receipt in both a pulley aperture and a rail aperture when installed, the rivet body having a hole for receiving a fastener for fastening the rail to a panel via the pulley rivet; wherein, when installed, the rivet body is positioned within the pulley aperture and within the rail aperture, such that engagement between the retaining lip and the pulley surface inhibits separation of the pulley from the rail while engagement of the retainer portion with the retaining surface inhibits separation of the pulley rivet from the rail aperture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing and other aspects will now be described by way of example only with reference to the attached drawings, in which:
[0008] FIG. 1 is a perspective view of a vehicle;
[0009] FIG. 2 is a perspective cross sectional view of a portion of the window regulator system shown in FIG. 1 ;
[0010] FIG. 3 is a further perspective cross sectional view of the window regulator system shown in FIG. 2 ;
[0011] FIG. 4 is perspective view of a pulley rivet of the window regulator system shown in FIG. 2 ; and
[0012] FIG. 5 is a cross sectional view of the pulley rivet shown in FIG. 2 .
DETAILED DESCRIPTION
[0013] FIG. 1 is a perspective view of a vehicle 10 that includes a vehicle body 12 and at least one vehicle door 14 (also referred to as a closure panel 14 ). The vehicle door 14 includes a latch 20 that is positioned on a frame 15 of the vehicle door 14 , the latch 20 releasably engageable with a striker 28 on the vehicle body 12 to releasably hold the vehicle door 14 in a closed position. The frame 15 also supports a window 13 via a window regulator assembly (not shown) mounted to the frame 15 , as further described below. An outside door handle 17 is provided for opening the latch 20 (i.e. for releasing the latch 20 from the striker 28 ) to open the vehicle door 14 , as well as optionally to operate the window regulator system. Further, the vehicle door 14 has an inside control 16 (e.g. door handle, window controls, etc.) for operating the latch 20 and the window regulator assembly. A door panel 18 is shown providing a finishing cover (e.g. interior panel) over the window regulator assembly positioned between the frame 15 and the door panel 18 .
[0014] For vehicles 10 , the closure panel 14 can be referred to as a partition or door, typically hinged, but sometimes attached by other mechanisms such as tracks, in front of an opening which is used for entering and exiting the vehicle 10 interior by people and/or cargo. In terms of vehicles 10 , the closure panel 14 may be a driver/passenger door, a lift gate, or it may be some other kind of closure panel 14 , such as an upward-swinging vehicle door (i.e. what is sometimes referred to as a gull-wing door) or a conventional type of door that is hinged at a front-facing or back-facing edge of the door, and so allows the door to swing (or slide) away from (or towards) the opening in the body 12 of the vehicle 10 . Also contemplated are sliding door embodiments of the closure panel 14 and canopy door embodiments of the closure panel 14 , such that sliding doors can be a type of door that open by sliding horizontally or vertically, whereby the door is either mounted on, or suspended from a track that provides for a larger opening. Canopy doors are a type of door that sits on top of the vehicle 10 and lifts up in some way, to provide access for vehicle passengers via the opening (e.g. car canopy, aircraft canopy, etc.). Canopy doors can be connected (e.g. hinged at a defined pivot axis and/or connected for travel along a track) to the body 12 of the vehicle at the front, side or back of the door, as the application permits. It is recognized that the body 12 can be represented as a body panel of the vehicle 10 , a frame of the vehicle 10 , and/or a combination frame and body panel assembly, as desired.
[0015] In general, the window can be coupled to a window regulator assembly (not shown) for moving the vehicle window 13 up and down, i.e. in and out of the an enclosure 31 provided between the frame 15 and the door panel 18 (see FIG. 3 ). The window regulator assembly can include a drive motor and drive mechanism (e.g. gearing—not shown) connected to a set of drive cables (not shown), one or more rails 36 for mounting on the frame 15 (or on an intervening carrier panel 19 as desired—see FIG. 2 ), a regulator carriage (not shown) connected to the window 13 and mounted on the rail 36 for riding along a track, and one or more pulleys 42 (e.g. upper pulley and lower pulley) for effecting changes in direction of the drive cables. In operation of the window regulator assembly, the drive motor causes movement of the drive cables which in turn propels the regulator carriage towards one end or the other end of the rail 36 , depending upon the rotational direction of the drive motor (e.g. as controlled by the door controls 16 , 17 ). It is recognized that the rails 36 can be mounted on the carrier panel 19 that is itself mounted to the frame 15 , as shown in FIG. 2 . Alternatively, the rails 36 can be mounted directly to the frame 15 (not shown) without the need for the intervening carrier panel 19 .
[0016] Referring to FIG. 2 , show is a perspective view of a cross section of the pulley 42 and associated attachment of the pulley 42 to the frame 15 . A pulley rivet 44 connects the pulley 42 to an aperture 46 in the rail 36 via an aperture 48 in the pulley 42 , such that a body 41 of the pulley rivet 44 extends from one side 43 of the pulley 42 facing the enclosure 31 (see FIG. 3 ) to the end 49 of the rail aperture 46 adjacent to the frame 15 . It is recognized that the pulley 42 is positioned on an interior side 35 of the rail 36 , and an exterior side 37 of the rail 36 is positioned adjacent to the frame 15 .
[0017] The pulley rivet 44 has a retaining lip 50 on one side 45 that overlaps with a pulley surface 52 (e.g. a retaining surface for the retaining lip 50 ) of the pulley 42 adjacent to the aperture 48 , in order to retain positioning of the pulley 42 adjacent to the rail 36 when installed by the pulley rivet 44 (i.e. adjacent to the interior side 35 ). At another side 47 of the pulley rivet 44 , opposite the one side 45 , can be an undercut (e.g. retainer portion) 54 for providing a snap fit against a corresponding retaining surface 56 , for example, adjacent to the aperture 46 in the rail 36 (i.e. on the exterior side 37 ), the snap fit between the undercut 54 and the retaining surface 56 acting as a detent mechanism to retain the pulley rivet 44 within the aperture 46 , once inserted. As such, the material (e.g. plastic) of the body 41 of the pulley rivet 44 is resilient to provide for deformation (e.g. elastic) of the body adjacent to the undercut 54 during travel of the pulley rivet 44 within (and through) the aperture 46 , such that the undercut 54 overlaps the retaining surface 56 once the undercut 54 inserted in (and optionally emerges out of) the aperture 46 . In other words, the body 41 (or portion thereof) of the pulley rivet 44 between the retaining lip 50 and the undercut 54 is of a cross sectional dimension smaller than a corresponding cross sectional dimension of the aperture 46 , while the undercut 54 itself (e.g. a barb) is of a cross sectional dimension greater than the cross sectional dimension of the aperture 46 in order to provide for the overlap between the undercut 54 and the retaining surface 56 as shown in FIGS. 2 and 3 . It is also recognized that the position of the retaining surface 56 can be other than shown. For example, the retaining surface 56 rather than being positioned external to the aperture 46 (i.e. on the surface 37 of the rail 36 ), the retaining surface 56 (or more than one retaining surface for mating with a corresponding number of undercuts 54 —not shown) can be positioned within the aperture 46 and as such the body 41 of the pulley rivet 44 may not extend through the aperture 46 . In other words, mating of the retaining surface 56 and the undercut 54 can occur within the aperture 46 rather than external to the aperture 46 , such that the retaining surface 56 and the undercut 54 function as the detent mechanism.
[0018] As shown in FIG. 4 , the cross sectional shape of the body 41 portion of the pulley rivet 44 positioned within the aperture 46 (see FIG. 2 ) can be other than circular, e.g. hexagonal. As such, the cross sectional shape of non-circular (e.g. hexagonal, square, oval, etc.) can inhibit rotation of the pulley rivet 44 in the aperture 46 when under influence of rotation of the pulley 42 as the window regulator assembly is operated by the drive motor, recognizing that the cross sectional shape of the aperture 46 corresponds (e.g. similarly shaped) to that of the body 41 to facilitate the inhibiting of body 41 rotation within.
[0019] Referring to FIG. 5 , shown is a hole 58 (e.g. extending from the one side 45 to the other side 47 , or not extending there through as desired) positioned in the body 41 of the pulley rivet 44 between the one side 45 and the other side 47 . A longitudinal axis of the hole 58 (in the body 41 ) can be aligned with a longitudinal axis of the rail aperture 46 . Further, the longitudinal axis of the rail aperture 46 can be aligned with a longitudinal axis of the pulley aperture 48 . For example, hole 58 in the rivet body 41 forms a tubular shaped wall about the longitudinal axis of the pulley rivet 44 , such that the fastener 60 is positioned within the interior of the tubular shaped wall and the undercut 54 is located on the exterior of the tubular shaped wall. The hole 58 can be threaded, or otherwise, in order to receive a fastener 60 used to fixedly attach the pulley rivet 44 (once installed on the pulley 42 and rail 36 ) to the carrier panel 19 and/or frame 15 (see FIG. 2 ). Accordingly, by example, the fastener 60 can be a screw or a bolt and nut combination, as desired.
[0020] In operation of the pulley rivet 44 , the pulley rivet 44 is placed through the aperture 48 of the pulley 42 such that the retaining lip 50 overlaps with the pulley surface 52 . The body 41 of the pulley rivet 44 with the undercut 54 is then pushed into (and optionally though) the aperture 46 of the rail 36 until the undercut 54 overlaps the retaining surface 56 of the aperture 46 , thus securing the pulley rivet 44 within the aperture 46 (through engagement of the retaining surface 56 with the undercut 54 ) and accordingly the pulley 42 on the rail 36 by means of the retaining lip 50 cooperating with the pulley surface 52 . The pulley rivet 44 is inserted into (e.g. received by) both the rail aperture 46 and the pulley aperture 48 when the apertures 46 , 48 are aligned. Once the rail 36 (with attached pulley 42 ) is in an assembly position with the carrier panel 16 (and/or frame 15 ), the installer can then insert the fastener through a hole in the carrier panel 16 (and/or frame 15 ) and then fasten the fastener 60 in the hole 58 of the pulley rivet 44 , thus securing the rail 36 and attached pulley 42 thereto via the rivet pulley 44 . It is recognized that some or all of the components of the window regulator system (e.g. one or more rails 36 , the regulator carriage connected to the window 13 and mounted on the rail 36 ) is/are ultimately connected to the carrier panel 16 and/or frame 15 via cooperation of the pulley rivet 44 and the fastener 60 . Preferably, the pulley rivet 44 is installed from the one side 35 of the rail 36 and the fastener 60 from the other side 37 of the rail 36 . Once the fastener 60 is fastened in the hole 60 , the window regulator system, if not already attached to the frame 15 , can then be attached via the carrier panel 16 to the frame 15 by other fasteners as desired. It is recognized that the aperture 46 of the rail 36 can be aligned with the corresponding hole in the carrier panel 16 and/or frame 15 when inserting the fastener 60 into the hole 58 of the pulley rivet 44 .
[0021] While the above description constitutes a plurality of embodiments, it will be appreciated that the present disclosure is susceptible to further modification and change without departing from the fair meaning of the accompanying claims. | A component for a window regulator system of a vehicle closure panel including: a rail having a rail aperture extending between a first side of the rail and a second side opposite the first side, the rail aperture having a retaining surface associated with the rail aperture; a pulley for mounting adjacent to the first side, the pulley having a pulley aperture with a pulley surface opposite the first side; a pulley rivet having a rivet body including a retaining lip for engaging with the pulley surface and a retainer portion for engaging with the retaining surface, the rivet body configured for receipt in both the pulley aperture and the rail aperture when installed, the rivet body having a hole for receiving a fastener for fastening the rail to a panel via the pulley rivet; wherein, when installed, the rivet body is positioned within the pulley aperture and within the rail aperture, such that engagement between the retaining lip and the pulley surface inhibits separation of the pulley from the rail while engagement of the retainer portion with the retaining surface inhibits separation of the pulley rivet from the rail aperture. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This non-provisional application claims the benefit of provisional application No. 61/753,887 filed on Jan. 17, 2013, entitled “Systems and Methods for Compiling and Storing Video with Static Panoramic Background”, which application is incorporated herein in its entirety by this reference.
[0002] This non-provisional application also claims the benefit of provisional application No. 61/753,893 filed on Jan. 17, 2013, entitled “Systems and Methods for Displaying Panoramic Videos with Auto-Tracking”, which application is incorporated herein in its entirety by this reference.
BACKGROUND
[0003] The present invention relates to systems and methods for compiling and displaying panoramic videos. More particularly, the present invention relates to efficiently extracting, storing and displaying video streams superimposed over static panoramic images.
[0004] The increasing wideband capabilities of wide area networks and proliferation of smart devices has been accompanied by the increasing expectation of users to be able to view video streams which include one or more objects of interest in real-time, such as during a panoramic tour.
[0005] However, conventional techniques for extracting, storing and displaying video streams require a lot of memory and bandwidth. Attempts have been made to reduce the memory requirements by superimposing videos over separately acquired still photographic images. Unfortunately, since the still photographic images were acquired separately, the still photo characteristics, e.g., the field of view and direction of view, may not match that of the respective video streams.
[0006] It is therefore apparent that an urgent need exists for efficiently extracting, storing and displaying video streams superimposed over static panoramic images without the need for separately acquiring still photographic images that may or may not be compatible.
SUMMARY
[0007] To achieve the foregoing and in accordance with the present invention, systems and methods for efficiently storing and displaying panoramic video streams is provided. In particular, these systems extract, store and display video streams with object(s) of interest superimposed over static panoramic images.
[0008] In one embodiment, a computerized system receives a video stream from a source, the video stream presenting a panning view of a panoramic environment at a plurality of different viewing angles. The system is configured to store angular metadata and sequential timestamp of each frame of the video stream, wherein the angular metadata includes at least one of yaw, pitch and roll. The system is further configured to extract overlapping frames from the video stream which may be optically aligned using keypoint tracking to compile a static panoramic background image.
[0009] Subsequently, during playback, a display device can align and present each frame of the video stream at a respective viewing angle relative to the panoramic environment, in sequence according to the sequential timestamp of each frame. In this embodiment, the plurality of different viewing angles radiate from a substantially fixed position within the panoramic environment.
[0010] In an additional embodiment, a computerized system is configured to display at least one auto-tracked object of interest superimposed on a composite panoramic background image, and includes a processor and a display screen. The processor receives an extracted video stream superimposed on a composite panoramic background image, the extracted video stream including at least one potential object of interest, and wherein the composite panoramic background image is incrementally compiled from a source video stream. At least one object of interest can be selected from the at least one potential object of interest. The display screen is configured to display the extracted video stream while auto-tracking thereby framing the at least one selected object of interest within the display screen.
[0011] Furthermore, in some embodiments, the framing includes substantially centering the at least one selected object of interest within the display screen, and the at least one selected object of interest includes at least two selected objects of interest. The processor can be further configured to auto-zooming to substantially frame the at least two selected objects of interest within the display screen.
[0012] Note that the various features of the present invention described above may be practiced alone or in combination. These and other features of the present invention will be described in more detail below in the detailed description of the invention and in conjunction with the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order that the present invention may be more clearly ascertained, some embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:
[0014] FIG. 1 is an exemplary high level flow diagram illustrating the extraction, storage and display of video streams superimposed over static panoramic images in accordance with one embodiment of the present invention;
[0015] FIG. 2 illustrates in greater detail the extraction of the still panoramic images for the embodiment of FIG. 1 ;
[0016] FIGS. 3 and 4 illustrate alternate methods for extracting video streams including objects of interest from source video streams for the embodiment of FIG. 1 ;
[0017] FIG. 5 is an exemplary screenshot illustrating a sequence of video frames within a static panoramic background for the embodiment of FIG. 1 ;
[0018] FIGS. 6A and 6B show in detail two of the video frames of FIG. 5 ;
[0019] FIG. 7 is a flow diagram illustrating the extraction and storage of video streams with framing metadata, for subsequent display on a static panoramic background in accordance with another embodiment the present invention;
[0020] FIGS. 8A and 8B are screenshots illustrating tracking and/or zooming in response to the identification of object(s) of interest in accordance with some embodiments of the present invention; and
[0021] FIGS. 9 and 10 are flow diagrams illustrating methods for identifying and/or selecting object(s) of interest for subsequent display in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION
[0022] The present invention will now be described in detail with reference to several embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent, however, to one skilled in the art, that embodiments may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the present invention. The features and advantages of embodiments may be better understood with reference to the drawings and discussions that follow.
[0023] Aspects, features and advantages of exemplary embodiments of the present invention will become better understood with regard to the following description in connection with the accompanying drawing(s). It should be apparent to those skilled in the art that the described embodiments of the present invention provided herein are illustrative only and not limiting, having been presented by way of example only. All features disclosed in this description may be replaced by alternative features serving the same or similar purpose, unless expressly stated otherwise. Therefore, numerous other embodiments of the modifications thereof are contemplated as falling within the scope of the present invention as defined herein and equivalents thereto. Hence, use of absolute and/or sequential terms, such as, for example, “will,” “will not,” “shall,” “shall not,” “must,” “must not,” “first,” “initially,” “next,” “subsequently,” “before,” “after,” “lastly,” and “finally,” are not meant to limit the scope of the present invention as the embodiments disclosed herein are merely exemplary.
[0024] The present invention relates to systems and methods for efficiently extracting, storing and displaying video streams with object(s) of interest superimposed over static panoramic images. To facilitate discussion, FIG. 1 is an exemplary high level flow diagram 100 illustrating the extraction, storage and display of video streams superimposed over static panoramic images, implementable in computerized devices, in accordance with one embodiment of the present invention. Suitable computerized devices include general purpose computers such as desktops and laptops, home entertainment systems such as smart televisions, cameras such as DSLRs and camcorders, and mobile devices such as smart phones and tablets.
[0025] More specifically, step 110 of flow diagram 100 includes receiving a source video stream, and in step 120 extracting and compiling a static panoramic background image from the video stream using, for example, a mapping and tracking algorithm. A video stream with one or more objects of interest (“OOI”) and associated projection metadata can be extracted from the source video stream and stored (step 130 ).
[0026] Depending on the implementation, a source video stream can be generated by one or more off-the-shelf computerized devices capable of recording typically between 8 degrees and 180 degrees, depending on the lens. Hence, a single computerized device such as a mobile smart phone can be used to record a source video stream by, for example, rotating the user about a vertical axis to cover 360 degrees horizontally.
[0027] Accordingly, it is also possible to synchronously record multiple video streams that together cover 360 degrees vertically and/or horizontally, thereby reducing the recording time and also simplifying the “stitching” of the individual frames, aligning component images to compose coherent panoramic background image.
[0028] In some embodiments, the otherwise static panoramic background image can be optionally enhanced by archiving animated background object(s) (“ABO”) (step 140 ). Accordingly ABOs can be identified, extracted from the source video source, and stored with associated projection metadata, thereby creating one or more ABO video streams (step 150 ).
[0029] Subsequently, upon demand, the OOI video stream is available for display superimposed on the previously compiled static background image together with any optional associated ABO video stream(s) (step 160 ).
[0030] FIG. 2 is a flow diagram 120 detailing the extraction and compilation of the still panoramic background images from the source video streams. An initial background image is created from at least one of the beginning images (“frames”) of the source video stream by extracting the background image data (step 222 ). As additional video images become available from the source video stream, a static panoramic background image can be incrementally complied using the image data from these additional video images (step 224 ). Alignment (“stitching”) of the component image data to compile the panoramic background can be accomplished using, for example, a mapping and tracking algorithm, described in greater detail below. The incremental compilation of the background panoramic image can be continued until the end of the source video stream (step 224 ).
[0031] Depending on the implementation, a source video stream can be generated by one or more off-the-shelf computerized devices capable of recording typically between 8 degrees and 180 degrees, depending on the field-of-view capability of the lens. Hence, a single computerized device such as a mobile smart phone can be used to record a source video stream by, for example, rotating the user about a vertical axis to cover 360 degrees horizontally.
[0032] In other words, a 360 static background image can be complied by incrementally aligning and adding newly recorded image portions to an initial static background image. For example, a mobile device records an initial static image covering 0 to 90 degrees. As the user rotates to his/her right, newly recorded image portions, e.g., 90 degrees to 120 degrees, can be aligned and then added to the initial static background image, thereby creating a composite background image that now covers 0 degrees to 120 degrees. This incremental process can be continued until a full 360 degrees static background image is compiled.
[0033] It is also possible to synchronously record multiple video streams that together cover 360 degrees vertically and/or horizontally by, for example, mounting multiple image sensors on a ball-like base. Such a strategy significantly reduces the recording time and also simplifies the process of “stitching” the individual frames, i.e., aligning component images to compose a coherent panoramic background image.
[0034] Real time mapping and tracking is a methodology useful for aligning component images to compose panoramic background image from, for example, frames of a source video stream. In this example, a sequence of images recorded in succession (such as a video stream) can be processed in real time to determine the placement of image data on a (virtual) canvas that can potentially include 360 degrees (horizontally) by 180 degrees (vertically) of image data, such as in an equi-rectangular image projection.
[0035] Each image frame from, for example, a video recorder device, can be processed to identify visual features in the images. These features are compared to images in a subsequent frame in order to calculate the relative change in orientation of the recording device between the two images. The resulting information can be further refined with respect to the parameters of the recording device, e.g., focal length and lens aberrations. Prior to mapping each subsequent frame onto the canvas, the image data can be warped and/or transformed as defined by the canvas projection style, e.g., equi-rectangular.
[0036] Since each video frame is projected onto the canvas relative to the previous frame, in the absence of additional information, it is challenging to derive the global orientation of the first frame. Accordingly, relative and/or global orientation sensors on the recording device can be used to place the first frame in an appropriate starting position relative to the center of the canvas. Further, if difficulty is experienced identifying and/or matching features in an image, the motion sensors can be used to determine the recording device's relative orientation and thus the correct placement of image data.
[0037] When the recording session is terminated, e.g., completed recording of 360 degrees in any one direction, the methodology attempts to “close the loop” by matching features at the extreme ends of the mapped image data. Upon a successful match, the entire image can be adjusted to substantially reduce any existing drift and/or global inconsistencies, thereby delivering a seamless 360 degrees panoramic viewing experience to the user.
[0038] Referring now to FIGS. 3 , 5 , 6 A- 6 B, FIG. 3 is a flow diagram 330 illustrating one method for identifying and extracting video streams with potential objects of interest from source video streams in a suitable computerized device, while FIG. 5 illustrates a sequence of video image frames 510 , 550 , 590 including a biker 505 riding on a curved platform 502 . FIGS. 6A and 6B illustrate the image areas and associated vectors of video image frames 510 and 550 , respectively, in greater detail.
[0039] In step 331 , optical flow calculations are performed on a source video stream to derive matched keypoint vector data. The keypoint vector data is compared against gyroscopic data from the mobile device (step 332 ). Areas, e.g., platform area 623 , within the source video images that include keypoint vectors, e.g., vectors 624 a , 624 b, which share complementary orientation and whose gyroscopic data are similar in magnitude are marked as background image data (step 333 ). Areas, e.g., platform area 621 , within the source video images that include keypoint vectors, e.g., vectors 622 a , which share complementary orientation and whose gyroscopic data are differing in magnitude are marked as parallax background image data (step 334 ).
[0040] In this embodiment, areas, e.g., biker nose region 611 , within the source video images that include keypoint vectors, e.g., vectors 612 a, 612 b, which share differing orientation when compared with gyroscopic data from the mobile device are marked as foreground objects (step 335 ). Note the different orientation of biker 505 between frame 510 and frame 550 , as shown in FIGS. 5 and 6 A- 6 B.
[0041] Extraction of the video streams with potential objects of interest from source video streams may be accomplished as described below. Once a corresponding set of keypoints is determined to indicate the presence of an object of interest (“OOI”), the boundaries of the OOI can be defined in order to properly isolate it from the background image, using one or more of the following techniques.
[0042] One technique is to increase the number of keypoints. For example, by either reducing confidence levels or processing the data at a higher resolution. After analyzing the motion (vector) of each keypoint, at some point (when enough keypoints have been examined), the shape of the object will become evident and the boundaries can be defined by drawing a polygon using the outermost keypoints of the OOI. This polygon can be refined using Bézier curves or a similar method for refining a path between each point of a polygon.
[0043] The second technique is to “align and stack” (for the purposes of compensating for the motion of the background) a subset of the frames of the video, thereby allowing for the mathematical comparison of each pixel from each frame relative to its corresponding pixel “deeper” within the stack. Stacked pixels that have a small deviation in color/brightness from frame to frame can be assumed to be the background. Pixels that deviate greatly can be assumed to be part of a foreground/obstructing object. Aggregating these foreground pixels and analyzing them over time allows the edge to be determined: As the object moves across the background (at times obscuring and at other times revealing parts of the background), one can determine the leading and trailing edge of the object thus determining its boundaries.
[0044] The third technique is to use an edge detection algorithm that can benefit from some samples of background and foreground pixel areas (“sample radius”). The optimal sample radius can be inferred by the number and/or distance of keypoints located inside or outside the OOI.
[0045] The fourth technique is to seek user input in defining the boundary. Such input could be manually drawing the boundary with touch input or presenting a plurality of potential boundaries inferred by any of the above methods and requesting that the user pick the best option.
[0046] In the video stream extraction approaches described above, once a boundary is defined using any (combination) of the above, it can be further refined by feathering or expanding the boundary.
[0047] Referring again to FIGS. 5 , 6 A- 6 B and now to FIG. 4 , flow diagram 430 illustrates an alternate method for identifying and extracting video streams with potential objects of interest from source video streams. In step 436 , optical flow calculations are performed on the source video stream to derive matched keypoint vector data. Statistical analysis can also be performed on the set of matched keypoint vectors (step 437 ). Areas, e.g., area 502 , which include keypoint vectors, e.g., vector 622 a, that share orientation when compared with statistically correlated majority are marked as background image data (step 438 ).
[0048] Conversely, areas, e.g., area 505 , which include keypoint vectors, e.g., vector 612 a, that share differing orientation when compared with statistically correlated majority are marked as foreground objects (step 439 ). Having identified potential objects of interest, such as these marked foreground objects, a video stream which includes these potential objects of interest can be extracted from the source video stream.
[0049] In another embodiment, as illustrated by the flow diagram of FIG. 7 , after receiving a source video stream (step 710 ), the source video stream and associated framing metadata, such as frame orientation relative to a panoramic background image and field of view, is stored (step 720 ). In step 730 , the composite panoramic background image can be compiled by extracting overlapping background image data from the source video stream, using for example, the keypoint methodology described above. It is also possible to use an existing panoramic background image generated by an external source such a static image or a sequence of static images.
[0050] Subsequently, during playback on for example the mobile device, the video stream can be presented to the user in substantial alignment to the panoramic background by using the framing metadata (step 740 ). One exemplary user can be a grandparent who was unable to attend a grandchild's birthday party which fortunately was recorded as a hybrid composite video panorama. The grandparent can navigate the birthday panorama and elect to view a video of the grandchild blowing out the birthday cake candle seamlessly superimposed on the static panoramic image, thereby providing a very realistic user experience without having to hog a lot of memory by avoiding the need to store the entire panoramic image in video format.
[0051] As shown in the screenshots of FIGS. 8A-8B and flow diagram of FIG. 9 , having identified and captured potential object(s) of interests (“POI”) in the form of video stream(s) extracted from at least one source video stream (step 961 ), and together with a static panoramic background image derived from the same source video stream(s) (step 962 ), the user can elect to view one or more objects of interest (“OOI”) superimposed on the static panoramic background image (step 963 ). User selection of the OOI can be accomplished manually by the user using one or more gestures, speech commands and/or eye movements. Suitable hand gestures include tapping, pinching, lassoing, and drawing cross-hairs.
[0052] In some embodiments, the user's viewing experience can be substantially enhanced by displaying optional animated background object(s) in combination with the static background image (steps 964 , 965 ). Using the example described above, the grandparent's viewing experience can be substantially enhanced by watching the grandchild, i.e., the selected OOI, blowing out the candle together with guests clapping in the background, i.e., the associated ABOs.
[0053] In the embodiment illustrated by FIG. 9 , the user can also activate an auto-tracking feature to frame the selected OOI within the viewing area of a screen (step 966 ). Hence auto-tracking can result in framing and also substantially centering the OOI within the viewing area.
[0054] The user can also activate an auto-zooming feature so as to display either more or less of the background image and/or to frame multiple selected OOIs (steps 967 , 968 ). Hence, when there are multiple OOIs, auto-zooming enables the user to see all the OOIs within the viewing frame, by for example zooming out (larger/wider viewing frame) when two or more OOIs are travelling away from each other, and zooming in (smaller/narrower viewing frame) when the two or more OOIs are approaching each other.
[0055] Screenshots 800 A and 800 B show the progressive effect of both auto-tracking and auto-zooming with respect to the two selected OOIs, e.g., runner 810 and cyclist 820 . Auto-tracking and/or auto-zooming can be activated by manually by the user using one or more gestures, speech commands and/or eye movements. Suitable hand gestures include flicking, tapping, drawing a lasso around the desired display area, long-tapping, manually tracking the OOI for a period of time to indicate the user's interest in continuing to follow the OOI.
[0056] In some embodiments, as illustrated by the flow diagram 1000 of FIG. 10 , an animated virtual tour is created from a source video stream, the virtual tour including one or more potential object of interest (“POI”) (step 1010 ). To economize on memory storage requirements, these POIs can be identified/recognized and stored as video streams (step 1020 ), while the remaining portion of the source video stream can be discarded if a compatible background panoramic image is available.
[0057] During playback, the user can elect to manually select and view one or more POIs as video images. Manual user selection of the POI(s) can be accomplished by one or more gestures, speech commands and/or eye movements. Suitable hand gestures include flicking, tapping, pinching, and drawing lassos or crosshairs.
[0058] Hence, during playback, it is also possible to select one or more POI (step 1030 ), and then optionally adjust the field-of-view (“FOV”), i.e., zoom control, and/or adjust the direction-of-view (“DOV”), i.e., pan control, either automatically and/or manually (steps 1040 , 1050 ).
[0059] FOV and/or POV can be controlled by user gestures, speech commands and/or eye movements. Suitable hand gestures for controlling FOV include flicking, lassoing, pinching moving the device forwards or backwards along the axis perpendicular to the devices screen while suitable hand gestures for controlling POV include tapping, clicking, swiping or reorienting the device.
[0060] Many modifications and additions are also possible. For example, instead of storing OOI video streams, it is possible to store video frame orientation and sequence within a spherical-projected panoramic background, i.e., storing video frames instead of OOI video streams.
[0061] In sum, the present invention provides systems and methods for efficiently storing and displaying panoramic video streams. These systems extract, store and display video streams with object(s) of interest superimposed over static panoramic images. The advantages of such systems and methods include substantial reduction in memory storage requirements and panorama retrieval times, while providing a pseudo-full-video panoramic user-controllable viewing experience.
[0062] While this invention has been described in terms of several embodiments, there are alterations, modifications, permutations, and substitute equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, modifications, permutations, and substitute equivalents as fall within the true spirit and scope of the present invention. | A computerized system receives a source video stream presenting a panning view of a panoramic environment at a plurality of different viewing angles. The system stores angular metadata and sequential timestamp of each frame of the video stream, and extracts overlapping frames from the video stream which may be optically aligned using keypoint tracking to compile a static panoramic background image. During playback, a display device can align and present each frame of the video stream at a respective viewing angle relative to the panoramic environment, in sequence according to the sequential timestamp of each frame. | 6 |
BACKGROUND OF THE INVENTION
A common grid tee construction comprises a metal strip formed into an upper bulb, a vertically extending double web and oppositely extending lower flanges. It is important for good appearance when there is no cap bridging the flanges and concealing the web elements that the spacing between these elements be uniform along the length of the web. This can be accomplished by fastening the web elements together adjacent the flanges. U.S. Pat. No. 4,489,529 to Ollinger proposes several ways to join the elements of the double web. One such proposal in this patent is to form stitches by lancing the double web elements at locations spaced along the length of the tee. A problem associated with this teaching is that the effective thickness of the web at the stitch locations is doubled. The resulting thickness variation makes it difficult to accurately hold the tee for subsequent forming and/or assembly operations during manufacture. Still further, variable thickness can present difficulties for the installer where the stitch exists or otherwise interferes at a cross tee slot.
Locating the stitches so that they do not interfere with critical parts of the tee is difficult and/or expensive where they are formed in a high speed rolling operation.
It is known to lance or stitch the double web elements in a manner where the material surrounding the lanced hole is coined to reduce the size of the hole after the lance is made to positively interlock the web elements together.
SUMMARY OF THE INVENTION
The invention provides a grid tee of the double web type in which the web elements are locked together by an integral stitch with a configuration that avoids an excessive increase in the local web thickness. The stitch is formed by lancing or shearing through the double thickness of the web to displace a slug out of the plane of the web and create a corresponding hole. The web material is coined or otherwise deformed so that the slug is unable to pass back through the hole. The material forming the slug is forced back into the hole area so that the final thickness of the web in the area of the stitch is not substantially greater than the original web thickness.
In the preferred form of the invention, the web is stitched by three stages of rolling dies that first lance the stitch slug out of the plane of the web. Thereafter, the material surrounding the stitch hole is coined to decrease the size of the hole and thereby prevent the slug from passing back through it. The slug is then rolled to substantially flatten it back into the space of the hole and coined area. Since the stitch, when completed, does not substantially increase the local thickness of the web, it does not interfere with normal manufacturing operations such as where the tee is held in a fixture for hole stamping or other finishing steps such as the assembly of an end clip. Moreover, the stitch pattern, which can have a uniform spacing between stitches even though randomly located along the length of a grid, does not interfere with the reception of transverse tee connectors in slots that happen to fall on the area of a stitch.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective fragmentary view of a tee for a suspended ceiling grid;
FIG. 2 is a somewhat schematic view of a first stage of apparatus for roll forming stitches in the tee of FIG. 1 wherein the web is lanced to form a displaced stitch slug;
FIG. 2a is a fragmentary, sectional view of the first stage of a stitch formation corresponding to the plane 4a--4a indicated in FIG. 1;
FIG. 3 is a somewhat schematic view of a second stage of apparatus for roll forming stitches wherein the stitch area is coined;
FIG. 3a is a fragmentary, sectional view of the coining stage of the stitch formation corresponding to the plane 4a--4a indicated in FIG. 1;
FIG. 4 is a somewhat schematic view of a third stage of apparatus for roll forming stitches, wherein the stitch area is flattened by compression rolls;
FIG. 4a is a fragmentary, sectional view of the third stage of the stitch formation taken in the plane 4a--4a of FIG. 1;
FIG. 4b is a fragmentary, sectional view of a third stage of the stitch formation taken in the plane 4b--4b indicated in FIG. 1; and
FIG. 5 is an example of another style of grid tee for which the invention has application.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is embodied in a grid tee or runner 10 and, as will be understood by those skilled in the art, can be embodied in a main tee or main runner as well as a cross tee or cross runner. The tee 10 is formed of a single metal strip bent, preferably by roll forming techniques known in the art, into the desired cross-sectional configuration. The metal of the tee 10 can be steel, which is suitably painted, coated, or otherwise protected against corrosion. At each end of the tee 10, a connector clip 11 is permanently attached in a known manner such as with a rivet-like formation extruded from the body of the tee 10. Alternatively, the connector clip 11 can be formed as an integral part of the tee 10. Holes 12 punched through the body of the tee are used for suspending the tee with wires or the like from the superstructure of a building.
The sheet stock forming the tee 10 is bent or folded in a known manner along lines parallel to its longitudinal direction to produce an upper bulb 16, a double web 17, and lower flanges 18, all integral with one another. The double web 17 is comprised of two generally flat vertical elements 21, 22. Each of the flanges 18 extends from an associated one of the web elements 21 or 22.
The web elements 21, 22 are mechanically locked together by stitches 23 formed out of the web elements themselves. Ideally, the stitches 23 are situated at uniformly spaced locations along the full length of the tee 10 adjacent the lower edge of the web elements 21, 22. FIGS. 2 through 4 illustrate details of a preferred method and apparatus for stitching the web elements 21, 22 together. At a first station shown in FIG. 2, the tee in an unfinished configuration is passed between a pair of opposed rolls 26, 27. The rolls 26, 27 are suitably mounted for rotation about their respective axes which are parallel to one another and the plane of the web 17. The rolls 26, 27 cooperate to lance a slug 28 of material out of the plane of the web elements 21, 22. One of the rolls 26, which can be power driven through a timing belt pulley 29, has a series of projecting punches 31 spaced uniformly along its circumference. The other roll, 27, which can be friction or power driven, has a continuous peripheral slot 32. Edges 33, 34 of each of the punches 31 and slot 32, respectively, lie in planes perpendicular to the axis of the respective roll 26, 27 and are sharp cutting edges capable of cooperating to shear a slug 28 from the web 17 as the tee 10 passes between the rolls.
The slug 28 is formed with edges 36, that are cut free of the main part of the web 17 and are parallel to the longitudinal axis of the tee 10. Longitudinal ends 37 of the slug 28, as shown in FIG. 4a, taken in a plane corresponding to the plane 4a--4a in FIG. 1 remain attached to the main part of the web 17. As seen from FIG. 2a, the slug 28 at this first forming stage has a center part which is completely displaced from the plane of the web 17. This slug formation leaves a corresponding hole 41 in the web 17.
FIG. 3 depicts a second stitch forming station encountered by the tee 10 as the tee is advanced through successive stitch forming stations. A pair of opposed rolls 43, 44 are suitably rotationally mounted at this station with their axes in parallel relation to each other and the previously described rolls 26, 27. One of the rolls 43 is power driven through a timing belt pulley 45 in synchronization with the roll 26. A series of projecting tools 46 are formed on the periphery of the roll 43 with a circumferential spacing equal to the circumferential spacing of the punches 31 on the roll 26. The opposed roll 44 has a circumferential slot 47 that has a width which fits the height of the slugs 28, i.e. the distance between the slug edges 36. The projecting tools or hammers 46 are angularly aligned so that they register on the web area surrounding the holes 41 being formed by displacement of the slugs 28.
As the roll 43 rotates, a projecting tool 46 coins the web area surrounding a hole 41 while the other roll 44 serves as an anvil to support these areas and the slug 28. FIG. 3a illustrates the web 17 and area of the slug 28 after the web is struck or coined by a tool projection 46. With the slug 28 rendered larger than the hole 41, as shown, by virtue of the hole being constricted by the coining process, the slug forms a permanent "stitch" that prevents separation of the web elements 21, 22 from each other in areas adjacent the stitch.
At the next stitch forming station represented in FIG. 4, the tee 10 passes between a pair of opposed rolls 51, 52. The rolls 51, 52 are suitably mounted for rotation about vertical axes parallel to the axes of the other rolls 26, 27 and 43, 44. The rolls 51, 52 have substantially cylindrical peripheral surfaces and are located so that they compress the slug 28 back towards the plane of the web as indicated in FIG. 4a. At least one of the rolls 51 can be power driven for rotation through a timing belt pulley 53.
At the first stitch forming stage depicted in FIGS. 2 and 2a, the thickness of the web 17 at the stitch is at least about twice the thickness of the non-stitched areas of the web which is twice the thickness of the sheet stock forming the tee 10. The stitch is flattened at the third stage, depicted in FIGS. 4 and 4a, to reduce the thickness at this zone as much as is practical. The degree to which the slug 28 is flattened back into the plane of the web 17 can depend, in part, on the original thickness of the web 17. The following table, given by way of example, shows the approximate finished flattened thickness of the web at a stitch for various gauge thicknesses where the tee is made of steel.
______________________________________MATERIAL FLATTENED STITCHTHICKNESS (in.) THICKNESS (in.)______________________________________.015/.017 prepainted steel .042.013/.015 prepainted steel .034.010/.013 prepainted steel .026______________________________________
The web 17 will have a nominal thickness apart from the stitch equal to twice the gauge or thickness of the sheet stock material. In the heavier sheet stock material, the stitch is flattened to where the thickness of the web is not more than about 1/3 thicker than the thickness of the web apart from the stitch. It will be seen from FIG. 4a, a large part of the slug 28 is driven back into the zone from which it is cut, both into the flattened or coined area and into the remaining part of the hole 41.
After passing through the stitch flattening rolls 51, 52, the illustrated tee 10 is subjected to additional roll forming operations, known in the art, to achieve the cross-sectional configuration shown in FIG. 1. In the subsequent roll forming operations or in supplementary roll forming operations, any curl imparted to the tee by the disclosed stitch forming operations can be worked out by techniques known in the art.
The disclosed stitches 23 are relatively closely spaced to one another and are formed along a line running the full length of the tee 10. The stitches are particularly useful in tee configurations where in the finished installation the areas of the sheet that are bent at the transition between the double web and the diverging flanges are visible. The stitches resist unsightly separation of the web elements 21, 22 and flanges 18 at this transition zone. The separation can occur in conventional tee constructions where the stitches are not provided particularly at the end of a tee that is field cut to length. Field cutting results in local distortion at the cut edges and, without the stitches, the distortion is visually exaggerated by a gap that appears between the web and flange elements.
The disclosed roll forming process for the stitches is particularly suited for the disclosed tee construction employing a series of relatively closely spaced stitches. Since, according to the invention, the stitches after being formed and locked are flattened, they can be located anywhere along a tee without regard, for example, to the location of the end of the tee where the connector 11 is joined or to the location of a cross hole 57 where a connector is received. The minimal increase in thickness to the web produced by the flattened stitch will have essentially no adverse effect on the factory joining of the end connector 11 or the field reception of a connector during erection of a grid where a stitch happens to be located in these areas. The roll formed stitching process is less expensive where it can be performed without precisely locating the stitches in the longitudinal direction.
FIG. 5 illustrates another example of a grid tee 10' with a cross section where the invention is particularly useful. The invention is also useful with double web tees made with a face cap known in the art.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. | A grid tee of the double web type in which the elements of the web are integrally stitched together to prevent their separation. The stitches are created in an inexpensive rolling process that does not require control of the position of the stitches relative to the ends or other parts of the tee. According to the invention, after the stitches are formed and locked, they are flattened back into the plane of the web to a limited degree where they do not substantially increase the thickness of the web so that they do not interfere with subsequent manufacturing steps or with field assembly. | 4 |
GRANT INFORMATION
This invention was made in part with United States Government support under contract DE-AR0000616 awarded by the Advanced Research Projects Administration—Energy, part of the U.S. Department of Energy. The U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
Field of the Invention
The presently disclosed subject matter provides a process to decompose hydrocarbons into carbon and hydrogen (H 2 gas), employing a cycle in which a secondary chemical is recycled and reused.
Background Information
Over 95% of hydrogen in the United States is produced from natural gas via steam-methane reforming (SMR) [http://energy.gov/eere/fuelcells/hydrogen-production-natural-gas-reforming], and is used to produce commodity chemicals such as ammonia, the chemical precursor for fertilizer, or is used as fuel. In SMR, natural gas (primarily methane, CH 4 ) reacts with water (H 2 O) to form hydrogen gas (H 2 ) and carbon monoxide (CO).
CH 4 +H 2 O→CO+3H 2
To increase reaction rates and yields, SMR is typically run at high temperatures and pressures (700-1000° C.) and high pressures (3-25 bar). Product CO is converted to carbon dioxide (CO 2 ) via the water-gas shift reaction, producing more hydrogen:
H 2 O+CO→CO 2 +H 2
Production of hydrogen will be improved with new processes that (a) allow production at lower temperatures and pressures, (b) do not produce CO 2 as a byproduct of hydrogen production, (c) require smaller energy input, and (d) do not deteriorate over time. The last issue is critical—for example, one process to produce hydrogen is thermal decomposition of methane into solid carbon and hydrogen, which occurs over suitable catalysts at temperatures typically greater than 900° C. Considering just the enthalpy of the chemical reactions involved, direct decomposition has a reaction enthalpy of 74.6 kJ/mol CH4 , or 37.3 kJ/mol H2 ; this is slightly less heat input than required for steam reforming (41.2 kJ/mol H2 ) and produces no CO 2 . Direct decomposition, unfortunately, leads to deactivation of the catalyst as it becomes coked with carbon. Furthermore, coking makes the catalyst difficult to recover for reuse.
SUMMARY OF THE INVENTION
The presently disclosed subject matter provides a process to decompose hydrocarbons into carbon and hydrogen (H 2 gas), employing a catalyst-free cycle in which a secondary chemical is recycled and reused. In the preferred embodiment of the process, the secondary chemical is primarily composed of anhydrous nickel chloride (NiCl 2 ). Other metal halides can also be suitable. First, hydrocarbons are input into the cycle and decomposed to carbon in a chemical reaction with nickel chloride at elevated temperatures in a dry and oxygen-free atmosphere to produce hydrogen chloride gas, nickel metal, and carbon. Then, these components are cooled until the hydrogen chloride gas reacts with nickel metal to re-form anhydrous NiCl 2 and hydrogen gas. The hydrogen gas is then collected as the reaction product. Carbon and NiCl 2 in the reaction chamber are separated by sublimating the NiCl 2 at temperatures near 1000° C., at which point the cycle can be run again. Carbon formed from this cycle can be removed from the reactor at any point.
Thermodynamic analysis of the process predicts a net heat input for the chemical reactions in the entire cycle of 37.3 kJ/mol H2 when the input hydrocarbon is methane. In the preferred embodiment, the process is operated at ambient pressures and at temperatures below that required for SMR or direct methane decomposition; the process can be repeated without deactivation of the secondary chemical; and the process produces no carbon dioxide from the feedstock.
Certain aspects of the presently disclosed subject matter having been stated hereinabove, which are addressed in whole or in part by the presently disclosed subject matter, other aspects will become evident as the description proceeds when taken in connection with the accompanying Examples and Figures as best described herein below.
BRIEF DESCRIPTION OF THE FIGURES
Having thus described the presently disclosed subject matter in general terms, reference will now be made to the accompanying Figures, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a schematic representation of the chemical reaction steps in the presently disclosed method for producing hydrogen without carbon dioxide using reactants and chemical intermediates associated with a particular embodiment;
FIG. 2 shows the reaction free energy of different chemical reactions associated with hydrocarbon reforming: (a) steam methane reforming, (b) thermal decomposition of methane, (c) methane decomposition via reaction with nickel chloride, and (d) ethane decomposition via reaction with nickel chloride.
DETAILED DESCRIPTION OF THE INVENTION
The presently disclosed subject matter now will be described more fully with reference to the accompanying Figures, in which some, but not all embodiments of the presently disclosed subject matter are shown. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated Figures. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.
It will be obvious to practitioners familiar with the art that values for the energy required for chemical reactions described herein may be expressed as kJ/mol CH4 when referring to the energy per input methane molecule, or kJ/mol H2 when referring to the energy per output hydrogen molecule.
In some embodiments, the presently disclosed subject matter provides methods for transforming hydrocarbons (molecules comprised primarily of carbon and hydrogen atoms) to elemental carbon and hydrogen molecules (H 2 ).
The cycle to produce hydrogen is schematically illustrated in FIG. 1 , which lists the chemical reactions in the cycle, and their relative order. We arbitrarily assign Stage 1 of the process as that step in which a reactant stream of hydrocarbons are introduced into a reaction chamber containing anhydrous nickel chloride (NiCl 2 ); the atmosphere of the chamber does not contain oxygen nor water. If the particular hydrocarbon is methane, the following reaction occurs under these conditions at temperatures preferably above 600° C., and most preferably above 650° C.:
CH 4 +2NiCl 2 →2Ni+C+4HCl
By 2Ni+C is meant a reactant product comprised of nickel metal (Ni) and carbon (C) in the stoichiometric ratio of 2:1. FIG. 2 shows the Gibbs reaction free energy for this reaction and other reactions referenced herein as a function of temperature, calculated from thermodynamic property values freely available in databases maintained by the National Institutes of Standards and Technology (NIST). It is a well-known chemical principle that if the Gibbs reaction free energy drops below zero for a particular chemical reaction, the chemical reaction becomes favorable to proceed. In the general case of methane reacting with a chloride salt, one molecule of hydrogen chloride gas (HCl) is created for each hydrogen atom in the input hydrocarbon stream. As long as the ratio of hydrogen to carbon in the input stream is greater than unity, there will be a positive reaction entropy, and thus a temperature at which the reaction free energy will drop below zero. In the specific case of methane reacting with nickel chloride, the Gibbs reaction free energy becomes negative near 570° C. In the case of ethane (C 2 H 6 ) reacting with nickel chloride, the Gibbs reaction free energy drops below zero near 455° C.
It is possible that hydrocarbons containing one or more C—C bonds will be difficult to dissociate due to slow reaction kinetics, and that catalysts suitable for cracking alkanes, such as the zeolite HZSM-5 [F. C. Jentoft, B. C. Gates, “Solid-acid-catalyzed alkane cracking mechanisms: evidence from reactions of small probe molecules,” Topics in Catalysis, 4 (1997), 1-13], may be required to lower the activation barrier for these reactions. In the specific embodiment of methane decomposition, no catalyst is required to produce hydrogen.
In the preferred embodiment of this process, nickel chloride is chosen to react with hydrocarbons, because the temperature at which reaction is predicted to proceed between 500 and 1000° C., more preferably between 600 and 800° C., and most preferably at 675° C. (below the temperatures at which steam reforming or direct methane decomposition are typically performed). However, any anhydrous metal halide salt can be used in this reaction, as long as more than one hydrogen halide molecule is produced per molecule of hydrocarbon molecule input. In the examples, chloride is preferred, but other halides will work. Other metals such as Mn, Cu, Zn, Ca, and Mg may also work.
Stage 1 of the process produces dehydrogenated carbon, nickel metal, and hydrogen chloride gas, in a ratio dictated by the chemical reaction stoichiometry. For instance, in the decomposition of methane, two nickel atoms of nickel metal, and four hydrogen chloride molecules are produced for each carbon atom from one methane molecule.
In Stage 2 of the process, nickel, carbon, and hydrogen chloride gas are cooled to temperatures below ˜550° C. Below this temperature, nickel metal spontaneously reacts with HCl according to the chemical reaction
2Ni+4HCl→2NiCl 2 +2H 2 .
(The stoichiometric coefficients of this equation have been adjusted to reflect that 2 hydrogen molecules are formed for each molecule of methane input into Stage 1 of the process.) When the system is cooled to below ˜550° C., nickel metal will be transformed back to nickel chloride via reaction with HCl. Carbon in the system is a spectator species to this chemical reaction. After the reaction is run to completion, hydrogen gas is removed from the reactor as the final reaction product.
At this stage, the cycle may be repeated. However, in certain embodiments, a Stage 3 may be added to the cycle where it of interest to separate the carbon from the nickel chloride as a second reaction product. In a preferred embodiment, nickel chloride is sublimed at 1000° C., and condensed away from the carbon, which can then be physically removed from the system. Other methods of separation will be known to those familiar with the art of chemical separations.
The following examples are intended to illustrate but not limit the invention.
EXAMPLES
The following Example is included to provide guidance to one of ordinary skill in the art for practicing representative embodiments of the presently disclosed subject matter. In light of the present disclosure and the general level of skill in the art, those of skill can appreciate that the following Examples are intended to be exemplary only and that numerous changes, modifications, and alterations can be employed without departing from the scope of the presently disclosed subject matter. The synthetic descriptions and specific examples that follow are only intended for the purposes of illustration, and are not to be construed as limiting in any manner to make compounds of the disclosure by other methods.
Example 1
10 g of anhydrous NiCl 2 was loaded into an alumina tube and placed in a tube furnace. A flow of 100% argon (Ar) gas was passed through the tube, and bubbled through a water beaker to create a non-oxygen containing atmosphere within the tube. A mass spectrometer connected to the gas stream between the tube and the bubbler sampled and measured the composition of the tube outlet stream. The sample in the tube furnace was heated to 700° C., and then the inlet stream composition was switched to 95% argon, 5% methane. Immediately, a hydrogen chloride signal was observed in the mass spectrometer, and the reaction was run until the hydrogen chloride signal dropped to zero. The gas inlet stream was then switched back to 100% Ar and the tube was cooled. It was found that the nickel chloride had been transformed to a black powder that elemental analysis confirmed was comprised of nickel and carbon. According to the chemical reactions described for each stage of the process, the reaction should yield 0.46 g of carbon. The powder was dissolved in hydrochloric acid solution, and the carbon filtered, rinsed, and dried; 0.49 g of carbon was collected, which is equivalent to the expected yield within the experimental error of the system. Hydrogen was generated during the dissolution of the powder in hydrochloric acid; the expected quantity produced was too small to assay.
REFERENCES
All publications, patent applications, patents, and other references mentioned in the specification are indicative of the level of those skilled in the art to which the presently disclosed subject matter pertains. All publications, patent applications, patents, and other references are herein incorporated by reference to the same extent as if each individual publication, patent application, patent, and other reference was specifically and individually indicated to be incorporated by reference. It will be understood that, although a number of patent applications, patents, and other references are referred to herein, such reference does not constitute an admission that any of these documents forms part of the common general knowledge in the art.
Although the invention has been described with reference to the above example, it will be understood that modifications and variations are encompassed within the spirit and scope of the invention. Accordingly, the invention is limited only by the following claims. | A process to decompose methane into carbon (graphitic powder) and hydrogen (H 2 gas) without secondary production of carbon dioxide, employing a cycle in which a secondary chemical is recycled and reused, is disclosed. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a valve mechanism in a multi-cylinder internal combusion engine. In particular, the invention relates to a valve mechanism which is capable of bringing the operation of an intake valve and an exhaust valve to a halt when partially halting cylinder operation in light and medium load conditions during engine operation.
In general, the pumping loss in an internal combustion engine increases in the compression stroke, so that the efficiency of fuel consumption becomes worse in what is called a "light load" condition in which there is an extra output, for example, when idling or when the vehicle descends a slope.
Hence, as a method to cope with this problem, multicylinder operation has been partially brought to a halt in accordance with the prior art, thereby enhancing the efficiency of fuel consumption.
As a method of partially halting cylinder operation in the multi-cylinder internal combustion engine, there has been employed a method temporarily stopping the jetting of fuel in an electronically injected engine. However, this method is not satisfactory since it is not available in an engine which is provided with a carburetor, and since the intake valve and the exhaust valve work as usual even in a cylinder for which fuel injection is stopped, so that air is introduced and discharged as the piston reciprocates.
Hence, as a method for partially bringing the cylinder operation to a halt, i.e. for disabling one or more cylinders, it has recently been attempted to stop the operation of the valve by forcibly increasing the gap between the rocker arm and the valve.
Until now, however, there has not been developed any valve mechanism capable of sufficiently favourably operating to stop the operation of the valve in accordance with this or other methods. Accordingly, the development of such a valve mechanism has been urgently required.
A pair of prior art mechanisms seeking to achieve this end are disclosed in Japanese Patant Publication No. 3843/1976 and Japanese Early Disclosure No. 115408/1978.
SUMMARY OF THE INVENTION
In view of the above, the present invention intends to provide an excellent valve mechanism of this type.
That is, in a multi-cylinder internal combustion engine constituted in such a way as to partially bring the cylinder operation to a halt when the engine is driven, the present invention is characterized in that a first bush is inserted on a rocker shaft in such a manner so as to be eccentric with respect to the axis of the rocker shaft, a second bush is inserted on the first bush such as to be eccentric in a direction opposite to the eccentric direction of the first bush with respect to the axis of the first bush, a rocker arm is idly inserted on the second bush, the first bush and the second bush are simultaneously rotated and controlled in directions which are opposite to each other by the same angle with repect to the axis of the rocker shaft, so that the rocker arm is moved in the perpendicularly upper direction, thereby detaching the rocker arm from the valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial front view in cross section, showing a valve mechanism in accordance with a first embodiment of this invention;
FIG. 2 is a side view of the mechanism of FIG. 1;
FIG. 3 is a cross sectional view taken along the line A--A of FIG. 2;
FIG. 4 is a cross sectional view taken along the line B--B of FIG. 2;
FIG. 5 is a front view, partially in cross section showing a valve mechanism in accordance with a second embodiment of this invention;
FIG. 6 is a front view, partially in cross section showing a valve mechanism in accordance with a third embodiment of this invention;
FIG. 7 is a partial cross sectional view schematically showing the working valve of FIG. 6; and
FIGS. 8 and 9 are partial cross sectional views showing additional embodiments of the valve in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment is shown in FIG. 1, wherein a rocker arm R undergoes a swinging motion while being in contact with a push rod 7 (a cam in the case of an OHC engine), so as to open and close a valve 8. A first bush 3 is fitted onto a rocker shaft 2 so as to be eccentric by an amount (e) with respect to the axis of the rocker shaft. A second bush 4 is fitted onto the first bush 3 so as to be eccentric by the amount (e) in a direction which is opposite to the eccentric direction of the first bush, with respect to the axis of the first bush. In other words, in this case, the axis of the rocker shaft coincides with that of the second bush. Referring now to FIG. 3, the first bush 3 and the second bush 4 are simultaneously rotated through the same angle with respect to the axis of the rocker shaft 2 and are controlled (the first bush 3 is rotated clockwise and the second bush 4 is rotated counter-clockwise), so that the rocker arm is moved perpendicularly upwards, thereby detaching the rocker arm from the valve 8.
The operations in accordance with the present invention will now be explained in turn. In FIG. 1, a transmitting member 5 is fitted to the rocker shaft 2, and a pin 41 is mounted onto the second bush 4, and is fitted into a groove 52 which is formed at an arbitrary location in the transmitting member 5 (a hole may be formed such that the pin fits into the hole,) so that the transmitting member and the second bush move in conjunction with each other. There are provided connecting pins 31, 51 respectively at locations equidistant from the axis of the rocker shaft on the first bush 3 and the transmitting member 5, and links 6, 6 of equal length are connected to the connecting pins 31, 51. The other ends of the links are connected to each other at a supporting point 9, which is connected to an air cylinder 10. In FIG. 1, the valve 8 which is in contact with the rocker arm R normally effects the intake operation as well as the exhaust operation by the swinging motion of the arm, but when partially bringing cylinder operation to a halt in the light load condition as well as in the middle load condition during operation of the multi-cylinder internal combustion engine, the air cylinder 10 (which may also be an oil cylinder, a solenoid or the like) is operated so that the supporting point 9 is moved horizontally to widen the links 6, 6. Thus, the first bush 3 and the second bush 4 are simultaneously rotated by the same angle in opposite directions with respect to the axis of the rocker shaft 2 via the links 6, 6 and via the transmitting member 5 respectively (the first bush is rotated clockwise and the second bush is rotated counter-clockwise), so as to move the rocker arm R perpendicularly upwards, thereby detaching the rocker arm R from the valve 8. Therefore, even if the rocker arm R swings due to engagement with the push rod 7, the valve 8 does not operate. Thus, cylinder operation is partially brought to a halt during this time.
If the rocker arm is operated by means of only one eccentric bush, the rocker arm may not move perpendicularly upwards but obliquely upwards, so that it does not contact the push rod but is detached therefrom. In addition, it is required for the eccentric bush to be rotated through a large angle with respect to the axis of the rocker shaft in order to move the rocker arm sufficiently upwardly. However, since eccentric bushes are fitted on the rocker shaft is a overlapping manner in accordance with the present invention, horizontal movement does not occur so that the movement is solely perpendicularly upward. Thus, the rocker arm R is not detached from the push rod 7. Furthermore, since there are two bushes, the eccentric amount is doubled. When compared with the case where only one eccentric bush is provided, the rocker arm is sufficiently moved perpendicularly upwardly with a rotary angle which is one half that when only one eccentric bush is provided. In accordance with another embodiment of this invention, as shown in FIG. 5, wires 6, 6 instead of the links may be respectively connected to the connecting portion 31 of the first bush 3 and to the connecting portion 51 of the transmitting member 5, and to the air cylinder 10. The air cylinder 10 is then operated and the wires 6, 6 are pulled. In so doing, the first bush 3 and the second bush 4 are simultaneously rotated in opposite directions by the same angle with respect to the axis of the rocker shaft, as previously. When it is desired to recover the original state, the elastic force of springs 12, 12 is utilized. The springs 12, 12 are connected and fixed respectively at the connecting portion 31 of the first bush and at the connecting portion 51 of the transmitting member on the side opposite the wires 6, 6.
In addition, the side of the rocker arm in contact with the push rod and the rocker shaft 2 may be connected by means of a coiled spring 11 (FIG. 4) (which may be a plate spring), so that the arm is urged against the push rod by the elastic force of the coiled spring 11 when the rocker arm R becomes free when cylinder operation is partially brought to a halt; in other words, when the rocker arm R is detached from the valve 8.
In the above embodiment, the first and second bushes are displaced in a horizontal direction from the axis of the rocker shaft 2. Thus, there is an advantage, for example, in that additional space in the vertical direction is not required when designing the engine. However, when the first and second bushes are perpendicularly displaced from the axis of the rocker shaft as in the third embodiment shown in FIGS. 6 and 7, another advantage can be seen. In the first embodiment, when the valve 8 which is in contact with the rocker arm R is performing the intake and exhaust operations under the control of the rocker arm, the first bush 3 is eccentric by an amount (e) on the line X--X which passes through the axis of the rocker shaft 2. On the other hand, the second bush 4 is eccentric by the amount (e) on the line X--X in a direction contrary to the eccentric direction of the first bush. As a result, the first bush 2 and the second bush 3 are subjected to forces in the A-direction and in the B-direction respectively with respect to the functional load in the F-direction when the valve operates, so that the rocker arm R undergoes rocking motion in an unstable state. On some occasions, it becomes difficult to maintain the normal position when the valve operates in the usual manner.
Thus, the third embodiment provides a valve mechanism in accordance with which the rocker arm is maintained in a stable manner and smooth operation is ensured both in normal operation and when partially bringing cylinder operation to a halt in light and middle load conditions.
As shown in FIG. 6, the rocker arm R is in contact wth a push rod 7' (a cam in the case of an OHC engine) and undergoes rocking motion, thereby opening and closing the valve 8'. The first bush 3' is fitted on the rocker shaft 2 in such a way as to be eccentric in a downward direction by an amount (e) on the line Y--Y which passes through the axis of the rocker shaft 2. The second bush is fitted on the first bush 3' in such a way as to be eccentric by an amount (e) on the line Y--Y in the same direction as the eccentric direction of the first bush, with respect to the axis of the first bush. Now, the principle of this arrangement will be explained with reference to FIG. 7. The first bush 3' and the second bush 4' are simultaneously rotated by the same angle in directions opposite to each other with respect to the axis of the rocker shaft 2 (the first bush is rotated clockwise and the second bush is rotated counterclockwise), and the rocker arm R is moved perpendicularly upwards, thereby detaching the rocker arm from the valve 8'.
Furthermore, since the first bush 3' and the second bush 4' are fitted and combined respectively in such a way as to be eccentric on the same line Y--Y with respect to the axis of the rocker shaft 2 as shown in FIG. 7, it is possible for the rocker arm to stably maintain the normal position with respect to a functional load in the F-direction when the valve in contact with the rocker arm performs the intake and exhaust operations under the control of the valve arm.
Now, the operation in accordance with this embodiment will be in turn explained. In FIG. 6, a transmitting member 5' is fitted to the rocker shaft 2, a pin 41' is mounted on the second bush 4' and is fitted into a hole or groove 52' which is formed at an arbitrary location in the transmitting member 5', so that the transmitting member and the second bush may move in conjunction with each other. There are provided connecting pins 31', 51' respectively at locations which are equidistant from the axis of the rocker shaft on the first bush 3' and the transmitting member 5', and links 6', 6' of equal lengths are connected to the connecting pins 31', 51' respectively, the other ends of the links being connected to each other at the supporting point 9, which is connected to an air cylinder 10'. The valve 8' in contact with the rocker arm R normally performs the intake and exhaust operations due to the rocking motion of the rocker arm shown in FIG. 6, and the air cylinder 10' (which may also be an oil cylinder, a solenoid or the like) is actuated when partially bringing cylinder operation to a halt in the light load and medium load conditions during operation of the multi-cylinder internal combustion engine. Thus, the supporting point 9 is moved perpendicularly upwards. Accordingly, the first bush 3' and the second bush 4' are simultaneously rotated by the same angle in either direction via the links 6', 6' and via the transmitting member 5' with respect to the axis of the rocker shaft 2 (the first bush is rotated clockwise and the second bush is rotated counter-clockwise), so that the rocker arm R is moved perpendicularly upwards and is detached from the valve 8'. Therefore, even if the rocker arm R continues to rock due to the push rod 7', the valve 8' does not work, and cylinder operation is partially brought to a halt.
A single bush could be used to effect the operation above, but would suffer from the same deficiencies noted with respect to the like arrangement of the first embodiment. In the case of this embodiment, horizontal movement does not occur; only the perpendicularly upward movement occurs, and the rocker arm R is not detached from the push rod 7. In addition, by using two bushes, the eccentric amount is doubled.
When partially halting cylinder operation in the above mentioned embodiment, that is, when the rocker arm is not in contact with the valve 8, the rocker arm R is in a free state. Thus, an elastic member such as a coiled spring is connected to the rocker shaft and an arbitrary location of the arm on the side to come in contact with the push rod of the rocker arm, so that it pushes against the push rod by the elastic force, or so as to push against the rocker arm from the side of the push rod. That is, there may be provided a gap ε (ε is taken larger than the maximum variable lift amount of the rocker arm) in a tappet 61 with a spring 62 interposed therein, which is in contact with a cam shaft 64 as shown in FIG. 8. A spindle 63 supports the push rod and is slidably fitted in the tappet, and the push rod 7 is pushed against the rocker arm R by the elastic force of the spring 62. This construction is effective since the rocker arm can be stably maintained. The above mentioned effects can also be sufficiently brought about in accordance with a construction such as shown in FIG. 9.
As will be clearly understood from the above, the present invention relates to a valve mechanism in a multi-cylinder internal combustion engine. In particular, the valve in accordance with the present invention provides a stably operating rocker arm which operates normally when the valve is operated in the used manner and which ensures smooth operation when cylinder operation is partially brought to a halt in the light and middle load conditions during the engine operation. Thus, excellent effects can be brought about. | A rocker arm mechanism is mounted on a rocker shaft via a pair of eccentric bushes, which, when made to rotate in opposite directions, disengage the rocker arm from an associated valve. The device is useful in controlling the number of operating cylinders in a multi-cylinder engine for more efficient fuel consumption. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of German Patent Application No. 10 2005 042 503.8, which was filed on Sep. 7, 2005, and the disclosure of which is incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a discharge device for a cleaning fluid or a treatment fluid, in particular to a lance of a high-pressure cleaning device.
BACKGROUND
[0003] Discharge devices of this type are generally known, in particular in the form of so-called lances which the user holds at the end facing him with one hand or with both hands and which are provided at their free working end with a nozzle head. The direction in which the cleaning fluid or treatment fluid is discharged via the nozzle head either coincides with the longitudinal axis of the lance or is angled by a fixed dimension with respect to it. It is already known, for example from DE 2 304 738 A1 to couple the nozzle head to an adjustment device. In this manner, the user can adjust the discharge direction of the fluid jet relative to the longitudinal axis of the lance “by remote control” so-to-say.
[0004] Lances of this type with a pivotable nozzle head can be used in a variety of applications The user can thus, for example, clean eaves gutters with a downwardly pivoted nozzle head and the underbody of his vehicle with an upwardly pivoted nozzle head without having to turn the lance itself.
SUMMARY
[0005] It is the object of the invention to further develop a discharge device of this type with a variable fluid discharge direction such that a simply and reliably operable “remote control” for the varying of the discharge direction is made possible for the user with a simple design of the device not prone to defects.
[0006] In accordance with the invention, the carrier holding the head piece runs inside the actuation member. A space-saving and compact design can thereby be achieved. It is furthermore of advantage that exposed transfer elements or adjustment elements can be at least largely avoided by the invention without additional covers and so without any disturbing additional weight. This brings about an enormous improvement in handling for the user, and indeed above all also because there is no risk of “getting caught” at exposed parts somewhere during working. Since a filigree design prone to defects is avoided in accordance with the invention, a robust lance can be realized overall which also functions reliably under adverse conditions.
[0007] Preferred embodiments of the invention are also set forth in the dependent claims, in the description and in the drawing.
[0008] A relative movement serving for the adjustment of the pivotable head piece between the actuation member and the carrier can consist, in accordance with a variant of the invention, of a displacement of at least one part of the actuation member relative to the carrier. The actuation member can be displaceable as a whole along the carrier.
[0009] Alternatively, only a part of the actuation member cooperating directly or indirectly with the head piece can be made as a sliding part which is coupled to an operating section of the actuation member rotatable relative to the carrier. This is so-to-say a hybrid solution in which, to rotate the head piece, the user carries out a rotary movement, in particular around a longitudinal axis of the holder, but the movement of the actuation member responsible for the pivoting of the head piece is a sliding movement, that is a translation movement, in particular along the longitudinal axis of the holder.
[0010] In a further alternative aspect, the actuation member as a whole can be rotatable relative to the carrier, in particular around a longitudinal axis of the holder, with this rotary movement being converted directly or indirectly into the pivot movement of the head piece.
[0011] The conversion of the rotary movement into the pivot movement of the head piece can in particular take place by a transmission. In a simple aspect, the transmission can be, for example, a spiral, helical or screw-shaped control cam at an end-face margin of the actuation member. In another embodiment, the transmission can be provided in the form of a miter gear.
[0012] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the present disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0014] FIGS. 1 and 2 illustrate different part views of an embodiment of a discharge device in accordance with the invention;
[0015] FIGS. 3 and 4 illustrate different part views of a further embodiment of a discharge device in accordance with the invention;
[0016] FIG. 5 illustrates a further embodiment in accordance with the invention; and
[0017] FIGS. 6 and 7 illustrate a further embodiment of a discharge device in accordance with the invention.
DETAILED DESCRIPTION
[0018] The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the present disclosure, its application, or uses.
[0019] The discharge devices in accordance with the invention are in particular so-called lances for high-pressure cleaning devices. At their end, not shown, facing the user, these lances have an operating part, made e.g. in the form of a pistol trigger, with which the supply of the cleaning fluid to the head region of the lance can be released or interrupted. For this purpose, the lance is connected to a supply line provided e.g. as a hose in the region of this operating part.
[0020] The discharge device in accordance with the invention includes a jointed piece 19 which can be flowed through and which has an inlet part 21 and an outlet part 23 . Details of this jointed piece 19 are not the subject of the present invention so that they will not be looked at in more detail.
[0021] The inlet part 21 of the joint 19 forms the end piece of an elongate carrier 11 not shown in full here which is made as a rigid supply line for the cleaning fluid and is also termed a carrier tube in the following. The section of the carrier 15 leading up to the user-side is connected to the inlet part 21 of the joint 19 by suitable means.
[0022] The outlet part 23 of the jointed piece 19 is a component of a pivotable head piece 11 and is provided with a nozzle member 45 for the output of the cleaning fluid. The cleaning fluid is supplied via the carrier 15 and its end piece (inlet part) 21 , flows through the jointed piece 19 and reaches the nozzle member 45 via the outlet part 23 .
[0023] Whereas the jointed piece 19 is manufactured from metal, in particular brass, a cover or jacket 41 of the outlet part 23 and a discharge stub 43 surrounding the nozzle member 45 preferably consist of plastic.
[0024] The carrier 15 , together with at least a part of its end piece forming the inlet part 21 of the joint 19 , extends inside an actuation member 17 which is provided in the form of a rigid, elongate sleeve with a square or rectangular cross-section. The arrangement of inwardly disposed carrier 15 and outer actuation member 17 forms an elongate holder for the pivotable head piece 11 whose length can generally be selected as desired.
[0025] The preferred embodiment of both the carrier tube 15 and the actuation sleeve 17 as a plastic part in each case results in a weight minimization so that the lance in accordance with the invention also remains easy to handle for the user with a relatively large length.
[0026] The actuation sleeve 17 is coupled to the outlet part 23 of the jointed piece 19 by an actuator in the form of a lever 27 . The lever 27 is connected at its one end to the end face of the actuation sleeve 17 and at its other end in the region of the end of the outlet part 23 at the nozzle side. By displacement of the actuation sleeve 17 relative to the carrier 15 , the head piece 11 is compulsorily guided via the actuation lever 27 and pivoted relative to the longitudinal axis of the holder formed by the carrier 15 and the actuation sleeve 17 .
[0027] In the extended state in accordance with FIG. 1 , i.e. with a pivot angle of 0° between the inlet part 21 and the outlet part 23 , the flat actuation lever 27 contacts the outer side of the head piece 11 .
[0028] The axis of rotation 12 of the joint 19 is arranged somewhat off center with respect to the hinge point of the lever 27 and is therefore disposed more closely to the hinge point at the nozzle side than to the hinge point of the actuation member 17 .
[0029] The pivoting of the head piece 11 can take place continuously. Alternatively, a latch mechanism only permitting discrete pivot positions can be provided. For this purpose, for example, a latch ball (not shown) pre-tensioned by means of a spring can be arranged in a latch bore 49 ( FIG. 2 ) of the inlet part 21 at the end face which cooperates with a series of latch recesses in the outlet part 23 . A latch mechanism can alternatively be effective at the joints of the actuation lever 27 .
[0030] The embodiment example in accordance with FIGS. 3 and 4 differs from the variant described above in particular by the manner of the actuation of the pivotable head piece 11 .
[0031] The actuation member 17 includes a rotary sleeve 18 which is coupled at its front end to a sliding part 16 which is connected in accordance with the embodiment of FIGS. 1 and 2 via an actuation lever 27 to the head piece 11 or to the outlet part 23 of the jointed piece 19 . The rotary sleeve 18 is guided in a compulsory manner on the outer side of the carrier tube 15 to convert a rotary movement into a translatory movement. For this purpose, the carrier tube 15 is provided with an external thread 25 which converts a rotary movement of the rotary sleeve 18 screwed onto the carrier tube 15 in this respect into the displacement movement of the sliding part 16 . The fine adjustment of the adjustment mechanism for the pivotable head piece 11 can be directly predetermined by the pitch of the thread 25 .
[0032] This combined variant of user-side rotation and head-piece-side translation has the advantage that the actuation is made possible by an extremely user-friendly rotation of an operating section (rotary sleeve) 18 while maintaining the constructionally simply and functionally extremely reliable pull/push lever arrangement for the adjustment of the head piece 11 . The pivot angle of the head piece 11 can thereby be set without any large expenditure of force and additionally very precisely by means of the rotary sleeve 18 .
[0033] As in particular the upper representations in FIG. 3 and in FIG. 4 show, the rear end of the operating section 18 is provided with cut-outs 51 into which an extension piece 37 can engage with corresponding engagement sections 53 to establish a rotationally fixed connection to the operating section 18 . The lance in accordance with the invention can generally be made as long as desired by the use of a plurality of extension pieces.
[0034] The embodiment shown in FIG. 5 is a purely rotary solution. The actuation member 17 forming the elongate holder 13 of the lance in accordance with the invention together with the carrier tube 15 includes an operating section 18 which is rotatable relative to the carrier 15 together with a control part 16 disposed In front of it.
[0035] The front end face of the tubular control part 16 is made as a screw-shaped control cam 31 which cooperates directly with the pivotable head piece 11 . The head piece 11 —i.e. the outlet part 23 of the joint 19 or its cover or jacket 41 —is acted on at a sufficient spacing from the axis of rotation 12 and is pivoted in accordance with the extent of the control cam 31 by rotation of the operating section 18 and thus of the rotary part 16 relative to the carrier 15 and thus to the inlet part 21 of the jointed piece 19 .
[0036] A further purely rotary solution is shown in FIGS. 6 and 7 . The actuation member 17 is made at the end face as a miter gear or pinion gear 33 which cooperates with two miter gears or crown gears 35 . The crown gears 35 are rotationally fixedly connected to the outlet part 23 of the jointed piece 19 whose inlet part 21 is rotationally fixedly connected to the carrier tube not shown here and extending through the rotatable actuation member 17 .
[0037] A rotation of the actuation member 17 by the user relative to the carrier and thus to the inlet part 21 thus effects a corresponding pivot movement of the head piece 11 provided with the nozzle member 45 via the miter gear formed by the toothed wheels 33 , 35 .
[0038] FIG. 7 shows the lance in accordance with the invention in the upper illustration partly with a pivotable housing part 55 which is pivoted around an axis 59 on the pivoting of the head piece by means of the miter gear 33 , 35 .
[0039] The two lower illustrations in FIG. 7 show the lance in accordance with the invention in the extended state and with a head piece 11 completely covered by the pivotable housing part 55 and a fixed housing part 57 . The miter gear 33 , 35 and the jointed piece 19 are ideally protected against external influences by this “all-round cover”.
[0040] In addition to the part carrying the pinion gear 33 at the end face, the actuation member 17 includes a plurality of extension pieces 37 which can be rotationally fixedly connected to one another and whose number can generally be selected as desired to obtain a lance with the desired working length.
[0041] The description of the present disclosure is merely exemplary in nature and, thus, variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.
REFERENCE NUMBER LIST
[0000]
11 head piece
12 pivot axis
13 holder
15 carrier, tube
16 part of the actuation member
17 actuation member
18 operating section, sleeve
19 jointed piece
21 inlet part
23 outlet part
25 thread
27 actuator, lever
29 transmission
31 control cam
33 miter gear of the actuation member, pinion gear
35 miter gear of the head piece, crown gear
37 extension piece
41 jacket, cover
43 discharge stub
45 nozzle member
49 latch bore
51 cut-out
53 engagement section
55 housing part
57 housing part
59 axis | The invention relates to a discharge device for a cleaning fluid or treatment fluid, in particular to a lance for a high-pressure cleaner, comprising a pivotable head piece and an elongate holder which carries the head piece at its one end and is made at its other end for holding and for remotely controlled pivoting of the head piece, wherein the holder includes a carrier for the holding of the head piece and an actuation member adjustable relative to the carrier for the pivoting of the head piece relative to the carrier, and wherein the carrier and the actuation member extend up to the head piece in an at least approximately axially parallel arrangement, and in particular coaxial arrangement, with the carrier extending inside the actuation member. | 1 |
This application is the national phase of international application PCT/FI97/00759 filed Dec. 4, 1997 which designated the U.S.
The present invention relates to digital telecommunication systems, and particularly to the detection of speech channel back-looping therein.
In conventional digital telecommunication systems, speech is transferred in a digital pulse code modulated (PCM) transmission channel as standard (A-law encoded or mu-law encoded) PCM samples, typically at a rate of 64 kbit/s, i.e. 8,000 samples/second. This provides excellent speech quality.
In some cases it has been possible to combine with digital speech samples other supplementary information, such as signalling messages or speech coding parameters of speech coded to a low bit rate. This supplementary information transfer can be based on what is known as the bit stealing technique, in which one or more bits (usually the least significant LSB) of the speech sample is chosen for this purpose. Since the LSB of a speech sample contains very little speech information, there is no detectable deterioration of speech quality. Such supplementary information is usually transmitted between the transmission devices or speech processing devices of the network.
In call switching, the following situation may arise. The speech processing device is activated before a call is switched forward in the telephone switching centre. In this case the speech processing device transmits PCM speech samples towards the telephone switching centre. It is the property of some telephone switching centres that speech channels are looped directly back to the sender if the switching forward is not ready. This results in the speech samples returning to the speech processing device which sent them. Usually this speech channel back-looping does not cause problems since call switching is not ready up to the user and consequently the back-looped speech/silence is not heard by anyone.
In contrast, in cases where supplementary information is sent in a speech sample, speech channel back-looping may cause problems. When the speech processing unit gets back supplementary information (e.g. a signalling message) it has sent, it may assume that the received information originates from some other device, not itself. Particularly if the signalling message is of a fixed format, it is impossible to distinguish the sender solely from said message.
In the following some examples will be given of cases involving the above problem.
In digital mobile communication systems, for example, the most limited resource is the radio path between mobile stations and base stations. To reduce the bandwidth required by one radio connection on the radio path, speech transfer utilizes speech coding for achieving a lower, e.g. 16 or 8 kbit/s, transfer rate than the 64 kbit/s transfer typically employed in telephone networks. The mobile station and the fixed network side must naturally have a speech encoder and decoder for the purposes of speech coding. On the network side the speech coding functions may be located in a plurality of alternative places, such as in a base station or in association with a mobile exchange. The speech encoder and decoder are often far away from the base station in the system as what is known as a remote transcoder unit, whereby speech coding parameters are transferred between the base station and the transcoder unit in the network in specific frames.
In each mobile terminating or originating speech call a transcoder is connected to the speech connection on the network side. The transcoder interface towards the mobile exchange is 64 kbit/s. The transcoder decodes a speech signal vocoded to a transmission channel of an 8/16 kbit/s rate from a mobile station (uplink) to a 64 kbit/s rate and encodes a 64 kbit/s speech signal to the mobile station (downlink) and from the mobile exchange to an 8/16 bit/s rate. Hence speech quality is lower than in a normal telephone network. This arrangement is trouble-free as long as one party of the call is a mobile station and the other e.g. a subscriber in the public switched telephone network (PSTN).
In the case of a mobile to mobile call MMC, the operation of the mobile communications network causes there to be one transcoder on a connection between a calling mobile station and a mobile exchange, and similarly another transcoder between a called mobile subscriber and (the same or another) mobile exchange. These transcoders are then coupled together via the mobile exchange(s) as a result of normal call switching. In other words, two transcoder units are coupled in tandem for each MMC call and the call is subjected twice to speech encoding and decoding. This is called tandem coding. Tandem coding is a problem in mobile communication networks since it impairs speech quality owing to extra speech encoding and decoding. Up to now tandem coding has not caused very much trouble since relatively few calls have been MMC calls. However, the number of MMC calls will continue to increase with an increasing number of mobile stations.
The applicant's Finnish patent application FI951807 discloses a transcoder having what is known as tandem coding prevention. An MMC call is switched as usual with the connection having two transcoders in a tandem configuration. The speech to be transferred between a transcoder and a mobile station has been coded by the vocoding method which decreases transfer rate. Both transcoders perform normal transcoding operations on the speech such that the speech is decoded in one transcoder into normal digital pulse code modulated (PCM) speech samples which are transferred to the other transcoder and encoded therein by said vocoding method. Speech information received from the mobile station and complying with said vocoding method, i.e. speech parameters, which are not subjected to transcoding operations (encoding and decoding) in either tandem connected transcoder, is transferred at the same time in a subchannel formed by one or two least significant bits of the PCM speech samples. The receiving transcoder selects the speech information complying primarily with this vocoding method for transmission across the interface to the receiving mobile station. As a result, vocoding is principally performed only in mobile stations and the vocoded speech information, i.e. speech parameters, are transferred through the mobile communication network without tandem coding, resulting in improved speech quality. When the receiving transcoder does not find vocoded speech information in the least significant bits of the PCM speech samples, the speech information to be transmitted over the radio interface is encoded as usual from the PCM speech samples.
The applicant's Finnish patent application FI960590 discloses a transmission equipment for optimizing the use of transmission resources on a transmission connection between telecommunication network elements, such as exchanges or base station controllers. Both ends of the connection are provided with a transmission equipment which is connected to a number of PCM channels originating from the switching centre. Between the transmission equipments is a lower-capacity PCM link where the bits of the PCM samples of each channel form subchannels in which lower-rate vocoded speech or data can be transferred. If a PCM coded speech signal in which one or more least significant bits of the PCM samples form a lower-rate subchannel is also received from the switching centre, the contents of this subchannel are multiplexed to one subchannel of the PCM link. If only a PCM coded speech signal is received from the switching centre, it is encoded into a lower-rate vocoded speech signal and the vocoded speech signal is multiplexed into one subchannel of the PCM link. At the other end of the connection the transmission equipment decodes the vocoded speech signal back to PCM samples, into whose least significant bits are placed the contents of the subchannel without decoding. This transmission equipment is suitable for use particularly in association with the tandem coding described in patent application FI951807.
EP application 0,333,345 describes tandem speech coding in a fixed telephone network using digital switches or vocoding. The speech codecs convert a 64 kbit/s speech signal into a lower rate vocoded signal, and vice versa. Each speech codec is adapted by means of special signalling to detect whether another corresponding speech codec is connected in series on the transmission path, which is 64 bit/s. This signalling is carried out in a signalling channel implemented in the least significant bits of conventional PCM speech samples. It a speech codec detects the presence of another speech codec on the transmission path, it suspends the decoding of a vocoded speech signal into a 64 kbit/s signal. Instead it “embeds” the vocoded speech parameters into a 64 kbit/s signal in whose extra bits are placed “place holder” bits. The other speech codec receives this 64 kbit/s “compressed” signal, extracts the “place holder” bits therefrom and forwards only the vocoding bits.
In all above examples, speech channel back-looping can cause tandem coding prevention to be switched on in a device when the transmission of the device is looped back from the speech channel and is interpreted as a transmission from another device.
SUMMARY OF THE INVENTION
The object of the invention are means and a method enabling self-sent information included in a speech channel to be distinguished from similar information sent by other parties.
The invention is based on the idea that, particularly at the beginning of a call, two speech processing functions and speech signals are typically independent of one another and random. Hence samples of speech from various senders are also independent of one another and random, whereby they can be utilized in identifying the sender thereof and consequently the sender of any supplementary information contained therein.
For identification, a check value is calculated on the basis of the speech samples which are sent simultaneously with the supplementary information frame, by using a predetermined calculation method. The check value is stored at the transmitting end. When a supplementary information frame is received from the speech channel, the speech samples associated therewith are used to calculate a check value in the same way as at the transmitting end. If the check values match, it is concluded that the supplementary information frame is the same as the one that was sent, i.e. speech channel back-looping to the sender has occurred. If the check values do not match, the supplementary information frame is interpreted to have been sent by another party, and the process continues accordingly. The check value according to the invention enables a self-sent transmission to be very reliably distinguished from other transmissions, since owing to the random character of speech signals, the likelihood of an exact match between the check values of a sent and a received supplementary information frame is very slight when the frames originate from different sources.
The starting and/or ending points of check value calculation in a sent and received speech sample flow are determined relative to the supplementary information frame, e.g. its start or end.
The check value may be calculated across all the speech samples sent with an information frame, or alternatively only some speech samples may be used for calculating the check value. Part of the speech bits, all speech bits or both speech and supplementary information bits of each speech sample may be used. The calculation of the check value may be extended to speech samples preceding or succeeding the supplementary information frame. Generally speaking the accuracy of the check value is the better the more speech sample information is used for calculating the check value.
The invention provides a plurality of advantages. The amount of supplementary information to be sent does not increase as would be the case if some kind of information about the sender, such as a random number or a sender identity, were appended to the supplementary information frame. The invention does not require much memory since the principle is that only one check value is calculated and stored for each supplementary information frame. Memory need is much less than in e.g. solutions in which the data transmitted is stored in a memory, and the data received is compared with the data stored. This requires an amount of memory that is equal to the transfer delay in the loop.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention will be described in greater detail by means of preferred embodiments with reference to the attached drawings, in which
FIG. 1 shows a mobile communication system to which the invention can be applied, and
FIGS. 2A and 2B illustrate providing subchannels into the least significant bits of a PCM sample,
FIG. 3 illustrates the positioning of a TRAU frame in 160 successive 8-bit PCM samples according to the invention,
FIG. 4 is a block diagram of a speech processing equipment according to the invention,
FIG. 5 is a PCM speech sample sequence containing a supplementary information frame F,
FIG. 6 is a flow diagram illustrating the operation of the message encoder of FIG. 4,
FIG. 7 is a flow diagram illustrating the operation of the message decoder of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention can be applied in a telecommunication system in which the intention is to transfer some supplementary information together with digital speech samples by e.g. the bit stealing technique. The supplementary information preferably comprises signalling messages or parameters of lower-rate vocoded speech.
An example is the European digital cellular telecommunication system GSM (Global System for Mobile Communication) which is becoming a world-wide standard for mobile communication systems. The basic structural parts of the GSM system are described in the GSM recommendations. As to a more precise description of the GSM system, reference in made to the GSM recommendations and the publication “The GSM System for Mobile Communications”, M. Mouly & M- B. Pautet, Palaiseau, France, 1992, ISBN:2-95071900-7.
The GSM and its modification DCS1800 (Digital Communication System) operating in the 1800-MHz frequency range, are the primary scope of application of the invention, but the invention is not to be limited to these systems.
FIG. 1 briefly describes some basic structural elements of the GSM system. A mobile exchange MSC switches incoming and outgoing calls. It performs tasks similar to those performed by an exchange in a fixed network. In addition is performs tasks typical of mobile telephone traffic only, such as e.g. subscriber location management. Mobile radio stations, i.e. mobile stations MS, are connected to the centre MSC via base station systems. A base station system consists of a base station controller BSC and base stations BTS. The base station controller BSC is used to control a plurality of base stations.
The GSM system is entirely digital with speech and data transfer also taking place in an entirely digital form. The speech coding method currently used in speech transfer is RPE-LTP (Regular Pulse Excitation-Long Term Prediction), which utilizes both long and short term prediction. The coding generates LAR, RPE and LTP parameters which are transferred instead of actual speech. Speech transfer is described in the GSM recommendations chapter 06, speech coding particularly in recommendation 06.10. In the near future other coding methods will also be employed, such as e.g. half-rate methods and reduced full-rate coding, in association with which the invention can be used as such. Since the actual invention is not directed to the actual speech coding method and is independent thereof, it will not be dealt with in greater detail herein. In the present application, the speech coding method is also called vocoding (voice coding), as a distinction between conventional PCM coding.
For speech coding a mobile station must of course comprise a speech coder and decoder. Since the implementation of a mobile station is not relevant to the invention and is not different from the conventional, it will not either be described in any greater detail herein.
On the network side various speech coding and rate adaptation functions are centralized into a transcoder unit TRAU (Transcoder/Rate Adaptor Unit). The TRAU can be located in a plurality of alternative places in the system according to the choices made by the manufacturer. The interfaces of the transcoder unit are a 64 kbit/s PCM (Pulse Code Modulation) interface (A interface) towards the mobile exchange MSC and a 16 or 8 kbit/s Abis interface towards the base station BTS.
When a transcoder unit TRAU is located remote from a base station BTS, information is transferred at the Abis interface between the base station BTS and the transcoder unit TRAU in what are known as TRAU frames comprising 320 bits when recommendation 08.60 is concerned or 160 bits when recommendation 08.61 is concerned. Four different types of frames are currently defined depending on the information contained therein. These include speech, operation/maintenance and data frames, and what is known as an idle speech frame. A transcoder unit located remote from a base station BTS has to receive information about the radio interface for efficient decoding. Special in-band signalling in an 8 or 16-kbit/s channel for transmitting speech or data between the base station and the transcoder unit is used for the control and synchronization of the transcoder unit. Such remote control of a transcoder unit has been defined in recommendation GSM 08.60 (16 kbit/s channel) and 08.61 (8 kbit/s channel).
Usually only PCM coded speech is transferred at the A interface between a transcoder TRAU and an MSC. In this case the transcoder TRAU is able to perform transcoding between vocoded speech and PCM coded speech.
The applicant's patent application FI951807 discloses an improved transcoder TRAU which, besides performing the usual transcoding operations between vocoded speech and PCM coded speech, also sends speech information received from a mobile station and complying with said vocoding method, i.e. speech parameters which are not subjected to a transcoding operation (decoding), in a subchannel formed by one (8 kbit/s capacity) or two (16 kbit/s capacity) least significant bits of PCM speech samples. Similarly, in the other transmission direction, the transcoder receives from a subchannel contained in the PCM samples of the A interface vocoded speech which is transferred to the Abis interface without transcoding operation (encoding). When switching an MMC call comprising two such transcoders in a tandem configuration, each transcoder in fact only forwards vocoded speech, possibly modifying or replacing parameters, but, however, without performing any extra vocoding. As a result, vocoding is mainly performed only in mobile stations MS, whereby tandem coding is avoided and speech quality improves. The implementation and operation of such an improved transcoder are described in greater detail in the above patent application.
Thus two type of signals can appear at the A interface: 1) normal 64 kbit/s PCM, 2) PCM in which one or two least significant bits of PCM samples form a subchannel for vocoded speech (or data). The transfer of vocoded speech in the least significant bits of PCM samples is illustrated in FIGS. 2A and 2B. Furthermore, FIG. 3 illustrates a possible location of a TRAU frame in 160 successive 8-bit PCM samples. Two TRAU frame bits are placed in each PCM sample in the two least significant bit locations in accordance with FIG. 2 A. PCM samples 1 to 8 contain synchronization zeros, PCM samples 9 to 18 control bits C 1 to C 15 , PCM samples 19 to 155 data bits, and PCM samples 156 to 160 control bits C 16 to C 21 and T 1 to T 4 . The six most significant bits of PCM samples are original PCM sample bits (marked with the symbol x). In the example of FIG. 2A, the transfer rate of PCM coded speech is 48 kbit/s and that of the subchannel 16 kbit/s. If the subchannel is implemented with one bit, such as in FIG. 2B, the transfer rate of PCM coded speech is 56 kbit/s and that of the subchannel 8 kbit/s.
The mobile exchange MSC switches calls at a nominal transfer rate of 64 kbit/s irrespective of whether the signal to be switched is of type 1) or 2).
In a conventional mobile communication network the links between switching centres also comprise one 64 kbit/s PCM channel for each A interface signal. Links between switching centres refer to links between mobile exchanges MSC and to links between a mobile exchange MSC and the gateway switching centres GW of the public switched telephone network PSTN.
In the example of FIG. 1 the capacity needed by the connection between the switching centres has been optimized by using the transmission or compression units TRACU 1 . . . TRACU 4 (Transcoding and Rate Adaptation Compressor Unit) disclosed in the above patent application FI960590. In other words, the switching centres are interconnected by two transmission equipments; each end of the connection comprising one equipment. Speech between the MSC (GW) and the TRACU is transferred as at the A interface, i.e. either as merely PCM coded speech (type 1) or as PCM coded speech containing a subchannel of vocoded speech (type 2). Between the TRACUs there is at least one 64 kbit/s PCM channel in which speech is always transferred as vocoded 8 kbits/s or 16 kbits/s speech in one or two bits of a PCM sample, respectively. The principle is the same as is illustrated in FIG. 2 for the A interface, but now all bits of a PCM sample are used as e.g. 8 or 16 kbit/s subchannels and PCM coded speech is not transferred at all. This way the TRACUs can multiplex 1 to 8 A interface PCM bit streams to one PCM bit stream for communication between the TRACUs. The compression equipment selects its mode of operation according to information received from the A interface, as was described above in association with the transcoder TRAU. This compression solution is described in greater detail in said patent application FI960590.
In these solutions the transcoders TRAU and compression equipments TRACU select their modes of operation according to the type of speech signal received from the A interface and/or the signalling contained therein. In this case back-looping of a self-sent signal in the switching centre may cause problems.
Let us assume for example in FIG. 1 that the establishment of an outgoing call from MS 2 to PSTN has progressed to a stage at which the TRAU 2 sends to the centre MSC 2 PCM samples according to FIG. 3, the samples containing TRAU frames as supplementary information. However, the call is not ready between the MSC 2 and the GW 2 , and hence the MSC 2 has temporarily coupled the A interface lines originating from the TRAU 2 back to the A interface lines terminating in the TRAU 2 . In this case the PCM samples sent by the TRAU 2 are looped back to itself. If no mechanism for identifying the sender exists, the TRAU 2 concludes that the received TRAU frames originate from another unit which also supports tandem prevention and selects the tandem prevention mode. However, the call is finally switched to the GW 2 which does not at all support this feature.
In addition to or instead of vocoded speech, PCM samples may contain various signalling messages used by the devices to negotiate the properties of a communication, such as the vocoding method used (in a multiple codec environment) etc. In this case the back-looping of self-sent messages may cause an erroneous equipment configuration even before the call has been switched up to the other device. The invention is based on the fact that two speech processing functions and speech signals are typically, particularly at the beginning of a call, independent of one another and random. Hence speech samples received from different senders are also independent of one another and random, and can therefore be utilized in the identification of their sender and thereby the sender of the supplementary information contained therein.
In the invention a check value is calculated for identification of a sender on the basis of the speech samples which are sent simultaneously with the supplementary information frame. This check value is stored at the transmitting end. Upon reception of a supplementary information frame from a speech channel, a check value is calculated on the basis of the speech samples associated therewith in the same way as at the transmitting end. If the check values match, the conclusion is that the supplementary information frame is the same as the one transmitted, i.e. the speech channel is looped back to the sender.
Let us assume for example that the TRAU 2 sends towards the MSC 2 a PCM sample sequence including a TRAU frame according to FIG. 3 . The TRAU 2 then (in this example) calculates a predetermined check value across all speech sample bits X of the PCM speech samples 1 to 160 and stores the check value. Let us assume further that the TRAU 2 receives from the direction of the MSC 2 a PCM sample sequence including a TRAU frame according to FIG. 4 . The TRAU 2 then calculates, using the same principle as in transmission, a check value across the speech bits X of the received PCM speech samples 1 to 160 and compares the calculated check value with the stored check value. If the sent and received speech bits X are the same, the check values also match, and the TRAU 2 is able to identify the received TRAU frame as a self-sent frame which the MSC 2 has back-looped. This way the problems caused by speech channel back-looping can be avoided at the A interface of the transcoders and compression devices of FIG. 1 .
The invention is, however, entirely independent of the nature of the transmitted supplementary information. In the following the invention will be described generally in a case in which the supplementary information is a signalling message.
FIG. 4 shows a block diagram of a speech processing unit of the invention. A speech processing block 51 generally represents speech processing which generates PCM speech samples for transmission and processes received PCM speech samples. Such speech processing can include vo-encoding and vo-decoding, in the same way as was described above in association with the transcoder TRAU and the compression device TRACU. Speech processing may also have a mode in which vocoding parameters are sent in the LSBs of PCM samples. A PCM transmitter 53 and a PCM receiver 54 represent functions and devices for interfacing to PCM lines terminating at the switching centre and originating therefrom, respectively. A message encoder 52 and a message decoder 55 represent functions and devices for carrying out the signalling message transmission and reception and the sender identification according to the invention. FIG. 6 is a flow diagram illustrating the operation of the message encoder of FIG. 4 . FIG. 7 is a flow diagram illustrating the operation of the message decoder.
Let us first study a situation in which the speech processing unit sends a signalling message. FIG. 5 shows a PCM sample sequence in the output of the message encoder 52 , with PCM samples (n−3) . . . (n+k+1) visible. The speech processing block 51 applies to the message encoder 52 PCM samples 56 containing only speech sample bits X. The message encoder 52 continuously checks (step 71 , FIG. 6) if the speech processing block 51 has a signalling frame F to be sent on a line 57 . If there is no signalling frame F to be sent, the message encoder 552 transmits the PCM samples 56 unchanged to the transmitter 53 (step 72 ) which sends them via an outgoing PCM line to the switching centre. This is what happens to the speech samples (n−3) . . . (n) in FIG. 5 . At speech sample n+1 the message encoder detects that the line 57 has a signalling frame F comprising 2*k bits M to be sent. The message encoder 52 then places the bits M of the frame F into the two least significant bits (LSB) of the speech samples (n+1) . . . (n+k), step 73 . In other words, at the output of the message encoder 52 , the six most significant bits (MSB) in each speech sample (n+1) . . . (n+k) are speech sample bits X and the two LSBs are message bits M, as illustrated in FIG. 5 . At the same time the message encoder 52 calculates across the speech bits X of the speech samples (n+1) . . . (n+k) the check value of the invention (step 74 ) and stores it in a check value memory 56 (step 75 ). Transmission of the frame F ends at speech sample (n+k+1) which again is sent unchanged (steps 71 and 72 ), as illustrated in FIG. 5 .
In the above example the check value was calculated across the speech bits X only. The check value could alternatively be calculated across the speech bits X and the message bits M. Furthermore, the check value can be alternatively calculated by using only some speech bits X, or some speech bits X and message bits M. It is also possible to use in addition or only the speech bits X of the sample(s) preceding or succeeding the frame F for calculating the check value. It is only essential to the invention that at least some speech information is used in calculating the check value to enable identification. The reliability of the identification improves the more speech information is used for calculating the check value.
The starting and ending point for calculating the check value is determined with respect to the frame F. In the above example, the calculation comprises k speech samples from the start of the frame. The calculation may alternatively be directed to e.g. the end of the frame F or to some identifiable field within the frame F.
The check value may be e.g. a cyclical code, such a cyclic redundancy code CRC, usually employed for error correction. All the bits of the code are determined by the bits used in the calculation, whereby bit strings with the same CRC are very likely to be identical. Thus the CRC can also be used reliably for identifying the sender, since the likelihood of two senders having exactly similar speech information is very small. Recommendation GSM 08.61 described a CRC calculation algorithm. The check value may also be e.g. some kind of check sum.
PCM samples received from a PCM line 59 originating from the switching centre are transferred from the receiver 54 to the message decoder 55 and further to the speech processing block. The message decoder 55 receives PCM samples (step 81 , FIG. 7) and checks whether the received speech samples include a supplementary information frame F (step 82 ). If so, the message decoder 55 calculates the check value across the speech bits X in k speech samples starting from the speech sample (n+1) where the frame F started (step 83 ). The message decoder 55 then compares the calculated check value with check values stored by the message encoder 52 in the check value memory 56 (steps 84 and 85 ). If the check values match, the message decoder 55 concludes that the switching centre has looped back the frame F sent by the message encoder 53 , and rejects the frame F (step 86 ). If the check values do not match, the message decoder 55 accepts the frame F (step 87 ) and transfers it via a line 60 to control speech processing.
The time the check values have to be stored in the memory 56 is equal to the time corresponding to the transfer delay from the transmitter 53 via the switching centre to the receiver 54 .
If the frame F is a TRAU frame or other frame containing vocoded speech information, the message encoder 52 and the message decoder are preferably only units that add the vocoding information to the PCM samples and similarly remove the vocoding information from the PCM samples. In addition they calculate the check value of the invention and identify the sender.
In principle the invention can be applied to detecting speech channel back-looping even when the speech samples do not contain supplementary information. In this case check values are simply calculated from the sent and received speech samples and compared with each other. However, determining the starting and ending point for the calculation may cause problems.
The attached figures and the related description are only intended to illustrate the present invention. The details of the invention may vary within the scope and spirit of the attached claims. | In some call-switching systems, transmitted speech samples may be sent back (back-looping) to the sender from a telephone switching center if the switching center is unable to send the speech samples forward. When supplementary information is sent with the speech sample, back-looping may cause a problem if the sending device interprets the signal as originating from another device. To avoid this problem, transmitted samples are subjected to a check value calucation such as a checksum or a cyclic redundancy check. The check value is stored in memory and any received samples are subjected to a check value calculation and compared to the stored samples. If the comparison yields a match, then the device will know that the received samples originated from itself and can be properly handled. | 7 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 12/623,203, entitled “Modular Floor Tile System With Transition Edge,” filed on 20 Nov. 2009, now pending, which is a continuation of U.S. patent application Ser. No. 10/898,494, entitled “Modular Floor Tile System with Transition Edge,” filed on 23 Jul. 2004, now U.S. Pat. No. 7,690,160, the disclosures of which are incorporated, in their entireties, by this reference.
TECHNICAL FIELD
[0002] This invention relates generally to floor tiles, and more particularly to modular floor systems with a transition edge.
BACKGROUND
[0003] Floor tiles have traditionally been used for many different purposes, including both aesthetic and utilitarian purposes. For example, floor tiles of a particular color may be used to accentuate an object displayed on top of the tiles. Alternatively, floor tiles may be used to simply protect the surface beneath the tiles from various forms of damage. Floor tiles typically comprise individual panels that are placed on the ground either permanently or temporarily depending on the application. A permanent application may involve adhering the tiles to the floor in some way, whereas a temporary application would simply involve setting the tiles on the floor. Some floor tiles can be interconnected to one another to cover large floor areas such as a garage, an office, or a show floor.
[0004] Various interconnection systems have been utilized to connect floor tiles horizontally with one another to maintain structural integrity and provide a desirable, unified appearance. In addition, floor tiles can be manufactured in many shapes, colors, and patterns. Some floor tiles contain holes such that fluid and small debris is able to pass through the floor tiles and onto a surface below. Tiles can also be equipped with special surface patterns or structures to provide various superficial or useful characteristics. For example, a diamond steel pattern may be used to provide increased surface traction on the tiles and to provide a desirable aesthetic appearance.
[0005] One method of making plastic floor tiles utilizes an injection molding process. Injection molding involves injecting heated liquid plastic into a mold. The mold is shaped to provide an enclosed space to form the desired shaped floor tile. The liquid plastic is allowed to cool and solidify, and the plastic floor tile is removed from the mold.
[0006] The perimeter of typical floor tiles generally comprises an abrupt step or edge. The size of the step is usually equal to the thickness of the floor tile. The thickness of typical floor tiles is generally ¼-¾ of an inch. For many purposes, however, the abrupt step presents a number of problems. For example, a step of ¼ to ¾ of an inch is enough to cause tripping. In addition, it can be difficult to move objects on rollers across the step and onto the floor tiles.
[0007] The present invention is directed to overcoming, or at least reducing the effect of, one or more of the problems presented above.
SUMMARY
[0008] In one of many possible embodiments, the present invention provides a modular floor edge system. The modular floor edge system comprises a first ramp, the first ramp comprising a leading edge, a major axis and a minor axis, and a substantially vertical back substantially parallel to the major axis. The substantially vertical back comprises a plurality of connecting members removably attachable to a modular floor tile. The first ramp may include a tapered surface, an open webbed structure supporting the tapered surface, and the ramp may be made of plastic. According to some embodiments, the leading edge may comprise a substantially straight portion and a rounded corner. The ramp may include a substantially vertical side surface adjacent to and perpendicular with the substantially vertical back, the side surface comprising a connecting member attachable to another ramp. The plurality of connecting members may include male tabs comprising a generally vertical component and generally horizontal component. The substantially vertical back may also include a female connecting member at one end that is connectable to another ramp. The plurality of connecting members may each comprise a semi-circular tab protruding laterally from the substantially vertical back, such that a curved portion of the semi-circular tab faces a floor. The modular floor edge system may include a second ramp removably attached longitudinally to the first ramp at an interface substantially parallel with the minor axis. The modular floor edge system may also include a second ramp having a major axis and minor axis, the second ramp removably attached perpendicularly to the first ramp at an interface substantially parallel to the minor axis of the first ramp and substantially parallel to the major axis of the second ramp.
[0009] Another embodiment of the present invention provides a modular flooring system. The modular floor system comprises a first modular floor panel having a top surface and a plurality of lateral edge connecting members, and a first modular ramp comprising a plurality of connecting members removably attached to one lateral edge of the first modular floor panel. The first modular ramp comprises a tapered surface extending from a leading edge adjacent to a floor to a trailing edge substantially flush with the top surface. The flooring system may comprise a plurality of modular floor panels removably connected with the first modular floor panel to create a polygonal shape having a perimeter. A plurality of modular ramps may be attached to one another and extend around or partially around the perimeter of the polygonal shape. The first modular ramp may comprise an angle ranging between approximately 20-60 degrees with respect to a floor or other support surface. According to some embodiments, the first modular ramp further comprises a top tapered surface and an open webbed structure supporting the top tapered surface. The first modular ramp may comprise injection molded plastic.
[0010] Another aspect of the invention provides a method of making a modular flooring edge. The method may include providing an injection mold and injection molding a modular ramp comprising a back having one or more connecting members attachable to a modular floor tile. The method may further include injection molding a side having one or more connecting members attachable to another modular ramp. The injection molding of the modular ramp may include creating an upper ramp surface and a lower webbed support structure. The injection molding of the modular ramp may further include creating a leading edge for placement adjacent to a floor, the leading edge comprising a generally straight portion and a rounded corner portion.
[0011] Another aspect of the invention provides a method of building a modular floor. The method may include providing a plurality of modular floor panels of generally rectangular shape comprising lateral edge connectors, and providing a plurality of modular ramps comprising back and side connectors. The method may further include connecting the plurality of modular floor panels to one another via the lateral edge connectors to form a polygonal shape, and connecting the plurality of modular ramps to the modular floor panels around a perimeter of the polygonal shape. Each of the plurality of modular ramps may also be connected to an adjacent one of the plurality of modular ramps.
[0012] The foregoing features and advantages, together with other features and advantages of the present invention, will become more apparent when referred to the following specification, claims and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings illustrate various embodiments of the present invention and are a part of the specification. The illustrated embodiments are merely examples of the present invention and do not limit the scope of the invention:
[0014] FIG. 1A is a top perspective view of a modular floor edge ramp according to one embodiment of the present invention;
[0015] FIG. 1B is a bottom perspective view of the modular floor edge ramp of FIG. 1A ;
[0016] FIG. 1C is a top perspective view of a modular floor edge ramp without a rounded corner according to one embodiment of the present invention;
[0017] FIG. 2 is a top perspective view of two modular floor edge ramps being attached to a modular floor panel according to one embodiment of the present invention;
[0018] FIG. 3A is a bottom perspective view of two modular floor edge ramps being attached to a modular floor panel according to one embodiment of the present invention;
[0019] FIG. 3B is a detailed inset of a corner of the modular floor panel shown in FIG. 3A ;
[0020] FIG. 3C is a bottom view of the two modular floor edge ramps attached to the modular floor panel according to one embodiment of the present invention.
[0021] FIG. 4 is a top view of two interconnected modular floor tiles according to one embodiment of the present invention;
[0022] FIG. 5A is a partial perspective view of a plurality of interconnected modular floor tiles with modular edge ramps attached to and extending around a perimeter of the modular floor tiles according to one embodiment of the present invention.
[0023] FIG. 5B is a side view of a portion of the tiles and ramps shown in FIG. 5A .
[0024] Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
DETAILED DESCRIPTION
[0025] As mentioned above, modular flooring typically includes a top surface that sets above a support surface or floor. It is often difficult to move certain objects onto and off of the top surface of the modular flooring as a result of the step between the floor and the top surface. The sharp step around the perimeter of the modular floor can also result in tripping or other safety concerns. The present invention describes methods and apparatus that provide an edge around at least a portion of a modular floor perimeter. Consequently, ingress and egress to the modular floor is simplified and safer than prior flooring systems. While the edge and flooring systems shown and described below include embodiments, the application of principles described herein to are not limited to the specific devices shown. The principles described herein may be used with any flooring system. Therefore, while the description below is directed primarily to interlocking plastic modular floors, the methods and apparatus are only limited by the appended claims.
[0026] As used throughout the claims and specification the term “rectangle” or “rectangular” refers to a four-sided object with four right angles. “Modular” means designed with regular or standardized units or dimensions, as to provide multiple components for assembly of flexible arrangements and uses. The words “including” and “having,” as used in the specification, including the claims, have the same meaning as the word “comprising.”
[0027] Referring now to the drawings, and in particular to FIGS. 1A-1B , one component of a modular floor edge system according to principles of the present invention is shown. FIGS. 1A-1B illustrates a ramp, for example a first elongate ramp 100 . The first elongate ramp 100 comprises a major axis 102 and a minor axis 104 . The first elongate ramp 100 also includes a leading edge 106 arranged adjacent to a support surface such as the ground or a floor. Opposite of the leading edge 106 is a trailing edge 108 . The trailing edge 108 is spaced from the support surface. A top surface 110 extends between the leading edge 106 and the trailing edge 108 . Accordingly, the top surface 110 tapers from a first height above the support surface at the trailing edge 108 , to the second height adjacent to the support surface at the leading edge 106 as shown in FIG. 1A . The top surface 110 includes both an angled portion 111 and a substantially horizontal portion 113 .
[0028] The ramp 100 includes a first end 112 and a second end 114 . According to the embodiment of FIG. 1A , the leading edge 106 comprises a substantially straight portion 116 , and a rounded corner portion 118 at the second end 114 . Alternatively, according to some embodiments such as the embodiment shown in FIG. 1C , there is no rounded corner portion 118 at the second end 114 and the leading edge 106 is substantially identical at both the first and second ends 112 , 114 . As shown in FIG. 1A , the straight portion 116 is parallel to the major axis 102 .
[0029] The ramp 100 also includes a substantially vertical back 120 shown more clearly in FIG. 1B . FIG. 1B illustrates the ramp 100 from a bottom perspective view. The substantially vertical back 120 is generally parallel to the major axis 102 and comprises at least one connecting member, for example a plurality of male tabs 122 and a female tab 123 , protruding therefrom. The male and female tabs 122 , 123 are shown and described in more detail below with reference to FIGS. 3A-3C . The female tab 123 is shown adjacent to, but opposite of, the rounded corner 118 . The male tabs 122 are removably attachable to a modular floor tile, such as the modular floor tile 124 shown in FIG. 2 . The female tab 123 is connectable to another ramp.
[0030] Continuing to refer to FIG. 1B , the ramp 100 includes an open webbed structure 126 that supports the top surface 110 ( FIG. 1A ). The ramp 100 may comprise plastic or other material and is preferably injection molded. Accordingly, the ramp 100 is strong, lightweight, and inexpensive to manufacture.
[0031] Adjacent to the substantially vertical back 120 is a substantially vertical side surface 128 . The substantially vertical side surface 128 is generally perpendicular to the vertical back 120 . The substantially vertical side surface 128 includes one or more connecting members, such as male tab 130 , for attachment with another ramp similar or identical to the ramp 100 shown in FIG. 1B . The male tab 130 may be replaced with a mating female tab (e.g. 123 ), if desired, to provide for attachment to a ramp with a connecting member of the opposite type. Further, embodiments that do not include the rounded corner portion 118 (such as the embodiment of FIG. 1C ) may include either a male or female tab 122 , 123 opposite of the tab 130 shown protruding from the side surface 128 .
[0032] Referring next to FIG. 2 , two ramps 100 , 200 are shown in relation to the modular floor panel 124 . The modular floor panel 124 comprises a top surface 132 and a plurality of lateral edge connecting members. According to the embodiment of FIG. 2 , the plurality lateral edge connecting members comprise a plurality of female tabs 134 arranged on two adjacent sides 136 , 138 of the rectangular modular floor panel 124 , and a plurality of male tabs 140 arranged on another two adjacent sides 142 , 144 of the modular floor panel 124 . The first ramp 100 is shown connected to the modular floor panel 124 at the first lateral side 136 . Accordingly, female tabs 134 (not shown) extending from the first lateral side 136 are receptive of the male tabs 122 ( FIG. 1B ) of the first ramp 100 . Likewise, the female tabs 134 of the second lateral side 138 are receptive of the male tabs 222 of the second ramp 200 . The attachment of the ramps 100 , 200 to the modular floor panel 124 provides a convenient, tapered interface between the lateral sides 136 , 138 and the top surface 132 . Moreover, other ramps may also be added to the periphery of the modular floor panel 124 .
[0033] The connection of the first and second ramps 100 , 200 to the modular floor panel 124 is shown in more detail in FIGS. 3A-3C . The male tabs 122 , 222 include a generally vertical component which, according to the embodiment of FIGS. 3A-3C , comprises semi-circular posts 146 , 246 ( FIG. 3B ). The male tabs 122 , 222 also comprise generally horizontal components which, according to the embodiment of FIGS. 3A-3C , comprise semi circular discs 148 , 248 ( FIG. 3B ). A curved portion 150 of the semi-circular discs 148 , 248 faces the floor or ground. The semi-circular discs 148 , 248 are received through the looping female tabs 134 , and extend at least partially under the modular floor panel 124 to removably secure the ramps 100 , 200 to the modular floor panel 124 as shown in FIG. 3C . The looping female tabs 134 each comprise a rigid hoop structure that is completely receptive of the semi-circular discs 148 , 248 ( FIG. 3B ). The semi-circular posts 146 , 246 ( FIG. 3B ) and the semi-circular disc 148 , 248 ( FIG. 3B ) are also rigid but compressible toward one another. When inserted into the female tabs 134 , the semi-circular posts 146 , 246 ( FIG. 3B ) and the semi-circular discs 148 , 248 ( FIG. 3B ) maintain a constant pressure against the female tabs 134 , thereby securing a connection between desired components (e.g. between two or more modular floor panels 124 , between a modular floor panel 124 and a ramp 100 , between two or more adjacent ramps 100 , 200 , etc.). The connection members engage one another such that the different components are joined tightly to one another and provide a consistent upper surface.
[0034] According to the embodiment of FIGS. 3A-3C , a male tab 148 of the first ramp 100 is received by and engages the female tab 223 of the second ramp 200 to secure the first and second ramps 100 , 200 together. As shown in FIGS. 3A-3C , the second ramp 200 is removably attached perpendicularly to the first ramp 100 . Consequently, an interface 152 of the first ramp 100 with the second ramp 200 is substantially parallel to the minor axis 104 ( FIG. 1 ) of the first ramp 100 , and an interface 254 of the second ramp is substantially parallel to the major axis 102 ( FIG. 1 ) of the second ramp 200 . However, the first and second ramps 100 , 200 may be attached longitudinally as well. FIG. 5A illustrates a combination of ramps 100 arranged longitudinally and perpendicularly to one another around a modular floor 160 . The skilled artisan having the benefit of this disclosure will understand that the placement of the connecting members such as the male and female tabs 122 , 134 shown in FIG. 3B may be reversed between components.
[0035] Referring to FIG. 4 , two or more modular floor panels 124 may be interconnected to form any polygonal shape. Ramps such as the ramps 100 , 200 shown in FIGS. 3A-3B may then be attached at least partially around the perimeter of the polygonal shape as shown in FIG. 5A . The tapered surface 110 of the ramp 100 extends from the leading edge 106 adjacent to the support surface or floor to the trailing edge 108 that is preferably flush with the top surface 132 of the modular floor panels 124 . An angle α between the floor and the ramp 100 may range between approximately 20 and 60 degrees, preferably between approximately 30 and 50 degrees, more preferably about 45 degrees.
[0036] The preceding description has been presented only to illustrate and describe exemplary embodiments of invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the following claims. | The present invention provides a modular flooring system including a ramp to facilitate entry and exit from the flooring system. The ramp may be modular and interconnect with all or parts of a perimeter of the flooring system, and the ramp may also interconnect with adjacent ramp members. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present international patent application claims the benefit of priority from commonly owned and co-pending U.S. Provisional Patent Application Ser. No. 60/847,022, entitled “Embroidery Using Soluble Thread,” filed on Sep. 25, 2006, the entire contents of which are hereby expressly incorporated by reference into this disclosure as if set forth fully herein.
BACKGROUND OF THE INVENTION
[0002] I. Field of the Invention
[0003] The present invention relates to medical devices and methods generally aimed at surgical implants. In particular, the disclosed system and associated methods are related to a manner of creating surgical implants via embroidery.
[0004] II. Discussion of the Prior Art
[0005] Embroidered structures are created on substrates. Some substrates are designed to stay in place with the embroidered structure while other substrates are removed at the end of the embroidery process. If the substrate is designed to be removed, the preferred method of removal is dissolution. The dissolution processes discussed, however, are not intended to preclude the use of other means of substrate removal which those skilled in the art would employ in the manufacture of an embroidered structure, or the omission of substrate removal.
[0006] As an initial step in the creation of embroidered structures, a plurality of parallel, stationary backing threads are placed and secured on one surface of a substrate, called the “backing surface.” On the opposing surface of the substrate, called the “stitching surface,” is a plurality of stitching threads with one-to-one correspondence to the backing threads. Stitching may be done between one pair of threads at a time or in simultaneous multiplicity, as is described below.
[0007] The plurality of stitching threads from the stitching surface are passed to the backing surface through openings created in the substrate by the passing of each individual thread. Each stitching thread is then looped over its corresponding backing thread, in essence picking up the backing thread, which creates a lock stitch. Once each stitching thread has picked up its corresponding backing thread, the plurality of stitching threads are returned to the stitching surface by passing through the openings in the substrate created by initially passing the stitching threads to the backing surface. The lock stitches prevent the stitching threads from completely pulling back out of the openings created in the substrate. The plurality of stitching threads are then moved to a new stitching site and the process repeats until all the backing threads are joined by lock stitches to the corresponding stitching threads, creating a plurality of thread pairs of some length.
[0008] A plurality of thread pairs may be enclosed by one or more pluralities of enclosing thread pairs. To enclose a plurality of thread pairs, a subsequent plurality of backing threads are placed and secured on the backing surface of a substrate already holding at least one plurality of thread pairs, such that the subsequent plurality of backing threads covers the previously stitched plurality of backing threads. A subsequent plurality of backing threads is usually not parallel with the previous plurality of backing and stitching threads. A subsequent plurality of stitching threads, with one-to-one correspondence to the subsequent plurality of backing threads, is then stitched to the subsequent plurality of backing threads by the stitching process described above.
[0009] When the subsequent plurality of backing threads are all joined to the subsequent plurality of stitching threads by lock stitches over a desired distance, a plurality of enclosing thread pairs has been formed, enclosing all previously stitched pairs. This process may be repeated by stitching even further subsequent pluralities of enclosing thread pairs over the previously stitched thread pairs and enclosing thread pairs, such that, for example, the first plurality is enclosed by a second plurality, which is enclosed by a third plurality, which is enclosed by a fourth plurality, and so forth. This process produces stable embroidered structures which do not unravel into a pile of threads if the substrate is removed.
[0010] If the substrate is intended to be removed, the removal process is dependent upon the material from which the substrate is composed. If dissolution is the removal method chosen, the substrate materials are chosen such that the process which dissolves the substrate will minimally affect the physical properties of the stitching or backing threads used in the embroidered structure. When the substrate is removed, only the stitching and backing threads remain, in whatever combination of thread pairs and enclosing thread pairs that were utilized. The embroidered structure remains intact despite the removal of the substrate because each stitching thread is stitched to its corresponding backing thread, and vice versa, which is enclosed in one or more pluralities of enclosing thread pairs, all of which provides structural support.
[0011] In some applications, it may be advantageous to have an independent, unpaired thread, referred to as a “lace,” existing within an embroidered structure. Based upon the methodology of embroidered structure creation above, however, any lace within an embroidered structure would have to be placed after completion of the embroidery process because all threads are stitched, and thus paired, during the embroidery process. On a basic level, one or more laces may be added to an embroidered structure by hand, but this is possible only with the simplest of embroidered structures. The manual placement of laces is also expensive, not easily repeatable, and not conducive to mass production.
[0012] Repeatability is paramount in medical applications because devices may work reliably in one configuration, but variations of such a configuration may cause the device to perform unreliably, inadequately, or even fail to perform altogether. Repeatable placement of a lace within an embroidered structure used for surgical implantation requires a level of reproducibility exceeding that which may be achieved manually. Repeatability notwithstanding, the expense required to manually add one or more laces to embroidered structures further limits the use of manual insertion techniques, as does the bottleneck such manual insertions would cause in a manufacturing environment.
[0013] The present invention overcomes, or at least minimizes, the limitations associated with placing one or more laces within an embroidered structure.
SUMMARY OF THE INVENTION
[0014] According to the present invention, there is provided a manufacturing process by which an embroidered structure may be created containing within the structure one or more independent, unpaired threads laces, in a manner which is repeatable, inexpensive, and conducive to mass production.
[0015] The advantages to placing laces using the process of the present invention are: (1) ease of manufacture of complex devices; (2) the ability to make more complex devices; (3) the ability to improve the repeatability of strength critical items; (4) the ability to pre-load seams; and (5) the ability to create three-dimensional shapes.
[0016] The process of the present invention may use any of a variety of commercially available, automated embroidery machines and/or any other non-manual technique used to manufacture embroidered structures. A soluble thread composed of acetate (for example) or other soluble material is used as the corresponding partner thread for the lace thread during the embroidery process. The lace thread is stitched with the soluble thread, forming in the embroidered structure a temporary thread pair in the same creation process in which all the other threads in the embroidered structure are stitched. The soluble thread may be either the stitching thread or backing thread, and thus the lace may be placed into the embroidered structure as either the stitching or backing thread.
[0017] After the stitching of the embroidered structure is complete, the soluble thread is dissolved. The dissolution process used must be suitable for dissolving the material of the soluble thread and should preferably not negatively alter the physical properties of the lace and other threads in the embroidered structure. Once the soluble thread is removed, the temporary thread pair formed by the soluble thread being stitched with the lace ceases to exist, and the lace is no longer a part of the support system of the embroidered structure. This leaves the lace as a single, unpaired thread within the embroidered structure of paired threads.
[0018] Removal of the substrate may be done before, during and/or after the dissolution of the soluble thread, depending upon the properties of the materials used for the substrate and soluble thread and any specific manufacturing concerns compelling the sequence of removal. If dissolution is the method of removal selected, the dissolution processes for the substrate will not only depend upon the substrate material, but also the material of the soluble threads, laces and other threads in the embroidered structure to ensure that the process only affects the materials targeted by the process.
[0019] Since the lace was a part of the embroidered structure as it was being created and not placed from outside the otherwise finished embroidered structure, and because the creation was performed non-manually, the positional repeatability of the lace within the embroidered structure is high. The replacement of standard threads with soluble threads and the addition of a process to remove the soluble thread, if not removed during a substrate dissolution process, only nominally increases the cost of manufacturing with laces as opposed to without, and the cost increase is significantly less that of the cost of placing laces by hand. Finally, since the method of creation may be automated using commercially available embroidery machines, the embroidered structures containing laces may be mass produced. Thus, the present invention overcomes, or at a minimum improves upon, the limitations associated with repeatability, expense, and mass producibility inherent to the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Many advantages of the present invention will be apparent to those skilled in the art with a reading of this specification in conjunction with the attached drawings, wherein like reference numerals are applied to like elements and wherein:
[0021] FIG. 1 is a flow chart depicting one example of a general process of placing laces in embroidered structures using one or more soluble threads, according to one embodiment of the present invention;
[0022] FIG. 2 is a perspective view one example of an embroidered structure having a plurality of thread pairs, including a temporary thread pair, formed according to the process of FIG. 1 ;
[0023] FIG. 3 is a plan view of a soluble thread stitched to a lace thread to form the temporary thread pair of FIG. 2 ;
[0024] FIG. 4 is a perspective view of the embroidered structure of FIG. 2 after enclosing thread pairs are used to enclose the initial thread pairs and temporary thread pair;
[0025] FIG. 5 is a perspective view of the embroidered structure of FIG. 4 after dissolution of the soluble thread and removal of the substrate;
[0026] FIG. 6 is a plan view depicting one example of a generally flat embroidered structure containing multiple laces manufactured according to the process of FIG. 1 ;
[0027] FIG. 7 is a perspective view of a three-dimensional curved embroidered structure formed by tensioning the laces of the embroidered structure shown in FIG. 6 ;
[0028] FIG. 8 is a plan view depicting a second example of a generally flat embroidered structure containing multiple laces manufactured according to the process of FIG. 1 ;
[0029] FIG. 9 is a perspective view of a generally cylindrical embroidered structure formed by tensioning and tying opposite ends of the laces of the embroidered structure shown in FIG. 8 ;
[0030] FIG. 10 is a plan view of a third example of a generally flat embroidered structure containing a single lace running through the embroidered structure multiple times manufactured according to the process of FIG. 1 ;
[0031] FIG. 11 is a perspective view of a generally cylindrical embroidered structure formed by tensioning the lace of the embroidered structure shown in FIG. 10 ;
[0032] FIG. 12 is a plan view of a fourth example of a generally flat embroidered structure containing multiple laces manufactured according to the process of FIG. 1 ;
[0033] FIG. 13 is a perspective view of a polygonal-shaped embroidered structure, with one side open, formed by tying opposite ends of the laces of the embroidered structure in FIG. 12 ;
[0034] FIG. 14 is a plan view of a fifth example of a generally flat embroidered structure containing multiple laces manufactured according to the process of FIG. 1 ;
[0035] FIG. 15 is a perspective view of a closed polygonal-shaped embroidered structure formed by tying opposite ends of the laces of the embroidered structure in FIG. 14 ;
[0036] FIG. 16 is a plan view of a system manufactured according to the process of FIG. 1 , including a series of individual embroidered structures which act as anchors for one or more laces running through the series of embroidered structures according to one embodiment of the present invention;
[0037] FIG. 17 is a perspective view of an embroidered structure manufactured according to the process of FIG. 1 , through which one or more laces are guided and thus prevented from crossing each other while being positioned along the curve of an object according to one embodiment of the present invention;
[0038] FIG. 18 is a plan view of a system manufactured by the process of FIG. 1 , including a series of embroidered structures with a single, integral lace running through each which, upon tensioning, causes the inwardly facing side surfaces of the embroidered structures to pull into a uniform line according to one embodiment of the present invention;
[0039] FIG. 19 is a plan view of an embroidered structure, manufactured according to the process of FIG. 1 , in which laces are interlaced in a honeycomb pattern according to one exemplary aspect of the invention;
[0040] FIG. 20 is a plan view of an embroidered structure, manufactured according to the process of FIG. 1 , in which laces are interlaced in a diagonal weave pattern according to another exemplary aspect of the invention;
[0041] FIG. 21 is a plan view of a pair of embroidered structures, manufactured according to the process of FIG. 1 , which are connected by a single, preloaded lace according to one embodiment of the present invention;
[0042] FIG. 22 is a plan view of the pair of embroidered structures of FIG. 21 , showing in particular that the seam of the embroidered structure in FIG. 21 may be used to reproducibly unite objects (not shown) connected to the embroidered structures upon tensioning of the lace according to one embodiment of the present invention;
[0043] FIG. 23 is a plan view of a pair of embroidered structures, manufactured according to the process of FIG. 1 , which are connected by two or more preloaded laces, according to one embodiment of the present invention;
[0044] FIG. 24 is a plan view of the pair of embroidered structures of FIG. 23 , showing in particular that the seam of the embroidered structure in FIG. 23 may be used to reproducibly unite objects (not shown) connected to the embroidered structures upon tensioning of the laces according to one embodiment of the present invention; and
[0045] FIG. 25 is a plan view of a load bearing strap manufactured according to the process of FIG. 1 .
DESCRIPTION OF PREFERRED EMBODIMENT
[0046] Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. The process of embroidery with soluble thread disclosed herein boasts a variety of inventive features and components that warrant patent protection, both individually and in combination.
[0047] FIG. 1 outlines the one example of the process of manufacturing an embroidered structure using soluble thread according to one embodiment of the present invention. The process begins with a substrate, upon which a plurality of backing threads are placed and secured on one side, called the backing surface. A soluble thread may be substituted for any backing thread within the plurality of backing threads. For each backing thread on the backing surface of the substrate, there is a corresponding stitching thread on the opposing side of the substrate, called the stitching surface. A soluble thread may be substituted for any stitching thread within the plurality of stitching threads. Any soluble thread, used on either the backing surface or the stitching surface, will correspond to a lace on the opposing surface. Laces may be physically identical to the stitching threads or backing threads or may be composed of different materials or possess different physical properties than the stitching threads or backing threads.
[0048] Stitching may be done between one pair of threads at a time or in simultaneous multiplicity, as is described below. The plurality of stitching threads, lace threads, and/or soluble threads on the stitching surface are passed from the stitching surface to the backing surface, making openings in the substrate for each individual thread, to meet with corresponding backing threads, soluble threads, and/or laces on the backing surface. Each stitching thread, lace, and/or soluble thread from the stitching surface is then looped over its corresponding backing thread, soluble thread, and/or laces on the backing surface. In essence, this looping over engages or “picks up” each thread from the backing surface, creating a “lock stitch.” Once each thread from the stitching surface has picked up its corresponding thread from the backing surface, the plurality of threads originating from the stitching surface are returned from the backing surface to the stitching surface through the same openings made upon initial passage through the substrate from the stitching surface. The lock stitch prevents the threads from completely pulling out of the openings made when returning to the stitching surface through the substrate.
[0049] The process then repeats at a distance from the last stitch site, and continues to repeat until each thread from the stitching surface and its corresponding thread from the backing surface are joined by lock stitches over a desired length. The end result is a plurality of stitching threads stitched to backing threads in thread pairs held together by lock stitches. Each thread pair is parallel to the rest of the thread pairs on the substrate. Also parallel to the thread pairs are the one or more temporary thread pairs formed by stitching laces to corresponding soluble threads.
[0050] A plurality of parallel stitched thread pairs and temporary thread pairs may be enclosed by enclosing thread pairs. To enclose a previously stitched plurality of thread pairs and temporary thread pairs, the embroidery process above is repeated over the previous embroidery already on the substrate. This process may be repeated further by embroidering subsequent pluralities of enclosing thread pairs over each other in a manner such that the first plurality of enclosing thread pairs is enclosed by the second plurality of enclosing thread pairs, which is enclosed by a third plurality, which is enclosed by a fourth plurality, and so forth. This process of producing embroidered structures containing multiple pluralities of enclosing thread pairs results in stable embroidered structures which do not unravel into a pile of threads upon removal of the substrate.
[0051] The process of substrate removal, if not omitted, is dependent upon the material from which the substrate is composed. Removal of the substrate may be done before, after or simultaneously with the dissolution of the soluble thread(s). If dissolution is the chosen method or removal, the selection of materials used to form the substrate and soluble thread will be in part compelled by any manufacturing concerns regarding the sequence of dissolution. Substrate and soluble thread materials are chosen such that the process or processes which dissolve the substrate and soluble thread will not negatively alter the physical properties of the stitching threads, backing threads, and/or laces.
[0052] If the substrate is removed and the soluble threads are dissolved, only the stitching threads, backing threads, and/or laces will remain. The embroidered structure remains intact despite the removal of the substrate because each stitching thread is stitched to its corresponding backing thread, and vice versa, which is enclosed in one or more pluralities of enclosing thread pairs, all of which provides structural support. Once both the soluble threads and substrate are removed, the laces are no longer a part of the support system of the embroidered structure because the temporary thread pairs cease to exist when the soluble threads are dissolved, leaving the laces as single, unpaired threads within the embroidered structure.
[0053] FIG. 2 is an example of an embroidered structure 10 during creation by the process of manufacture according to one embodiment of the present invention. Each thread pair 20 is created by stitching together a stitching thread 11 and a backing thread 13 to form lock stitches 15 on a substrate 16 . The temporary thread pair 30 is created by stitching together a lace 12 and a soluble thread 14 to form lock stitches 15 .
[0054] FIG. 3 is a closer view of the temporary thread pair 30 from the embroidered structure 10 in FIG. 2 . The lace 12 is substituted for a stitching thread and has passed from the stitching surface 18 , creating an opening 19 through the substrate 16 , to the backing surface 17 . There it engaged the soluble thread 14 forming a lock stitch 15 and returned to the stitching surface 18 through the same opening 19 . This process is repeated at intervals along the path of the soluble thread 14 until the desired length of stitching has been achieved. Although the lace 12 has been substituted for a stitching thread in this embodiment, the inverse is equally applicable, where a soluble thread 14 could be substituted for a stitching thread to form a temporary thread pair 30 with a lace 12 having been substituted for a backing thread.
[0055] FIG. 4 depicts the embroidered structure 10 created by enclosing the thread pairs 20 and temporary thread pair 30 from FIG. 2 with enclosing thread pairs 22 . The enclosing thread pairs 22 contain enclosing backing threads 23 and enclosing stitching threads 21 . The enclosing backing threads 23 are placed and secured on the backing surface of the substrate 16 over the thread pairs 20 and temporary thread pair 30 . The enclosing stitching threads 21 are stitched from over the thread pairs 20 and temporary thread pair 30 on the stitching surface 18 of the substrate 16 by the process discussed above. The result is an embroidered structure 10 where thread pairs 20 and temporary thread pairs 30 are enclosed within the enclosing thread pairs 22 .
[0056] The embroidered structure 10 is shown by way of example enclosed by a first plurality of enclosing thread pairs 22 . The same stitching process or a different stitching process may be repeated or performed one or more times using the same or different thread materials to enclose thread pairs 20 and temporary thread pairs 30 by multiple pluralities of enclosing thread pairs 22 such that each subsequent plurality of enclosing thread pairs encloses all thread pairs 20 , temporary thread pairs 30 and previous enclosing thread pairs 22 over which it is embroidered.
[0057] FIG. 5 shows the embroidered structure 10 from FIG. 4 after dissolution of the soluble thread 14 and dissolvable substrate 16 . Once the structure 10 from FIG. 4 is embroidered with the desired number of thread pairs 20 and temporary thread pairs 30 , and enclosed by the desired number of enclosing thread pairs 22 , the soluble thread 14 may be dissolved and the substrate 16 may be removed. The dissolution of the soluble thread 14 and removal of the substrate 16 may be done in the same or different processes, and in any order. If dissolution is the chosen method of substrate removal, the dissolution processes will depend upon the composition of the soluble threads 14 and the stitching threads 11 , laces 12 , backing threads 13 , enclosing stitching threads 21 , and enclosing backing threads 23 as well as the composition of the substrate 16 upon which the embroidered structure 10 was created. These compositions are application dependent and different materials may be used according to not only dissolution processes, but also the function of the completed embroidered structure 10 . After dissolution of the soluble thread 14 and substrate 16 is completed, the lace 12 is no longer a part of a temporary thread pair, and thus is unpaired within the embroidered structure 10 .
[0058] FIGS. 6-25 illustrate multiple embodiments of embroidered structures created using the manufacturing process described above. For the purposes of simplicity and consistency, features common to those shown and described in relation to embroidered structure 10 of FIGS. 2-5 are designated with common numbers.
[0059] FIG. 6 depicts an example of an embroidered structure 40 according to a first embodiment of the present invention. The embroidered structure 40 is shown by way of example as being generally flat, having a generally circular shape, and containing a series of laces 12 placed into the embroidery by the process of manufacture described above. The laces 12 are substituted for some of the stitching threads and soluble threads are substituted for the corresponding backing threads. The lace threads 12 and soluble threads are then stitched together forming temporary thread pairs while the remaining stitching threads and backing threads are stitched together forming a plurality of thread pairs 20 . The thread pairs 20 and temporary thread pairs may then be enclosed by enclosing thread pairs 22 formed from enclosing stitching threads and enclosing backing threads. When the embroidering is completed, the soluble threads may be dissolved and the substrate may be removed. After dissolution of the soluble threads and removal of the substrate, the laces 12 will no longer be paired and will be free to move through the embroidered structure 10 . Surrounding structures may be engineered to form eyelets for the laces 12 to run through.
[0060] FIG. 7 illustrates the effect of tensioning the multiple laces 12 contained in the embroidered structure 40 from FIG. 6 . Tensioning the laces 12 decreases the circumference of the generally circular path in which the laces 12 run around the fixed area of embroidered thread pairs 20 and enclosing thread pairs 22 . This decreased circumference causes doming as the fixed area takes the three-dimensional shape due to the constraining of the fixed embroidered area within the decreased lace 12 circumference.
[0061] FIG. 8 depicts an example of an embroidered structure 50 according to a second embodiment of the present invention. The embroidered structure 50 is shown by way of example as being a generally flat, generally rectangular structure through which more than one lace 12 has been placed by the process of manufacture described above. The rectangular embroidered structure 50 necessarily has four edges; two shorter edges 52 and two longer edges 54 . In this embodiment, the laces 12 run parallel to the two short edges 52 from one long edge 54 to the other long edge 54 . Alternatively, the embroidered structure 50 could be arranged such that the laces 12 could run between short edges 54 parallel to the long edges 52 , in which case the resulting cylindrical shape (see below) would be short and wide.
[0062] FIG. 9 illustrates the effect of tensioning and tying together the opposing ends of the laces 12 contained within the embroidered structure 50 from FIG. 8 . The laces 12 as laid out in the embroidered structure 50 in FIG. 8 are generally flat, straight lines in the same plane as the stitched pairs 20 and enclosing pairs 22 . When opposite ends of the laces 12 are brought together to make knots 24 , the paths of the laces 12 becomes generally circular rather than linear, as in FIG. 8 . Since the laces 12 are enclosed within the thread pairs 20 within the enclosing thread pairs 22 , putting the laces 12 into circular paths also pulls the short edges 52 of the embroidered structure 50 into a generally circular shape while drawing together the opposing long edges 54 of the embroidered structure 50 . Once the long edges 54 meet, the opposing ends of each lace 12 are tied together in knots 24 to secure the now cylindrical shape of the embroidered structure 50 . In forming the cylindrical structure, the short edges 52 become generally circular and the long edges 54 meet to form a seam 56 which is parallel to the height aspect of the cylindrically shaped embroidered structure 50 .
[0063] FIG. 10 depicts an example of an embroidered structure 60 according to a third embodiment of the present invention. The embroidered structure 60 is shown by way of example as being a generally flat, generally rectangular structure through which a single lace 12 was placed multiple times by the process of manufacture described above. The generally rectangular embroidered structure 60 necessarily has four edges; two short edges 62 and two long edges 64 . In this embodiment, the lace 12 runs generally diagonally from one long edge 64 to the other long edge 64 , then around the outside of the embroidered structure 60 and back to the first long edge 64 where it enters the embroidered structure again. In an alternative embodiment, the lace 12 could be run between the short edges 62 to result in a differently dimensioned structure than the one described below.
[0064] As shown in FIG. 11 , a three-dimensional, generally cylindrical embroidered structure 60 may be formed by tensioning the lace 12 of the embroidered structure 60 shown in FIG. 10 . The lace 12 is laid out in the shape of a flat spiral in FIG. 10 , but as the lace 12 is tensioned, the radii of the spiral loops of the lace 12 begin to decrease until the two-dimensional lace 12 spiral takes the shape of a three-dimensional helix. Since the lace 12 is enclosed within the thread pairs 20 within the enclosing thread pairs 22 , putting the lace 12 in a helical shape causes the embroidered structure 10 enclosing it to curl around the axis of the spiral path of the lace 12 . The curling causes the long edges 64 of the embroidered structure 10 to come closer together such that the edges will eventually meet. Once the long edges 64 meet, the embroidered structure 60 is in the general shape of a cylinder with the long edges 64 forming a seam 66 parallel to the axis of the helix and the height aspect of the cylinder.
[0065] FIG. 12 depicts an example of an embroidered structure 70 according to a fourth embodiment of the present invention. The embroidered structure 70 is shown by way of example as being a generally flat, polygonal shaped structure through which several laces 12 are placed by the process of manufacture described above. The polygon may have a central panel 72 which shares each of its sides with one of four outer panels 74 . The laces 12 are run through each of the outer panels 74 without running through the central panel 72 , such that the lace 12 runs through one outer panel 74 , then through open space 76 , then through another outer panel 74 , then through open space 76 and so on until the two ends of each lace 12 occupy the same open space 76 . In the example shown in FIG. 12 , the central panel 72 and outer panels 74 are all square shaped, and thus are dimensionally identical to one another. However, it is contemplated that any variety of complementary polygonal shapes and configurations may be used, such as for example a generally rectangular central panel 72 in combination with a pair of opposing generally rectangular outer panels 72 and a pair or opposing generally square outer panels 72 . Such a configuration would result in a generally rectangular box shape upon tensioning of the laces 12 (as described below). Further embodiments may include combinations of triangles, quadrilaterals, pentagons, hexagons, etc.
[0066] As shown in FIG. 13 , a three-dimensional polyhedron open box-shaped embroidered structure 70 may be formed by tensioning the laces 12 shown in FIG. 12 . Tensioning the laces 12 pulls the length of each lace 12 from the open space 76 between outer panels 74 , which in turn draws the edges of the outer panels 74 together. When all the length of laces 12 between the outer panels 74 has been pulled through the outer panels 74 , the edges of the polygonal embroidered structure 70 unite such that a polyhedron shaped embroidered structure 70 with one open side is formed. Tying the opposite ends of the laces 12 in knots 24 secures the shape of the embroidered structure 70 .
[0067] FIG. 14 depicts an example of an embroidered structure 80 according to a fifth embodiment of the present invention. The embroidered structure 80 is shown by way of example as being a generally flat, polygonal-shaped structure enclosing a series of laces 12 placed therein by the process of manufacture described above. The polygonal shape may have a first major panel 82 which shares each of its sides with one side of each of four minor panels 84 a , 84 b , 84 c , and 84 d . In the example shown, each of the four minor panels 84 a - d is the same height, and has a length defined by the side it shares with the first major panel 82 . Minor panel 84 c is positioned between the first major panel 82 and a second major panel 86 , in that the minor panel 84 c shares one length-defining side with the first major panel 84 and a second, identical length-defining side with the second major panel 86 . By way of example only, the second major panel 86 is identically dimensioned relative to the first major panel 82 . The laces 12 are distributed in three ways. The laces 12 a run lengthwise successively through the four minor panels 84 a - d . The laces 12 a originate in a first open space 88 a , pass through the first minor panel 84 a in a lengthwise direction and into a second open space 88 b . This path continues in succession through minor panel 84 b , open space 88 c , minor panel 84 c , open space 88 d , and minor panel 84 d until the laces 12 a emerge within open space 88 a at which point both ends of each lace 12 a are in the same open space. The laces 12 b pass into the second major panel 86 , straight through the minor panel 84 c (and generally perpendicular to the laces 12 a therein), through the first major panel 82 and out the end of the polygon through the minor panel 84 a (and generally perpendicular to the laces 12 a therein). Laces 12 c follow a generally horseshoe-shaped path, for example entering minor panel 84 d and passing through such that laces 12 c are generally perpendicular to laces 12 a within minor panel 84 d . Laces 12 c continue through major panel 82 (such that laces 12 c are generally perpendicular to laces 12 b within major panel 82 ) and through the minor panel 84 b (also such that laces 12 c are generally perpendicular to laces 12 a within minor panel 84 b ). Upon exiting minor panel 84 b , laces 12 c curve back to the polygon to pass through the major panel 86 in a direction generally parallel to the laces 12 c within major panel 82 and generally perpendicular to laces 12 b within major panel 86 . Surrounding structures may be engineered to form eyelets for the laces 12 a - c to run through.
[0068] FIG. 15 shows the three-dimensional embroidered hexahedron structure 80 created by tensioning and tying the opposite ends of each laces 12 a - c from FIG. 14 . Upon tensioning the laces 12 a , the length of lace 12 a in the open spaces 88 a - d shorten, which in turn pulls the edges of the minor panels 84 a - d together. When all the length of lace 12 a between the minor panels 84 a - d has been pulled through the minor panels 84 a - d , the edges of the polygonal embroidered structure 80 unite to form a polyhedron-shaped embroidered structure 80 with one open side, and with the major panel 86 attached to an edge of the open side of the polyhedron (minor panel 84 c ). Tying the opposite ends of the laces 12 a in knots 24 a secures the shape of the embroidered structure 80 . Tensioning and tying laces 12 b into knots 24 b draws the major panel 86 on top of the open side, thus closing the open box structure by adding the sixth side necessary to have a closed hexahedron. Tensioning and tying laces 12 c into knots 24 c secures the last remaining unfixed edge of the closed hexahedron.
[0069] FIG. 16 depicts a set of generally flat embroidered structures 90 according to a sixth embodiment of the present invention, used to anchor and guide a lace 12 which runs through each of the embroidered structures 90 . The process for manufacturing the embroidered structure 90 is described above. The completed embroidered structures 90 may be affixed to a surface or surfaces using the fastener holes 25 to facilitate mechanical attachment between each embroidered structure 90 and the surface to which it is joined. Once in place, the embroidered structures 90 act as anchors and guide the lace 12 as it is pulled through the embroidered structures 90 . The predictability of the path of the lace 12 allows for the lace 12 to be protected from fouling on surrounding objects and protects surrounding objects from being damaged or disturbed through contact with the lace 12 .
[0070] FIG. 17 shows a generally flat embroidered structure 100 according to a seventh embodiment of the present invention. The embroidered structure 100 has a generally rectangular shape and is used to guide laces 12 in a predictable path around an object. The process for manufacturing the embroidered structure 100 is described above. The completed embroidered structure 100 may be affixed to a surface using the fastener holes 25 to facilitate mechanical attachment between the embroidered structure 100 and the surface to which it is joined. The embroidered structure 100 allows the laces 12 to be guided in a predictable path when positioned partially around an object, such as a generally cylindrical, generally polyhedral or object of some other shape. This guided running prevents the laces 12 from crossing, which would inhibit their freedom of movement. Surrounding structures may be engineered to form eyelets for the laces 12 to run through.
[0071] FIG. 18 shows a set of generally flat embroidered structures 110 according to an eighth embodiment of the present invention, used to reproducibly position objects in a line. The process for manufacturing the embroidered structure 110 is described above. The embroidered structures 110 are generally rectangular, and may have one or more fastener holes 25 . A single, integral lace 12 runs through all of the embroidered structures 10 , and may run through the embroidered structures 12 either close to the facing sides, over the fastener holes 25 along the periphery opposite the facing sides or at any position there between. The completed embroidered structures 110 may each be affixed to an object using the fastener holes 25 to facilitate mechanical attachment between each embroidered structure 110 and the object to which it is joined. Once the embroidered structures are attached to objects, tensioning the lace 12 by pulling its ends in opposite directions will cause the lace 12 to straighten. As the lace 12 straightens, it will pull the embroidered structures 110 , and the objects to which they are attached, into a line defined by the directions in which the two ends of the lace 12 are pulled.
[0072] FIG. 19 depicts a woven structure 26 according to one aspect of the present invention, created from laces 12 using the embroidery techniques of the present invention. Each of the woven laces 12 , individually numbered L1-L40, is laid down by stitching to a corresponding soluble thread on a substrate, forming temporary thread pairs. When all of the laces 12 are stitched to corresponding soluble threads, there is an embroidered structure of temporary thread pairs on the substrate. The soluble threads may then be dissolved and substrate may be removed. After dissolution of the soluble thread and substrate, the pairing of the soluble thread with the lace thread 12 is destroyed. As there are no longer any paired threads, but instead only interwoven laces 12 holding each other in the woven structure 26 . The dissolution of the soluble thread and substrate turn what is created as an embroidered structure into a woven structure 26 .
[0073] The woven structure 26 is exemplary of the use of the embroidering techniques of the present invention to create non-embroidered finished products. The extent of these non-embroidered products is not limited to those which are woven, but includes all other methods of creating structures from filamentary materials. The finished products may be completely non-embroidered or a hybrid of embroidery and one or more other techniques including, but not limited to, weaving.
[0074] Woven structures may also take many shapes. For example, the woven structure 26 from FIG. 19 is created by embroidering in the following order and positions:
[0000]
Lace Number
and Stitching Order
Orientation
Location
L1
Vertical
Centered
L2
Horizontal
Centered
L3
Vertical
Right of L1
L4
Horizontal
Below L2
L5
Vertical
Left of L1
L6
Horizontal
Above L2
L7
Vertical
Right of L3
L8
Horizontal
Below L4
L9
Vertical
Left of L5
L10
Horizontal
Above L6
L11
Vertical
Right of L7
L12
Horizontal
Below L8
L13
Vertical
Left of L9
L14
Horizontal
Above L10
L15
Vertical
Right of L11
L16
Horizontal
Below L12
L17
Vertical
Left of L13
L18
Horizontal
Above L14
L19
Vertical
Right of L15
L20
Horizontal
Below L16
L21
Vertical
Left of L17
L22
Horizontal
Above L18
L23
Vertical
Right of L20
L24
Horizontal
Below L30
L25
Vertical
Left of L21
L26
Horizontal
Above L22
L27
Vertical
Right of L23
L28
Horizontal
Below L24
L29
Vertical
Left of L25
L30
Horizontal
Above L26
L31
Vertical
Right of L27
L32
Horizontal
Below L28
L33
Vertical
Left of L29
L34
Horizontal
Above L30
L35
Vertical
Right of L31
L36
Horizontal
Below L32
L37
Vertical
Left of L33
L38
Horizontal
Above L34
L39
Vertical
Right of L35
L40
Horizontal
Below L36
[0075] This order and position creates a honeycomb-shaped woven structure 26 . However, different weaving effects give structures different properties, including but not limited to flexibility and feel.
[0076] FIG. 20 depicts a woven structure 26 created by the same process as the woven structure in FIG. 19 , differing only in the number, order, and position of the laces 12 (individually numbered L1-L36). The woven structure 26 in FIG. 20 is woven in the following order and positions:
[0000]
Lace Number
and Stitching Order
Orientation
Location
L1
Vertical
Left Edge
L2
Horizontal
Top Edge
L3
Vertical
Right of L1
L4
Horizontal
Below L2
L5
Vertical
Btw L1 & L3
L6
Horizontal
Btw L2 & L4
L7
Vertical
Right of L3
L8
Horizontal
Below L4
L9
Vertical
Between L3 & L7
L10
Horizontal
Between L4 & L8
L11
Vertical
Right of L7
L12
Horizontal
Below L8
L13
Vertical
Between L7 & L11
L14
Horizontal
Between L8 & L12
L15
Vertical
Right of L11
L16
Horizontal
Below L12
L17
Vertical
Between L11 & L13
L18
Horizontal
Between L12 & L16
L19
Vertical
Right of L15
L20
Horizontal
Below L16
L21
Vertical
Between L15 & L20
L22
Horizontal
Between L16 & L30
L23
Vertical
Right of L20
L24
Horizontal
Below L30
L25
Vertical
Between L20 & L23
L26
Horizontal
Between L30 & L24
L27
Vertical
Right of L23
L28
Horizontal
Below L24
L29
Vertical
Between L23 & L27
L30
Horizontal
Between L24 & L28
L31
Vertical
Right of L27
L32
Horizontal
Below L28
L33
Vertical
Between L27 & L31
L34
Horizontal
Between L28 & L32
L35
Vertical
Right of L31
L36
Horizontal
Below L32
[0077] After dissolution of the soluble thread and substrate, this order and position creates a diagonal weave throughout the woven structure 26 . This weave will have different characteristics, including but not limited to flexibility and feel, than that of the woven structure 26 in FIG. 19 . The patterns from FIG. 19 and FIG. 20 are merely examples of the numerous patterns possible from interlacing by the process of the present invention.
[0078] FIG. 21 shows a pair of embroidered structures 10 separated by a seam preloaded with one lace 12 according one example of a ninth embodiment of the present invention. The process for manufacturing the embroidered structure 10 is described above. During the embroidery process of the present invention, a lace 12 is stitched to a soluble thread such that the temporary thread pair zigzags between the pair of embroidered structures 10 . Eyelet threads 28 are then sewn around the lace 12 and soluble thread on each of the embroidered structures 10 . The soluble thread and substrate are then dissolved. The two embroidered structures 10 are now independent of each other, and the lace 12 , no longer a part of a temporary thread pair after dissolution of the soluble thread, is free to run through the eyelet threads 28 between the two embroidered structures 10 .
[0079] FIG. 22 illustrates the result of tensioning the lace 12 between the embroidered structures 10 in FIG. 21 . When tensioned, the lace 12 will pull into as straight a line as possible. This straightening imparts a force from the lace 12 onto the embroidered structures 10 , drawing the embroidered structures 10 closer together along the seam 27 separating them. When the embroidered structures 10 are attached to two or more objects, this embodiment provides a manner in which the attached objects may be united in a highly consistent, repeatable manner.
[0080] FIG. 23 shows a pair of embroidered structures 10 separated by a seam preloaded with more than one lace 12 by the process of the present invention. After the embroidered structures are created according to the process described in the explanation of FIG. 21 above, two or more laces 12 are stitched to soluble threads such that the temporary thread pairs zigzag between the pair of embroidered structures 10 , one mirroring the path of the other. Eyelet threads 28 are then sewn around the laces 12 and soluble threads on each of the embroidered structures 10 . The soluble threads and substrate are then dissolved. The two embroidered structures 10 are now independent of each other and the laces 12 , no longer a part of temporary thread pairs after dissolution of the soluble threads, are free to run through the eyelet threads 28 between the two embroidered structures 10 .
[0081] FIG. 24 illustrates the result of tensioning the laces 12 between the embroidered structures 10 in FIG. 23 . As in the single lace version in FIG. 22 above, the tensioned laces 12 will pull into as straight a line as possible. This imparts a force from the laces onto the embroidered structures 10 , drawing them closer together along the seam 27 separating them. When the embroidered structures 10 are attached to two or more objects, this embodiment provides a manner in which the attached objects may be united in a highly consistent, repeatable manner.
[0082] FIG. 25 shows an embroidered structure 10 manufactured according to one embodiment of the present invention in the form of a load bearing structure. During the embroidery process of the present invention, the lace 12 is stitched to a soluble thread on a substrate. The whipping thread 31 is then stitched around the lace 12 and soluble thread such that the whipping thread 31 will hold the stem of the embroidered structure 10 together. The dissolution of the soluble threads and dissolvable substrate may be performed once the stitching of the embroidered structure 10 has been completed. After dissolution, the embroidered structure 10 may be used as a load bearing device such as by coupling the resulting loops 29 between two structures or two regions within a single structure. The use of the embroidery techniques in the production of the embroidered structure 10 ensures the uniformity of the free loops 29 and the equalized length of the lace 12 , thus improving the consistency of performance of embroidered structures 10 through the repeatability of its manufacture.
[0083] As evidenced above, the present invention overcomes, or at least minimizes, the drawbacks of the prior art. The devices described herein may be repeatably mass produced based on the automated nature of the embroidery process of the present invention. Embroidery with one soluble thread allows for a single, unpaired lace to be laid down reliably, cost effectively, and in a manner conducive to mass production.
[0084] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined herein. | A manufacturing process and resultant medical devices and components thereof wherein one or more individual laces ( 12 ) is placed within an embroidered structure ( 10 ) using an automated process allowing for the manufacture of embroidered surgical implants containing laces to be mass produced repeatably and cost effectively. | 3 |
BACKGROUND
[0001] Inkjet printing systems that include two or more print carriages align the print carriages with one another to prevent print defects from occurring when printing an image onto a print medium. The process of aligning the print carriages may be affected by environmental changes inside printing systems such as increases in temperature and humidity. The environmental changes may be caused by the application of heat to dry ink applied to a print medium. It would be desirable to prevent print defects from occurring as a result of environmental changes in a printing system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIGS. 1A-1B are block diagrams illustrating one embodiment of an inkjet printing system.
[0003] FIG. 2 is a schematic diagram illustrating one embodiment of selected portions of an inkjet printing system.
[0004] FIG. 3 is a schematic diagram illustrating one embodiment of encoders and an encoder strip.
[0005] FIG. 4 is a timing diagram illustrating one embodiment of encoder signals.
[0006] FIGS. 5A-5B are flow charts illustrating embodiments of a method for compensating for the expansion of an encoder strip.
DETAILED DESCRIPTION
[0007] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the disclosed subject matter may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims.
[0008] According to one embodiment, an inkjet printing system compensates for the expansion of encoder strips due to environmental changes by measuring a phase difference in signals generated by a pair of encoders on each print carriage as the encoders move along an encoder strip. The inkjet printing system determines a measured unit change from the phase difference and adjusts the printing of image using the measured unit change to prevent print defects from appearing on a print medium.
[0009] Figure IA is a block diagram illustrating one embodiment of an inkjet printing system 100 . Inkjet printing system 100 is configured to receive image data 102 that represents an image and cause a reproduction of the image to be formed on a print medium 104 such as paper. Inkjet printing system 100 may also include other imaging units such as a scanner and/or a fax machine (not shown).
[0010] Inkjet printing system 100 receives image data 102 from any suitable image data source (not shown) such as a computer system, a mobile device, or a storage system. Inkjet printing system 100 may connect to the image data source by any suitable connection that allows image data 102 to be received by inkjet printing system 100 such as a wired or wireless point-to-point connection or a wired or wireless network connection. The network connection may connect to a local area network (LAN), a wide area network (WAN), or a global communications network such as the Internet.
[0011] A controller 110 in system 100 includes a processor 112 and a memory 114 . Controller 110 receives image data 102 and stores each set of image data 102 as an image 106 in memory 114 . Image 106 represents, for example, all or a portion of a document and/or a file to be printed. Controller 110 provides signals that include print data corresponding to image 106 and control signals to a media transport unit 120 , two or more carriage drive mechanisms 130 ( 1 )- 130 (N), and two or more print carriages 132 ( 1 )- 132 (N) to cause image 106 to be reproduced on print medium 104 . Processor 112 executes instructions stored in memory 114 to operate system 100 . Memory 114 is any suitable storage medium that is accessible to processor 112 to allow processor 112 to access and store instructions and/or data. Memory 114 may include any suitable type and/or combination of volatile and non-volatile memory devices in any suitable configuration. A carriage positioning unit 116 aligns print carriages 132 with respect to one another using encoders 142 and 144 (shown in FIG. 1B ) and an encoder strip 124 for each print carriage 132 as described in additional detail below.
[0012] To print image 106 , media transport unit 120 moves print medium 104 past print carriages 132 ( 1 )- 132 (N) in response to signals from controller 110 . As print medium 104 moves past print carriages 132 ( 1 )- 132 (N), controller 110 provides signals and print data to carriage drive mechanisms 130 ( 1 )- 130 (N) and print carriages 132 ( 1 )- 132 (N). Carriage drive mechanisms 130 ( 1 )- 130 (N) scan print carriages 132 ( 1 )- 132 (N), respectively, back and forth across print medium 104 and print carriages 132 ( 1 )- 132 (N) selectively deposit or eject ink drops 134 ( 1 )- 134 (N), respectively, onto print medium 104 in accordance with the print data to reproduce image 106 on print medium 104 . Media transport mechanism 120 may also include a media feed mechanism (not shown) to feed print medium 104 and/or one or more media supply tray (not shown) to store additional print media 104 .
[0013] Referring to FIG. 1B , each print carriage 132 includes a printhead array 136 of one or more printheads 138 mounted on, attached to, integrally formed with, or otherwise affixed to a substrate 140 . Each printhead 138 is configured to selectively deposit or eject drops of ink 134 onto print medium 104 . The ink deposited or ejected by printheads 138 may be propelled by thermal heating, piezoelectric actuators, or another suitable mechanism. The set of printheads 138 in each printhead array 136 may deposit or eject one or more colors of ink. A dryer 146 provides heat to dry the ink on print medium 104 in response to signals from controller, 110 .
[0014] Each print carriage 132 also includes a pair of encoders 142 and 144 that are used in conjunction with an encoder strip 124 (shown in FIG. 1A ) to align print carriages 132 with respect to one another. Each encoder strip 124 is positioned relative to media transport mechanism 120 so that corresponding pairs of encoders 142 and 144 pass over each encoder strip 124 as a print carriage 132 moves across print medium 104 as will be described in additional detail below.
[0015] FIG. 2 is a schematic diagram illustrating one embodiment of selected portions of inkjet printing system 100 with two print carriages 132 ( 1 ) and 132 ( 2 ) where each print carriage 132 ( 1 ) and 132 ( 2 ) prints to a different portion of a page width of print medium 104 .
[0016] In the embodiment of FIG. 2 , media transport unit 120 includes a cylindrical drum 160 . Drum 160 rotates around an axis 162 that is parallel to a outer surface 164 of drum 160 and centered with reference to side surfaces 166 of drum 160 . Media transport unit 120 rotates drum 160 to move print medium 104 past printheads 138 on print carriages 132 ( 1 ) and 132 ( 2 ) as indicated by an arrow 168 . As it rotates past print carriages 132 ( 1 ) and 132 ( 2 ), print medium 104 is held stationary on drum 160 by air suction or another suitable technique.
[0017] To print swaths of image 106 along the width of print medium 104 , media transport unit 120 rotates drum 160 to position print medium 104 with respect to printhead arrays 136 ( 1 ) and/or 136 ( 2 ). Printhead arrays 136 ( 1 ) and/or 136 ( 2 ) deposit or eject ink onto print medium 104 as print carriages 132 ( 1 ) and/or 132 ( 2 ) are moved along the width of print medium 104 (i.e., parallel to axis 162 ) as indicated by arrows 150 ( 1 ) and 150 ( 2 ), respectively, while drum 160 is stationary. Each printhead array 136 ( 1 ) and 136 ( 2 ) prints to a different portion of a page width of print medium 104 where the page width is parallel with axis 162 . After printhead arrays 136 ( 1 ) and/or 136 ( 2 ) complete the swath or swaths, media transport unit 120 rotates drum 160 to advance print medium 104 with respect to printhead arrays 136 ( 1 ) and/or 136 ( 2 ) for a next swath or swaths. Each print swath may have a width of approximately one inch, for example.
[0018] Printhead arrays 136 ( 1 ) and 136 ( 2 ) may form the entire image 106 on print medium 104 in one revolution of drum 160 (i.e., print medium 104 moves past printhead arrays 136 ( 1 ) and 136 ( 2 ) once) or multiple revolutions of drum 160 (i.e., print medium 104 moves past printhead arrays 136 ( 1 ) and 136 ( 2 ) more than once).
[0019] Because printhead arrays 136 ( 1 ) and 136 ( 2 ) print to different portions of the page width of print medium 104 , inkjet printing system 100 accurately positions print carriages 132 ( 1 ) and 132 ( 2 ) relative to each other to prevent print defects from occurring where the print boundaries of the portions formed by printhead arrays 136 ( 1 ) and 136 ( 2 ) on print medium 104 intersect. If print carriages 132 ( 1 ) and 132 ( 2 ) are not properly aligned, defects such as a light or dark line or a visible discontinuity at the joint may occur at the intersection of the print boundaries.
[0020] Inkjet printing system 100 uses the pair of encoders 142 and 144 in conjunction with a corresponding encoder strip 124 to align each print carriage 132 with respect to the remaining print carriages 132 . In the embodiment of FIG. 2 , inkjet printing system 100 uses encoders 142 ( 1 ) and 144 ( 1 ) and encoder strip 124 ( 1 ) to track a location of print carriage 132 ( 1 ). Similarly, inkjet printing system 100 uses encoders 142 ( 2 ) and 144 ( 2 ) and encoder strip 124 ( 2 ) to track a location of print carriage 132 ( 2 ). By tracking the location of print carriages 132 ( 1 ) and 132 ( 2 ), inkjet printing system 100 is able to align print carriages 132 ( 1 ) and 132 ( 2 ) with respect to each other to prevent print defects from occurring on print medium 104 .
[0021] Each encoder strip 124 spans the width of drum 160 parallel to axis 162 of rotation and has encoder markings 126 at set intervals along the width. One end of each encoder strip 124 is in a fixed position relative to drum 160 and the other end of each encoder strip 124 is spring loaded to allow for expansion along the width of drum 160 . In one embodiment, each encoder strip 124 is made out of a transparent material such as Mylar or polyester film with encoder markings 126 that are dark or opaque regions to form a sharp visible contrast with the transparent material. In other embodiments, encoder strips 124 may be formed with other materials with other suitable encoder markings 126 . In one embodiment, encoder markings 126 are spaced at 1/200 inch intervals along the length of encoder strip 124 . In other embodiments, encoder markings 126 may be spaced at other intervals along the length of encoder strip 124 .
[0022] In operation, inkjet printing system 100 may produce variations in temperature and humidity that cause encoder strips 124 to expand. For example, heat from dryer 146 and/or humidity from deposited or ejected ink may increase the temperature and/or humidity in inkjet printing system 100 . As a result of hygroscopic and/or thermal expansions of encoder strips 124 , the relative positions of print carriages 132 with respect to encoder strips 124 may change and, if not compensated for, may produce print defects from dot placement errors at the intersection of the print boundaries between print carriages 132 .
[0023] Inkjet printing system 100 compensates for the expansion of encoder strips 124 by measuring a phase difference in signals generated by encoders 142 and 144 on each print carriage 132 as encoders 142 and 144 move along encoder strip 124 . Inkjet printing system 100 determines a measured unit change from the phase difference and adjusts the printing of image 106 by printheads 138 using the measured unit change to prevent print defects from appearing on print medium 104 .
[0024] Inkjet printing system 100 may determine the phase difference between encoder signals any time encoders 142 and 144 move along encoder strip 124 . Accordingly, inkjet printing system 100 may determine the phase difference while image 106 is being printed or at any suitable time before or after image 106 is printed (e.g. during an alignment or servicing routine for printheads 138 ).
[0025] FIG. 3 is a schematic diagram illustrating one embodiment of encoders 142 and 144 and encoder strip 124 . As shown in FIG. 3 , encoders 142 and 144 are mounted on, attached to, integrally formed with, or otherwise affixed to substrate 140 at a fixed distance D from one another. The fixed distance D is sufficient to allow a reasonable measurement of expansion of encoder strip 124 . For example, the fixed distance D may be 100 mm in one embodiment.
[0026] Substrate 140 is formed of either a relatively invariant material such as Invar or a material with well known expansion coefficient. Invar is an alloy material with a very small coefficient of thermal expansion and substantially no hygroscopic expansion that was originally developed for use in mechanical clocks. If a material with well known expansion coefficient is used, a temperature reading device (not shown) may also be used to estimate the thermal expansion of substrate 140 . Substrate 140 positioned with sufficient proximity to encoder strip 124 that allows encoders 142 and 144 to detect encoder markings 126 as encoders 142 and 144 are moved along encoder strip 124 .
[0027] Encoders 142 and 144 each optically scan encoder strip 124 to generate one or more analog electrical signals that indicate the presence or absence of encoder marks 126 as encoders 142 and 144 are moved in unison along encoder strip 124 . Because of the fixed distance between encoders 142 and 144 , the signals generated by encoders 142 and 144 correspond to at least partially different sets of encoder marks 126 . In one embodiment, each encoder 142 and 144 generates four signals—a channel A signal, a channel B signal, an inverted channel A signal, and an inverted channel B signal. In other embodiments, encoder 142 and 144 generate another signal or signals.
[0028] Encoders 142 and 144 each provide the signal or signals to controller 110 . In one embodiment, encoders 142 and 144 are directly coupled to general purpose input/output (GPIO) ports of processor 112 and each provide a signal as a digital input to a GPIO port of processor 112 . In other embodiments, encoders 142 and 144 each provide the signal or signals directly or indirectly to controller 110 in other suitable ways.
[0029] FIG. 4 is a timing diagram illustrating one embodiment of an encoder signal 402 generated by encoder 142 and an encoder signal 404 generated by encoder 144 as encoders 142 and 144 are moved along encoder strip 124 . In signals 402 and 404 , the signal transitions (i.e., the signal changes from a low to a high signal level or from a high to a low signal level) each indicate an edge, and therefore a location, of a corresponding encoder mark 126 . Accordingly, one signal level (e.g., a low signal level) indicates the presence of a corresponding encoder mark 126 and the other signal level (e.g., a high signal level) indicates the absence of a corresponding encoder mark 126 .
[0030] One embodiment of the operation of compensating for the expansion of encoder strip 124 will now be described with reference to FIG. 5A . FIG. 5A is a flow chart illustrating one embodiment of a method for compensating for the expansion of an encoder strip. The method of FIG. 5A will be described as being performed by carriage positioning unit 116 . In other embodiments, other components of controller 110 may perform all or portions of the method of FIG. 5A . Carriage positioning unit 116 performs the method of FIG. 5A for each print carriage 132 ( 1 )- 132 (N) with respective encoder strip 124 ( 1 )- 124 (N) in one embodiment.
[0031] In FIG. 5A , carriage positioning unit 116 is configured to determine a phase difference between encoder signals over multiple encoder strip markings as indicated in a block 502 . Carriage positioning unit 116 examines the encoder signals from encoders 142 and 144 over two or more encoder markings 126 for each encoder 142 and 144 to determine two or more phase lags. Carriage positioning unit 116 determines each phase lag by comparing corresponding signal transitions (e.g., rising or falling edges), which each indicate the location of an encoder marking 126 ) in the encoder signals. In the example of FIG. 4 , carriage positioning unit 116 determines phase lags 406 ( 1 ), 406 ( 2 ), and 406 ( 3 ) between rising edges of signals 402 and 404 . In one embodiment, carriage positioning unit 116 determines each phase lag 406 by counting the number of clock cycles of processor 112 between each rising edge in signal 402 and each rising edge in signal 404 . In this embodiment, the clock frequency of the clock of processor 112 is substantially higher than the frequency of the encoder signals to allow a sufficient number of processor clock cycles to occur between the rising or falling edges of the encoder signals.
[0032] Carriage positioning unit 116 averages or otherwise combines phase lags 406 ( 1 ), 406 ( 2 ), and 406 ( 3 ) to determine the phase difference. By determining the phase difference from two or more phase lags, carriage positioning unit 116 may minimize the effect of noise on the encoder signals.
[0033] Carriage positioning unit 116 determines a measured unit change using the phase difference as indicated in a block 504 . Carriage positioning unit 116 determines the measured unit change by comparing the current phase difference with a previously determined phase difference. Carriage positioning unit 116 may determine the previous phase difference using the method of FIG. 5A at any time prior to determining the current phase difference. For example, carriage positioning unit 116 may determine the previous phase difference during an initial alignment of printheads 138 or during the printing of image 106 or a previous image 106 .
[0034] Carriage positioning unit 116 determines the measured unit change as any suitable function of the current phase difference, the previous phase difference, and the spacing of encoder markings 126 on encoder strip 124 . For example, carriage positioning unit 116 may determine the measured unit change as proportional to the difference between the current and previous phase differences. Where the current and previous phase differences, Ph cur and Ph prev , respectively, are measure in electrical degrees, carriage positioning unit 116 may determine an approximation of the measured unit change, Δ, as shown in Equation I where Space represents the spacing of encoder markings 126 .
[0000]
Δ
=
(
Ph
cur
-
Ph
prev
360
°
)
Space
Equation
I
[0035] Using the measured unit change, carriage positioning unit 116 adjusts the printing of image 106 by printheads 138 to prevent print defects from appearing on print medium 104 as a result of the expansion of encoder strip 124 .
[0036] Another embodiment of the operation of compensating for the expansion of encoder strip 124 will now be described with reference to FIG. 5B . FIG. 5B is a flow chart illustrating one embodiment of a method for compensating for the expansion of an encoder strip. The method of FIG. 5B will be described as being performed by carriage positioning unit 116 . In other embodiments, other components of controller 110 may perform all or portions of the method of FIG. 5B . Carriage positioning unit 116 performs the method of FIG. 5B for each print carriage 132 ( 1 )- 132 (N) with respective encoder strip 124 ( 1 )- 124 (N) in one embodiment.
[0037] In FIG. 5B , carriage positioning unit 116 determines an initial phase difference between encoder signals from encoders 142 and 144 as indicated in a block 512 . Carriage positioning unit 116 determines a subsequent phase difference between encoder signals from encoders 142 and 144 as indicated in a block 514 .
[0038] Carriage positioning unit 116 may determine the initial phase difference at any suitable time such as during an initial alignment of printheads 138 or during the printing of image 106 or a previous image 106 . Carriage positioning unit 116 may determine the subsequent phase difference at any suitable time subsequent to the determination of the initial phase difference. For example, carriage positioning unit 116 may determine the subsequent phase difference at continuous or periodic intervals and/or in response to certain events occurring such as the printing of image 106 .
[0039] Carriage positioning unit 116 may determine each of the initial and subsequent phase differences from two or more phase lags corresponding to two or more encoder markings 126 in each of the encoder signals from encoders 142 and 144 . For example, where encoder markings 126 are spaced at 1/200 inch intervals, carriage positioning unit 116 may determine each of the initial and subsequent phase differences by averaging approximately 800 phase lags over four inch moves (i.e., 200 phase lags per inch) of encoders 142 and 144 along encoder strip 124 at different times.
[0040] Carriage positioning unit 116 may determine each phase lag by counting the number of clock cycles of processor 112 between corresponding rising or falling edges in the encoder signals from encoders 142 and 144 . Carriage positioning unit 116 may record the number of clock cycles of processor 112 as a fraction of the clock cycles in a full period of the encoder channels. Carriage positioning unit 116 may determine the full period from consecutive two or more rising or falling edges in the encoder signal from encoder 142 and/or two or more rising or falling edges in the encoder signal from encoder 144 . As an example, carriage positioning unit 116 may determine the initial phase difference to be 15 electrical degrees and the subsequent phase difference to be 105 electrical degrees.
[0041] Carriage positioning unit 116 determines a measured unit change from the initial and subsequent phase differences as indicated in a block 516 . Carriage positioning unit 116 determines the measured unit change as proportional to the difference between the initial and subsequent phase differences. Using Equation I with the above example initial and subsequent phase differences and encoder markings 126 spaced at 1/200 inch intervals or 0.127 mm/100 mm, the measured unit change may be determined to be ((105-15 degrees)/ 360 degrees))(0.127 mm/100 mm) or 0.03175 mm/100 mm. Accordingly, carriage positioning unit 116 determines that encoder strip 124 has expanded by 0.03175 mm over 100 mm of length of encoder strip 124 .
[0042] Carriage positioning unit 116 compensates for the expansion of encoder strip 124 using the measured unit change as indicated in a block 518 . Carriage positioning unit 116 adjusts the printing of image 106 by printheads 138 using the measured unit change to prevent print defects from appearing on print medium 104 as a result of the expansion of encoder strip 124 . In one embodiment, carriage positioning unit 116 adjusts the positioning of print carriage 132 in accordance with Equation II where N POS is the nominal position of print carriage 132 and N CORR is the corrected position of print carriage 132 .
[0000]
N
CORR
=
N
POS
1
+
Δ
Equation
II
[0043] Because the term 1+Δ may be very close to a value of one, the calculation of N CORR using Equation II may be a numerically sensitive calculation that may result in rounding errors and/or the use of a significant amount of computing power. By substituting Equation III into Equation II, Equation IV may be derived.
[0000]
1
1
+
Δ
≈
1
-
Δ
Equation
III
N
CORR
=
N
POS
(
1
-
Δ
)
=
N
POS
-
(
N
POS
*
Δ
)
Equation
IV
[0044] In another embodiment, carriage positioning unit 116 adjusts the positioning of print carriage 132 in accordance with Equation IV to achieve a more stable calculation compared to the calculation of Equation II.
[0045] For example, if the desired nominal position of print carriage 132 is 350 mm from the fixed end of encoder strip 124 and the measured unit change is 0.03175 mm/100 mm from the example above, carriage positioning unit 116 determines the corrected position to be (350 mm)−(350 mm*(0.03175 mm/100 mm))=349.888875 mm from the fixed end of encoder strip 132 .
[0046] In some embodiments, the expansion of encoder strip 124 may be large enough to cause the phase difference to exceed 360 degrees. In these embodiments, carriage positioning unit 116 may sample the phase difference frequently to detect when the phase difference exceeds 360 degrees. In other embodiments, the resolution of encoders 142 and 144 and/or the spacing between encoders 142 and 144 may be selected to allow for expansion ranges of encoder strip 124 where the phase difference does not exceed 360 degrees.
[0047] The above embodiments may provide advantages over other techniques for compensating for the expansion of encoder strips. For example, the above embodiments may perform the compensation without printing alignment markings onto a print medium. In addition, the above embodiments may reduce the effect of any noise in the samples by using a large number of measurement samples to significantly attenuate the noise from external noise sources such as mechanical vibrations caused by the measurement. Further, the above embodiments may be performed at any time during the normal operation of inkjet printing system. As a result, the measured unit change may be updated frequently (e.g., every few seconds) without reducing the throughput of inkjet printing system 100 .
[0048] Although specific embodiments have been illustrated and described herein for purposes of description of the embodiments, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. Those with skill in the art will readily appreciate that the present disclosure may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the disclosed embodiments discussed herein. Therefore, it is manifestly intended that the scope of the present disclosure be limited by the claims and the equivalents thereof. | A system is provided that includes an encoder strip having encoder markings, first and second optical encoders positioned at a fixed distance from one another on a substrate and, responsive to being moved along the encoder strip, configured to generate first and second signals, respectively, that each indicate detection of the encoder markings on the encoder strip and processing circuitry configured to determine a current phase difference between the first and the second signals using a first portion of the first signal that corresponds to a first plurality of encoder markings and a second portion of the second signal that corresponds to a second plurality of encoder markings. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to ultrasonic cutting. More particularly, the invention pertains to an improved method for ultrasonic cutting of food products for use in automated systems.
2. Description of the Prior Art
Commercial food products are typically prepared in bulk sizes which are cut into desired dimensions. It is highly desirably that the cut food product is of visually good appearance with minimal waste. Poor cutting can result in deformed, crushed, or torn product with significant waste.
In recent years, the application of ultrasonic food cutting has been introduced which provides many significant benefits for use in commercial food processing applications. For example, the quality of the cut face is especially clean in visual appearance, multi-layer food products can be easily cut without smearing of the layers, and the cutting operation is especially sanitary in comparison to conventional cutting methods, which is of significant importance in the food preparation industry.
In known ultrasonic food product cutting machines, a cutting blade is generally caused to vibrate at 20-40 kHz to move a cutting tip of the blade rapidly back and forth. This very high frequency movement effectively reduces the co-efficient of friction to a very low level, enabling the blade to slide through the food product.
After each cut, a food product can be repositioned by a rotary table, for example, where multiple cuts in the product are desired. It may be appreciated that the proper positioning of the food product with the ultrasonic cutter is important, especially in cutting bakery products, such as pies and cakes, where the multiple cuts of the bakery product are to converge at a center point. However, movements of the food product to the ultrasonic cutter can often become problematic resulting in damage to the appearance of the product. Many food products, such as multi-layer bakery products, become relatively unstable after multiple cuts have been made. Accordingly, the start and stop motion of the food product to move and position the product to the ultrasonic cutter can become undesirable where damage to an unstable product occurs.
As will be described in greater detail hereinafter, the method of the present invention differs from those previously proposed and employs a number of novel features that render it highly advantageous over the prior art, as well as solving the aforementioned problems.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a method for ultrasonic cutting food products which moves the cutting assembly to and about the food product for effectuating cuts of the food product in comparison to prior art ultrasonic cutting systems which move the food product to the cutter.
Another object of this invention is to provide a method designed for use in automated systems of commercial food processing.
Still another object of this invention is to provide a method which allows for increased production capacity.
Yet another object of this invention is to provide a method which is well suited for cutting multi-layer food products, such as cakes and other bakery products, where such products typically require multiple cuts which render the product relatively unstable.
To achieve the foregoing and other objectives, and in accordance with the purposes of the present invention a method of ultrasonic cutting of food product is provided which includes the steps of: moving the food product on a conveyor; providing an ultrasonic knife assembly having a blade adapted for cutting the food product; moving the knife assembly along a horizontal x-axis and/or a horizontal y-axis perpendicular to the x-axis to a cutting position when the conveyor has moved the food product within a cutting range; and cutting the food product with the blade of the knife assembly by vibrating the blade at an ultrasonic frequency while moving the blade into the food product by lowering the blade through a vertically oriented z-axis.
Other objects, features and advantages of the invention will become more readily apparent upon reference to the following description when taken in conjunction with the accompanying drawings, which drawings illustrate several embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a first embodiment of the present invention;
FIG. 2 is a perspective view of a second embodiment of the present invention;
FIG. 3 is an enlarged plan view of one embodiment of an ultrasonic knife positioning assembly for use with the first and second embodiments of the present invention;
FIG. 4 is side view of the knife positioning assembly taken along line 4--4 of FIG. 3;
FIG. 5 is a perspective view of a rotary axis assembly;
FIG. 6 is a diagrammatic perspective view illustrating a series of ultrasonic cuts being applied to a rectangular shaped food product;
FIG. 7 is a diagrammatic perspective view illustrating a series of ultrasonic cuts being applied to a round shaped food product;
FIG. 8 is a block diagram of the present invention;
FIG. 9 is a flowchart illustrating operational program logic of the second embodiment of the present invention;
FIGS. 10A-10D are side views diagrammatically illustrating the method of operation of the second embodiment;
FIGS. 11A-11D are side views diagrammatically illustrating the method of operation of a third embodiment; and
FIG. 12 is a perspective view of the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, an ultrasonic food product cutting apparatus 10 is illustrated in FIG. 1 for cutting food products.
The apparatus 10 includes a base frame 12 formed of a plurality metal vertical and horizontal frame members 14,15 secured to one another. An infeed conveyor or conveyor assembly 16 is mounted to the base frame 12 for moving a food product 18 (FIG. 7) supported thereon. The conveyor assembly 16 includes a conveyor belt 19 mounted for rotation on an idler roller 20 mounted at a first or infeed end 22 of the conveyor assembly 16 and a drive roller 24 mounted at a second end 26 of the conveyor assembly 16. A drive shaft 28 extends from the drive roller 24 is connected to a sprocket 30. Chain 32 is operatively connected between sprocket 30 and motor sprocket 34. A shaft 36 is connected between sprocket 34 and an electric drive motor 38 of conventional design which provides rotational forces to drive the conveyor assembly 16 which is controlled by an infeed conveyor controller 17 (FIG. 8). It should be understood that other drive mechanisms of known design could be employed to drive the conveyor assembly 16.
In a first embodiment of apparatus 10 shown in FIG. 1, the apparatus is constructed for use in a indexing type mode where a food product is conveyed in a first direction indicated by the numeral 40 to a stationary position within a cutting range 42 of an ultrasonic knife positioning assembly 44. After cutting, as later described, the food product is conveyed away from the positioning assembly by moving the food product in the first direction 40, or alternatively in a second direction indicated by the numeral 46.
Preferably, the apparatus 10, as shown in a second embodiment of FIG. 2, includes a conveyor assembly 16 which operates continuously to move the food product 18 in a single horizontal direction indicated by the numeral 47 from an infeed end 48 to an outfeed end 50. Additional conveyor assemblies 53 constructed similarly to conveyor assembly 16 may be provided at the infeed and outfeed ends 48,50 for moving the food product 18 in an automated system to a succeeding food processing or packaging station.
Referring to FIG. 4, an ultrasonic knife assembly 52 has a blade 54 adapted for cutting the food product 18. The cutting action is a combination of the sharp cutting edge 56 and mechanical vibration of the blade 54. The blade 54 is designed to vibrate generally between 20 to 40 khz depending on the type of food product 18 in a longitudinal or piston type mode and is driven by an electromechanical transducer 58 including an ultrasonic generator and amplifier. The ultrasonic knife assembly 52 per se may be of the type commercially available for use in food cutting.
Referring to FIGS. 3 and 4, the ultrasonic knife positioning assembly 44 is mounted to the base frame 12 and supports the ultrasonic knife assembly 52 above the conveyor belt 19 for moving the knife assembly 52 to the food product in a cutting position. The area of the cutting position is indicated by the numeral 60 (FIG. 3). The knife positioning assembly 44 provides movement of the knife assembly 44 about an x-axis 62, y-axis 64, and z-axis 66.
A pair of servopneumatic x-cylinders 68 are secured to horizontal members 15 on opposite sides 70 of the frame 12. The x-cylinders 68 extend parallel to one another in a spaced apart relationship. An x-y cylinder connection bracket 72 is mounted to each of the x-cylinders 68 for movement in the x-axis 62 therewith. One of the x-cylinders 68 includes an x-transducer 69 operatively connected therewith. A servopneumatic y-cylinder 74 has opposite ends 76 with each end 76 mounted to one of the brackets 72. The y-cylinder 74 extends perpendicular to the x-cylinders 68 and generally across the width of the conveyor belt 19. A y-z connection bracket 78 is mounted to the y-cylinder 74 for movement in the y-axis 64 therewith. The y-cylinder 74 includes a y-transducer 75 operatively connected therewith. A servopneumatic z-cylinder 80 is mounted to the bracket 78 and extends vertically to provide movement in the z-axis 66 or vertical plane perpendicular to the planes of movement of the x-cylinders 68 and y-cylinder 74. The z-cylinder 80 includes a z-transducer 81 operatively connected therewith. With respect to the servopneumatic cylinders 68,74,80, and corresponding transducers 69,75,81, these components per se are of conventional design and it should be understood that other known motor or actuator assemblies could be employed with the present invention, such as electric servomotors, servohydraulics, and mechanical drive mechanisms, where such assemblies would be configured in accordance with teachings of the present invention.
Referring to FIGS. 3-5, a rotary motor assembly 82 is connected to the z-cylinder for movement therewith and provides rotational movement of the knife assembly 52 about the z-axis 66. The rotary motor assembly 82 includes a bracket 84 having upper and lower portions 86,87. A rotary motor and reducer 88 of conventional design is secured to the upper portion 86. A knife assembly support 90 is rotationally secured at the lower portion 87 of the bracket 84. The knife support 90 includes a mounting plate 92 adapted to mount the ultrasonic knife assembly 52 in fixed assembly therewith, as best illustrated in FIG. 4. A shaft 94 is interconnected between the motor 88 and knife assembly support 90 for transmitting rotational forces from the motor 88 to the knife assembly support 90.
In a preferred embodiment shown in FIG. 7, the motor 88 provides up to 360° of rotation to the knife assembly support 90 to allow for pie shaped cuts 92 in round food products where the blade 54 is center positioned above the food product 18 such that 180° of rotation of the blade 54 can produce cuts 92 at 360° around the food product 18.
Referring to FIG. 8, a control system 95 of the apparatus 10 is illustrated. Each of servopneumatic cylinders 68,74,80 are electronically connected to respective controllers 94. The rotary motor assembly 82 is electronically connected to controller 96. In turn the controllers 94,96 work together to move the cutting blade 54 to specified positions dictated by a processor 98. The processor 98 is preferably a programmable logic controller or personal computer based system of conventional design. In the preferred embodiment, the controllers 94,96 and processor 98 operate using control algorithms which include a command signal to cause motion, a driver to respond to the command signal, and a feedback system which indicates the actual position of the system.
With this control logic, the acceleration, speed, deceleration, and position of the cylinders can all be controlled to prescribed limits. Thus the cutting blade 54 can be accelerated to the proper speed, maintained at that speed, decelerated to a stop, and returned to the stop position.
In the preferred embodiment shown in FIG. 2, the knife assembly 52 is moved at a rate of speed synchronous to a rate of speed of the moving conveyor 16 for maintaining the cutting position for a specific time period to allow the ultrasonic knife assembly 52 to effectuate a cut. In particular, the first part of the motion required for the x-axis consists of accelerating the cutting blade 54 to a linear speed that is the same as the linear speed of the conveyor 16 within the prescribed distance and time. The speed of the cutting blade 54 is then maintained at the matching speed to the conveyor 16 while the cut or cuts are being made. At the end of the cut, the cutting blade 54 is decelerated to a stop. The cutting blade 54 is then returned to its original position.
The motion required for the y-axis is a movement to adjust the position to align the cutting blade 54 with the food product 18. The motion consists of an acceleration portion, a constant speed portion if required, and a deceleration portion to a stop at the final position.
The motion required for the z-axis is a smooth movement down to perform the product cut and a rapid retraction of the blade 54 from the food product 18. The ultrasonic knife assembly 52 is activated at the start of the motion and deactivated after the return of the cutting blade to its original vertical position. The motion consists of a high acceleration period to obtain the required cutting speed, fast advance into the product at cutting speed, decelerating rapidly to a predetermined stop position which is sufficient to cut the product 18 but not damage the carrier of the product 18 or the conveyor 16, a rapid acceleration to the required retraction speed, retraction of the cutting blade 54 from the product 18, and then stopping at its original position. The stops on both the top and bottom of the travel are programmable by use of the control system 95 with processor 98.
The motion required for rotation about an θ axis 100 (FIG. 3) is a rapid rotary motion to move the cutting blade 54 from one rotary orientation to another. The motion consists of a high acceleration period, high speed rotary movement and high deceleration period to rotate the blade 54 from its initial position to its next required position. The cutting blade 54 can be activated at each position and the cutting can be accomplished by the proper movement in the z-axis as described above. After the final cut is made, the cutting blade 54 is rotated back to its original position.
Referring to FIGS. 2 and 8, a product detector or sensor 102, such as a photoelectric sensor or vision camera of the type known in the art of optical sensing, is mounted at the infeed end 22 of the conveyor 16 and is electronically connected with the controllers 94 of the knife positioning assembly 44 through the processor 98 to sense the proximity of the food product 18 within the cutting range 42. The control system 95 is responsive to the sensor 102 to cause the knife positioning assembly 44 to move the knife assembly 52 to the food product 18 in the cutting position and for movement about the food product 18 for positioning the knife assembly 52 to effectuate a series of preselected cuts as desired. An encoder 104 is mounted at the infeed end 22 of the conveyor 16 and is electronically connected to the processor 98 for determining exact position and dimensions of the food product 18 as it moves past the product detector 102 at a specific rate of speed on the conveyor 16. Safety switches and electronic stop mechanisms 99 of conventional design may be employed to automatically stop the operation of the apparatus 10 when in use pursuant to a particular selected conditions being satisfied.
Referring to FIG. 8, an operator interface 106 is electronically connected with the processor 98. The operator interface 106 per se is of conventional design and when connected with the present invention it can be configured to allow a user to programmably select a shape of food product and a number of cuts to be given to the food product and where these selections may be saved as a formula for later use (FIGS. 9A and 9B). For example, referring to FIG. 6, a rectangular shaped food product is selected having a plurality of cuts 108 along the products width and length. Referring to FIG. 7, a round shaped food product is selected having a plurality of pie shaped cuts 92. It should be understood that food products of any size could be used, however, in baking applications round and rectangular shapes are particularly common.
Referring to FIGS. 1 and 8, an infeed gate assembly 110 is provided which is raised and lowered when a food product 18 enters or exits the cutting range 42 when the apparatus 10 is operated in accordance with the first embodiment previously described. The gate assembly 110 includes an infeed gate controller 112 (FIG. 8) which is electronically interconnected between the processor 98 and an air piston 114 of the assembly. The assembly 110 includes a pair of slider brackets 116 secured to the frame 12 in opposing space apart relationship with one another at the first end 22 of the conveyor assembly 16. A gate member 118 has opposite sides 120. Each slider bracket 116 has a channel 122 for receiving a respective side 120 in slidable engagement therewith. The gate member has the air piston 114 connected therewith for actuating the gate member.
Referring to FIGS. 9A and 9B, a flowchart is provided which illustrates program logic being carried out during operation of the second embodiment of the apparatus 10 where the conveyor 16 moves continuously during the ultrasonic cutting. It should be understood that the program logic illustrates only one preferred embodiment and that alternative program logic could be employed in accordance with the purposes of the present invention described above.
Referring to FIGS. 10A-10D, a series of consecutive side views diagrammatically illustrate the method of operation of the second embodiment taken at various time increments. In FIG. 10A, the blade 54 being actuated by a knife positioning assembly as previously described is caused to move towards a food product 18 which is moving continuously on a conveyor 16. In FIG. 10B, the blade 54 meets the food product 18 and is momentarily positioned at a stationary position whereafter the blade 54 is caused to move in a common direction and speed with the food product 18 in a cutting position. In FIG. 10C, the blade 54 is shown effectuating a cut in the food product 18 while continuing to move with the food product 18. After all desired cuts are completed, the blade 54 is shown in FIG. 10D as having reached an end of the cutting range of the blade 54 whereafter the blade 54 will be caused to reverse direction to move towards a succeeding food product 18 as shown in FIG. 10A.
Referring to FIG. 12, a third embodiment of the present invention is indicated by the numeral 123. The blade 54 of the third embodiment is operatively connected with an orbital knife positioning assembly 124. The assembly 124 provides rotary movement of the blade 54 in a vertical plane about an orbit 126 which is shown moving in a counter clockwise direction through the x-axis 62 and z-axis 66. Blade 54 is operatively connected with the ultrasonic knife assembly 52 as previously described. The knife assembly 52 is mounted to a knife support 128. The knife support 128 is rotatably mounted to a rotary mechanism 130 so that the blade 54 is maintained in a vertical plane. The rotary mechanism 130 provides the orbital movement of the assembly 124 and may include camming so that movement of the blade 54 at a lower portion of the orbit 126 (FIG. 11B) is timed to provide synchronized movement of the blade 54 with the food product 18 along the x-axis 62.
Referring to FIGS. 11A-11D, a series of consecutive side views diagrammatically illustrate the method of operation of the third embodiment taken at various time increments. In FIG. 11A, the blade 54 is actuated by the knife positioning assembly 124 as previously described and is caused to move towards a food product 18 which is moving continuously on a conveyor 16. In FIG. 11B, the blade 54 is shown in a cutting position as the blade 54 cuts the food product 18 and travels with the food product 18 at a common speed in the x-axis. Whereafter, the blade 54 is moved about the orbit 126 to form succeeding cuts in the food product 18, as shown in FIGS. 11C and 11D.
Although the invention has been described by reference to some embodiments it is not intended that the novel device be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosure, the following claims and the appended drawings. | A conveyor moves food product, such as pies or cakes, within a cutting range of a knife positioning assembly. The knife positioning assembly supports an ultrasonic knife assembly which has a blade adapted for cutting the food product. The knife assembly is disposed above the conveyor and is moved to the food product in a cutting position therewith when the conveyor has the food product within the cutting range. The knife assembly is movable through at least two axes by the positioning assembly for positioning and cutting with the blade. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to an evacuation refuge for a maritime unit meant for maritime purposes, such as for shipping, operating at the sea and/or like, in connection with which there exists at least the said evacuation refuge for people existing on the maritime unit and life boats or like for emergency exit.
It is usual nowadays within maritime operations for e.g. shipping or operating at the sea to place the life boats e.g. on the open deck of ship or e.g. at the side of an oil drilling rig, from where the same may be lowered to the sea by dropping. This causes many problems in practice, one of the most crucial of which worth be mentioning is particularly insecurity during an actual emergency, whereby moving to the life boats takes place in open space totally exposed to the roll of the sea and weather circumstances. On the other hand one crucial problem related to the traditional type of placement of the life boats is that, that the life boats as well as the supporting and lifting apparatuses for the same are continuously under very demanding circumstances, that is why effects e.g. by corrosion can be seen already after a very short period of use. This is why the life boats and the operating apparatuses of the same require regular observation and active maintenance in order to confirm usability of the same during an actual emergency.
The problems described above are furthermore emphasized when speaking of actual maritime units, that are meant for operating at the sea, such as immovable oil drilling rig units. In this type of use such situations may arise for most heterogeneous reasons, that the personnel has to seek shelter and get prepared for emergency exit. This is why present rigs have according to the present stipulations temporary refuges, that may be closed airtight from the surroundings. Such temporary refuges are meant however for a very short stay, that is for a residence lasting about 30 minutes at the maximum. Such rooms are generally in practice usual cabins only, that have not been designed for protecting purposes so, that they could be easily separated airtight from the surroundings or that they would have structures increasing fire or explosion safety. After this time at the latest one must leave the protecting facility in question to the life boats placed at the side of the drilling rig or to the helicopter deck, in case evacuation is possible that way. The situation may thus be such, that the sea underneath and/or a part of the drilling rig is burning, whereby getting to the life boats is impossible because of toxic combustion gases existing in the surroundings or because of high temperatures. In addition to that problems may be caused under such situations also by high roll of the sea and by otherwise disadvantageous weather circumstances so, that helicopter transportations being used typically for emergency exit may not be used.
In Finnish patents numbers 96896 and 100197 there has been presented solutions, that are meant for developing particularly traditional drilling rigs of jack-up type. In this connection it may be stated, that it is nowadays known to use both so called semi-submersible drilling rigs and the type of so called jack-up drilling rigs as described above, which have feet, that may be moved with respect to the frame part of the drilling vertically in order to support the drilling rig to the bottom of the sea during an operating situation. The semi-submersible drilling rigs comprise an underwater part, which supports the actual working deck existing on the sea level. Such a drilling rig is not supported stationary on the ground at all during a drilling situation, that is why the type of drilling rig requires expensive and complicated joint and movement arrangements between the drilling device drilling the ground and the drilling rig, which enable drilling despite the roll of the sea. Both the costs of manufacturing and operating of such type of drilling rigs are multiple, when compared to the same of those drilling rigs of jack-up type described above. One crucial advantage of the type of drilling rigs above compared to nowadays drilling rigs of jack-up type is, however, that because of a massive construction of the same they may be transported in most heterogeneous circumstances, even during a relatively high roll of the sea. In addition to that, they may be used with clearly deeper depths of water than jack-up rigs, which may be used when the depth of water is usually below 150 meter.
The solutions presented in the Finnish patents mentioned above are meant particularly to improve the safety and feasibility of a drilling rig of jack-up type, whereby the former of the same is meant particularly to improve the safety and feasibility of the drilling rig in a way, that the residence unit belonging to the drilling rig is arranged moveable, whereby it is moved at least for the time of the drilling situation essentially away from the drilling unit, advantageously in a direction, that is essentially opposite to the moving direction of the drilling unit.
The latter patent discloses a solution, that is meant to improve the feasibility of a drilling rig of jackup type particularly with a view to the safety of an attachment phase and a detachment phase. In this case under the bottom of the frame part there has been arranged an airspace, that may be discharged for the transportation position of the drilling rig, whereby air is blown to the same in order to achieve an airbed or like, particularly for the time of the attachment and/or the detachment phase.
The risks related to maritime may be classified to the following main groups: cases of sinking, collision, fire, explosion and structural damage. In addition to that typical risks related particularly to off-shore oil drilling are: gas leakages, which cause danger to life due to an explosion or poisoning, oil leakages, yielding of the sea bottom, a pipe damage of the bore, helicopter accident, a threat to terrorism.
The evacuation stipulations for different kinds of risk situations are always slightly differing, but in serious cases they according to the main rule always end up to exiting the rig either by helicopter transportation or by life boats. As an example of the above increasing of hydrogen sulphide to a level of 0,04% may be mentioned. In such a case the rig must be evacuated immediately. When an evacuation is taking place, it is safest to carry it out by helicopters, in case they may be used under those circumstances or if there is enough time to use them. In case use of a helicopter is prevented because of the weather circumstances or because of urgency of the evacuation, people must enter the life boats. Moving to the life boats is always a risk already as such. It has been said, that most lives, that have been lost in sea accidents all over the world are just result of life boat accidents, because fatal accidents have occured while handling the life boats. They may be caused by the bad shape of the life boat or of its treatment apparatus, by circumstances during exit to the boats, by roll of the sea while staying in the boats and to a high degree also by exiting the life boats to the rescuing ship.
SUMMARY OF THE INVENTION
Despite the developed solutions according to the patents described above, in which there has been suggested first of all to place the helicopter deck in connection with the upper part of the residence unit above the life boats in a way, that a covered sheltering space is achieved, that protects moving of the personnel to the life boats, and on the other hand also that, that in connection with the residence unit there has been arranged built-in a sheltered emergency exit space, the present art for the part of the life boats has remained unchanged in such respect, that the life boats are completely uncovered at the sides of the drilling rig, so that the problems presented above are related also to the solutions according to the above mentioned patents.
It is the aim of the evacuation refuge according to this invention to achieve a decisive improvement in the problems presented above and thus to raise substantially the level of knowledge in the field. To achieve this aim, the evacuation refuge according to the invention is primarily characterized in, that the evacuation refuge is arranged as a rescue station, that is arranged to be closed essentially completely and preferably airtight from the surroundings and in which long lasting residence is enabled and furthermore inside of which the said life boats or like are being placed.
The evacuation refuge according to the invention improves significantly safety of maritime units meant for most heterogeneous purposes particularly with a view to different kinds of protecting, emergency, emergency exit situations or like. This is first of all thanks to the fact, that the life boats are placed in a space, which is totally protected from the surroundings so, that safe moving to the same is always enabled under most heterogeneous circumstances and surroundings. As an advantageous embodiment the evacuation refuge according to the invention is being exploited particularly in a maritime unit that is meant for operating at the sea, such as an oil drilling rig or like, whereby in connection with the rescue station there has been arranged processing devices for breathing air, such as ventilation arrangements, reserve of breathing air, regeneration and/or filtration units for breathing air, in order to keep the air suitable for breathing inside the rescue station, that is particularly to be closed airtight with respect to the surroundings, which enables long lasting residence in the rescue station. The invention has one crucial meaning in such respect as well, that the life boats, that are totally protected from the roll of sea and weather circumstances, are despite demanding surroundings maintained in good shape, whereby maintenance and service of the same may be minimized without however risking their reliability. One more advantage of keeping the life boats protected is the fact, that also the operating apparatuses of the same are kept in good condition with significantly less maintenance than presently. The evacuation refuge according to the invention improves thus significantly the general safety of maritime decreasing simultaneously significantly also maintenance and service expenses.
Advantageous embodiments of the evacuation refuge according to the invention are represented in the dependent claims related to the evacuation refuge.
BRIEF DESCRIPTION OF THE DRAWINGS
In following description, the invention is illustrated in detail with reference to the depended drawings, in which
FIG. 1 a shows one advantageous purpose for use of the evacuation refuge according to the invention, that is a drilling rig of jack-up type during a transportation situation seen from above,
FIG. 1 b shows the corresponding embodiment during a drilling situation and
FIG. 2 shows the corresponding drilling rig during a drilling situation as a side view.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to evacuation refuge for a maritime unit meant for maritime purposes, such as for shipping, operating at the sea and/or like, in connection with which there exists at least the said evacuation refuge for the people existing on the maritime unit and life boats 8 a or like for emergency exit. The evacuation refuge is arranged as a rescue station, that is arranged to be closed essentially completely and advantageousely with respect to the surroundings and in which long lasting residence is enabled and furthermore inside of which the said life boats 8 a or like are being placed.
The principle above may be found from all of the FIGS. 1 a - 2 , in which there is shown a drilling rig of so called jack-up type as an example of applying the invention. In this connection it must be stated, that the evacuation refuge according to the invention may naturally be used in addition to e.g. in shipping vessels in most heterogeneous maritime units meant for operating at the sea, such as e.g. in immovable oil drilling rig units or e.g. in so called rigid production plants or in those drilling rigs of submersible-type being described in the beginning. Particularly in this kind of operative use a rescue station X has been applied, that is advantageously thermally insulated and equipped with a structure reinforced against explosions and in connection with which there has been arranged furthermore processing devices X 1 for breathing air, such as ventilation arrangements, reserve of breathing air, regeneration and/or filtration units for breathing air, in order to keep the air suitable for breathing inside the rescue station X, that is particularly to be closed airtight with respect to the surroundings.
As an advantageous embodiment with reference particularly to the view shown in FIG. 2, there has been arranged in connection with the rescue station X sanitary facilities X 2 , that are to be closed airtight with respect to the surroundings, such as WC's, chemical toilets, washing facilities and/or like.
With respect to the drilling rig 1 of jack-up type shown in FIGS. 1 a - 2 , the drilling rig 1 has a frame part 2 comprising a working deck 1 a and an essentially plane shaped bottom 1 b , inside of which there has been arranged at least a part of the power production and operating equipment of the drilling rig 1 . In connection with the frame part 2 there has been arranged at least three feet 3 operated by lifting devices 5 , by means of which the drilling rig 1 may be supported on the sea bottom during an attachment phase through lowering the same from a standby position required by a transportation position of the drilling rig 1 essentially in a vertical direction in respect to the frame part 2 to a working position enabling at least a drilling situation (FIG. 2 ). In connection with the frame part 2 there is also a drilling unit 4 for drilling, that is arranged moveable essentially in a horizontal plane in respect with the frame part 2 by means of a first transferring apparatus 6 , such as by actuators driven by electricity, pressurized medium and/or correspondingly and a slide rail assembly or a like, to perform the drilling during the drilling situation essentially form outside the frame part 2 (FIGS. 1 b and 2 ). Furthermore as an advantageous embodiment the drilling rig 1 comprises also a residence unit 7 , that is arranged according to the patents described in the beginning moveable at least for the time of the drilling situation essentially away from the drilling unit 4 . Particularly in this type of connection there has been arranged in connection with the rescue station X a food stuffs unit X 3 for food and drink maintenance enabling long standing residence, which unit is to be closed airtight with respect to the surroundings and that is preferably common to the residence unit 7 , which residence unit 7 is advantageously moveable in direction s e.g. by means of a second transferring apparatus 9 . In the drilling rig embodiment shown in the drawings there has been shown furthermore a helicopter deck 8 b for air transportations, that is placed advantageously in connection with the upper part of the residence unit 7 , whereby in connection with the same there has been arranged advantageously a safe exit way also directly from the rescue station to the helicopter deck.
Furthermore as an advantageous embodiment with reference particularly to FIG. 2 there has been arranged a heating/cooling apparatus X 4 in connection with the rescue station X, in order to keep the temperature inside the rescue station X within preferably adjustable temperature limits.
Particularly due to risk involved with the type of operating at the sea described above, it is furthermore advantageous to arrange in connection with the rescue station X also observation arrangements X 5 in order to observe the state of the surroundings visually, such as by means of windows, video cameras and/or like, and/or by measuring techniques, such as by means of gas, temperature, pressure detectors and/or like, whereby particularly by means of e.g. a gas detector it is possible to observe the carbon monoxide, combustion gases, hydrogen sulphide, hydrocarbon contents or like of the surroundings. The above described observation arrangements based on measuring techniques enable furthermore use of the processing devices X 1 for breathing air so, that air, that has been purified only by a filtering unit, is being led to the rescue station X, whenever it is possible. On the other hand during very difficult situations it is possible to use the reserve of breathing air and the regeneration unit for breathing air, whereby the breathing air of the rescue station X is maintained by means of a closed cycle by limiting the carbon dioxide of the recycling air by means of the regeneration unit and by purifying it with the filtration unit.
Furthermore with reference to FIG. 2 there has been arranged to the outside wall of the rescue station X an openable/a removable wall structure SR placed essentially in connection with the life boats 8 a in order to enable removing of the same from the side.
As an advantageous embodiment with reference particularly to FIG. 2, the bottom of the rescue station X is arranged openable/removable from under the life boats 8 a in order to enable removing of the same from below through an exhaust opening PA formed into the bottom. It is also possible to arrange in connection with the rescue station X and/or the life boats 8 a a folding apparatus X 6 in order to lower the life boats nearer to the sea level before dropping them down. This type of arrangements are necessary particularly during such situations, when the maritime unit is for some reason in very declined position so, that the dropping height of the life boats is too high.
Furthermore as an advantageous embodiment of the invention, there has been arranged in connection with the rescue station X an extra command post X 7 for controlling of the operative functionings of the maritime unit, such as of a drilling unit 4 performing drilling, of a residence unit 7 , of a transferring apparatus 6 , 9 and/or of an energy supply and operating apparatus of an immovable or a moveable oil drilling rig or like.
The invention described above gives extra time to make an evacuation decision and makes maybe even the whole evacuation decision unnecessary. The people may stay safely in the rescue station and monitor development of the situation from there. It is whenever possible to exit the station by going to the life boats, but however not until then, that the people are considered to be safer in the boats than in the rescue station.
It is also always possible to exit the rescue station to the helicopter deck in order to carry on the evacuation from that point. In case the weather circumstances prevent use of the helicopters, the people may in very many situations wait till the last moment sitting in the life boats if necessary and wait for improvement of the weather conditions and in case they get better, exit the station by helicopter transportation.
In many situations the invention may even make the present evacuation decisions according to the present stipulations totally unnecessary so, that the risk of danger goes by during the time, that the people spend in the rescue station; a gas leakage stops and the direction of wind changes, a fire is being extinguished etc. Rescuing may be waited for, though some kind of explosion would have destroyed structures concerning actual operations, whereby there is enough time by equipping the rescue station with equipment, that safeguard survival e.g. for two weeks.
When a premature evacuation may be avoided, also the great risks caused by the evacuation as such may be avoided. Also the high expenses must be kept in mind, that are caused by evacuation. If evacuation may be avoided at least for once, it may be, that the invention has paid back itself economically. So, the primary aim and purpose of the invention is to decrease risks involved with evacuation at the sea by increasing safety with arrangements, the costs of which are very often also more profitable that present arrangements.
It is also possible as a rescue station according to the invention is being used e.g. in passenger ships, that the passengers could be determined to go the station much earlier, than such an order about moving to the life boats would be given nowadays. There may be even certain stages during moving to the rescue station, e.g. first of all moving to the rescue station, after that transferring therein to the life boats without however discharging the life boats etc. The rescue station could be thus preventive with respect to damages. As the dangers involved with transferring to the life boats are known, such an order need not be given, but the people would however be much better prepared for leaving the ship in case a final evacuation order proves out to be necessary.
The invention causes in this connection as well many evacuation stipulations to be rewritten, but simultaneously it improves safety, spares unnecessary risks and is in most cases in addition to better safety also a more advantageous alternative.
It is obvious, that the invention is not limited to the embodiments shown or presented above, but it can be modified within the basic idea even to a great extent. Thus the evacuation refuge according to the invention may be carried out technically by very many types of constructions depending very much on the purpose for use. E.g. in connection with maritime vessels, the evacuation refuge may be arranged technically by very many kind of constructions, whereby easy entrance of the passangers and personnel to the rescue station is enabled and on the other hand also the safe lowering of the life boats from the same to the sea. In addition to that it is also possible to equip an evacuation refuge according to the invention more abundantly than described above e.g. with first aid devices and equipments, locationing devices, data communication devices etc. It is naturally advantageous to connect the rescue station according to the invention with suitable sheltered passages to certain critical points in order to enable going to the rescue station safe also. | An evacuation refuge for a maritime unit. A rescue station includes at least one space operable to be completely closed from a surrounding environment for longterm occupation therein. A plurality of life boats are arranged within the rescue station for emergency exit. The life boats are operable to be occupied while inside the rescue station prior to deployment. An openable or removable structure is operable to permit deployment of the life boats arranged within the rescue station by removal of the occupied life boats from the rescue station. Breathing air processing devices are operable to maintain air within the evacuation refuge breathable. | 4 |
TECHNICAL FIELD
[0001] This invention relates to a deadbolt.
[0002] BACKGROUND OF THE INVENTION
[0003] There are known deadbolts of the type where a bolt is secured in a housing which is adapted to be mounted on the face of a door or window or the like. The bolt can be moved into an extended position to engage with a keeper or the like. Such arrangements have been used in window or door security locks.
[0004] There is a need for an arrangement which would ameliorate at least one of the above problems.
[0005] Limitations exist in commonly known deadbolt arrangements and the present applicants envisage that new and useful alternatives with enhanced functionality would be desirable.
SUMMARY OF THE INVENTION
[0006] In a first aspect, the present invention provides a deadbolt having a housing, a bolt mounted in the housing and movable in the direction of the length of the bolt between a retracted position and an extended position, locking means which can lock the bolt in the extended position and retaining means to prevent removal of the bolt from the housing without disassembly of the deadbolt. In this way, the bolt cannot be removed from the housing and thus cannot be accidentally separated or lost.
[0007] Accordingly, a new and useful alternative over the known deadbolts is provided for with the more sophisticated construction which will be exemplified in more detail below and for the purpose of retaining the bolt in the housing to prevent its accidental separation or loss.
[0008] The retaining means may include a projection extending laterally from the bolt for retaining the bolt in the housing. Use of such a projection avoids machining a narrowed portion of the bolt for locking purposes, thereby avoiding weakening the bolt.
[0009] A further advantageous feature now proposed by the present applicants is to provide an arrangement whereby the bolt can be secured and preferably locked in a retracted position so that it is not inadvertently moved to the extended or normal locking position with possible damage to surrounding structure. This may be achieved by providing for the locking means to lock the bolt in the retracted position and then the key can be removed to prevent unintentional locking or movement of the bolt.
[0010] The retaining means can include first and second abutment regions against which the projection will abut to restrain further axial motion of the bolt and to prevent removal of the bolt from the housing. This provides a simple mechanism for preventing removal of the bolt from the housing.
[0011] The deadbolt with advantage may include a detent such as a spring loaded finger which engages in a recess in the bolt so that it is positively located at each limit position, ie extended and retracted, and the user can feel and/or hear that this position has been reached. The spring loading will retain the bolt in that position to permit the user then to use a key to achieve any desired locking.
[0012] The locking means can further include a locking tongue which is movable between a locked and an unlocked position, for example by actuation of a key through a lock. In the locked position the projection is trapped between the locking tongue and either one of the abutment regions to restrain axial movement of the bolt.
[0013] With advantage, a lock of cylindrical form is provided for engagement with a key and, upon rotation of the key, there is motion transmitted through a cam and cam follower arrangement to displace the locking tongue.
[0014] The present invention lends itself to embodiments in which the orientation of the bolt within the housing may be reversed so that the lock may be selectively configured for right hand or left hand operation. This enables one model of lock to be manufactured.
[0015] For the purpose of providing improved durability, embodiments of the invention may utilise two laterally extending projections which, when locking is achieved, restrain axial movement of the bolt. This may be achieved by providing a pin extending through a transverse bore in the bolt, the respective projecting tip portions of the pin providing the engagement projections.
[0016] Advantageously, the pin may be a spring pin which is radially compressible for fitting into the bore so that easy installation during manufacture is possible.
[0017] Preferably, the deadbolt further includes another projection extending in an opposite direction to the projection. This improves the durability of the deadbolt over a single projection arrangement.
[0018] A further embodiment provides an alternative and advantageous structure wherein the bolt has an axial groove of relatively shallow depth extending into the side wall of the bolt, a recess deeper than the groove intersecting the groove at at least one end of the groove, and a displaceable projecting element is mounted to be operable when the bolt is in an extended position, responsive to operation of the locking means to engage in the recess thereby locking the bolt, unlocking of the bolt causing partial retraction of the projecting element whereby a tip of the projection is engaged within the groove and the bolt may be slideably moved from the locked position to a retracted position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, of which:
[0020] FIG. 1 is a front elevation of a deadbolt embodying the present invention;
[0021] FIG. 2 is a side elevation of the deadbolt of FIG. 1 ;
[0022] FIG. 3 is an underside view of the deadbolt of FIG. 1 ;
[0023] FIG. 4 is a side cross-sectional view of the deadbolt of FIG. 1 taken along the line A-A;
[0024] FIG. 5 is an inverted plan cross-sectional view of the deadbolt of FIG. 1 along the line B-B;
[0025] FIG. 6 is a plan cross-sectional view of the deadbolt of FIG. 1 along the line C-C;
[0026] FIG. 7 is an exploded view of the deadbolt of FIG. 1 ;
[0027] FIG. 8 is an isometric view of the deadbolt of FIG. 1 along with a keeper with the bolt in the extended position;
[0028] FIG. 9 is an isometric view of the deadbolt of FIG. 1 along with a keeper with the bolt in the retracted position;
[0029] FIG. 10 is an isometric view of the deadbolt of FIG. 1 shown with an alternative keeper;
[0030] FIG. 11 is a part-assembled side view taken along the lines XI-XI of FIG. 7 ;
[0031] FIG. 12 is an inverted plan, central cross-sectional view of a second embodiment and taken along the line E-E of FIG. 14 ;
[0032] FIG. 13 is a plan cross-sectional view through the axis of the cylinder lock of the embodiment of FIG. 14 and taken along the line F-F;
[0033] FIG. 14 is a front view of the second embodiment in the extended, locked position of the bolt;
[0034] FIG. 15 is a right hand end elevation of the embodiment of FIG. 14 ;
[0035] FIG. 16 is an inverted plan view of the embodiment of FIG. 14 ;
[0036] FIG. 17 is a cross-sectional side elevation taken along the line D-D of FIG. 14 ;
[0037] FIG. 18 is an exploded view of components of the deadbolt of FIGS. 12 to 17 ;
[0038] FIG. 19 is a partial view on an enlarged scale showing detail of the configuration in the locked position; and
[0039] FIG. 20 is a view corresponding to FIG. 19 but showing the components in the unlocked position.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0040] Referring to FIGS. 1 to 7 , a deadbolt 10 is shown including a housing 12 and a bolt 14 mounted in housing 12 . The housing 12 has a front cover 13 and backing plate 28 . The bolt may be moved between a retracted position (see FIG. 9 ) and an extended position (see FIGS. 1-6 and 8 ).
[0041] The bolt 14 includes a cylindrical insert 15 (see FIG. 5 ) made from hardened metal located in an axial bore in the bolt to provide added security by resisting cutting of the bolt.
[0042] Bolt 14 includes a plastic handle 17 . This allows a user to easily grasp bolt 14 for the purpose of moving it between the extended position and the retracted position.
[0043] The bolt mounts a transverse spring pin 20 , having respective end projections 16 and 18 , mounted in a cross-bore drilled in the bolt 14 . Projection 16 extends into channel piece 30 which defines a channel 29 , extending from an opening 31 which allows a locking tongue 32 to move into channel 29 . When the locking tongue 32 is outside channel 29 , projection 16 is free to move along the length of channel 29 . When projection 16 is at either end of channel 29 , locking tongue 32 may be introduced into channel 29 through opening 31 so that the locking tongue 32 then obstructs channel 29 and restricts the movement of projection 16 and hence restricts axial movement of bolt 14 . The end of channel 29 , at which projection 16 is located when locking tongue 32 enters channel 29 , dictates whether bolt 14 is locked in the extended position or the retracted position.
[0044] The deadbolt 10 includes transverse abutment shoulders 22 , 24 extending respectively in the cover 13 and baseplate 28 at right angles to the axis of the bolt 14 , the shoulders 24 defining the ends of the channel 29 . The projections 16 , 18 of the spring pin 20 abut against these shoulders at the end of axial travel of the bolt to prevent removal of the bolt from the housing.
[0045] The deadbolt 10 includes a detent 34 which, as most clearly seen in FIG. 7 , comprising spaced interconnected arms 35 , 36 extending parallel to the bolt and biased onto bolt 14 by way of a spring (not shown) positioned between detent 34 and front cover 13 . When bolt 14 is in the extended position, tip projections 37 (at the right hand end of the arm when viewed as in FIG. 7 but at the left hand end when viewed as in FIG. 5 but hidden from view in that Figure) engage with an annular recess 40 in the periphery of the bolt. The tip projections 37 and the recess 40 are obscured in FIG. 5 but shown in FIG. 7 . When bolt 14 is in the retracted position, a second set of tip projections 38 engage with the annular recess 40 . The bolt 14 may be pushed or pulled by hand to release engagement of the detent projections from the recess 40 .
[0046] The bolt is mounted in the housing by being held between the detent 34 and channel piece 30 . Detent 34 biases bolt 14 against channel piece 30 by way of the spring (not shown) to reduce rattle. Detent 34 and channel piece 30 are formed from a material which exhibits low friction when in contact with the material of the bolt to provide for smooth movement of the bolt. Typically detent 34 and channel piece 30 are moulded from an engineering grade polymer such as nylon and the bolt 14 is formed from metal such as stainless steel.
[0047] As most clearly shown in FIG. 7 , a lock cylinder 48 is provided for key actuation and mounted in the housing. Lock cylinder 48 is retained in the front cover 13 by retaining element 49 which is secured by a screw (not shown) onto the interior of the cover 13 . The lock has a rearwardly projecting tab 43 which engages in a corresponding slot 45 in a rotor 46 which has a cam groove 42 in which a lug 44 (functioning as a cam follower) is engaged, the lug 44 projecting from a base portion of the locking tongue 32 . The locking tongue 32 has a rear spline 47 for engaging in a corresponding vertical groovelike guide 27 formed in the baseplate 28 . Thus, rotation of a key in the lock cylinder 48 rotates the rotor 46 and the cam function then raises or lowers the tongue 32 into the channel 29 to establish a locked position and retracts the tongue out of the channel for an unlocked position.
[0048] A U-shaped spring clip 41 has legs which are biased against either sides of a dog 50 mounted on rotor 46 . Clip 41 serves to positively locate rotor 46 at a selected rotary position. The angle of rotation required of rotor 46 to move locking tongue 32 between the locked position and the unlocked position is 90° and this corresponds to the profile of the dog 50 . This feature gives the user tactile feedback that the correct amount of rotation has been performed by the key. Assembly is achieved by locating the upper portion of the spring 41 over a lug 58 (shown in FIG. 5 ) of the baseplate. The channel piece 30 is located in a cradle 27 of the baseplate with lugs 56 projecting rearwardly from the channel piece engaging in holes 57 in the baseplate and thereby aligning tapped bores 59 in the channel piece with screw-receiving holes 60 in the baseplate. The locking tongue 32 is inserted from below into the channel piece 30 and fixing screws used to retain the components on the baseplate.
[0049] The tip 55 of rotor 46 is inserted into a central aperture 52 of the baseplate with the dog 50 snap-fitting between the legs of the spring dip.
[0050] The deadbolt 10 is arranged such that it may be disassembled for the purpose of reversing the orientation of bolt 14 . This allows the deadbolt 10 to operate in either a left handed or right handed configuration.
[0051] Installation, e.g. on a door, is achieved by assembly of the lock with screws (not shown) which pass through corner holes 61 in the backplate (see FIG. 7 ), the screws extending into an engaging tapped bores 62 formed in an internal body structure of the housing 12 . The assembled unit is fixed to a structure such as a door by mounting screws 63 which pass through larger apertures to 64 in the baseplate to engage in respective major tapped bores 65 in the interior of the body of the housing 13 .
[0052] Thus, no screws or bolts remain accessible from the front side of deadbolt 10 when it is mounted for use.
[0053] Referring to FIGS. 8 and 9 , the deadbolt 10 is shown in use mounted to adjacent door frame member 70 , FIG. 8 showing the deadbolt 10 in the extended or locked position in which the bolt 14 engages with keeper 72 mounted on a frame element 73 . Keeper 72 is exposed and thus is fabricated to be strong for the purpose of resisting forcing of the lock.
[0054] Referring to FIG. 10 , the deadbolt 10 is shown with alternative keeper 74 . This form of keeper may be used when bolt engages with a hole drilled into a wall or into the floor, ground or ceiling or the like. The keeper 74 reinforces the hole and protects the hole from damage. If the material into which the hole is drilled is tough, keeper 74 may be dispensed with.
[0055] FIGS. 8, 9 and 10 show the deadbolt mounted vertically. It can also be mounted horizontally at the bottom of a frame to engage with the ground or at the top of a frame to engage with the top of the frame mounting member. The frame can be a hinged or sliding door.
[0056] The pin 20 is designed with a resilient form so that by its resilience it has retained the desired illustrated position in the cross-bore in the bolt. However, that form of pin may be replaced by a solid pin retained in a bore through bolt 14 by an interference fit.
[0057] Reference will now be made to the second embodiment of FIGS. 12 to 20 where like parts have been given like reference numerals and only the variations will now be described in detail.
[0058] The principal differences in the second embodiment are a modification to the bolt 14 and the locking tongue arrangement to provide a different form of retention and locking of the bolt.
[0059] As most clearly shown in FIG. 18 , the bolt 14 has an axially extending groove 100 having a central shallower profile 101 and deeper profiles 102 (best shown in FIG. 12 ) in the form of cylindrical partial cross-bores at each end region. The locking tongue is modified to form a two-part unit comprising a locking element 104 , a vertically displaceable main body 103 which inter-engages with the backplate 28 on one side and the rotor 46 on the other side in the same manner as the first embodiment. However, the locking element 104 is displaceably mounted on the main body 103 with a cam action to cause it to have its axially projecting locking pin 105 move transversely to the axis of the bolt 14 and into its groove 100 . Reference to FIGS. 19 and 20 shows the detail wherein the main body 103 has spaced, upwardly extending walls 106 across which a spring pin 107 is inserted after positioning the locking element 104 so that a slot 108 through the locking element receives the spring pin therethrough for retention purposes. An angled face 109 of the locking element extends parallel to the groove and provides a cam follower surface while the main body provides a corresponding cam surface 110 below the region of the spring pin. As shown in FIG. 20 , in the unlocked position, the locking projection 105 of the locking element extends into the groove, but not into a deeper cross-bore 102 , one of which is at each end of the groove. Therefore, the bolt can slide freely within the limits of the groove and is constrained against removal by axial end walls of the groove.
[0060] When the cylinder lock is rotated, the main body 103 is displaced vertically upwardly while constrained in a corresponding guideway 27 extending from the base plate 28 by engagement of the spline 47 and the cam surfaces engage to displace the locking pin 105 into the bolt 14 . This can only occur when the bolt is at one of its end positions and the locking pin can extend into one of the deeper cross-bores 102 .
[0061] Assembly of the unit is achieved by firstly positioning the spring clip 41 over the locating lug 58 on the baseplate and with the legs extending downwardly outside the location guide 27 . The main body and locking element are assembled as shown most clearly in FIG. 20 and inserted upwardly into the channel piece 130 with the spline 47 engaging in the guide 27 and the channel piece then inter-engages with a cradle 131 of the baseplate, the cradle being integrally formed with the baseplate. The locating lugs 56 are engaged within the locating bores 57 in the baseplate in a similar manner to the mounting arrangement for the first embodiment.
[0062] A further minor alteration is that mounting of the cylinder lock is by a saddle 112 and two mounting screws 113 as shown in FIG. 18 . | A lockable deadlock for face mounting has a housing and an axially displaceable securing bolt mounted in the housing and moveable between a retracted position and an extended position, the deadbolt further comprising locking means to lock the bolt in at least the extended position and retaining means to retain the bolt in the housing. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to seedling starting frames, or seedling house, for the plant or garden hobbyist or horticulturist. The urban gardener frequently is limited in space for the setting out of seedlings from starting pots which have been germinated indoors because of the conventional utilization of living space in the house or apartment for traditional function. The urban gardener is faced with the choice of dedicating a portion of sleeping, eating or living rooms of the house or apartment to the gardening effort and loss of utility of the area or the pursuit of the hobby in full view of visitors. While the trappings of the gardener produce the beauty and joy of mature fruit and flowers, pots, cold flats and peat pots don't always add to the pleasantness and order of the usual sitting room. The present invention provides an attractive plant starting frame which will complement the decor of the living space and may be conveniently disassembled or folded for storage during the period of non-use.
Moreover, the present invention provides both a decorative and attractive aspect to the in-house gardening function. With the disclosed seedling house, the structure may be readily assembled and utilized for the period necessary to germinate and grow such as garden vegetables to sufficient size that they may then be transplanted to the outdoor location to grow and mature. The seedling house may then be quickly be disassembled and stored for the next opportunity for use. In the interim of the growing season, the seeding house provides an attractive, compact and functional addition to the living space of the house or apartment. While the structure is functional and sturdy, the simplistic design and assembly provides an attractive help-mate to the gardener's tools.
Further application of the present invention may be found in the portability of the seedling house as used for early planting of vegetable seedlings. In such application, the seedling house may be set out of doors during the warmer, sunny days to encourage the germination and growth of the seeds. The frame is then readily returned indoors for the cool evenings or colder, dark days which could inhibit plant growth. The outdoor use of the seedling house is enhanced by the inclusion of an illustrated cover, with which the warmth of the sun is enhanced and the soil moisture evaporation is inhibited.
DESCRIPTION OF THE PRIOR ART
While there are numerous devices illustrated in the prior art for the growing of plants and/or flowers, there are none directed to periodic indoor usage. Likewise, none are adapted for the germination of seeds and growing of seedlings for the hobbyist or urban gardener who needs a compact, attractive structure that may be quickly and easily disassembled and stored during the off-season period.
An early device is that illustrated in U.S. Pat. No. 147,849 to T. Leslie. The illustrated Flower Stand is a decorative outdoor structure (or for use in a large indoor areas such as an enclosed arboretum) including internal watering and drainage system. The focus of this invention is in such arrangement of supply, drainage and basin systems as to ensure adequate yet contained watering of the plants. Later improvements to plant and flower stands are illustrated in U.S. Pat. No. 1,153,128 to Chaulk and U.S. Pat. No. 1,720,057 to Babich. Both of these structures are inverted conical devices having ringed or circular adaptations for the placing of plants and flowers. Likewise, both structures are constructed primarily for the growing or display of mature plants, though the Babich Plant Propagator does describe the growing of the plants from seed. The Babich device is a large concrete or pottery-type, earth-filled structure suitable for outdoor display in decorative garden arrangement. The Chalk stand is designed for primary use of flower display, either for commercial use or a large internal display such as would be utilized in the lobby of an office building. Both devices include watering/drainage systems to ensure adequate moisture to the contained vegetation.
More recent related patents to Brownlee, U.S. Pat. No. 4,899,487 and U.S. Pat. No. 5,095,649 illustrates a structure with several tiers, however the invention is directed to a commercial floral display or storage device. As with the previously described structures, intricate watering and drainage schemes are included rendering the device large, cumbersome and ill-suited for home or apartment usage. Likewise, the Brownlee inventions are not readily disassembled for storage or periodic usage.
SUMMARY OF THE INVENTION
The present invention provides a seedling house for the hobbyist gardener which is attractive, functional and readily assembled and disassembled for the periodic use contemplated by such a person. The seedling house is sturdy when assembled and capable of providing additional desirable features to the hobbyist. Includable are individual seedling containers that are readily removed when the plant reaches sufficient maturity to be translated to a vegetable garden, or to a decorative pot in the case of flowers or shrubs. Additional features permit the ready assembly and disassembly for storage of the seedling house including such as interlocking frame and shelves, multi-function pins for fastening shelving and support structure.
Other objects of the invention include a growth cover to protect and enhance the germination and growing of the plants. Preferably the growth cover is a translucent material and serves to retain a favorable humid atmosphere for the plants and enhances the warming effect of sunlight by allowing the light to directly impinge upon the growth environment however retaining the heating effect over a prolonged period. In keeping with the objectives of ready assembly and disassembly, the growth cover is adapted to be quickly, yet securely, fastened to the seedling house for the periods when its usage is preferable.
Additional objects of the seedling house invention include an integral case for the support and storage of the seedling house during the relevant periods therefor. Included in the several objectives of the integral case are means for the securing of seedling house walls for structural strength and means to facilitate storage of the several components of the seedling house so that tit may be readily reassembled as desired.
These and the several other objectives of the seedling house invention will be more readily apparent from the following description of the preferred embodiments as such are considered in conjunction with the appended drawings and attached claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a seedling house for the germination of seeds and protection of seedlings during their growth to the time to be set out, according to the present invention.
FIG. 1a is a partial perspective view of an alternative embodiment of the invention illustrating accommodation for varying sized seedlings.
FIG. 2 is a partially exploded perspective view of alternative embodiments to the present invention.
FIG. 2a is a rear perspective view of an alternative embodiment of the present invention illustrating optional bracing for the seedling house.
FIG. 3 is a partially exploded perspective view of still further alternative embodiments to the present invention, including optional cover and an alternative profile.
FIG. 4 is a perspective view of further alternative embodiments of the various elements to the seedling house of the present invention.
FIG. 5 is a perspective view of the seedling house according to the present invention including embodiments for a supporting case and storage capacity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The seedling house 1 illustrated in FIG. 1 includes side walls 2 arranged in parallel, vertical alignment. Side walls 2 are adapted with a stepped profile edge 3 on one side including riser 4 and shelf support 6. A plurality of shelves 8 are mounted on shelf supports 6, and each of the shelves 8 are adapted with openings 10 for receiving plant containers or starter pots 12. In the embodiment illustrated in FIG. 1, each shelf 8 includes a plurality of openings 10, arranged generally linearly along the length of the shelf. For matters of convenience and economy, the openings 10 are adapted to be circular and of a diameter to accept one or more of a variety of peat cups which are commercially available in hardware stores and nurseries. Alternatively, the seedling house 1 might utilize include the smaller drinking (bathroom-size) cups. It is advantageous to use as small a container 12 as a particular seedling will permit so as to maximize the numbers of starter cups 12 on a particular shelf 8. Likewise, as may be appreciated, shelves 8 may be adapted with openings 10 of different diameters so as to permit the placement of a variety of sizes of starter cups 12 thereby accommodating plants of different sizes at transplanting maturity. The experienced gardener will recognize that such as tomato plants are customarily larger in size at "setting out" than are peppers.
In the seedling house 1 illustrated, the width, breadth and height of the house are conveniently 24 inches each. Risers 4 and shelves are conveniently 3 inches in height and depth, respectively. Though risers 4 and shelf supports 6 are illustrated as having relatively equal dimensions in FIG. 1, it is considered within the scope of the present invention to vary the sizes of risers 4 and shelf supports 6 such that the seedling house may be adapted to accommodate seedlings of varying sizes on selected shelves 8. Reference to FIG. 1a illustrates such an alternative embodiment wherein risers 4 and 4a are of different sizes as are shelf supports 6 and 6a. Accordingly, shelves 8 and 8a are of comparable sizes to their respective riser and shelf supports such that starter cup 12a of shelf 8a may accommodate a larger seedling whereby sections of the seedling house may thus accommodate the different size needs of a variety of seedlings being grown by the gardener. Also considered to be within the scope of the invention is the embodiment wherein shelf support 6 is adapted to receive any of a variety of shelves 8 each having a different selection of larger or smaller openings 10 such that the gardener may elect to place either larger or smaller pots 12 according to the type of seedling being planted.
In the embodiment of the seedling house 1 illustrated in FIG. 1, risers 4 are unadorned with any closure device, as a slat or screen whereby an airspace at 14 exists between adjacent shelves 8. The experienced gardener will recognize that some general flow of air around plants is advantageous for the prevention of fungus, molds and harmful bacteria. While the space between adjacent shelves 8 is illustrated as completely open, it is considered to be within the scope of the present invention to partially close the airspace 14 as is illustrated in FIG. 2 wherein a slat 16 is disposed on the riser 6 and intermediate adjacent shelves 8. The placement of the slat 16 at the top, bottom or intermediate the airspace 14 is a matter of gardener's choice, depending upon relative growing conditions and the particular selection of plants. The slat is preferably affixed to the riser in the manner described below for shelves 8.
Referring further to FIG. 2 the various means for securing the various components of the seedling house in an assembled arrangement are illustrated. As in FIG. 1, the seedling house 1 is illustrated in pictorial view partially exploded for ease in illustrating the various mechanisms for securing the components of the seedling house 1. Side walls 2 are in parallel vertical relationship and the upper two shelves 8 are illustrated in assembled condition. The bottom-most shelf 8" is illustrated in exploded fashion so that it may be appreciated how pins 20 cooperate with shelves 8, by which a secure, yet readily assembled and disassembled seedling house is achieved. Pins 20 include head 22 disposed on shaft 24. In assembled condition as illustrated at 25 pin 20 is inserted in pin opening 26 in side 2 in the shelf support 6, having been inserted through a cooperating shelf pin opening 28 in shelf 8. In the illustrated embodiment of FIG. 2, pin 20 is fully seated against shelf 8. Likewise, in the preferred embodiment illustrated, pin opening 26 and shelf pin opening 28 are of a diameter and depth to snugly receive pin shaft 24 such that the friction occurring between them provides a mechanical link adding rigidity to the seedling house 1 structure. Material preferably utilized for sides 2 and shelves 8 is selected from a group of building materials including woods and plastics which are readily available in sheet configuration and on the order of one-eighth inch to one-half inch in thickness. Naturally, choice of material will be determined by the relative size of the seedling house 1 desired as well as the load to be imposed by the seedling pots 12 and such choices are considered within the skill of an experienced fabricator. It should be recognized by those skilled in the art that a functional alternative is to dispose a screw thread (as are commonly found on wood screws and multi-purpose hooks) on pin shaft 24 whereby the pin 20 might be turned into pin opening 26 and a similar mechanical link established. Additionally, pin head 22 may be adapted with a conventional standard or Phillips-type slot or a conventional bolt-head configuration should a user determine that additional control is required for insertion of pins 20 into sides 2. Slats 16 may be affixed to risers 4 with pins 20 in a manner similar to that described above. It should be also recognized that the addition of slats 16 will provide additional structural support when in place. Likewise, in the instance that a fabricator elect to form sides 2 and shelves 8 of a plastic or similar material, it is considered within the scope of the invention to adapt shelves 8 or sides 2 with pin means 20 (as being integrally molded therein) to be received within a complementary opening 26 in a respective side 2 or shelf 8. Through known snap-fit or equivalent locking means, the desired structural integrity may be readily achieved.
Thus, it may also be preferable, depending upon how large a fabricator elects to construct a seedling house 1 (as by enlarging sides 2 and providing a greater number of shelves as are illustrated herein) one or more slats 16 might be disposed at the back of the seedling house so as to connect sides 2. An alternative embodiment for additional structural security is illustrated by the inclusion of bar 17 disposed within slots 18 and closely received therein. Disposed on bar 17 at the ends thereof am heads 19 which preferably are so located by sizing of the length of bar 17 so that heads 19 engage sides 2 when bar 17 is disposed in slots 18. Additional structural support may be achieved by including second heads 19' disposed adjacent heads 19, however spaced apart therefrom a distance approximately equal the thickness of sides 2. Such a bar 17 and head 19, 19' configuration may be constructed of a rod, threaded at the ends including a pair of suitably sized nuts threaded thereon. Likewise, bar 17 may be specially fabricated including heads 19, 19' secured thereon by welding or equivalent means. FIG. 2a further illustrates the manner in which bar 17 may be received into slots 18 such that adjacent heads 19, 19' may receive sides 2 therebetween.
Continuing with FIG. 2, and referring now to end pins 30 which are disposed in the foremost and rearmost positions on the top and bottom shelves 8 of the seedling house 1, it will be observed that a pin extender 32 is disposed on the upper side of pin head 34. End pins 30 may otherwise be similar to pins 20 in construction and usage. Such end pins 30 are advantageously utilized when a translucent cover such as is illustrated in FIG. 3 is disposed over the starting cups 12. As will be evident to experienced gardeners, the greenhouse effect of such a translucent cover facilitates the germination of seeds through the retention of heat and moisture in the grow space.
Turning now to FIG. 3, an alternative embodiment of a seedling house 1 is illustrated which includes a cover 40 disposed in extending relation from top to bottom of seedling house 1 over shelves 8. As was earlier described, the inclusion of cover 40 is advantageous when the seedling house 1 is transported out of doors during daylight hours to take advantage of the warming and growth inducement of natural sunlight. Cover 40 serves to enhance and retain both the warmth of the sunlight and assist in the retention of soil moisture.
In the embodiment illustrated in FIG. 3, seedling house 1 includes side portions 2 which are generally curved or arcuate in shape along their edges 2" adjacent the shelves 8. Disposed along the interior surfaces of sides 2 are shelf supports 42 which function in a fashion analogous to shelf supports 6 in FIG. 1. Shelf supports 42 are conveniently rectangular bead material tacked, glued or otherwise secured to sides 2. As in the embodiment illustrated in FIG. 1, the shelves 8 are disposed in stepped relation from the lowermost shelf to the uppermost shelf. Shelves 8 are affixed to shelf supports 42 with pins 20 similar to, and in similar manner as, those illustrated in FIGS. 1 and 2. In the illustrated embodiment, single pins are used on each end of shelves 8 with supports 42. As was described in the earlier embodiments, the numbers and types (threaded or smooth, circular or of other cross section) of pins 20 and 30 are optional to the fabricator.
Cover 40 is made of a translucent and readily formable material such as clear or slightly opaque plastic and is optionally disposed over shelves 8 being supported by sides 2 at their edges 2". Cover 40 includes grommets 44 at operative locations, such as at the corners of cover 40 whereby the cover 40 may be readily attached to sides 2. In the illustrated embodiment, grommets 44 are placed over pin extenders 32 of end pins 30. Cover 40 is sized so as to approximately extend over the entire surface area described by shelves 8, between sides 2. In such arrangement, cover 40 forms a green house like structure with seedling house 1 whereby a more stable moisture and temperature environment advantageous to germination of seeds may be created. Cover 40 in FIG. 3 contains a reinforced border 46 which is conveniently formed by doubling of the material at the edge and stitching, either with thread or by glue or thermal bond.
As an alternative to moving the seedling house 1 out of doors for natural sunlight, artificial light may be utilized to enhance the growth environment. It may be convenient to place a light stand outfitted with any incandescent or florescent bulb adjacent seedling house 1. Inclusion of an ultra violet light producing bulb such as are available in garden shops provides an enhanced growing environment. Likewise, the seedling house 1 may be conveniently fitted with such as a small florescent tube type ultra violet light bulb. Such tubes may be placed on the under sides of shelves 8, thereby being located proximate and above the adjacent lower shelf. By such self-contained growth enhancing lights, seedling house 1 may be located in a wider variety of locations indoors, including those with minimal natural light.
FIG. 4 illustrates an alternative embodiment of seedling house 2 wherein the cover 40 is disposed over the style of seedling house 1 illustrated in FIG. 1 and extends over the back portion to be secured at the rear base of sides 2. This embodiment illustrates the manner in which cover 40 may be disposed over a variety of styles of seedling house 1 and be optionally disposed over the shelf area or more fully encase the seedling house. In this illustrated embodiment, cover 40 is secured at its respective ends using such as hooks 48 (which are also illustrated in FIG. 2) rather than pins 30. All of these embodiments are considered within the scope of the present invention.
FIG. 5 illustrates further alternatives for embodiments of the present invention wherein seedling house is adapted to be mounted within a carrying case 50 which may contain all of the respective elements of the seedling house 1 when disassembled and stored therein. Case 50 conveniently includes means such as bead 52 which is disposed inside case 50 on the interior of base 54. Bead 52 may be formed of rectangular material and affixed therein in a manner similar to shelf supports 42 which are illustrated in FIG. 3. Case 50 includes top 60 which cooperates with base to be secured when closed. Such means for securing top 60 to base 54 may include hinges, hooks 62, clasps and related hardware, all of which are commercially available and the use of which is within the skill of an experienced fabricator, cabinet maker or carpenter.
FIG. 5 further illustrates an alternative embodiment of the arrangement of shelves 8 in tiers within sides 2. In this embodiment, shelves 8 are received within slots 56 disposed within the interior of sides 2 at intervals similar to shelf supports 6 of FIG. 2 or shelf supports 42 of FIG. 3. Such a construction of shelves as is illustrated in FIG. 5 is particularly feasible in conjunction with the mounting of seedling house 1 including cover 50 as is also illustrated. Disposing sides 2 in beads 52 within base 54 maintains sides 2 in secure relationship within base 54 so that additional means for securing shelves 8 to sides 2 are not required. It is preferable however, to secure top-most shelf 8" to sides 2 in a manner as described in relation to the other Figures such that the necessary structural security is maintained at the top of seedling house 1 as assembled.
These and other embodiments of the invention described and illustrated in the appended drawings are to be understood as inclusive and not exclusive and that various other forms and changes may be perceived without departing form the spirit and scope of the invention herein disclosed and claimed. | A seedling house for the germination and growing of seedling vegetables and flowers for the hobbyist gardener which is decorative and attractive, portable and disassemblable. In assembled relation, the seedling house includes shelves arranged in an ascending, step-wise fashion adapted with openings to receive plant pots containing the seeds or seedlings to be grown. The seedling house may be adapted with a covering and lighting to enhance the temperature/soil moisture growing conditions for the particular seeds/seedlings being grown. | 0 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/181,487 filed on Feb. 10, 2000.
COMPUTER PROGRAM LISTING
A CD-ROM containing a computer program listing appendix has been submitted and is herein incorporated by reference. The CD-ROM contains a single ASII text file named “buy D”, created on Feb. 19, 2003, 20,2 KB in size.
TECHNICAL FIELD
The present invention relates generally to robotic toys, and more particularly relates to an animatronic, radio-controlled walking robotic toy.
BACKGROUND OF THE INVENTION
While the 1980's were considered the decade of the computer, and the 1990's were the decade of the internet, it has been predicted that the first decade of the new millennium will be the decade of robots. Robots are being used to mow lawns, vacuum clean houses, deliver mail and other inter office communications in large corporations, as well as many other uses. Of course, robotics and automated manufacturing systems have been in place for decades as their cost became justified. However, robots for everyday entertainment and home consumption have generally been too expensive.
Regardless of their cost, however, the Sony robotic dog, priced at approximately $2,000, has received more orders than Sony Corporation can manufacture. As these are times of great personal wealth, the children of the wealthy individuals have toys available to them, such as the Sony dog, which are unaffordable for most middle-class families. Furthermore, general interest in toy robots is at an all time high, as indicated by the television show “Battlebots” which is listed as a “sport” on the Comedy Central cable television channel. Radio-controlled toys, including airplanes, trains, cars and the like, are more popular than ever. Hobby shops are being frequented not only by children, but by adults looking for entertainment. Parents would love to buy “Little Johnnie” a nice radio-controlled robot toy for Christmas, but it has been too expensive.
Consequently, there is a market for a radio-controlled robotic toy which is less expensive than the Sony dog and more on the order of a radio-controlled car or airplane. There has been a long felt need for a moderately priced robotic toy for children in middle-income families. It would be advantageous for this robotic toy to be nearly indestructible, as well as being able to receive various outer body shells which can change the appearance of the robot without having to change the motor-driven body or its electronics.
Therefore, it is an object of the present invention to provide an inexpensive, effective, durable robotic toy which is useful in these arts.
It is also an object of the present invention to provide a robotic toy which is adapted for receiving various outer body shells to portray various insects, animals, winged demons, dinosaurs, and the like.
SUMMARY OF THE INVENTION
Therefore, in accordance with the objects and advantages listed above, and in achieving those objects, the present invention discloses a walking robotic toy which includes a radio-controlled electrically driven motor within a chassis, a transmission therein coupled to a drive wheel assembly, and at least two motor-driven middle legs and at least two pivotal corner legs, both being attached to drive mechanisms. In one of the preferred embodiments, a robotic head is also included, said head having at least one servo motor attached to a gear assembly for activating movable components, such as teeth clenching, jaw pinching, head up-and-down movement, and head side-to-side movement. Further, in the preferred embodiment, the invention includes a six-legged walking animatronic toy, powered by a rechargeable battery, and controlled via a radio-controlled transmitter and receiver pair.
Interchangeable outer body shells depicting various animals and insects may be clipped or easily attached to the top of the robot toy chassis. These shells may be made of rigid plastic materials, or of soft rubber-like materials for depicting various animals, including dinosaurs and the like. Furthermore, the shell may be a three-dimensionally blow-molded material having hard and soft portions for attachment and movement, wherein the hard portions may be attached to the chassis, while the soft portions may receive and cover mechanical components for depicting, for example, a dinosaur with a long neck. The servo motors attached to the legs to engage and cause movement are controlled by a standard transmitter/receiver pair interfaced with control electronics. The servo interface from the receiver includes inputs to a printed circuit board for controlling the individual motors attached to the various legs. A printed circuit board receives input information from the first and second servo motors, and controls individual movements via pulse width modulation position signals. Through this mechanism, the control electronics decode the servo signals and generate proportional direction control for the individual motors in communication with the various legs.
Computer software for the motor control input is disclosed in detail further herein below. Servo control and parameters can be mixed for all four quadrants through the computer software. Software for controlling the individual leg movements on both port and starboard sides of the chassis are further described.
Therefore, in accordance with the present invention, an inexpensive, effective and durable robotic toy has been disclosed and claimed which meets or exceeds all of the objects and advantages desired as detailed above.
While the invention has been described herein above, the preferred embodiments and best mode of the invention are described below with reference to the appended drawings and disclosure. The following is a brief description of the drawings and a detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . is a perspective view of a preferred embodiment in accordance with the present invention without its outer body shell;
FIG. 2 is a perspective detail of the head portion of the preferred embodiment;
FIG. 3A is an isometric exploded view of the drive wheel assembly;
FIG. 3B is an isometric view of the transmission housing of the present invention;
FIG. 3C is a top plan view of a drive arm;
FIG. 3D is a front elevational view of the fore-aft linkage between the drive gear and the corner legs;
FIG. 4A is a side elevational view of a corner leg;
FIG. 4B is a perspective view of a corner leg;
FIG. 4C is a top view of the corner leg of FIG. 4A, showing the bend of the leg;
FIG. 4D is a perspective view of the notched pivot for use with a corner leg;
FIG. 5A is a top plan view of the unbent middle leg;
FIG. 5B is the middle leg base plate before attachment to the middle leg;
FIG. 5C shows the relative placement of the middle leg base plate when attached to the middle leg;
FIG. 5D is a perspective view of the assembled middle leg;
FIG. 6 is a block diagram of the transmitter/receiver control board configuration;
FIG. 7A is a schematic diagram of the microcontrol unit for the animatron electronics;
FIG. 7B is a schematic diagram of the voltage regulator configuration;
FIG. 7C is a schematic diagram of the leg drive motor;
FIG. 7D is a schematic diagram of an H-bridge driver circuit,
FIG. 7E is a schematic diagram of another H-bridge driver circuit,
FIG. 8A is an illustration of the top of the printed circuit board showing the electrical connections;
FIG. 8B is an illustration of the bottom of the printed circuit board; and
FIG. 8C illustrates the relative placement of the electronic components on the printed circuit board.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, a preferred embodiment is shown in FIG. 1 as an animatronic toy generally denoted by the numeral 10 is shown including a main robot body chassis 12 , including a top plate 14 , a bottom plate 16 , side plates 18 on either side, and front and back walls 20 having a substantially longitudinal axis. Attached thereto in a pivotal and/or rotating fashion are corner legs 22 and middle legs 24 . Middle legs 24 are attached to robot body chassis 12 by a doubler 26 , including a standoff 28 engaged to a drive wheel, as disclosed in greater detail further herein below. An optional backbone, or middle plate, may be secured through the middle of the chassis 12 . Although a six-legged walking robot is illustrated, it must be understood that the most basic component of the animatronic toy of the present invention includes robot body chassis 12 and at least two corner legs and at least two middle legs. Furthermore, a single corner leg can be removed as well. One of ordinary skill in the art could remove or add additional legs without undue experimentation.
Looking still to FIG. 1, robot body chassis 12 includes indented portions for receiving upwardly extending alignment notches in the sidewalls 18 . Although any securement means which is suitable will work, the preferred method includes using a methylmethacrylate-based epoxy or other adhesive for securing the top and bottom plates 14 and 16 , respectively, to side plates and front and rear plates 18 and 20 , respectively. The upwardly extending alignment tabs on side plates 18 and front and rear plates 20 fit snuggly into the alignment indentations of the top plate 14 . As one can imagine, the final plate securement is done after the pivot extensions 32 are in place so as to hold the pivots for pivoting by top and bottom plates 14 and 16 , respectively. Side plate 18 includes a side plate extension 30 also fitting into an alignment indentation at the center of the sides of top plate 14 . A motor, not shown in this illustration, is mounted within the robot body chassis 12 as described in further detail with reference to FIGS. 3A-3D.
Looking again to FIG. 1, there is also shown a head portion attached to top plate 14 , including a top head plate 42 , head bottom plate 48 , the two being separated by standoffs 49 . The height of standoffs 49 is calculated to accommodate jaws 46 and jaw driver wheels 47 . The servo motor 44 is attached to top plate 42 by servo mounting block 40 . Servo motor 44 is in communication with jaw driver wheels 47 and creates an in-and-out motion when the drive wheel is moved back and forth by servo motor 44 . Optional eyes may be attached to the head by eye mount bracket 50 . An additional servo motor may be included for movement of the head of the robotic toy. As can be imagined, further servo motors may be included for up and down movement, and for other desired movements. These servos can receive information and direction in the same manner as the other servo motors.
Looking next to FIG. 2, a more detailed illustration of the robot head is shown, with a servo motor 44 for moving jaw pincers 46 . Head top plate 42 and head bottom plate 48 are spaced apart by standoffs 49 , which has a height adapted for receiving jaw pincers 46 and jaw driver wheels 47 therebetween. Servo 44 is in electrical communication with the electronic control board as described later herein below. When activated by a radio-controlled signal, servo 44 moves its jaw driver wheels 47 which is in communication with jaw pincer 46 , thereby moving jaws in and out. Jaw servo 44 may either be a single servo, or potentially may be multiple servos depending upon the actions which are desired. Eye mount bracket 50 acts as a housing for the servo, and is adapted to be attached to top head plate 42 while simultaneously securing standoffs 49 and bottom head plate 48 . As can be seen in FIG. 1, the top head plate 42 has an extension which can be secured to the bottom of top body plate 14 .
Looking next to FIGS. 3A through 3D, portions of the drive mechanism are illustrated and will be discussed. FIG. 3A illustrates the drive wheel 52 and drive shaft 54 with relative placement of standoff 56 . After assembly, the drive wheel assembly of FIG. 3A is fit through the openings in the transmission housing 58 shown in FIG. 3 B. As it is fit through one of the holes in the transmission housing 58 , drive shaft 54 is press fit onto a diametral pitch worm-drive gear (not shown) with a bore and a hub. Once the press fit is complete, and drive shaft 54 extends out the opposite side of transmission housing 58 , it is attached to a drive arm 60 as shown in FIG. 3 C. Drive arm 60 is press fit onto drive shaft 54 , taking care that the dihedral angle is 0°, substantially in phase, as defined from the hole through the drive arm 60 , across drive shaft 54 , and into standoff 28 . This guarantees the proper alignment of the legs before operation.
Another embodiment of the present invention is shown in FIG. 3D, wherein the fore-aft linkage 64 has a different configuration between the drive gear and corner legs 22 . In this diagram, as pivot 66 on drive wheel 52 goes around, it moves the fore-aft linkage 64 from side-to-side, which moves corner legs 22 in proper phase with middle leg 24 . Depending upon the application, the worm-drive gear may be preferably a 0.833″ diameter 48 diametral pitch worm gear drive, having a 0.188″ bore, or a 50:1 worm gear drive or a conventional spur gear drive train.
Although many small electric motors available at hobby shops across the country are suitable, the preferred motor was purchased from Sun Motor Industries, Ltd., of 106 King Fuk Street, San Po Kong, KLN, Hong Kong. The motor type is a small PMDC motor, with a 7.2 voltage DC constant rated voltage between motor terminals. The direction of rotation is counter-clockwise when viewed from the output shaft side of the motor. With such a motor, a small bushing may be press fit onto the motor shaft. Spacers, preferably about 5/1,000 thick, may be threaded onto the shaft of the motor to separate the motor housing from the shaft bushing. Thereafter, a worm-drive gear may be press fit onto the bushing. The motor assembly may then be attached to the transmission housing with pan head screws, inserted through the holes from the inside of the transmission housing. Once completed, the motor can be attached to the outside of the transmission housing with the worm and drive gears engaging. With the transmission being complete, and when power is supplied to the motor, the drive shaft spins about its axis and drives the standoff 28 and drive arm 54 .
Referring now to FIGS. 4A through 4C, there is shown an example of a corner leg such as corner leg 22 of FIG. 1. A corner leg in accordance with the present invention is generally denoted by numeral 70 , and includes structural member 72 , pivot doubler 74 , and pivot 76 . Like numerals will refer to like elements in FIGS. 4A-4C. In FIGS. 4B and 4C, the bend 78 of corner leg 70 can be seen. Although corner leg 70 may not incorporate a bend, such a bend adds to the stability and walking capability of the animatronic toy of the present invention. Referring back to FIG. 1, it can be seen that corner legs 22 are bent outwardly in a radial fashion from the center of the robot body chassis 12 , adding stability and functionality.
Looking to FIG. 4D, the pivot generally denoted by numeral 80 is shown with a pivot notch 82 and a pivot extension 84 . Pivot notch 82 is formed in pivot 80 to be received by and secured to corner leg 70 as illustrated in FIG. 4 A. Pivot extension 76 of FIG. 4A is shown having pivot extension 84 extending upwardly and downwardly therefrom. The radius of pivot extension 84 is smaller than the rest of pivot 76 so as to be received in pivot receptor holes 32 of top plate 14 and bottom plate 16 (not shown). The ball joint ends 62 of FIG. 3D are attached to the pivot doubler 74 of corner leg 70 and driven via drive wheel 52 .
Looking next to FIGS. 5A through 5D, there is shown a middle leg in accordance with the present invention generally denoted by the numeral 90 , including structural outer shell members 92 and a bend line 94 . Middle leg base plate 96 is illustrated in FIG. 5B showing standoff receptor slot 98 and middle leg securement receptor 100 . When assembling together the middle leg base plate of FIG. 5 B and the middle leg of FIG. 5A, the device of FIG. 5C results with base plate 96 and structural outer shell members 92 being illustrated. FIG. 5D is a perspective view of middle leg 92 with base plate . 96 attached thereto. Reviewing now FIG. 1 in the context of FIGS. 5A-5D, the middle leg is shown as attached to side plate upper extension 30 , through standoff 28 and secured by doubler 26 .
In FIG. 6, the transmitter/receiver control board configuration is shown as a block diagram wherein the control board is generally denoted by the numeral 110 , and includes a receiver 112 having four outputs, although any number of outputs are possible, and more or less are also envisioned by the inventors. In the event that there are additional servo motors for more or additional body parts, or directional movement needed, additional outputs would be required. Although there is a limit to the number of signals which can be generated by an off the shelf radio controlled transmitter, 10 channel transmitters are easy to purchase, and could be used for up/down head movement, side-to-side head/body/tail movements, depending upon the number of moving parts in the animatronic robot toy. In the event of a dinosaur animatron, there may be up/down and side/side movements of the head as well as independent neck and tail movements desired, for instance a brontosaurus or the like. Any type of insect, animal or robot is envisioned by the present invention. These possible animatrons may have fingers, toes, grippers, or any other moving parts which will require a servo motor to be activated by a channel on the transmitter. The addition of more inputs in the electronics of the present invention is known in the art and can be managed without undue experimentation.
In the preferred embodiment insect animatronic toy shown here in FIGS. 1-6, there is included a jaw servo 114 and a head servo 116 which receive their inputs from receiver outputs 1 and 2 . Leg drive motors 1 and 2 are controlled via the servo motor # 1 input 118 and servo motor # 2 input 120 through printed circuit board 122 . Leg drive motor # 1 124 is in electrical communication with one of the middle legs, as well as the corner legs via the fore-aft linkage as shown earlier. Likewise, leg drive motor # 2 126 operates the opposite side of the robotic toy middle leg, in conjunction with the corner legs also via a fore-aft linkage as described above.
FIGS. 7A through 7E illustrate the schematic diagram for the electronics. Included are the microcontrol unit of FIG. 7A, the voltage regulator of FIG. 7 B and the microprocessor as shown in FIG. 7C, as well the H-bridge driver circuits of FIGS. 7D and 7E which control the middle and corner legs of either side of the animatron. The microcontrol unit, voltage regulator, microprocessor and H-bridge driver circuits are standard electronic features selected for their applicability to the present embodiment. Of course, as additional servos would be added to the present invention to yield more animatron body part movements, more of these same controls would be added to make accommodations for those additional servos.
FIGS. 8A through 8C illustrate the component layout for the printed circuit board, including an illustration of the printed circuit board top (FIG. 8A) and the layout of the printed circuit board bottom (FIG. 8 B). The component layout is illustrated in FIG. 8 C and shows the relative placement of all of the resistors, MOSFETs, and all of the other transistor components. To operate the printed circuit board, computer software is employed for regulating the radio-controlled transceiver output into messages to control the servo motors, and thereby control the movements of the animatronic robot toy. The following computer software is illustrative of the software which may be used in order to operate the present invention, although as can be imagined by one of ordinary skill in the art, modifications and alterations can be made while still achieving the same purpose.
Therefore, in accordance with the present invention, there has been disclosed a robotic toy that meets or exceeds the objects and advantages described above. As one of ordinary skill in the art could envision many modifications, alterations and changes which could be made to the present invention, it must be noted that the scope of the claims is not to be limited by the recitation of the preferred embodiments above, but rather by the scope and breadth of the appended claims. | A radio controlled robotic toy having a main body chassis with at least two middle legs and at least two corner legs attached to the chassis, the legs being interconnected and driven by a linkage drive arm which is, in turn, operated by a radio-controlled electric motor which has computer electronics and software to control and cause movement of the legs for propelling the toy forward and backward. A six-legged walking animatronic robot toy is one of the preferred embodiments, including a moving head with jaw pincers, six moving legs, which yields a versatile, durable, speedy robot toy. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for determining the rotational speed of a part among a plurality of components included in a torsional vibration prone system and coupled with respect to their rotatability. The invention furthermore relates to a method for determining the slippage of a continuously variable transmission (CVT) and a method for controlling a CVT. Additionally the invention relates to a belt-driven conical-pulley transmission.
2. Description of the Related Art
Transmissions with continuously variable gear ratios, so-called continuously variable transmissions (CVT) (for example belt-driven conical-pulley transmissions, friction gear transmissions, etc), are increasingly being used in motor vehicles for reasons of comfort and reduced fuel consumption, which are actuated such by a control unit that depending on the activation of a gas pedal or a request that can be input by the driver on one hand, a satisfactory dynamic vehicle behavior results, and on the other hand driving occurs with low fuel consumption. FIG. 1 shows an example of a motor vehicle power train.
A motor vehicle has an engine 2 , which in the illustrated example is connected to a cardan shaft 8 by means of a clutch 4 and a transmission 6 . By means of a differential 10 , the cardan shaft drives the drive shafts 12 , which are non-rotatably connected to rear wheels 14 . The front wheels 16 are also shown in the illustrated example.
An electronic control unit 18 with a microprocessor and corresponding storage devices has inputs 20 that are connected to sensors. A sensor 22 for detecting the rotational speed of a transmission input shaft, a throttle valve sensor 24 , an engine speed sensor 26 , a wheel rotational speed sensor 28 , for example, and possibly further sensors are provided. Outputs of the control unit 18 are connected to a clutch-activating device 32 and a transmission-activating device 34 , as well as possibly with additional actuators of the power train, such as a throttle valve regulating unit, etc.
The transmission 6 is a CVT in the example represented, the activating device 34 of which is selected hydraulically. By means of a selector lever 36 a reverse travel step as well as several shifting programs can be activated.
Various problems arise in the practical operation of such power trains equipped with continuously variable transmissions, the solution of which is important for a comfortable and also reliable use of the CVT over extended operating periods. It is important, for example, for the control or regulation unit of the CVT to know the exact rotational speed of its input shaft. The ability to use an input rotational speed signal detected directly on the input shaft for control or regulating purposes, of for example the transmission ratio of the CVT, is limited since the input rotational speed can have oscillations that are present in the power train. Moreover it is required for various reasons to detect slippage of the CVT operating with frictional engagement to avert permanent damage. The gear ratio change is also subject to problems, especially in the case of belt-driven conical-pulley transmissions whose conical pulley pairs each have only one pressure chamber for pressing and adjustment.
The invention is based upon the objective of providing remedies for the aforementioned problems occurring in practice.
SUMMARY OF THE INVENTION
A solution to the task of determining the rotational speed of a part among a plurality of components contained in a torsional vibration prone system coupled with respect to their rotatability is achieved in that the rotational speed of a component arranged in or on a vibration node is measured, and the rotational speed of the part is calculated from the measured rotational speed and the transmission ratio between the component and the part.
When two components are arranged on two different sides of a vibration node, it is advantageous to use the average value of the rotational speeds of the components for calculating the rotational speed of the part.
Advantageously, the previously described method is used to determine the input rotational speed of a CVT contained in a power train of a motor vehicle, wherein the rotational speed of at least one wheel driven by the CVT is measured, and the input rotational speed is calculated from the transmission ratio of the CVT as well as possibly additional gear ratios between the output of the CVT and the wheel.
It is advantageous to measure the at least one wheel rotational speed as well as the input rotational speed and the output rotational speed of the CVT, and to use the transmission input rotational speed, which has been calculated based on the measured variables as well as possibly additional gear ratios between the output of the CVT and the wheel, for controlling and/or regulating power train components.
Advantageously, a measured transmission input rotational speed and the calculated one are used at a predetermined weighting level for controlling and/or regulating power train components.
It is useful if the weighting depends on the transmission ratio of the CVT.
One method for determining the slippage of a CVT is characterized in that the rate of change of the transmission ratio is determined, and in that the determined rate of change is compared to a predetermined rate of change that has been calculated from operating parameters of the CVT, and is ascertained as slippage when the determined rate of change deviates from the calculated rate of change beyond a predetermined level.
A maximum value of the calculated rate of change is advantageously proportional to 1/transmission ratio n , wherein n has a value between 1.5 and 2, and is ascertained as slippage when the determined rate of change exceeds the maximum value by a predetermined extent.
Another method for determining the slippage of a CVT is characterized in that at least one value of an acoustic parameter of the CVT that changes during slippage is stored. The acoustic parameter is measured and ascertained as slippage or imminent slippage when the measured parameter approaches the stored value in a predetermined fashion.
In an advantageous method for determining the slippage of a CVT, the timewise change of the output rotational speed of the transmission is determined and considered as at least imminent slippage when the timewise change of the output rotational speed exceeds a predetermined limit value.
Another advantageous method for determining the slippage of a CVT is characterized in that the timewise change of the force acting upon at least one of the wheel brakes of a vehicle equipped with the CVT is determined and is considered as at least imminent slippage when the timewise change of the force exceeds a predetermined value.
Advantageously, when slippage or imminent slippage is determined, a correcting variable of the CVT is adjusted such that the slippage is counteracted.
One method for controlling a CVT with a belt apparatus embracing two conical pulley pairs, wherein each conical pulley pair includes a single pressure chamber that is subject to fluid pressure for adjusting the contact pressure between the conical pulley pair and the belt apparatus, as well as for changing the transmission ratio of the CVT, is characterized in that the opening cross-section of a control valve contained in the fluid connecting lines of the pressure chambers is pre-controlled as a function of a difference between the fluid pressures present in the pressure chambers that is required for a predetermined rate of change of the transmission ratio.
A belt-driven conical-pulley transmission with two conical pulley pairs with two conical pulleys each (the distance between which is adjustable), a belt apparatus embracing the conical pulleys, a slide rail guiding one strand of the belt apparatus having on its end facing the other strand at least one rib extending parallel to the belt apparatus and increasing in thickness from the changing slide rails to the center. A tube is arranged in the area of the center of the rib and extending approximately perpendicular to a plane in which the belt apparatus runs, for the purpose of spraying fluid at least into the spaces between the conical pulleys of the conical pulley pairs, and is advantageously designed such that the rib on its surface facing the other strand includes a groove in the region of its center such that fluid sprayed out of the holes formed in the pipe passing through the groove reaches directly into the spaces between the conical pulleys.
The tube preferably contains at least one additional hole, from which the sprayed fluid directly reaches the other side.
The invention, which can be used in CVTs of different designs in the most diverse applications, is explained precisely below through examples.
Another advantageous embodiment of the method according to the invention relates to an evaluation of slippage events, which are detected and recorded or stored, for example in a control unit of the vehicle. Here, advantageously, the output of a slippage event is calculated, and depending on whether the output exceeds a predetermined limit an error entry occurs in the control unit. Tests have shown that not every slippage event leads to damage of the surface of the variable speed transmission discs or the rocker members of the chain. It has also been shown that damage at greater output does not necessarily lead to permanent damage, so that one or more limit values may be introduced, specifically with respect to the output of a slippage event as well as the frequency. Then, a corresponding assessment can take place in the vehicle directly or in a repair shop.
The time-dependent output P of a slippage event can be determined, for example according to
P=M×Δω
with the torque M present on the variable speed transmission, which can be determined, for example, from a pressure sensor for the contact pressure, and the differential angular speed Δω, which can be determined from the excess variable speed transmission ratio during a slippage event, between the slipping chain and the variable speed transmission.
Advantageously the maximum value of the output P determined this way is used for comparisons. Nonetheless, it may also be advantageous to use other variables, such as the output integral over time or statistically approximated values. The use of more exact methods than the evaluation of the maximum value can then occur when this is enabled by the processor power of the control unit.
It has been shown that a classification of the output levels of the slippage events in output ranges is advantageous. For example, output levels of up to 5.10 kW can be classified as minor damage and values above as severe damage. The number of slippage events can be recorded hereby in an error memory in accordance with this classification. An error counter can moreover be integrated such that the slippage events are weighted and added. A weighting of the errors can likewise occur by means of prior damage since a slippage event following damage can have a more serious effect than in the case of an undamaged transmission. The error counter can be dimensioned as a function of materials used in the transmissions and their characteristics such as variable speed transmission surfaces, of the output of the internal combustion engine, the gear oil that is used, and the like. When exceeding a limit in the error counter, the driver can receive a warning, for example in a single step or multiple steps from a simple display, regarding a request to drive to a repair shop, all the way to a forced shut-off of the vehicle to protect it from further-reaching damage.
BRIEF DESCRIPTION OF THE DRAWINGS
The attached figures show:
FIG. 1 a power train of a vehicle that has already been explained,
FIG. 2 curves to explain the early detection of slippage,
FIG. 3 a schematic diagram of a hydraulic selection of a belt-driven conical-pulley transmission,
FIG. 4 a graph showing pre-control characteristic lines for opening a valve,
FIG. 5 a side view of a belt-driven conical-pulley transmission, and
FIG. 6 a perspective view of a portion of a slide rail.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Methods are known in which the control of the transmission 6 , which is implemented in the control unit 18 or in decentralized additional control units, is based on the control of the input rotational speed of the transmission 6 . When the transmission input rotational speed is measured directly, the measurement signal contains jerking and harsh frequencies. These frequencies have an interfering effect on the transmission ratio control and obstruct a good adjustment of the command variables. In the extreme case feedback may occur, which influences the transmission ratio control. For this reason a signal that does not contain such vibrations, or only to a limited extent, is desirable. Strong filtration with high time constants, which leads to smoothing, is not permissible due to the clearly reduced dynamics.
A solution to this problem is in the measurement of a little vibration-prone rotational speed in a region that from a vibration-technical point forms a vibration node or is arranged close to such a node.
A power train with an engine, a transmission, and a vehicle wheel coupled with a street by means of a tire, wherein the components are connected to each other by means of shafts, represents a system capable of torsional vibration. Here, engine and transmission can vibrate against the vehicle mass, wherein the natural frequency is typically 7.1 Hertz and the rotational speed of the second order is 212 min −1 . In a different mode, the transmission vibrates between engine and vehicle mass, wherein the natural frequency is typically 19.8 Hertz and the rotational speed of the second order is 593 min −1 . In another mode, the wheel vibrates between transmission and vehicle mass. The natural frequency is then typically 47.9 Hertz and the rotational speed of the second order is 1,436 min −1 . In another mode the transmission input vibrates between motor and the remainder of the drive drain with a natural frequency of typically 71.4 Hertz, which corresponds to a rotational speed of the second order of 2,143 min −1 . In the case of a belt-driven conical-pulley transmission, the transmission ratio of the variable speed transmission (conical pulley pairs with belt apparatus) can be calculated from the measurement of the rotational speeds of the first conical pulley pair and the second conical pulley pair. Since the variable speed transmission from a vibration-technical point is very rigid, no jerking or harsh frequencies can be found in the calculated transmission ratio. The wheel rotational speed can advantageously be taken from an ABS control unit, to which rotational speed signals that are taken directly from the wheel are fed. It is important that the wheel rotational speed is recorded directly on the wheel and not on the transmission output, for example the beginning of a drive shaft 12 ( FIG. 1 ), since the rotational speed there contains jerking frequencies as well.
From the measured wheel rotational speed and the measured transmission ratio, as well as further gear ratios of the power train, in the illustrated example the gear ratio of the differential 10 , the transmission input rotational speed n b can be calculated from the following equation:
n b =i CVT ·i p ·n R ,
wherein i CVT is the transmission ratio of the CVT, i p the gear ratio of the differential, and n R the wheel rotational speed.
Of course, further gear ratios may be added when additional gear steps are located between the input disc pair of the CVT and its input shaft or in a different location.
Should a vibration node be located between two measuring areas, a vibration-free rotational speed signal can be generated by forming the average of the rotational speeds measured on both sides of the vibration node.
With the illustrated method the resistance of the gear ratio control towards power train vibrations is improved. The risk of influence during high control amplifications is clearly diminished. Through correspondingly higher permissible control amplification the control behavior can be improved.
The described method can be employed in all types of continuously variable transmissions, such as friction gears, belt-driven conical-pulley transmissions, for example in a geared neutral design, or in 12 structure, etc. In particular when changing their transmission ratio, such CVTs can be the source for generating jerking vibrations, can increase or dampen jerking vibrations, or be impaired in their own function by jerking vibrations.
The transmission ratio of a belt-driven conical-pulley transmission is adjusted by modifying the contact forces between the conical pulley pairs and the belt apparatus. This modification takes place by means of selection of hydraulic valves, which adjust corresponding pressure levels. Due to the complex adjusting behavior of belt transmissions (dependent upon rotational speed, torque, transmission ratio, and the contact forces themselves), control circuits are used in which, for example, an actual transmission ratio is calculated using the measured rotational speed, and a target transmission ratio is calculated using the current driving situation (speed, gas pedal actuation, etc.). Moreover control units are known in which the actual rotational speed of the transmission input is measured and a target rotational speed is determined based on the current driving situation. It is likewise known that these control units not only counteract the target/actual deviation very quickly, but in doing so also limit the actual change of the rotational speed through a target change of the rotational speed that corresponds to the current driving situation. This way, dynamic torque released during the adjustment process is limited while increasing driving comfort.
When the measured actual input rotational speed is not used directly as the actual input rotational speed of the transmission that is fed to the control unit, but instead, as described above, in a first step the transmission ratio of the transmission is calculated from the measured rotational speeds on the transmission input and on the transmission output, and then the rotational speed on the transmission input is calculated from this transmission ratio and the measured rotational speed of a driven wheel, this offers the advantage that no special adjustment of band-pass filters to the jerking frequency, which is dependent upon the transmission ratio, is required. By insulating and dampening the jerking vibrations, the comfort and control quality of the CVT control unit can be improved.
It is advantageous to further develop the previously described method such that an input rotational speed n E of the transmission, which is determined based on the following formula, is used as the input variable for a control unit used to adjust the transmission ratio of the CVT:
n E =α×n b +(1−α)× n g , wherein
n b is the input rotational speed calculated based on formula (1), n g the directly measured transmission input rotational speed n g , and α is a weighting factor. For α=0 only the measured transmission input rotational speed, which is subject to jerking, is used for control purposes. For α=1 the jerking-decoupled calculated input rotational speed n b is used. For α>1 the control unit creates a counter-coupling situation; for values of α<0, a regeneration is created by the control unit; for intermediate values “partial decoupling” arises. Depending on the control unit structure, through a suitable selection of α, hence the CVT adjustment can be modulated such that jerking vibrations are dampened.
According to the invention the control unit can be implemented with a fixed value of α. It is advantageous to make the value of α dependent upon the current transmission ratio since jerking vibrations can occur in isolated transmission ratio ranges. The required value of α can be deduced from the occurrence of jerking vibrations. The occurrence of jerking vibrations can be detected using filters.
Another problem recurring during the operation of continuously variable transmissions is that the pressure force between the frictionally engaged transmitting parts is not sufficient for transmitting the present torque so that slippage occurs, which can damage the transmission irreversibly. Slippage cannot be detected solely by evaluation of the speed differentials, as is common, for example, for clutches, since in a CVT due to the variable transmission ratio no fixed rotational speed ratio exists.
According to the invention slippage detection occurs with the aid of transmission ratio gradients. CVTs have a finite adjusting speed, i.e., for a change in the transmission ratio certain duration is required. When a transmission ratio change occurs at a greater rate of change than is possible in slippage-free operation, then slippage can be inferred.
Due to the physical properties of a continuously variable transmission based on the belt wrap principle, a maximum possible adjusting speed is not a constant, but rather depends on various parameters such as rotational speed, torque, and current transmission ratio. The strongest influence is provided by the current transmission ratio. Theoretically, it can be estimated that the maximum possible transmission ratio rate of change is proportional to 1/transmission ratio n . A value of n=2 is the maximum permissible value; suitable are values between 1.5 and 2, advantageous is 1.7. The permissible transmission ratio gradient is roughly the same in both adjusting directions.
In practice the maximum possible adjusting speed can be determined with a specified transmission ratio, for example at maximum underdrive. Due to the above-mentioned equation then, the maximum adjusting speed for the other transmission ratios can be calculated, wherein for the calculation of the current maximum adjusting speed, rotational speeds are used that are filtered prior to processing and rescanned with a different scanning frequency. Likewise, filters and rescanning algorithms can be used for the transmission ratio.
In the case of desired quick transmission ratio changes, adjusting gradients can be greater than a limit criterion. To prevent this from leading to undesired error entry in an error memory of the control unit, slippage monitoring is shut off in such situations. Slippage events with low adjusting gradients are not recorded with the described method. Slippage events with initially low gradients, however, typically reach adjusting speeds above the limit criterion when slippage is decreased.
As a modification of the described method, the change in the variable speed transmission ratio can be calculated in a mathematical model as a function of different operating parameters, such as the engine speed, the transmission input speed, the transmission ratio, the input torque, the temperature, and of axial forces. During operation these variables are known so that based on the mathematical model the adjustment dynamics di/dt can be calculated, wherein i is the transmission or variable speed transmission ratio. When an actually measured adjusting gradient deviates from the calculated rate of change beyond a predetermined level, then this points to slippage.
Advantageously, a lower limit can be defined for the adjustment dynamics, beneath which no evaluation occurs. This way it is prevented that in the case of only small expected adjusting gradients, erroneously slippage is detected due to possible numerical inaccuracies.
For reasons of calculation time, the mathematical model can be simplified in that only the main influencing parameters are taken into consideration. In the case of a belt-driven conical-pulley transmission, the adjustment dynamics primarily depend on the axial force and the variable speed transmission ratio. Axial force here should not be interpreted as the absolute force, but instead a force differential to the stationary operating point, which is described by the static zeta progression.
The following applies to this force differential:
F diff =F s1 −ξ×F s2 ;
wherein ξ designates the force ratio between the force on the first disc pair and the force on the second disc pair in the stationary operating state on a transmission ratio=F s1 — stat /F s2 — stat , wherein F s1 or F s2 represent the current force on the first or second disc pair, respectively.
The transmission ratio dependency can be described by means of an adjusting coefficient k i (which is dependent upon the transmission ratio i and the adjusting direction) so that the adjustment dynamics can be described with the following formula:
di/dt=k i ×( F s1 −ξ×F s2 ).
The value k i can be stored in a characteristic line for the upshift or back shift.
In a continuously variable transmission, what applied force will lead to what adjustment can be calculated or measured. When taking the adjustment dynamics known from (3) into consideration, it can be determined whether the adjustment occurs from the applied force differential or was caused by other events (slippage).
In order to make slippage detection even safer and reduce the influence of variations, a factor between 1.5 and 3, for example, can be inserted into formula (3) in order to define an upper limit, which must be exceeded to detect slippage. In this way, it is ensured that small fluctuations in the adjustment dynamics are not interpreted as slippage. It also ensures that slippage detection does not result when an error occurs or a high noise level exists when determining the actual gradient.
It has surprisingly turned out that another possibility for detecting slippage in a CVT, especially in a belt-driven conical-pulley transmission, is in its acoustic analysis. When a sensor having a sensitivity level in the frequency range of solid-borne sound and/or ultrasound is installed on the input or output shaft directly on the conical pulley, or in a region having a solid-borne sound transmitting connection to a conical pulley, a characteristic sound line or a characteristic sound field can be detected, which indicates the sound behavior of the variable speed transmission as a function of slippage at various transmitted torque levels and contact pressure levels as well as possibly different rotational speeds. When the acoustic behavior of the variable speed transmission is known in this fashion and stored, then a currently measured acoustic parameter, or its progression for example, can allow a conclusion of imminent slippage, and this slippage can be counteracted in a timely fashion by increasing the contact pressure so that damage can be prevented. Of course, when arranging the sound sensor directly on a conical pulley, familiar non-contact signal transmission techniques may be employed.
In the aforementioned method used to detect slippage, only very little time is available for taking counter-measures against the slippage (for example increasing the contact pressure of the conical pulleys in CVT's with electronic control), or it is too late to completely prevent slippage since a certain period of time is required for signal processing, for example signal filtration. It is therefore desirable to have information about imminent slippage events available already prior to the actual slippage event, so that, e.g., the contact pressure can be raised in time.
An advantageous method for the early detection of slippage involves determining the timewise change of the output rotational speed n Ab and evaluating it as an imminent slippage event when the timewise change value exceeds a predetermined limit. In numerous vehicle measurements, it has been found that a slippage event in CVTs is always preceded by a large value of the timewise derivation of the output rotational speed of the transmission, for example due to heavy braking or ABS braking. Due to a blocking or alternately slipping and not slipping wheel, high dynamic torque levels are introduced into the power train, leading to a slippage of the continuously variable transmission when no special countermeasures are taken. The advantage to using dn Ab /dt for detecting imminent slippage consists not only of the reaction time that is gained, but also of the fact that the limit is constant or at most depends on the type of its calculation. The calculation is advantageously performed such that the timewise change of the output rotational speed is averaged across two or three values that are determined within a very short time. This averaging is useful in order to reduce variations in the determined rate of change values. In the averaging, however, not too many values should be included, because then the time advantage of the described method is lost.
It is possible with this method to take timely countermeasures to avoid slippage events for CVT transmissions, the contact pressure of which, for example, is controlled completely electronically, or which apart from a torque sensor possess additional possibilities (electric motor, additional valves, etc.) for an electronically controlled adjustment. The method can also be employed for pre-control purposes in a slippage-controlled/slippage-regulated adjustment.
Moreover it is advantageous to combine the method for determining the timewise change of the output rotational speed with the method described further above for determining the rate of change or the timewise change of the transmission ratio of the CVT. The method, just as the other methods, can be employed in unbranched and power-branched transmissions.
Based on FIG. 2 , the benefits of the described method will be explained in the following: In FIG. 2 the time in the normal progression of a measurement is entered on the x-axis, i.e., the measurement results are shown for the time from 94.6 seconds to 96.4 seconds. The di/dt curve indicates the timewise change of the transmission ratio i of the CVT. The dn Ab /dt curve indicates the timewise change of the output rotational speed. The arrow marked with “brake active” indicates the beginning of a braking operation. The arrow marked with “ABS active” indicates the beginning of the actions of an ABS system. The horizontal double arrow marked with “slippage” indicates the time period during which the CVT slips when no counter-measures are taken. The line G 1 represents the limit, which must be exceeded by dn Ab /dt (absolute value) to be able to interpret the high delay in the output rotational speed as imminent slippage of the transmission. The line G 2 represents the limit, which must be exceeded by the timewise change of the transmission ratio i of the CVT to be able to interpret it as slippage of the continuously variable transmission.
As is apparent, dn Ab /dt exceeds the permissible limit G 1 already significantly prior to the occurrence of the slippage (and then again at the beginning of the slippage), while di/dt does not exceed the permissible limit G 2 until the transmission is already slipping. The time period of about 150 ms between the detection of the imminent slippage and the actual slippage is sufficient to avoid slippage through suitable counter-measures. Typical values for G 1 are for example between 1500 and 2000 RPM.
In a further method for the early detection of slippage in a continuously variable transmission, the rate of change of the braking pressure that is fed to a wheel is measured or, in the case of otherwise actuation of the brake, the braking force with which the brake is actuated. When the timewise change of one of these variables exceeds certain limits, similar measures for preventing slippage of the CVT can be taken as in the above-described method for determining the timewise change of the output rotational speed.
FIG. 3 shows a diagram of a hydraulic control of a CVT.
An input shaft 38 drives a first conical pulley pair 40 , which is connected in a frictionally engaged manner via a belt apparatus 42 to a second conical pulley pair 44 , which drives an output shaft 46 . For pressing purposes between the conical pulleys of each conical pulley pair and the belt apparatus 42 , and for adjusting the distance between the conical pulleys of each cone pulley pair or the transmission ratio of the belt-driven conical-pulley transmission, each conical pulley pair is assigned a pressure chamber 48 or 50 , which is connected to a pump 52 by means of pressure lines and valves.
In the embodiment according to FIG. 3 a valve A controls the pressure that is applied to the conical pulley pair 42 . A valve B controls the pressure that is applied to the input-side conical pulley pair 40 . Hence, the contact pressure can be controlled via the valve A, while adjustment of the transmission ratio occurs together with valve B. The valves are controlled by the control unit 18 ( FIG. 1 ).
The pressure that is built up in the pressure chambers 48 and 50 must be large enough at all times that a slippage-free condition is guaranteed between the belt apparatus 52 and the conical pulley pairs. At the same time pressure differentials must be adjusted between the disc pairs in order to adjust the respectively desired transmission ratio.
During the adjustment in the transmission ratio, also the volume of the respective pressure chamber changes due to the axial movement of a conical pulley. One problem resulting from this is that in the event of a change in pressure that is required due to a change in the transmitted torque, hardly any hydraulic fluid or oil is moved without a transmission ratio adjustment, while during an adjustment in the transmission ratio high volume currents flow, depending on the desired adjusting speed. Changes in pressure are this way associated with extraordinarily varying volume currents, or an extraordinarily varying segment behavior of the variable speed transmission.
The torque-dependent contract pressure is determined by a contact pressure rule in harmony with the respective variator. The adjusting pressure required for maintaining or adjusting a desired transmission ratio is supplied by a transmission ratio regulator. The adjusting pressures active in each of the pressure chambers allow a conclusion of the adjusting force based on the geometric conditions of the pressure chambers. The difference in the adjusting forces is a good measure for the developing adjusting speed and hence the required volume current.
If a pre-control unit is used parallel to the actual pressure regulator which opens the valve or valves more or less far as a function of the adjusting force differential, or the adjusting pressure differential, the variable segment behavior can be compensated.
Pre-control takes place in the control software. It pre-controls the pressure circuit in the sense of disturbance variable compensation.
Such pre-control is advantageous for all types of disc designs, which operate with only one pressure chamber per disc set or disc pair. It is also possible to implement an individual selection for each disc pair with one valve, respectively, which would be a modification to the embodiment according to FIG. 2 .
FIG. 4 illustrates a connection between the pre-control value and the adjusting force differential in scaled form. A negative adjusting force differential corresponds to a transmission ratio adjustment in the direction of underdrive, a positive one in the direction towards overdrive. The adjusting force differential is supplied by the transmission ratio regulator. A pre-control value can be determined from the characteristic lines, and in accordance with this value the pre-control valve can be opened. The characteristic line I is assigned to the disc pair 40 , the characteristic line II to the disc pair 42 .
For a flawless long-term function of a belt-driven conical-pulley transmission, good lubrication of the conical surfaces of the cone pulley pairs is important. FIGS. 5 and 6 show a solution to this problem:
According to FIG. 5 , which shows a side view of a belt-driven conical-pulley transmission with one conical pulley removed, the belt apparatus 42 wrapping around the two conical pulley pairs extends along a guide or slide rail 64 , which is seated in the familiar fashion, such that the undriven half runs resting safely on the slide rail 54 , regardless of the respective transmission ratio.
According to FIG. 6 , which shows a perspective view, the slide rail 54 comprises two slide plates connected via a bar 55 , these plates forming between them a guide channel 56 in which the belt apparatus, for example a metal chain, runs. To reinforce it mechanically, the slide rail 54 is equipped on its side facing the other half of the belt apparatus with a rib 58 , the thickness of which increases from the ends of the slide rail towards the center. At least in the region of the center, the rib 58 includes parallel to its longitudinal extension a groove 60 , the depth of which has its maximum in the region of the center of the rib 58 . In the region of the groove 60 the rib, as is shown in FIG. 6 , has a Y-shaped cross-section. A channel 64 , which accommodates a spraying pipe 66 (not shown in the perspective view) having spraying holes 68 (see small cross-sectional view) in the region of the groove 60 , extends transversely to the groove 60 through the rib 58 and through an additional reinforcement projection 62 . The groove 60 , or its base, is shaped such that oil that is sprayed from the spraying holes and serves the cooling and lubrication of the belt-driven conical-pulley transmission, reaches the spaces between the conical pulleys and onto the shafts of the conical pulley pairs, regardless of the respective transmission ratio. Advantageously additional holes are provided, from which oil is sprayed onto the opposite half.
Of course, the illustrated design can be modified in various ways as long as it is ensured that oil reaches the intermediate spaces between the conical pulley pairs continuously. For example, the channel 64 can be closed so that it forms directly the spraying tube, and spraying holes are incorporated in it. In this case a hydraulic line is connected to the channel.
The patent claims submitted with the application are formulation suggestions without prejudice for achieving farther-reaching patent protection. The applicant reserves the right to claim additional feature combinations that have so far only been disclosed in the description and/or drawings.
References used in the dependent claims point to the further development of the object of the main claim by features of the respective dependent claim. They should not be interpreted as a waiver for obtaining independent object-related protection for the feature combinations of the referenced dependent claims.
Since the objects of the dependent claims with respect to the state of the art can form their own and independent inventions on the priority date, the applicant reserves the right to make them the object of independent claims or declarations of division, having a form that is independent from the objects of the preceding dependent claims.
The embodiments should not be interpreted as a limitation of the invention. Rather, within the framework of the present disclosure numerous changes and modifications are possible, especially such variations, elements, and combinations, and/or materials, that are obvious to those skilled in the art with respect to the solution of the task at hand, for example by combining or modifying individual features and/or elements or procedural steps described in connection with the general description and embodiments, as well as contained in the drawings, and by features that can be combined into a novel object or novel procedural steps or procedural step sequences, also to the extent that they relate to manufacturing, testing, and operating methods. | The input rotational speed of a belt-driven conical-pulley transmission is determined by measuring a wheel rotational speed and the transmission ratio and by calculating the input rotational speed therefrom. In order to ascertain the slipping of a CVT transmission, the rate of change in the transmission ratio is drawn upon, or an acoustic parameter of the transmission is used. In the fluid control system, a valve is used whose opening cross-section is controlled according to the one differential pressure. In order to oil the conical discs, injection holes of an injection tube are used that passes through a slot provided in a slide rail resting against a strand of a flexible torque transmitting member of a conical disc flexible drive. | 5 |
TECHNICAL FIELD
The present invention relates to a long magnetic circuit.
BACKGROUND ART
Unexamined Japanese Patent Application Kokai Publication No. H10-47651 (refer to Patent Literature 1) discloses a long magnetic circuit in which a plurality of permanent magnets are arranged with a space between so that surfaces having the same magnetic polarity face each other, and a plurality of magnetic yokes are inserted between each of the permanent magnets so that the permanent magnets and magnetic yokes come in close contact.
Unexamined Japanese Patent Application Kokai Publication No. H09-159068 (refer to Patent Literature 2) discloses a sandwiched-type magnetic circuit in which both sides in the magnetic pole direction of a permanent magnet are sandwiched between yokes, and is a magnetic adhesion member for pipelines that is used in a magnetic pipeline hoist that adheres to a solid magnetic body when hoisting and supporting pipeline.
CITATION LIST
Patent Literature
Patent Literature 1: Unexamined Japanese Patent Application Kokai Publication No. H 10-47651
Patent Literature 2: Unexamined Japanese Patent Application Kokai Publication No. H09-159068
SUMMARY OF INVENTION
Technical Problem
In the invention disclosed in Patent Literature 1, a plurality of permanent magnets are arranged with a space between so that surfaces having the same magnetic polarity face each other, so there was a problem in that the magnetic field intensity distribution in the length direction was not uniform.
In the invention disclosed in Patent Literature 2, by making a sandwiched type magnetic circuit in which both sides in the magnetic pole direction of a permanent magnet are sandwiched between yokes, the magnetic field intensity of the magnetic circuit is strengthened, however, in order to form a long sandwiched type magnetic circuit, a long permanent magnet is necessary, and there was a problem in that processing a long permanent magnet is difficult and the long permanent magnet breaks easily.
In order to solve the problems above, the object of the present disclosure is to obtain a long magnetic circuit that uses a plurality of short magnets that are arranged in an array, and that has a uniform magnetic flux density distribution in the array direction.
Solution to Problem
The magnetic circuit of this invention comprises: a plurality of magnets that are arranged in an array; and a pair of yokes that are provided so as to sandwich the plurality of magnets; wherein the plurality of magnets are arranged respectively with a predetermined gap or less between the magnets in the arrangement direction of the array, and have one magnetic pole that is on the side of one of the pair of yokes, and the other magnetic pole on the side of the other of the pair of yokes.
Advantageous Effects of Invention
The magnetic circuit of this invention comprises a plurality of magnets that are arranged in an array and spaced apart by a predetermined gap or less, and yokes that are provided on the plurality of magnets, so it is possible to obtain uniform magnetic flux density in the arrangement direction of the array even when adjacent magnets are not in close contact with each other.
Moreover, it is possible to use magnets having a short length and high production yield, so productivity is improved.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side view of a magnetic circuit of a first embodiment of the present disclosure;
FIG. 2 is a perspective view illustrating a magnetic circuit of a first embodiment of the present disclosure;
FIG. 3A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit of a first embodiment of the present disclosure;
FIG. 3B is a drawing for explaining the installation position of a measurement device;
FIG. 4 is a side view of a magnetic circuit with the yokes removed from a magnetic circuit of a first embodiment of the present disclosure;
FIG. 5A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit with the yokes removed from a magnetic circuit of a first embodiment of the present disclosure;
FIG. 5B is a drawing for explaining the installation position of a measurement device;
FIG. 6 is a side view of another example of a magnetic circuit of a first embodiment of the present disclosure;
FIG. 7 is a perspective view illustrating a magnetic circuit of a second embodiment of the present disclosure;
FIG. 8 is a side view illustrating a magnetic circuit of a third embodiment of the present disclosure;
FIG. 9 is a perspective view illustrating a magnetic circuit of a third embodiment of the present disclosure;
FIG. 10A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit of a third embodiment of the present disclosure;
FIG. 10B is a drawing for explaining the installation position of a measurement device;
FIG. 11A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit with the yokes removed from a magnetic circuit of a third embodiment of the present disclosure;
FIG. 11B is a drawing for explaining the installation position of a measurement device;
FIG. 12 is a side view illustrating another example of a magnetic circuit of a third embodiment of the present disclosure;
FIG. 13 is a side view illustrating a magnetic circuit of a fourth embodiment of the present disclosure;
FIG. 14 is a perspective view illustrating a magnetic circuit of a fourth embodiment of the present disclosure;
FIG. 15A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit of a fourth embodiment of the present disclosure;
FIG. 15B is a drawing for explaining the installation position of a measurement device;
FIG. 16A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit with the yokes removed from a magnetic circuit of a fourth embodiment of the present disclosure;
FIG. 16B is a drawing for explaining the installation position of a measurement device;
FIG. 17A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit of a fourth embodiment of the present disclosure;
FIG. 17B is a drawing for explaining the installation position of a measurement device;
FIG. 18A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit with the yokes removed from a magnetic circuit of a fourth embodiment of the present disclosure; and
FIG. 18B is a drawing for explaining the installation position of a measurement device.
DESCRIPTION OF EMBODIMENTS
Embodiment 1
A first embodiment of the present disclosure will be explained using the drawings. FIG. 1 is a side view illustrating a magnetic circuit of a first embodiment of the present disclosure, and FIG. 2 is a perspective view illustrating a magnetic circuit of a first embodiment of the present disclosure. In FIG. 1 and FIG. 2, 1 is a magnet body, 1 a and 1 b are magnets, and 2 a and 2 b are ferrous-based metal yokes. The magnet body 1 comprises magnet 1 a and magnet 1 b . Magnet 1 a and magnet 1 b are arranged so that the magnetic poles are in the direction where the yoke 2 a and yoke 2 b are positioned respectively. Moreover, magnet 1 a and magnet 1 b are arranged so that the same magnetic poles are facing the same direction. For example, the magnet 1 a and magnet 1 b are arranged so that the N poles are on the side where the yoke 2 a is located, and the S poles are on the side where the yoke 2 b is located. Furthermore, the magnet 1 a and magnet 1 b are arranged in an array in the axial direction. The magnet 1 a and magnet 1 b are arranged so that there is a 2 mm gap 3 between the magnets, for example. A ferrous-based metal yoke 2 a is provided in the magnetic circuit so as to span across the N pole of the magnet 1 a and the N pole of the magnet 1 b . A ferrous-based metal yoke 2 b is provided in the magnetic circuit so as to span across the S pole of the magnet 1 a and the S pole of the magnet 1 b . The yoke 2 a and yoke 2 b are arranged so as to sandwich the magnet 1 a and magnet 1 b to form one body. The gap 3 between magnets can be an empty gap, or can be filled with a resin such as an adhesive and the like.
The operation of the magnetic circuit will be explained using FIG. 3A and FIG. 3B . FIG. 3A is a drawing illustrating the magnetic flux density distribution of the magnetic circuit of the first embodiment of the present disclosure. The same reference numbers are used for components that are the same as in FIG. 1 , and explanations of those components will be omitted. In FIG. 3A, 5 is a graph illustrating the magnetic flux density distribution in the axial direction of the magnetic circuit at a position (position of a measurement device 4 that is illustrated in FIG. 3B ) separated 2.5 mm from the surface of the magnets of the magnetic circuit in a direction that is orthogonal to the direction of the magnetic poles and the arrangement direction of the array.
In the graph 5 illustrated in FIG. 3A , the vertical axis is the magnetic flux density, and the horizontal axis is the length in the axial direction of the magnetic circuit. The dashed lines in FIG. 3A indicate the correspondence between the horizontal axis in the graph 5 and the magnetic circuit (in other words, the magnetic circuit is positioned in the permanent magnet range illustrated in the graph 5 ). In the graph 5 , the magnetic flux density distribution is illustrated for the cases in which the gap 3 between the magnet 1 a and the magnet 1 b is changed from 0 mm to 5 mm. Even when the gap 3 between magnets becomes large, the magnetic flux density around the gap 3 between magnets does not fluctuate much. Furthermore, up to 3 mm of a gap 3 between magnets, the magnetic flux density around the gap 3 between magnets hardly fluctuates. Therefore, uniform magnetic flux density is obtained over the entire length in the axial direction of the magnetic circuit.
In order to explain the effect of the first embodiment of the present disclosure, the embodiment will be explained by comparing it with the case in which the yokes 2 a, 2 b are not provided. FIG. 4 is a side view of a magnetic circuit from which the yokes 2 a, 2 b have been removed from the magnetic circuit of the first embodiment of the present disclosure. In FIG. 4 , the same reference numbers are used for components that are the same as those in FIG. 1 , and an explanation of those components is omitted.
The operation of the magnetic circuit will be explained using FIG. 5A and FIG. 5B . FIG. 5A is a drawing illustrating the magnetic flux density distribution of a magnetic circuit from which the yokes have been removed from the magnetic circuit of the first embodiment of the present disclosure. In FIG. 5A and FIG. 5B , the same reference numbers will be used for components that are the same as those in FIGS. 3A and 3B , and explanations of those components will be omitted. In FIG. 5A, 51 is a graph illustrating the magnetic flux density distribution along the axial direction of the magnetic circuit at a position (position of a measurement device 4 that is illustrated in FIG. 5B ) separated 2.5 mm from the surface of the magnets of the magnetic circuit in a direction that is orthogonal to the direction of the magnetic poles and the arrangement direction of the array.
In the graph 51 illustrated in FIG. 5A , the vertical axis is the magnetic flux density, and the horizontal axis is the length direction in the axial direction of the magnetic circuit. The dashed lines in FIG. 5A indicate the correspondence between the horizontal axis in the graph 51 and the magnetic circuit. In the graph 51 , the magnetic flux density distribution is illustrated for the cases in which the gap 3 between the magnet 1 a and the magnet 1 b is changed from 0 mm to 5 mm. As the gap 3 between magnets becomes larger, the magnetic flux density around the gap 3 between magnets fluctuates even more. It can be seen that as the magnet 1 a and the magnet 1 b become separated, the magnetic flux density around the gap 3 between magnets fluctuates a large amount.
When the yoke 2 a and the yoke 2 b are not provided, a uniform magnetic flux density around the gap 3 between magnets cannot be maintained as the magnet 1 a and the magnet 1 b become separated.
As described above, with the magnetic circuit of the first embodiment of the present disclosure, even when the magnet 1 a and the magnet 1 b are not allowed to come in contact, as illustrated in FIGS. 3A, 3B , it is possible to suppress fluctuation of the magnetic flux density that occurs between the magnet 1 a and the magnet 1 b , as illustrated in FIGS. 5A, 5B , by providing ferrous-based metal yokes 2 a and 2 b that span across the magnet 1 a and magnet 1 b . As a result, it is possible to obtain a magnetic flux density that is uniform in the axial direction.
In the first embodiment of the present disclosure, the case was explained in which two magnets were arranged in an array in the axial direction, however, as illustrated in FIG. 6 , it is also possible to arrange three or more magnets in an array in the axial direction, and to provide yokes along all of the arranged magnets. The same effect as in the case of the magnetic circuit described above will be obtained.
Embodiment 2
A second embodiment of the present disclosure will be explained using the drawings. FIG. 7 is a perspective view of a magnetic circuit of the second embodiment of the present disclosure. In FIG. 7 , the same reference numbers are used for components that are the same as in FIG. 2 , and explanations of those components will be omitted.
The magnetic circuit of the second embodiment of the present disclosure is shaped such that the yokes 2 a, 2 b protrude from the flat surfaces (surface A(a) and surface A(b)) that are surrounded in the axial direction and magnetic pole direction of the magnets 1 a , 1 b.
The magnetic force lines that are emitted from the magnets 1 a , 1 b are concentrated in the yokes 2 a, 2 b by way of the contact surfaces between the magnets 1 a , 1 b and the yokes 2 a, 2 b. The concentrated magnetic force lines make a loop from the N pole on the tip-end section of the protruding section of the yoke 2 a toward the S pole on the tip-end section of the protruding section of the yoke 2 b.
By making the yokes 2 a, 2 b protrude out from the magnets 1 a , 1 b , the magnetic flux is concentrated in the yokes 2 a, 2 b, which is effective in making the magnetic flux density stronger.
Embodiment 3
A third embodiment of the present disclosure will be explained with reference to the drawings. FIG. 8 is a side view illustrating a magnetic circuit of the third embodiment of the present disclosure. Moreover, FIG. 9 is a perspective view illustrating the magnetic circuit of the third embodiment of the present disclosure.
The magnetic circuit of the third embodiment of the present disclosure is a magnetic circuit in which a ferrous-based metal yoke 2 c is provided on one magnetic pole side (for example the N pole side). The other construction is the same as that of the magnetic circuit of the first embodiment. In the figures, the yoke 2 c is provided on the N pole side, however, it is also possible to provide the yoke 2 c on the S pole side instead of the N pole side.
Next, the uniformity of the magnetic flux density of this magnetic circuit will be explained using FIG. 10A , FIG. 10B , FIG. 11A and FIG. 11B .
The graph 6 illustrated in FIG. 10A is a graph illustrating the magnetic flux density distribution at a position that is separated 2 mm from the surface of the N pole side of the magnets with the yoke 2 c in between (in other words, the position where the measurement device 4 illustrated in FIG. 10A and FIG. 10B is located). The dashed lines in FIG. 10A indicate the correlation between the horizontal axis of graph 6 and the magnetic circuit. Graph 6 illustrates the measurement results when the gap 3 between magnets is changed in 1 mm units from 0 mm to 5 mm. The vertical axis is the magnetic flux density, and the horizontal axis is the length in the axial direction of the magnetic circuit. It can be seen that even when the gap 3 between magnets increases, the magnetic flux density around the gap 3 between magnets does not change much. From this, it can also be seen that even though a yoke 2 c is provided on only one magnetic pole side, uniform magnetic flux density can be obtained over the entire length in the axial direction.
For a comparison, the yoke 2 c was removed from the construction described above and the magnetic flux density was measured. The graph 61 illustrated in FIG. 11A is a graph illustrating the results of measuring the magnetic flux density under the same conditions as in the graph 6 illustrated in FIG. 10A (in other words, the results of measuring the magnetic flux density at the position where the measurement device 4 illustrated in FIG. 11A and FIG. 11B is located). The dashed lines in FIG. 11A indicate the correlation between the horizontal axis of graph 61 and the magnetic circuit. As in graph 6 , graph 61 illustrates the measurement results when the gap 3 between magnets is changed in 1 mm units from 0 mm to 5 mm. It can be seen that as the gap 3 between magnets increases, the magnetic flux density around the gap 3 between magnets greatly changes. Therefore, it can be seen that when a yoke 2 c is not provided, uniform magnetic flux density cannot be maintained around the gap 3 between magnets.
As described above, with the magnetic circuit of the third embodiment of the present disclosure, even though a ferrous-based metal yoke 2 c is provided on only one magnetic pole side, it is possible to obtain uniform magnetic flux density in the axial direction as in the case of the magnetic circuit of the first embodiment.
In the third embodiment, the case of arranging two magnets in an array was explained, however, the number of magnets arranged is not limited to two. For example, as illustrated in FIG. 12 , it is also possible to arrange three magnets in an array, and to provide a yoke that spans across all of the arranged magnets. Naturally, construction is also possible in which four or more magnets are arranged. Even in the case where three or more magnets are arranged in an array, the same effect as when two magnets are arranged can be obtained.
Embodiment 4
A fourth embodiment of the present disclosure will be explained with reference to the drawings. FIG. 13 is a side view illustrating a magnetic circuit of the fourth embodiment of the present disclosure. Moreover, FIG. 14 is a perspective view illustrating the magnetic circuit of the fourth embodiment of the present disclosure.
In the magnetic circuit of the fourth embodiment of the present disclosure, a ferrous-based metal plate 9 is provided. The metal plate 9 is arranged parallel to the arrangement direction (arrangement direction of the array) of the magnet 1 a and the magnet 1 b . Moreover, the metal plate 9 is located at a position that is separated from the surface of the outside yoke 2 b by a distance d so that an object 10 is positioned between the yoke 2 b and the metal plate 9 . The object 10 is an object to which the magnetic effect of the magnetic circuit will be applied. As illustrated in FIG. 14 , the width w 2 of the yoke 2 a and the yoke 2 b is shorter than the width w 1 of the magnet 1 a and the magnet 1 b . The other construction is the same as that of the magnetic circuit of the first embodiment.
In the figures, the metal plate 9 is provided on the S pole side, however, construction is also possible in which the metal plate 9 is provided on the N pole side instead of the S pole side. Moreover, construction is also possible in which a metal plate 9 is provided on both the N pole side and the S pole side.
Next, the uniformity of the magnetic flux density of this magnetic circuit will be explained using FIG. 15A , FIG. 15B , FIG. 16A and FIG. 16B .
The graph 7 illustrated in FIG. 15A is a graph illustrating the magnetic flux density distribution at a position that is separated 2.5 mm from the surface of the S pole side of the magnets with the yoke 2 b in between (in other words, the position where the measurement device 4 illustrated in FIG. 15A and FIG. 15B is located). The dashed lines in FIG. 15A indicate the correlation between the horizontal axis of graph 7 and the magnetic circuit. Graph 7 illustrates the measurement results when the gap 3 between magnets is changed in 1 mm units from 0 mm to 5 mm. The vertical axis is the magnetic flux density, and the horizontal axis is the length in the axial direction of the magnetic circuit. It can be seen that even when the gap 3 between magnets increases, the magnetic flux density around the gap 3 between magnets does not change much.
For comparison, the yoke 2 a and the yoke 2 b were removed from the construction above and the magnetic flux density was measured. The graph 71 illustrated in FIG. 16A is a graph illustrating the results of measuring the magnetic flux density under the same conditions as the graph 7 illustrated in FIG. 15A (in other words, the results of measuring the magnetic flux at the position where the measurement device 4 illustrated in FIG. 16A is located). The dashed lines in FIG. 16A indicate the correlation between the horizontal axis of graph 71 and the magnetic circuit. As in graph 7 , graph 71 illustrates the measurement results when the gap 3 between magnets is changed in 1 mm units from 0 mm to 5 mm. It can be seen that as the gap 3 between magnets increases, the magnetic flux density around the gap 3 between magnets greatly changes. Therefore, it can be seen that when the yoke 2 a and the yoke 2 b are not provided, uniformity of magnetic flux density cannot be maintained around the gap 3 between magnets.
In order to illustrate the uniformity of the magnetic flux density of this magnetic circuit, the magnetic flux density was also measured at other locations. The measurement results are explained using FIG. 17A , FIG. 17B , FIG. 18A and FIG. 18B .
FIG. 17A illustrates the results of measuring the magnetic flux density using construction that is the same as that of the magnetic circuit illustrated in FIG. 15A . The graph 8 illustrated in FIG. 17A is a graph illustrating the magnetic flux density distribution at a position that is separated 2.5 mm from the side surface of the magnet 1 a and the magnet 1 b (in other words, the position where the measurement device 4 illustrated in FIG. 17A and FIG. 17B is located). The dashed lines in FIG. 17A indicate the correlation between the horizontal axis of graph 8 and the magnetic circuit. Graph 8 illustrates the measurement results when the gap 3 between magnets is changed in 1 mm units from 0 mm to 5 mm. It can be seen that even when the gap 3 between magnets increases, the magnetic flux density around the gap 3 between magnets does not change much.
FIG. 18A is a drawing illustrating the measurement results when using construction that is the same as that of the magnetic circuit illustrated in FIG. 16A (in other words, a magnetic circuit that is obtained by removing the yoke 2 a and yoke 2 b from the magnetic circuit illustrated in FIG. 17A ) and only the position of the measurement device 4 is changed. The graph 81 illustrated in FIG. 18A is a graph illustrating the results of measuring the magnetic flux density of a magnetic circuit under the same conditions as the graph 8 illustrated in FIG. 17A (in other words, is a graph illustrating the measurement results of measuring the magnetic flux density at the position where the measurement device 4 illustrated in FIG. 18A and FIG. 18B is located). The dashed lines in FIG. 18A indicate the correlation between the horizontal axis of graph 81 and the magnetic circuit. As in graph 8 , graph 81 illustrates the measurement results when the gap 3 between magnets is changed in 1 mm units from 0 mm to 5 mm. Even though not as large as that of the graph 71 illustrated in FIG. 16A , it can be seen that as the gap 3 between magnets increases, the magnetic flux density around the gap 3 between magnets greatly changes.
As described above, with the magnetic circuit of the fourth embodiment of the present disclosure, it is possible to obtain uniform magnetic flux density along the axial direction.
The embodiments above can undergo various changes or modifications within the range of the scope of the present disclosure. The embodiments described above are for explaining the present disclosure, and are not intended to limit the range of the invention. The range of the present disclosure is as disclosed in the accompanying claims rather than in the embodiments. Various changes and modifications that are within the range disclosed in the claims or that are within a range that is equivalent to the claims of the invention are also included within the range of the present disclosure.
This specification claims priority over Japanese Patent Application No. 2012-016847, including the description, claims, drawings and abstract, as filed on Jan. 30, 2012. This original Patent Application is included in its entirety in this specification by reference.
REFERENCE SIGNS LIST
1 Magnet body
1 a , 1 b , 1 c Magnet
2 a, 2 b, 2 c Yoke
3 , 3 a, 3 b Gap between magnets
4 Measurement device
5 , 6 , 7 , 8 , 51 , 61 , 71 , 81 Graph
9 Metal plate
10 Object | A magnetic circuit, provided with a short magnet and short magnet that are arranged in an array, and a yoke and a yoke provided so as to sandwich the short magnet and short magnet. The short magnet and short magnet, are arranged, that have a space between them that is a predetermined gap or less in the arrangement direction of the array respectively. In addition, the short magnet and short magnet are arranged so that one magnetic pole is located on the side toward one of the pair of yokes and, and the other magnetic pole is located on the side toward the other yoke. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a flashlight. More specifically, it relates to an extremely durable and long lasting flashlight utilizing a light emitting diode (hereinafter “LED”) light source in combination with a pair of paraboloid reflectors making the flashlight particularly useful for police, fire, rescue and emergency services workers and military personnel.
2. Description of the Prior Art
A variety of prior art flashlights have been proposed.
Matthews, U.S. Pat. No. 6,386,730, discloses a flashlight having a head with two merged yet independent lamp/reflector systems. While Matthews teaches the provision of two reflectors, both reflectors are simply used to independently focus light from two light sources into the forwardly directed beam configurations.
McDermott, U.S. Pat. No. 5,894,196, discloses a compact lighting device including a light concentrating reflector directing light emitted by a light source toward a curved light refracting surface where it is refracted and thereby redirected. McDermott teaches the generation of substantially elliptical patterns of light.
Sharrah et al., U.S. Pat. No. 5,871,272, discloses a flashlight having a lamp head including a reflector having a major paraboloid reflective surface and a minor reflective paraboloid surface not interacting on the same light source.
Matthews et al., U.S. Pat. No. 6,046,574, discloses a flashlight having a first cell or set of cells (batteries) arranged in a first pattern and alternatively a second cell or set of cells (batteries) arranged in a second pattern with switching between or interconnecting the two cells or sets of cells disclosed. An on off switch is provided which includes a push button switch and a rotary switch that blocks the on off push button switch. A momentary on switching function is provided. A flashlight beam is cast with a first lamp and reflector and an alternative second lamp and reflector assembly is substituted for the first lamp and reflector to provide a different configuration of beam illumination.
Lebens et al., U.S. Pat. No. 6,095,661, discloses an LED flashlight which includes a control circuit that selectively applies power from a source of electric power to the LEDs, thus maintaining or controlling the light output level of the LEDs at a generally constant level as the charge on the battery cell varies.
Copeland, U.S. Pat. No. 5,015,918, discloses a bicycle lighting system utilizing red LEDs which includes a means to maintain the charging current at a relatively constant average value thus supplying a constant current and power to the LEDs.
Krietzman, U.S. Pat. No. 5,909,062, provides an LED flashlight which has a second or redundant battery supply which nests in-line in a tubular or oval housing.
Sinclair, U.S. Pat. No. 6,331,062, discloses a portable electric LED flashlight having a light source in the form of an LED with a high internal resistance. The use of such a high resistance element, while initial costs are low, is undesirable as it unnecessarily wastes battery power.
There remains a need for a high intensity light LED powered flashlight which is highly efficient and long lasting for use by fire fighting personnel, law enforcement personnel, EMS personnel and civilians and the like.
SUMMARY OF THE INVENTION
The present invention provides a flashlight which, in its preferred form, is intended to run continuously over a 10 hour period or more on one set of “D” cells or over 20 hours on 2 sets. It will be obvious that any size of cells can be utilized and it currently contemplated that a smaller version of the flashlight which utilizes 2 sets of “AA” cells would be of particular utility although, with smaller cells, the number of hours of continuous illumination without replacement of cells would be significantly fewer. A second microprocessor controlled circuit allows the flashlight to switch from one set of cells to the other, which provides uninterrupted use. An indicator is provided to show which set of cells is in use and, preferably, to also show the degree to which such cells have been drained. A new set of cells can replace the drained set while the flashlight is in use. A microprocessor circuit also allows the light to remain bright white throughout the life of the cells. The flashlight uses a pair of paraboloid reflectors that work together to focus the light into a concentrated beam. The housing of the flashlight is made from a high strength polycarbonate material. An emergency strobe light is preferably imbedded into the handle of the flashlight. A sliding thumb switch activates the LED or the strobe. The switch is hermetically sealed to enable the unit to be water resistant. The flashlight can be placed in several positions using a multi-position stand which is mounted to the bottom of the housing. The multi-position stand also features a retractable stainless steel split ring to allow the user to attach the flashlight to many devices including the key ring holders that many of the above personnel utilize. The split ring may be used in conjunction with the multi-position stand to suspend the flashlight in a variety of positions. The flashlight is preferably sealed with o-rings making the flashlight water resistant.
The present invention has a number of specific objects and features including but not limited to the following:
Presently, a single one watt bright white LED light source is preferred. A five watt bright white LED light source is also contemplated.
The LED light source is intended to have a long operating life of up to 100,000 hours.
It is an object of the invention to provide a flashlight which provides non-dimming light throughout the life of the cells.
It is an object of the invention to utilize two paraboloid focusing reflectors to direct a concentrated light beam.
It is an object of the invention to utilize two sets of cells with one working set and one auto switched back-up set.
It is an object of the present invention to provide the switching from one cell set to the other with a microprocessor controlled circuit.
It is also an object of the invention to utilize a second microprocessor controlled circuit to maintain a generally constant LED current with thermal input over a temperature range of approximately −40° to 120° F.
It is an object of the invention to allow for the replacement of one set of cells without interruption of the light.
It is an object of the invention to provide an emergency strobe light imbedded in the housing or the handle of the flashlight.
It is an object of the invention to provide a hermetically sealed switch.
It is an object of the invention to provide a multi-position stand which is pivotally mounted for 180 degrees of rotation.
And it is an object of the invention to provide a retractable stainless steel split ring for belt attachment or the like.
The flashlight of the present invention preferably comprises a housing adapted to receive at least one cell and having a transparent lens on a forward end thereof; an LED light source adapted to be connected to said at least one cell, said LED light source when energized emitting rays of light in a generally hemispherical light pattern; collimating optics positioned adjacent said LED to direct (by refraction or reflection or both) said rays of light into a first generally cylindrical pattern of light with light rays being generally parallel to one another and directed in a forward direction along an optical axis; a first paraboloid reflector having a concave reflective surface positioned within said housing and preferably attached to an inner side of said transparent lens, said first paraboloid reflector having a focus point positioned on said optical axis and positioned to receive rays of light from said first generally cylindrical pattern of light and to reflect said rays rearwardly generally through said focus point; and a second paraboloid reflector having a concave reflective surface positioned within said housing and having a focus point positioned on said optical axis to receive rays of light reflected rearwardly from said first paraboloid reflector and to further reflect said rays into a second generally cylindrical pattern of light with light rays being generally parallel to one another and directed in a forward direction along an optical axis and out of the housing through said transparent lens.
Preferably said focus point of said first paraboloid reflector and said focus point of said second paraboloid reflector are located at the same point along said optical axis.
Preferably, said at least one cell further comprises at least two cells which are controlled by a first microprocessor control circuit to independently energize said LED light source at different times. Preferably said at least one cell further comprises at least two pairs of cells.
The flashlight of the present invention preferably has a housing which further comprises a stand pivotally mounted thereon. Said stand preferably may rotate though 180 degrees of rotation to allow said flashlight when laid upon a surface to selectively direct light a number of different directions. Preferably, said stand further comprises at least two toothed disks urged together by at least one wave spring washer whereby said stand is restrained from pivotal motion by said toothed disks unless force is applied to said stand sufficient to overcome the force applied by said wave spring washer. Said stand also preferably includes a spring loaded ring which is urged to remain in a secured location which prevents rotation thereof absent the application of force and upon the application of force said ring moves away from said secured location and is free to rotate relative to said stand.
The flashlight housing preferably includes a handle for carrying said flashlight.
Preferably, the flashlight also further comprises a strobe light in said housing or in said handle.
The flashlight preferably has a switch to selectively energize said LED light source. The switch is preferably a four position switch including an LED on position, a spring loaded momentary LED on position, an off position and a strobe on position. The switch is preferably hermetically sealed.
A second microprocessor control circuit is preferably provided to produce a generally constant electrical current to the LED light source. Preferably, such circuit provides a generally constant current over a range of temperatures between −40 degrees F. to 120 degrees F. Finally, the LED light source is preferably mounted on a heat sink to remove heat from said LED light source.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the front of the flashlight of the present invention.
FIG. 2 is a cross sectional view showing the collimating optics, first paraboloid reflector and second paraboloid reflector and a single ray of light directed thereby.
FIG. 3 is a cross sectional view of the collimating optics, first paraboloid reflector and second paraboloid reflector showing the paths of three different rays of light.
FIG. 4 is an isometric view showing the rear of the flashlight of the present invention.
FIG. 5 is an isometric view showing the flashlight attached to the belt of an emergency services worker.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the figures, the flashlight 10 has a housing 20 . The housing 20 has a cell compartment 42 which can be accessed by a pair of end caps 22 . A rubber o-ring 23 is preferably provided on each end cap 22 to provide a water resistant means to enclose the cells 40 within the housing 20 . A pair of cylindrical (rather than typical conical) shaped coil springs 41 are utilized to firmly hold the cells 40 in electrical contact with the necessary components to illuminate LED 30 or strobe 80 when desired. The housing 20 also includes a transparent lens 24 on the front end of the housing and a carrying handle 26 is provided.
A one watt bright white light LED light source 30 is provided. Collimating optics 50 are attached adjacent said LED light source 30 . A first paraboloid reflector 60 is provided on an inner surface of transparent lens 24 . Depending upon the desired location for the focus point F 1 of the first paraboloid reflector 60 , however, it may be necessary to mount said first paraboloid reflector with the housing 20 at a location rearwardly of the inner surface of transparent lens 24 . As is well known, the location of focal point F 1 will be closer to the first paraboloid reflector if the curvature of the paraboloid reflector is great and further away as the curvature becomes more flattened with F 1 located at infinity with a planar paraboloid surface.
A second paraboloid reflector 70 is also provided on the inner surface of transparent lens 24 as best shown in FIGS. 2 and 3 . A multi-position stand 100 is mounted to the lower side of housing 20 . The multipurpose stand 100 includes a pair of legs 102 , a cross member 104 and a front end portion 106 formed in a semi-annular configuration. The front end portion 106 includes a semi-annular groove 108 which is adapted to receive a stainless steel split ring 120 . A split ring 120 is attached to a release button 110 which is urged by spring 112 to secure ring 120 in groove 108 . When outward force is applied to ring 120 , ring 120 moves outwardly away from end 106 and is then free to rotate as it is then outside of groove 108 . The rotation of ring 120 is best shown in FIG. 5 . FIG. 1 shows ring 120 as secured in groove 108 .
FIG. 5 shows the ring 120 attached to an emergency service worker's utility belt 200 by means of a clip 202 . It is noted that the stand 100 is adapted to rotate through 180° of rotation. When rotated rearwardly in the direction of arrow R shown in FIG. 4 , the stand may extend outwardly from the rear of the flashlight as shown in FIG. 5 . When the stand is moved forwardly in the direction of arrow F in FIG. 4 , it is adapted to lie flat against the lower portion of the housing 20 to allow the flashlight to have a compact storage configuration. A variety of intermediate positions can be selected so that the light from the flashlight may be directed in a desired direction.
The legs 102 are pivotally mounted in the base 101 of stand 100 by means of a screws or rivets 118 . A pair of toothed discs 114 in combination with a wave spring washer 116 are utilized to restrain the stand from pivotal motion unless forces applied to said stand sufficient to overcome the force applied by said wave spring washer. This allows any one of a desired of rotational positions to be selected and for the stand to remain firmly affixed to said selected position until sufficient force is applied to move it to a different position.
The handle 26 on the flashlight preferably has a strobe light 80 embedded therein as shown in FIG. 1. A hermetically sealed four position thumb switch 90 is also provided on handle 26 .
A first microprocessor controlled circuit 44 is provided to control the switching from one set of cells to the other. A second microprocessor controlled circuit 45 is provided to provide generally constant current to the LED 30 over a broad range of temperatures.
Referring now specifically to FIGS. 2 and 3 , the LED 30 is provided on a heat sink 32 and collimating optics 50 are provided adjacent thereto. Preferably, the LED and collimating optics are assembled as a single unit such as, for example, the commercially available product sold under the trademark “LUXEON STAR/O” which is the presently preferred LED light source/collimating optics element. The first paraboloid reflector 60 and the second paraboloid reflector 70 are preferably formed of molded plastic and are then metallized by either a vacuum metallization process or by sputtering to create a highly reflective paraboloid surfaces 61 and 71 , respectively.
FIG. 2 specifically shows the path of a ray of light identified as R 1 as it travels from the light source 30 until the time that it passes forwardly through the transparent lens 24 . Ray R 1 first travels radially outward from source 30 as shown by segment R 1 A. The collimating optics 50 utilize the principals of refraction and reflection to direct the R 1 into a path R 1 B which is parallel to an optical axis labeled A. Ray R 1 at the end of segment R 1 B strikes the metallized surface 61 of the first paraboloid reflector 60 is reflected through a focus F 1 of said paraboloid reflector 60 onto the metallized surface 71 of the second paraboloid reflector 70 . This path is designated as R 1 C. Ray R 1 is then finally reflected off of said surface 71 of the second paraboloid reflector in the forward direction of segment R 1 D. Segment R 1 D is also parallel to the optical axis A. As shown in FIG. 2 , the focus F 1 of the paraboloid reflector 60 is shown to be located in the same position as the focus F 2 of the second paraboloid reflector 70 which is the presently preferred embodiment of the invention. Both of these focuses F 1 and F 2 are located on the optical axis A. It is also contemplated that F 1 and F 2 may be located at different spaced apart locations on the optical axis A.
FIG. 3 shows a similar pathway for three rays of light designated respectively as R 1 , R 2 and R 3 . As can be seen by looking at segments R 1 B, R 2 B and R 3 B, as the light rays R 1 , R 2 and R 3 leave the collimating optics element 50 , such rays of light form a first generally cylindrical pattern of light which is directed toward the first paraboloid reflector 60 . It can also be seen that after being reflected off from second paraboloid reflector 70 said rays of light R 1 , R 2 and R 3 form a second generally cylindrical pattern of light, as shown by ray segments R 1 D, R 2 D and R 3 D.
Said second generally cylindrical pattern of light forms a concentrated beam of light which provides uniform illumination over the entire circular area to which the cylindrical beam of light is directed. Obviously, because of imperfections in the optics and because of refraction which occurs at each surface, the light beam is not limited solely to the cylindrical beam described herein and some portion of the light generated by said light source 30 will spread over a larger area.
While it is preferred that the collimating optics 50 generate a first generally cylindrical pattern of light rays and that the second paraboloid reflector 70 generate a second generally cylindrical pattern if light rays, such light patterns are not required. While such cylindrical patterns of light rays are believed to provide the greatest degree of concentrated illumination at the greatest distance, it is also contemplated that some situations may desirably require a larger area to be generally illuminated rather than providing only a concentrated beam of light rays. By varying the shape of the paraboloid reflectors (and location of F 1 and F 2 ) it is a simple modification to cause said second generally cylindrical pattern of light to be altered to form a generally conical pattern of light, thus allowing for illumination of a larger area. It is also contemplated that by providing a means to move to location of one or more of the paraboloid reflectors along the optical axis (and the location of F 1 or F 2 ) it is possible to allow for an adjustment of the concentration of the beam from the flashlight from a narrow to a wide beam by methods which are well known in the art.
Because of the use of a low energy LED coupled with the unique arrangement of paraboloid reflectors and independent dual power supply, the present invention provides an extremely useful flashlight for fire, police and other emergency service workers. The light is intended to provide illumination during an extended period without interruption. Further, since cells can be replaced on the fly without turning the light off, no interruption of illumination will occur. The provision of a strobe light in the handle makes an extremely effective signal to mark danger or to allow emergency helicopters to locate the sight of an emergency event. Finally, because of the durability of each of the components utilized, the flashlight will continue to provide illumination even when subjected to substantial trauma, abuse or adverse conditions.
While we have shown and described the presently preferred embodiment of our invention, the invention is not limited thereto and may be otherwise variously practiced within the scope of the following claims: | A flashlight is disclosed which includes a housing adapted to receive one or more battery cells and having a transparent lens on a forward end thereof. An LED light source connected to the cell is utilized in conjunction with collimating optics positioned adjacent the LED to refract rays of light from the LED forwardly. A first paraboloid reflector having a concave reflective surface is positioned within said housing to receive rays of light from the collimating optics and to reflect the rays rearwardly and a second paraboloid reflector having a concave reflective surface is positioned within said housing to receive rays of light reflected rearwardly from the first paraboloid reflector and to further reflect the rays forwardly through the transparent lens. | 5 |
FIELD OF THE INVENTION
This invention relates to a composition that provides hypobromous acid for disinfecting water systems such as swimming pools, spas, decorative fountains, recirculating water cooling systems and health related baths.
1. BACKGROUND
A number of different compositions and methods that provide hypobromous acid for disinfecting water systems have been utilized. These technologies currently in use have some serious deficiencies. One of these technologies is a two part system ulitizing two products. The first product is a bromide salt solution. The second product is an oxidizing agent containing potassium peroxymonosulfate. This technology is not very efficient and difficult to use. The chemical must be hand fed.
Other technologies include blended compositions containing trichloro-s-triazinetrione (T.C.C.A.) and sodium bromide. These blends are normally pressed into a solid composition such as a stick, tablet or puck and are placed in an erosion feeder, skimmer, or a floating slow release device. An example of this type is a blend containing 96% T.C.C.A., 2% Sodium Bromide and 2% inert.
It is preferred to use the disinfectant in an erosion feeder, skimmer or a floating release device in order to slowly release the disinfectant into the water system in most applications. The sodium bromide and T.C.C.A. are compressed into either a stick, tablet or puck and use in one of the release feeder devices. However, these sticks, tablets or pucks do not maintain their integrity as water is circulated through the release device. Consequently the disinfectant splits, cracks, and breaks into small pieces. These small pieces expose more surface area and an increased rate of erosion occurs. The disinfectant is released too rapidly and is not satisfactory for the treatment of most water systems.
2. Prior Art
There are several commercial blends of sodium bromide and trichloro-s-triazinetrione available as disinfectants. There are also commercial products which use sodium bromide as the only active ingredient.
U.S. Pat. No. 4,557,926 (Nelson et al) discloses a combination of an alkali metal salt of dichloroisocyanuric acid and either sodium bromide or potassium bromide for use in disinfecting toilets. The patents which disclose the use of a bromide salt to bleach and disinfect are as follows:
3,519,569 (Diaz) issued Jul. 7, 1970
3,575,865 (Burke et al) issued Apr. 20, 1971
3,580,833 (Koceich et al) issued Nov. 26, 1974
4,235,599 (Davis et al) issued Nov, 25, 1980
4,382,799 (Davis et al) issued May 10, 1983
4,600,406 (Corte) issued Jul. 15, 1986
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a solid composition that provides hypobromous acid for use in a slow release device for disinfecting water system which would dissolve at a relatively slow rate so that the disinfectant will be released uniformly into the water system over an extended period of time.
It is a further object of this invention to add an oxidizer stable dye or pigment to a slowly dissolving solid disinfectant so that it can be distinguished from solid disinfectants that would otherwise be similar in appearance. A further object of this invention is for the dye or pigment to decompose in the water system so that the water is not colored by the dye. This would be objectional to users of the water system in many cases, particularly in the case of swimming pools, as it would stain the walls and bottom surfaces of the pool.
These objects have been obtained by developing a solid disinfectant comprising from 80%-99% trichloro-s-triazinetrione (T.C.C.A.) and from 1%-20% of potassium bromide (KBr). These two disinfectants are mixed together and compressed into solid forms such as a tablet, stick or puck. The disinfectant can then be placed in a release device through which water circulates to disinfect a water system such as a swimming pool or cooling tower.
It has further been found that the pigment lazurite can be added to the composition to color the solid disinfectant. This pigment is oxidizer stable and consequently does not decompose when added to the solid disinfectant, but is decomposed by the oxidizer in the water system so that the pigment will not color the water or stain hard surfaces. This pigment is added in an amount 0.01%-0.5% . The amount of KBr or T.C.C.A. is accordingly reduced.
The disinfectant of this invention dissolves at a slower rate in release devices than comparable compositions of sodium bromide and T.C.C.A. Consequently the disinfectant of this invention adds disinfectant to a water system at a controlled and uniform rate over a long period of time.
DESCRIPTION OF THE INVENTION
This invention produces a solid disinfectant that dissolves at a slow and relatively uniform rate when placed in a release device in a water system. The disinfectant is composed of from 80%-99% trichloro-s-triazinetrione (T.C.C.A.) and from 1%-20% potassium bromide. These two compounds are in solid form and can be mixed together and pressed into a stick, tablet or puck which is suitable for use in various types of release devices such as erosion feeders, skimmers or floating release devices. Water circulates through the release device and gradually erodes the solid composition releasing hypobromous acid to serve as the disinfectant in the water system. It is preferred that from 90%-97% T.C.C.A. be used and from 3%-10% potassium bromide (KBr) be used in the composition.
In order to differentiate this solid composition from other disinfectants otherwise similar in appearance, a chlorine stable pigment has been added to the composition. This pigment is ultramarine blue or lazurite, commonly sold under the trade name Pylam Pylaklor Dry Blue™* S-726 (Pigment Blue 29; CI 77007). It has the following composition [(Na, Ca) 4 (AlSi O 4 ) 3 (SO 4 , S, Cl)] or [Ca 2 Na 6 (Al 6 (SiO 4 ) 6 SO 4 S] or [Na 5 (Al 3 (SiO 4 ) 3 S] or [Na 5 (Al 3 (SiO 4 ) 3 S) (Cl). This pigment is blue, blue-violet or greenish-blue in color. Lazurite is oxidizer stable so that the solid composition is blue in color. Lazurite is decomposed by the oxidizer in the water systems. This is important for some applications as pigment would be objectionable to users of certain water systems such as swimming pools.
Lazurite is added in an amount from 0.01%-0.5% by weight. The preferred composition incorporating the pigment is as follows in parts by weight:
T.C.C.A.: 90%-97%
KBr: 3%-9.5%
Lazurite: 0.01%-0.5%
It is also possible for the formulation to include a filler. The filler is an inert substance, such as sodium chloride or boric acid, that can be used to assist in the tablettability as a composition. A filler can be used in any concentration provided the composition contains the required amount of the disinfectant. The filler is preferably present from 5%-10% by weight.
In addition to the components of the disinfectant described above, the formulation may also contain other ingredients, such as tabletting aids, e.g., mold release agents, binders, corrosion inhibitors, scale inhibitors and other components known to one skilled in the art. The tablet sticks or pucks are formed in the usual manner.
It is preferred that the disinfectant of this invention be used in a release device so that the disinfectant is immersed or partially immersed in water within an enclosure in which the disinfectant is gradually eroded and hypobromous acid are released to disinfect that water system.
Commercial solid formulations of sodium bromide and T.C.C.A. are known. The problem with these formulations is that they dissolve too rapidly in release devices as illustrated in the examples that follow. However, the combination of potassium bromide and T.C.C.A. dissolve at a much lower rate.
The solid disinfectant of this invention is useful in disinfecting water systems such as swimming pools, spas, hot tubs and cooling towers. Its composition is normally pressed into tablets, sticks or pucks and placed in a release device such as an erosion feeder, skimmer, in-line halogenator or floating release device in the system.
EXAMPLE 1
Tablets of disinfectant for this test were prepared by mixing the ingredients and pressing in a conventional tablet machine to form tablets one inch in diameter. Sticks were prepared by mixing the ingredients and forming under pressure in a conventional stick-forming machine to form one-half pound sticks.
Trichloro-s-triazinetrione in an amount of 96% parts by weight was mixed with sodium bromide in an amount of 4% parts by weight and formed into sticks and tablets. A disinfecting composition was prepared composed of 96% parts by weight trichloro-s-triazinetrione and 4% potassium bromide and formed into sticks and tablets.
These two compositions were compared placing them in a commercially available erosion control device through which water was circulated at a controlled rate of gallons per hour (gph). Water temperature was maintained at 80°-81° F. Total alkalinity of the water was controlled at 100 parts per million. The calcium hardness was at 200-300 parts per million. The pH was at 7.4 to 7.6. Tablets or sticks were put in a release device and allowed to operate until the output had stabilized. The following table shows the results.
TABLE 1______________________________________ 0.5 lb 0.5 lb 1" tablets 1" tablets stick stick 96% 96% 96% 96% T.C.C.A. T.C.C.A. T.C.C.A. T.C.C.A. 4% KBr 4% KBr 4% KBr 4% KBrFlow lbs Cl.sub.2 lbs Br.sub.2 lbs Cl.sub.2 lbs Br.sub.2Rate per 8 per 8 per 8 per 8(GPH) hours hours hours hours______________________________________10 0.96 (2.2) 0.35 (0.79)20 1.2 (2.8) 0.46 (1.0)30 1.6 (3.6) 0.52 (1.2)40 1.9 (4.2) 0.59 (1.3)50 2.2 (4.9) 0.69 (1.6)______________________________________
TABLE 2______________________________________ 0.5 lb 0.5 lb 1" tablets 1" tablets stick stick 96% 96% 96% 96% T.C.C.A. T.C.C.A. T.C.C.A. T.C.C.A. 4% NaBr 4% NaBr 4% NaBr 4% NaBrFlow lbs Cl.sub.2 lbs Br.sub.2 lbs Cl.sub.2 lbs Br.sub.2Rate per 8 per 8 per 8 per 8(GPH) hours hours hours hours______________________________________10 1.1 (2.5) 0.44 (1.0)20 1.5 (3.3) 0.58 (1.3)30 1.8 (4.0) 0.67 (1.5)40 2.1 (4.8) 0.80 (1.8)50 2.5 (5.7) 0.90 (2.0)______________________________________
In comparing the 1" tablet with KBr with those with NaBr, it will be noticed the pounds of chlorine released in an eight hour period are significantly less with the KBr than with the NaBr formulations. For example at a flow rate of 20 gallons per minute, the output rate of the formulation with the KBr is approximately 20% less than with NaBr. At 50 gallons per minute, the release of chlorine for eight hours is approximately 12% less with the KBr than with the NaBr. In comparing the sticks, it will be noticed that the release rate for the chlorine for eight hours is significantly less for the KBr formulation than for the NaBr formulation. For example at a flow rate of 40 gallons per hour, the output of chlorine for eight hours is approximately 26% less for the KBr than for the NaBr.
The bromine output for eight hours is also significantly less for sticks and tablets formed with KBr than those formed with NaBr. For example at a flow rate of 20 gallons per minute, the bromine output rate for the tablets formed with KBr was approximately 15% less than with the NaBr. The bromine output rate for these tablets at a flow rate of 50 gallons per minute was 14% less for the KBr tablets than for the NaBr containing tablets. The output rate was 20% less for the KBr sticks at 30 gallons per minute than for the NaBr sticks.
EXAMPLE 2
Tablets and sticks of 100% trichloro-s-triazinetrione were prepared in accordance with the procedure of Example 1 and tested in the same manner. The following table shows the results.
TABLE 3______________________________________ 0.5 lb 0.5 lb 1" tablets 1" tablets stick stick 100% 100% 100% 100% T.C.C.A. T.C.C.A. T.C.C.A. T.C.C.A.Flow lbs Cl.sub.2 lbs Br.sub.2 lbs Cl.sub.2 lbs Br.sub.2Rate per 8 per 8 per 8 per 8(GPH) hours hours hours hours______________________________________10 1.1 (2.5) 0.32 (0.72)20 1.7 (3.8) 0.40 (0.90)30 2.0 (4.5) 0.48 (1.1)40 2.3 (5.2) 0.56 (1.3)50 2.8 (6.3) 0.64 (1.4)______________________________________
In comparing the 1" tablet with 96% T.C.C.A. and 4% NaBr (Table 1) with 100% T.C.C.A. (Table 3), it will be noticed with T.C.C.A. alone. For example, at a flow rate of 20 gallons per minute the KBr tablets had a chlorine output rate that was 29% less than of the T.C.C.A. tablet alone (Table 2). The KBr sticks (Table 1) at a flow rate of 20 gallons rate per minute had a chlorine output rate that was 13% less than of the T.C.C.A. tablets (Table 2). The bromine output rate with a 1" tablet at a flow rate of 40 gallons per minute was 19% less with the KBr tablet (Table 1) than with the T.C.C.A. tablets (Table 3).
EXAMPLE 3
The disinfectant composition was prepared by mixing the following ingredients in accordance with the following formulation: T.C.C.A. 95.8%, KBr 4%, Lazurite 0.2%. These compositions were blended until a uniform blue mixture was obtained. These compositions were stored using a thirty day accelerated stability testing method at 50° C. Compositions remained blue at the conclusion of the test. The stability of the pigment in water containing an oxidizer has measured in accordance with the following procedure: 0.5 gm of the composition was added to 1000 gm of distilled water. An additional 0.1 gm of Lazurite was added for visual effect. These mixtures were allowed to mix over a 24 hour period. The color of the water immediately upon adding the composition was blue, but the water become colorless after 11/2 hours and remained so at the end of the 24 hour period. | Disclosed is a solid composition that provides hypobromous for disinfecting water systems comprising from about 80-99% trichloro-s-triazinetrione and from 1-20% potassium bromide. Also disclosed is the incorporation of a chlorine stable dye in the composition. | 2 |
FIELD OF THE INVENTION
The present invention relates to a process for ensuring the remote positioning of a tool in relation to a specific reference and more particularly of a work appliance in relation to a tube of a steam generator of the type of those used in nuclear power stations for the generation of electricity. The invention is also concerned with a device for carrying out this process.
BACKGROUND OF THE INVENTION
The use of a work tool on such steam generators, conventionally comprising, within a closed containment, at least one transverse plate, called a tube plate, which separates this containment and from which extends a plurality of parallel tubes which pass through the plate and through which flows a pressurized fluid exchanging heat by way of their wall, demands rapid, accurate and reliable positioning of the tool in relation to the axis of each tube on which work is to be carried out, from a region located on one side of the tube plate which is located within the containment and into which this tool is introduced.
In view of the conditions prevailing in the containment and particularly because of the presence of radioactive radiation, it is obvious that this positioning of the tool in relation to any of the tubes to be treated has to be carried out at a distance and by remote control, the tool being loaded on or fastened to a remote manipulator arm making it possible to displace it in the three spacial directions, especially to reset it in relation to a given reference direction which is usually formed by the axis of the tube in question. Moreover, to prevent any risk of damage to the tubes or to the tool, it is virtually indispensable that the centering of one tube in relation to another should take place without any physical contact between them.
There are already known devices of this type suitable for executing the centering of such a tool in relation to the generally vertical axis of a tube belonging particularly to a steam generator, these devices employing mechanical feelers which, precisely, necessitate direct contact between the tool and the tube plate, with the disadvantages already mentioned, which the subject of the invention proposes to avoid.
Moreover, other solutions have been considered, such as particularly in FR-A-2,628,671, which illustrates a remote-manipulation assembly ensuring the desired centering, controlled at a distance and without any physical contact between the tool and the tube. In principle, the device described in this prior patent comprises a rail-shaped radial support capable of pivoting about the center of the tube plate and extending under and parallel to this plate. A carriage designed to slide along the length of this arm comprises an axle on which a photographic camera is mounted and a second axle carrying the working and monitoring tool. The camera objective, which is directed towards the tube plate, and the axis of which is thus parallel to that of the tubes, determines the contour at the end of this tube as a result of the contrast generated by activating means for illuminating the inner zone of the tube viewed by the camera. Computation and control means connected to the camera are then operated in order to locate exactly the position of the axis of this tube, with which the axis of the camera is brought into close coincidence as a result of a suitable displacement of the carriage. Once this operation has been carried out, the carriage is displaced once again in order to center the tool in the axis of the tube by means of a second translational movement, which thereby substitutes the tool for the camera, making it possible to work inside the tube with a perfect positioning in relation to the latter.
The disadvantage of such a device is that it is necessary to employ means which are generally complex to control and normally costly, these means comprising particularly a computer and carriage-position monitoring sensors, the indications of which are managed by this computer. Furthermore, since the sight axis of the camera is different from that of the tool, a translational movement is necessary each time in order to substitute one for the other, thus adversely affecting the final accuracy of the centering obtained.
SUMMARY OF THE INVENTION
The subject of the present invention is a process and a device of simple design and of high accuracy for centering a tool, mounted on a manipulating arm or a similar remote-controlled carrier structure, in relation to the axis of a tube flush with the surface of a tube plate for a steam generator of a nuclear reactor, this centering being carried out directly by means of the carrier arm of the tool, brought substantially into the axis of the tube which is to be treated and in relation to which the work tool is to be resecured accurately and quickly.
To this end, the process in question, for the positioning of a tool carried by a manipulating arm or similar support, capable of being displaced in three respectively perpendicular directions of space in relation to a reference axis, especially the vertical axis of a tube carried by a plate, called a tube plate, of a steam generator for a nuclear reactor, involves arranging symmetrically on this arm a set of at least three lighting sources, each providing a light beam directed tangentially towards the periphery of a tube, retransmitting, by means of an optical assembly likewise carried by the arm, the images of three specific points of the tube illuminated by the sources in the direction of a video monitor, the screen of which comprises three reticles delimiting the actual contour of this tube, and then bringing these images into coincidence with the reticles in order to center the axis of the tool strictly on the axis of the tube.
Preferably, the three lighting sources consist of point lamps, especially of the halogen-lamp type, of which the light beams which they supply, after being reflected on the end of the tube, are received by three independent optical systems returning the images of the three points of the tube illuminated by the sources towards a common camera connected to the video monitor. Likewise preferably, each source is associated with an optical system located in the vicinity, the three sources and the three optical systems being respectively distributed substantially at 120° about the axis of the work tool.
The invention also relates to a device for carrying out this process, comprising a horseshoe-shaped supporting frame surrounding partially and without direct contact the body of a work tool, the spindle of which is intended to be placed coaxially with the axis of a tube, this frame comprising at least three lighting sources arranged substantially at 120° about the spindle and three optical systems, each source supplying a narrow light beam directed tangentially onto the periphery of the tube in its end flush with the face of the tube plate, in order to provide an image of a point of the latter collected by the optical system associated with each source, the images of the three points being retransmitted to the screen of a video monitor comprising three reticles delimiting the actual contour of the tube, and means for displacing the tool in relation to the tube in order to bring these images into coincidence with the reticles so as to center the axis of the tool on the axis of the tube.
Preferably, each optical system consists of an optical fiber, the three systems corresponding to the three lighting sources likewise being distributed substantially at 120° about the axis of the tool and being carried by the supporting frame in the immediate vicinity of each source. Likewise preferably, the three sources consist of halogen point lamps.
The images of the three points of the tube, collected separately by the three fibers, are advantageously returned to a single solid-state sensor, particularly of the charge-transfer type, connected to a common camera transmitting these images simultaneously to the screen of the video monitor comprising the three positioning reticles.
According to another characteristic, the supporting frame comprises a bracket for fastening to the body of the work tool by means of adjusting screws or the like, making it possible to bring the center of the horseshoe frame into coincidence with the axis of the tool.
According to another characteristic, the end face of each optical system is arranged in such a way that the perpendicular to the latter delimits a specific angle with the direction of the axis of the tube, the narrow light beam supplied by the associated source having a given aperture angle centered on this perpendicular, in such a way that this beam, made tangent to the periphery of the tube, provides an image representing a fraction of the inner part of this tube and simultaneously a fraction of the part outside this tube in the tube plate.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics of the process for the remote positioning of a tool in relation to the axis of a tube of a steam generator for a nuclear reactor and of the device for carrying out this process will emerge from the following description of an exemplary embodiment given with reference to the accompanying drawings.
FIG. 1 is a partially sectional schematic perspective view of a tube plate of a steam generator and of a work tool on any tube of this plate, comprising automatic centering means designed according to the invention.
FIGS. 2 and 3 show on two different scales the supporting frame and the means which it comprises, which are intended to be mounted on the body of the tool in order to allow centering of the latter in relation to the axis of the selected tube.
FIG. 4 is a cross-sectional view on a larger scale of the frame and more particularly of one of the optical systems carried by the latter, making it possible to explain more specifically the use of the device in question.
FIGS. 5 and 6 are schematic front views of a video screen associated with the means carried by the supporting frame, showing the tube image obtained respectively before and after centering of the tool in relation to the axis of this tube.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 shows the containment 1 of a steam generator for a nuclear reactor, this generator comprising an outer casing 2, the lower bottom 3 of which takes the form particularly of a spherical dome which is connected to the casing 2 in line with a transverse plate 4, called a tube plate, the latter being associated with a plurality of tubes 5 passing through the plate 4, while being suitably immobilized in relation to the latter. Preferably, the tubes 5 are fixed to the plate 4, being expanded in relation to it so as to make their connection leakproof, these tubes 5 opening at their lower end 6 onto the corresponding surface 7 of the plate 4.
In the conventional way, the tube plate 4 extends transversely in the containment 2, the tubes 5 together forming a bundle of parallel tubes of vertical axis, these tubes being intended to have flowing internally through them a pressurized primary fluid exchanging heat by way of the wall of these tubes with a secondary fluid circulating on the outside of these tubes in order to be evaporated, the steam produced being collected on the outside of the generator, in particular to ensure by its expansion the driving of a turbine controlling that of an electricity-generating machine.
The tube plate 4 delimits with the spherical dome 3, in the lower part of the generator 1, a region 8, usually called a water box, into which the primary fluid is introduced by means of a feed connection 9 made in the dome 3, the orifice of the latter also making it possible to introduce into the region 8 a work tool diagrammatically as a whole by the reference tool comprising in simplified form a body 11 equipped with a central spindle 12 intended for carrying out a repair or a particular maintenance operation on the lower end 6 of any of the tubes 5 of the bundle or within this tube in its part fixed to the plate 4.
The tool body 11 is carried by a remote-manipulator arm or similar appliance, of which only the end 13 connected to the tool has been indicated, this arm represented by the dot-and-dash line 14 making it possible to execute displacements of the tool 10 in any one of the three spatial directions, particularly according to a rising or falling movement, in order to bring the spindle 12 nearer to or further from any tube 5 in the bundle of tubes of the plate 4 and also to displace this tool from one tube to the other within the region 8. For this purpose, the arm 14 is connected, on the outside of the generator 1, to a control assembly 15 which makes it possible to monitor these movements and position the spindle 12 accurately in the axis of the selected tube 5 or in any other position made necessary by the work to be carried out on this tube.
According to the invention, the body 11 of the tool 10 is directly equipped with optical means and with means for processing the information provided by these means in order to make it possible to bring into coincidence reliably, quickly and accurately the axis of the spindle and that of the tube on which this work is to be carried out.
For this purpose, the body 11 is associated with a supporting frame 16 carrying lighting members 17 (shown schematically in FIG. 3) for illuminating the lower end 6 of the selected tube 5, flush with the face 7 of the plate 4 directed towards the region 8, and optical systems 18 interacting with lighting members 17, in such a way that the image of given points, such as 19, belonging to this end 6 can be transmitted directly by the optical systems to a camera 20, itself providing an image on the screen 21 of a video monitor, representing the corresponding cross-section of the tube in question.
FIGS. 2 and 3 illustrate more specifically the mounting of the supporting frame 16 on the body 11 of the tool 10, this frame preferably taking the form of a horseshoe-shaped element 22 equipped with a fastening bracket 23 comprising blind bores 24 suitable for interacting with locking screws 25 mounted at the end of two positioning right-angle brackets 26 extending parallel to one another and symmetrically on each side of the body 11. As shown on a larger scale in FIG. 3, it can be seen that, as a result of these arrangements, the horseshoe element 22 of the frame 16 can partially surround the body of the tool, while at the same time leaving a circumferential play 27 free relative to the latter, with the lighting means 17 and the optical systems 18 carried by the frame 16 being arranged symmetrically in relation to the vertical axis 28 of the tool, this being achieved without the need to proceed with any dismounting of the spindle, the frame coming into place simply by means of a lateral displacement relative to the body 11.
In the exemplary embodiment more particularly under consideration, the frame 16 comprises three lamps or other similar lighting means 17, preferably consisting of halogen lamps capable of supplying a narrow light beam in the direction of the lower end 6 of the tube 5 when the tool 10 is brought suitably near to the plate 4. These three lamps 17 are distributed substantially at 120° relative to one another about the axis 28, each lamp being associated with an optical system 18, which, likewise preferably, consists of the endpiece 29 of an optical fiber 30, as shown more specifically in FIG. 4.
By virtue of construction, each of the three lamps 17 is arranged on the supporting frame 16 in the immediate vicinity of the endpiece 29 of the associated optical system 18, each endpiece having particularly a truncated plane face 31 and being mounted in a suitable receptacle 32 provided in the element 22, in such a way that the perpendicular 33 to the face 31 delimits an angle a with the vertical direction 34, the narrow light beam coming from the associated source 17 having an aperture angle b about this perpendicular 33.
During operation, the arm of the remote manipulator 14 is controlled in the vertical direction, in such a way that the light beam coming from each source 17 comes tangent with the point 19 of the lower part 6 of the tube 5 at the location where the latter opens onto the face 7 of the plate 4, the aperture b of the beam making it possible to obtain an image of this part of the tube representing a fraction of the interior of the latter and, simultaneously, a fraction of the exterior in line with the plate 4.
The images of the points 19, thus corresponding to each of the three lighting lamps 17, picked up by the three optical fibers 30 of the associated optical systems 18, are then combined and transmitted to a single sensor (not shown), preferably of the solid-state charge-transfer sensor type (CCD), of the photographic camera 20 which sends these images to the screen 21 of the video monitor which is arranged outside the generator 1 and from which the user controls the monitoring device 15 ensuring the displacements of the arm of the remote manipulator 14 and consequently of the tool 10.
By virtue of the arrangement of the light sources 17 and of the optical systems 18 mounted at 120° about the axis 28 of the tool, therefore, the three images obtained each represent a portion of the tube and of the tube plate in the region adjacent to this with an acceptable magnification compatible with the requisite accuracy. Under these conditions, when the axis 28 of the tool 10 is shifted relative to the axis 35 of the tube 5 in question (FIG. 5), the three partial images of the tube examined are represented by three fractions of a circle 36, 37 and 38, the contours of which are inscribed differently from one another within three identical circles, 39, 40 and 41 centered respectively in three reticles 42, 43 and 44 appearing on the screen 21 and arranged in such a way that they define the contour of the tube 5 examined. In contrast, when the tool is centered perfectly in relation to the tube, i.e., when the axis 28 coincides strictly with the axis 35 (FIG. 6), the three images 36, 37 and 38 are identical and all have a point of intersection with the reticles 42, 43 and 44 of the circles 39, 40 and 41, the image of the end 6 of the tube which corresponds on the screen to the circle 45 passing from then on through these three reticles.
As a result of these arrangements, it will be seen that it is immediately possible to reset the tool on the tube in which work is to be carried out, the operator who is viewing the video screen 21 ensuring, by the control of the device 15, the necessary displacements of the tool suitable for bringing its spindle 12 into the axis of the tube, this resetting corresponding directly on the screen to the centering of the circle 45 on the reticles.
In the foregoing example, the processing of the image of the end of the tube provided by the camera is carried out by an operator. Alternatively, it could be executed by an image-processing system generating positioning error signals proportional to the misalignment of the axes of the tube and of the tool. Likewise, although the example described entails the use of three lighting sources and of three associated optical systems, it would be possible just as easily to conceive of a larger number of such components maintaining a symmetrical arrangement about the axis of the body of the tool.
Likewise preferably, there has been provision for using halogen lamps on the supporting frame carried coaxially by the body of the tool, allowing appreciable lighting of the end of the tube and substantial contrast between the actual tube plate and the inner region of this tube. Other optical systems could, of course, be considered, these providing narrow directional radiation, particularly by laser beams or the like, at all events these lighting members advantageously being associated with means for controlling their extinguishing to prevent them from interfering with the other optical monitoring mean used for checking the correct functioning of the arm of the remote manipulator ensuring the positioning of the tool.
The device according to the invention does not itself have any movable element, thus giving the assurance of good mechanical resistance and an appreciable lifetime. Moreover, its overall size, particularly in terms of height, can be greatly reduced so as not to impede the movements of the arm of the remote manipulator. Finally, the time needed for an operation for centering the tool can be very short, thereby proportionately reducing the duration of the maintenance work to be carried out on the tubes of the steam-generator plate, this operating rapidity being accompanied by excellent reliability, the positioning accuracy being capable of being better than 0.2 mm. | Process and device for the positioning of a tool (10) carried by a manipulating arm displaceable in three respectively perpendicular directions of space in relation to the vertical axis of a tube carried by the tube plate of a steam generator for a nuclear reactor. The process involves arranging symmetrically on the arm a set of at least three lighting sources (17) each supplying a light beam directed tangentially towards the periphery of a tube (5), retransmitting, via an optical assembly (18) also carried by the arm, the images of three specific points of the tube illuminated by the sources in the direction of a video monitor, the screen (21) of which comprises three reticles (42, 43, 44) delimiting the actual contour of the tube, and then bringing these images into coincidence with the reticles in order to center the axis (28) of the tools strictly on the axis (35) of the tube. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to compositions and methods useful for potentiating the activity of drugs affecting the Central Nervous System.
BACKGROUND OF THE INVENTION
[0002] The following is a list of references which may be important in understanding the background of the invention:
1. U.S. Pat. No. 5,942,241; 2. Mancusi L. et al., Minerva Anestesiol, 53(1-2), 19-26, 1987; 3. Huang K S et al., Ma Tsui Hsueh Tsa Chi, 31(4), 245-8, 1993; 4. Goyagi T et al., Anesth Analg, 81(3), 508-13, 1995; 10 5. Niemi G et al., Acta Anaesthesiol Scand, 42(8), 897-909, 1998; 6. Russian Patent No. SU 2,088,233 7. 8 th Sardinian Conference on Neuroscience. Anxiety and depression neurobiology, pharmacology and clinic . Tanka Village, Villasimius, May 24-28 th 1995. Behavioral Pharmacology, Vol. 6 (Supplement 1), 1995, P.152.
[0010] The references are referred to in the specification by their respective numbers.
[0011] Currently, two principal methods of potentiation of the effect of central nervous system (CNS) active drugs (potentiated synergism) are known: (1) pharmacokinetic; and (2) pharmacodynamic.
[0012] The pharmacokinetic method provides potentiation by creating a maximum concentration of the drug at the site of the primary pharmacological 5 response due to improved absorption, increased bioavailability, accelerated distribution and retarded elimination of the drug ( Goodman & Gilman's The Pharmacological Basis of Therapeutics 9th ed. Hardman Paperback, McGraw-Hill Book Company, 1996). The known methods of pharmacokinetic potentiation are connected, as a rule, with the development of new and improved dosage forms and ways of drug administration.
[0013] In recent years, the method of controlled extended release of active ingredients from micro-particles and microcapsules (e.g. U.S. Pat. No. 6,022,562) has been considered the most popular and promising of these methods. Each micro-particle generally represents a matrix of nontoxic polymer containing a drug and osmotically active polyatomic alcohols (e.g. U.S. Pat. No. 5,431,922). Micro-particles are included in traditional dosage forms for oral administration (tablets, capsules, suspensions, granules), which most frequently contain polymers such as polyvinylpyrilidone (PVP) or polyethylene oxide (PEO), and osmotically active alcohols such as sorbitol, xylitol and mannitol.
[0014] The main drawback of this method is the necessity for permanent administration of a high dose of the active ingredient. This may lead, in the case of long-term administration, to the potentiation not only of its therapeutic action, but also of side effects in case of poor selectivity of the drug effect. In addition, the production of traditional oral dosage forms on the basis of micro-particles and microcapsules leads to a manifold increase in their cost, which often greatly exceeds the cost of-the active ingredient. Despite its numerous advantages, the aforementioned pharmacokinetic method does not achieve a manifold intensification of the effect of drugs.
[0015] Osmotically active polymers (PVP, PEO) and polyatomic alcohols (xylitol, sorbitol, mannitol), included in the composition of both traditional monolithic dosage forms as well as forms intended for controlled release of active ingredients, play an important role in pharmacokinetic potentiation of CNS active drugs (e.g. U.S. Pat. Nos. 4,952,402 and 5,552,429). However, they are not active components of the compositions, but rather they only provide optimal conditions for the pharmacokinetics of a CNS active drug.
[0016] A combined application of the α-1-adrenomimetics phenylephrine or midodrine, as well as the nonselective adrenomimetic adrenalin, together with narcotic analgesics and local anesthetics has been found to lead to a pharmacokinetic potentiation of analgesic and anesthetic effect. However, these compositions were only administered locally to intensify local anesthesia (1) or intrathecally to intensify spinal anesthesia (2-5). Intensification and prolongation of the effect of analgesics and anesthetics was caused by an increase in their local concentration, which is due to a decrease in the amount of analgesics and anesthetics entering the blood as a result of a local spasm of vessels caused by the adrenomimetics.
[0017] The pharmacodynamic method also provides potentiation by a joint administration of active ingredients causing unidirectional pharmacological effects, but affecting different molecular substrates (having different mechanisms) (Goodman&Gilman's The Pharmacological Basis of Therapeutics, op. cit.).
[0018] Two main types of pharmacodynamic methods of the potentiation of 25 CNS active drugs are known:
[0019] (1) Potentiation of the effects of CNS active drugs caused by joint administration of CNS active drugs only;
[0020] (2) Potentiation of the effects of CNS active drugs caused by joint administration of a CNS active drug and a peripherally active drug.
[0021] The well-known first method consists in joint administration of two CNS active drugs that act unidirectionally and mutually potentiate each other's effect. In cases of grave depressions, pain syndrome, parkinsonism, epilepsy and psychoses, potentiation of the maximal effect of antidepressants, neuroleptics, analgesics, psychostimulants, anti-parkinson and anticonvulsive agents is required. As a rule, potentiation is possible only by joint administration of CNS active drugs in submaximal doses. Potentiating of submaximal doses effects of CNS active drugs results in maximum possible intensification of their therapeutic activity. On the other hand potentiating of their central toxic effect is also caused resulting in multiple side effects and complications. (e.g. U.S. Pat. No. 4,788,189; Winter J C et al., Pharmacol Biochem Behav, 63(3), 507-13, 1999; Sills T S et al., Behav Pharmacol, 11(2), 109-16, 2000); Fredriksson A. et al., J Neural Transm Cen Sect, 97(3), 197-209, 1994).
[0022] U.S. Pat. No. 3,947,579 discloses a method for potentiating the neuroleptic activity of drugs such as butyrophenone derivatives by administrating them together with an amino acid known to cross the blood brain barrier and have muscle relaxant properties useful in the treatment of spinal origin spasticity.
[0023] At mild and moderate severity (or stage) of a disease, maximal or even submaximal effect caused by CNS active drug is quite sufficient. In this case therapeutic activity may usually be achieved by potentiating threshold doses of CNS active drugs. (e.g. U.S. Pat. No. 5,891,842; Freedman G M, Mt Sinai J Med, 62(3), 221-5, 1995; Kaminsky R et al., Pharmacol Res, 37(5), 375-81, 1998). The potentiation of the effect of threshold doses significantly reduces the probability of the development of side effects and complications inherent to CNS active drugs at maximal doses, as well as the development of tolerance and dependence due to their prolonged administration. However, even this, the safest of all known methods of pharmacodynamic potentiation has its own drawbacks:
1) The effect achieved by potentiating low doses of drugs does not exceed, as a rule, the maximal effect of the drug itself. 2) When the elimination of active ingredients is decelerated (childhood age, diseases of liver or kidneys) or the permeability of the hematoencephalic barrier is increased, threshold dosages of CNS active drugs can become submaximal and even toxic in their effect. Therefore, their combined administration even at such threshold doses becomes impossible due to the potentiation of their CNS side effects. 3) The risk of potentiating not only therapeutic, but also toxic effects of CNS active drugs by even small doses of other safe CNS active drugs.
[0027] The potentiation of the effects of threshold doses of CNS active drugs can also be realized by a combined administration of a CNS active and a peripherally osmotically active drug. It is known that oral or intramuscular administration of osmotically active copolymers of N-vinyl-pyrrolidone with N,N,N,N, triethylmethacryloidoxyethylammonium iodide (6), potentiate the effects of threshold doses of analgesics, antidepressant, antishock and antihypoxic agents without any side effects and complications. Among the drawbacks of the method there should be mentioned the insufficient potentiation of the CNS active drugs when administered at threshold doses. Although potentiation occurs, it does not reach the level of the maximal effect of the CNS drug tested.
[0028] Another drawback is the complexity of the synthesis and high cost of the polymers comprised in these compositions.
[0029] In rats under urethan anaesthesia, peripherally administered serotonin produced cardiopulmonary reflex. Administration of phenylephrine or adrenaline to unaesthesized rats potentiated 5-10 fold the cardiopulmonary reflex caused by injection of serotonin in short-sleeping rats (7). This is a peripheral rather than a CNS effect, since peripherally administered serotonin cannot penetrate the hematoencephalic barrier.
[0030] U.S. Pat. No. 4,631,284 discloses acetaminophen compositions containing a substantially high amount of acetaminophen and a low amount of pheniramine maleate. This patent teaches a method of tabletting using such compositions.
SUMMARY OF THE INVENTION
[0031] It is an object of the invention to provide a pharmaceutical composition comprising a CNS active drug whose activity is potentiated.
[0032] It is a further object of the invention to provide a method for potentiating CNS active drugs.
[0033] In a first aspect of the invention, there is provided a pharmaceutical composition for systemic administration comprising: (a) an effective dose of a drug which affects the central nervous system (CNS); (b) a compound which stimulates peripheral chemoreceptors of vagal afferents; and, optionally, (c) a compound which stimulates peripheral osmoreceptors of vagal afferents.
[0034] It has suprisingly been found that the activity of systemically administered CNS drugs may be significantly potentiated by the co-administration of a compound which stimulates peripheral chemoreceptors of vagal afferents and further by a compound which stimulates peripheral osmoreceptors of vagal afferents. The “active ingredients” of the invention are the CNS drug and the potentiating element, i.e. compound which stimulates peripheral chemoreceptors and a compound which stimulates peripheral osmoreceptors of vagal afferents.
[0035] In the present specification, a CNS active drug is a drug that modifies the function of the CNS by directly affecting the CNS or a portion thereof. Such drugs include but are not limited to analgesics, antidepressants, neuroleptics, tranquilizers, psychostimulants, hypnotic drugs, anti-parkinson and anti-convulsive agents.
[0036] The term “effective dose” with respect to the CNS drug refers to an amount of the drug which is effective in bringing about a desired effect in the CNS. This amount may be within the usual dosage range of the drug, or it may be less than the usual dosage range of the drug, as defined below, due to the potentiating effect(s) of the additional components of the composition.
[0037] In one embodiment of the invention, the “effective dose” is less than the usual, conventional dosage range of the drug. The usual dose of a CNS drug may be ascertained by reference to standard drug and pharmacological handbooks, such as Goodman & Gilman's The Pharmacological Basis of Therapeutics 9th ed. Hardman Paperback, McGraw-Hill Book Company, 1996, the Physician's Desk Reference, the Israel Drug Index, or drug product inserts provided by the drug manufacturer. This information is well known and available to the average skilled man of the art.
[0038] In a preferred embodiment, “less than the usual, conventional dosage range of the drug” means less than 50%, more preferrably less than 20%, still more preferably less than 10%, most preferably less than 5% of the usual dose of a CNS drug as defined above.
[0039] The terms “compound which stimulates peripheral chemoreceptors of vagal afferents” and “compound which stimulates peripheral osmoreceptors of vagal afferents” are well known terms in the art, as appear, for example, in the following articles:
[0040] BerthoucT, Hans-Rudolf and Neuhuber, W. L. (2000) Functional and chemical anatomy of the afferent vagal system ; Autonomic Neuroscience: Basic and Clinical 85:1-17.
[0041] Carlson, Scott H. and Osbom, J. W. (1998) Splanchnic and vagal denervation attenuate central Fos but not A VP responses to intragastric salt in rats ; Am. J. Physiol. 274:R1243-R1252.
[0042] Kobashi, M. and Adachi, A. (1995) Chemosensitivity of neurons in the dorsal motor nucleus of the vagus that responded to portal infusion of hypertonic saline in rats ; Brain Research Bulletin 38:11-15.
[0043] Schwartz, Gary J. (2000) The role of gastrointestinal vagal afferents in the contol of food intake:current prospects ; Nutrition 16:866-873.
[0044] Powley T L, Phillips R J. Musings on the wanderer: what's new in our understanding of vago-vagal reflexes? L Morphology and topography of vagal afferents innervating the GI tract . Am J Physiol Gastrointest Liver Physiol. 2002 December; 283(6):G1217-25. Epub 2002 Jul. 31.
[0045] Page, A. J., C. M. Martin, and L. A. Blackshaw. Vagal Mechanoreceptors and Chemoreceptors in Mouse Stomach and Esophagus . J. Neurophysiol. 87: 2095-2103, 2002).
[0046] The compounds which stimulate either chemoreceptors or osmoreceptors of the vagal afferents may be identified by one or more of the following methods:
[0047] 1. Direct registration of excitation of chemoreceptors or osmoreceptors of vagal afferents (electrophysiological measurement of action potentials in endings of vagal afferents) induced by compounds or osmotic agents (BerthoucT op. cit.; Verbeme, A. J. M., Saita, M. and Sartor, D. M. (2003) Chemical stimulation of vagal afferent neurons and sympathetic vasomotor tone Brain Research Reviews, 41:288-305; Powley T L, op. cit.)
[0048] 2. Measurement of action potentials in trunk of cardiopulmonary and subdiaphragmatic vagal afferents after stimulation of cardiac chemoreceptors or chemoreceptors or osmoreceptors of gastrointestinal mucosa by chemical compounds or osmotic agents (BerthoucT op. cit.; Verbeme, op.cit; Powley T L, op. cit.).
[0049] 3. Elimination of excitation of endings of vagal afferents, induced by compounds and osmotic agents, after local anaesthesia or deafferentation of endings of vagal afferents by lidocaine and the neurotoxin capsaicin (Powley T L, op. cit.; BerthoucT op. cit.; Uneyama, H, Niijima, A. Tanaka, T. and Torii, K. (2002) Receptor subtype specific activation of the rat gastric vagal afferent fibers to serotonin , Life|Sciences 72:414-423).
4. Elimination of excitation of trunk of vagal afferents, induced by chemical compounds and osmotic agents, after local anaesthesia or deafferentation of endings of vagal afferents by lidocaine and the neurotoxin capsaicin.(Schwartz, op. cit.; Uneyama op. cit.; BerthoucT op. cit.; Verbeme, op. cit; Powley T L, op. cit. Blackshaw L A, Page A J, Partosoedarso E R. Acute effects of capsaicin on gastrointestinal vagal afferents . Neuroscience. 2000; 96(2):407-16).
[0051] 5. Elimination of excitation of trunk of vagal afferents, induced by chemical compounds and osmotic agent after surgical trunk vagotomy and systemic administration of antagonists of CCKA receptors of subdiaphragmatic vagal afferents (proglumide, loxiglumide) (BerthoucT op. cit.; Verbeme, op.cit; Schwartz, op. cit. Moriarty P, Dimaline R, Thompson D G, Dockray G J. Characterization of cholecystokinin A and cholecystokinin B receptors expressed by vagal afferent neurons . Neuroscience. 1997 August;79(3):905-13.)
[0052] 6. Indirect registration of activation of subdiaphragmatic vagal afferents by compounds and osmotic agents: measurement of growth of concentration of endogenous CCK in the blood caused stimulation of chemoreceptor and osmoreceptor vagal afferents in gastrointestinal mucosa (Moriarty P, op.cit., Schwartz, op. cit., Lal S, Kirkup A J, Brunsden A M, Thompson D G, Grundy D. Vagal afferent responses to fatty acids of different chain length in the rat . Am J Physiol Gastrointest Liver Physiol. 2001 October;281 (4):G907- 15).
[0053] 7. Elimination of growth of concentration of endogenous CCK in the blood induced by compounds and osmotic agents after surgical vagotomy, local anaesthesia by lidocaine, or deafferentation of endings of vagal afferents by neurotoxin capsaicin.(BerthoucT op. cit.; Schwartz, op. cit., Blackshaw L A, op. cit., Moriarty P, op. cit.,)
[0054] 8. Measurement of cardiopulmonary and gastrointestinal reflex-induced stimulation of chemoreceptors and osmoreceptors of vagal afferents by compounds and osmotic agents (BerthoucT op. cit.; Verberne, op.cit; Schwartz, op. cit., Storr M, Sattler D, Hahn A, Schusdziarra V, Allescher H D. Endogenous CCK depresses contractile activity within the ascending myenteric reflex pathway of rat ileum . Neuropharmacology. 2003 March;44(4):524-32; Travagli R A, Hermann G E, Browning K N, Rogers R C. Musings on the wanderer: what's new in our understanding of vago - vagal reflexes ? III. Activity - dependent plasticity in vago-vagal reflexes controlling the stomach . Am J Physiol Gastrointest Liver Physiol. 2003 February;284(2):G180-7; Serdiuk S E, Gmiro V E The analgesic and antidepressant action of adrenaline - induced stress in the endogenous activation of the gastric afferent systems in rats Ross Fiziol Zh Im I M Sechenova. 1997 August;83(8):111-20; Serdiuk S E, Gmiro V E The participation of gastric afferents in the reflex mechanisms of immediate adaptation to stress exposures Fiziol Zh Im I M Sechenova. 1995 September;81(9):40-51).
[0055] 9. Elimination of gastrointestinal and cardiopulmonary reflex induced by compounds and osmotic agents, after surgical vagotomy, local anaesthesia by lidocaine, or deafferentation of endings of vagal afferents by the neurotoxin capsaicin (BerthoucT op. cit.; Verbeme, op.cit; Powley T L, op. cit. Lal S, op.cit., Serdiuk S E, 1997 op.cit.. Serdiuk S E, 1995 op.cit.).
[0056] 10. Elimination of gastrointestinal reflex, induced by compounds and osmotic agent, after systemic administration of antagonists of CCKA receptors of subdiaphragmatic vagal afferents (proglumide,loxiglumide). (BerthoucT op. cit.; Verbeme, op.cit; Powley T L, op. cit.; Lal S, op. cit.; Moriarty P, op. cit.).
[0057] 11. Measurement of analgesic, anxiolitic, antidepressive, anticonvulsive, neuroprotective and stress-protective action, induced by stimulation of chemoreceptors and osmoreceptors of vagal afferents by compounds and osmotic agents (Hosomi N., Mizushige K., Kitadai M., Ohyama H., Ichihara S. I., Takahashi T., Matsuo H. Induced hypertension treatment to improve cerebral ischemic injury after transient forebrain ischemia . Brain Res. 835(2): 188-196. 1999; Jensen R. A. Modulation of memory storage processes by peripherally acting pharmacological agents . Proc. West Pharmacol. Soc. 39: 85-89. 1996; Krahl S. E., Senanayake S. S., Handforth A. Seizure suppression by systemic epinephrine is mediated by the vagus nerve . Epilepsy Res. 38(2-3): 171-175. 2000; Randich A., Gebhart G. F. Vagal afferent modulation of nociception . Brain Res. Brain Res. Rev. 17(2):77-99. 1992; Sevoz-Couche C., Hamon M., Laguzzi R. Antinociceptive effect of cardiopulmonary chemoreceptor and baroreceptor reflex activation in the rat . Pain. 99(1-2): 71-81. 2002. Stacher G. Effects of cholecystokinin and caerulein on human eating behavior and pain sensation: a review . Psychoneuroendocrinology, 11(1): 39-48. 1986; Tirassa P., Aloe L., Stenfors C., Turrini P., Lundeberg T. Cholecystokinin -8 protects central cholinergic neurons against fimbria - fornix lesion through the up-regulation of nerve growth factor synthesis . Proc. Natl. Acad. Sci. U.S.A. 96(11): 6473-6477. 1999; Verbeme, op. cit, Watkins L. L., Grossman P. Association of depressive symptoms with reduced baroreflex cardiac control in coronary artery disease. Am. Heart. J. 137(3): 453-457. 1999; Serdiuk 1997 op. cit.; Serdiuk 1995 op. cit.).
[0058] 12. Elimination of analgesic, anxiolitic, antidepressive, anticonvulsive, neuroprotective and stress-protective action, induced by compounds and osmotic agent, after surgical vagotomy ,local anaesthesia by lidocaine and deafferentation ending of vagal afferents by neurotoxin capsaicin (Verbeme, op. cit.; Krahl S. E., op. cit.; Randich A., op. cit.; Sevoz-Couche C., op. cit.; Tirassa P., op. cit.; Serdiuk 1997 op. cit.; Serdiuk 1995 op. cit.)..
[0059] 13. Elimination of analgesic,anxiolitic,antidepressive, anticonvulsive, neuroprotective and stress-protective action induced by compounds and osmotic agent after systemic administration of antagonists of CCKA receptors of subdiaphragmatic vagal afferents (proglumide, loxiglumide) (Feinle C, Grundy D, Fried M. Modulation of gastric distension - induced sensations by small intestinal receptors . Am J Physiol Gastrointest Liver Physiol. 2001 January;280(1):G51-7).Verbeme, op.cit.; Tirassa P op. cit.; Stacher op. cit.; Serdiuk, 1997 op. cit.; Serdiuk, 1995 op. cit.)
[0060] Examples of types of compounds which stimulates peripheral chemoreceptors of vagal afferents are an α-1-adrenomimetic; a catecholamine; serotonin; a serotoninomimetic; gastrointestinal peptide or trypsin inhibitor; a bradykinin; an amino acid; stimulators of NMDA, AMPA/kainate or GABA receptors; metal cations; M-cholinomimetics; an acetylcholinesterase inhibitor; N-cholinomimetic; hystamine or hystaminomimetic; purine derivative; polyamines; stimulator of vanilloid receptors; stimulator of opioid receptors; prostoglandin; nitric oxide or stimulator of receptors of nitric oxide; surfactant; cytokine; carbohydrate; fatty acid; bile acid or salt; and potassium or cloride channel opener.
[0061] Non-limiting examples of α-1-adrenomimetics are the compounds phenylephrine and midodrine. Non-limiting examples of catecholamines are epinephrine, norepinephrine, dopamine, and their combination. A non-limiting example of a serotoninomimetic is a stimulator of 5-HT3 receptors. Non-limiting examples of gastrointestinal peptides are cholecystokinin (CCK), calcitonin gene related peptide (CGRP), leptin, gastrin, substance P, somatostatin, vasointestinal peptide (VIP), and atrial natriuretic peptide (ANP). Non-limiting examples of amino acids are glutamate, aspartate, N-methyl-D-aspartate (NMDA), kainate, 1-arginine or Gamma- aminobutiric acid (GABA). Non-limiting examples of methal cation are Ca 2+ , H + , Mg 2+ , Na + , K + , Zn 2+ , Mn 2+ , Cu 2+ , Ag + , Hg 2+ , Cd 2+ , Ni + , Co 2+ , Al 3+ , Al 2+ , Fe 2+ , Fe 2+ or Bi 2+ . Non-limiting examples of M-cholinomimetic are acetylcholine, carbocholine, or pilocarpine. Non-limiting examples of N-cholinomimetic are subecholine or tetramethylammonium (TMA). Non-limiting examples of purine derivative are adenosine, adenosine monophospatis, adenosine diphosphatis, adenosine triphosphatis or inositol. Non-limiting examples of polyamine are spermine, spermidine, putrescine or agmatine. Non-limiting examples of stimulator of vanilloid receptors are capsaicin, palmitoylethanolamide or anandamide. A non-limiting example of a stimulator of opioid receptors is loperamide. Non-limiting examples of stimulators of receptor of nitric oxide are nitroglycerin or sodium nitroprusside. Non-limiting examples of cytokine are IL-1β, TNF, IL-6, IL-10 or IL-13. Non-limiting examples of carbohydrates are glucose, sucrose or polycose.
[0062] In one embodiment of the invention, the compound which stimulates peripheral chemoreceptors of vagal afferents does not include one or more of the following compounds: an α-1-adrenomimetic such as phenylephrine or midodrine; a catecholamine such as epinephrine, norepinephrine and dopamine; serotonin; a serotoninomimetic; gastrointestinal peptide or trypsin inhibitor; a bradykinin; an amino acid; stimulators of NMDA, AMPA/kainate or GABA receptors; metal cations; M-cholinomimetics; an acetylcholinesterase inhibitor; N-cholinomimetic; hystamine or hystaminomimetic; purine derivative; polyamines; stimulator of vanilloid receptors; stimulator of opioid receptors; prostoglandin; nitric oxide or stimulator of receptors of nitric oxide; surfactant; cytokine; carbohydrate; fatty acid; bile acid or salt; and potassium or cloride channel opener, or one or more of the compounds listed above.
[0063] In another embodiment of the invention, the compound which stimulates peripheral chemoreceptors of vagal afferents does not include specific carbohdrates and/or amino acids such as, for example, glucose, sucrose, tyrosine, phenylalanine and tryptophan.
[0064] In a further embodiment of the invention, the compound which stimulates peripheral chemoreceptors of vagal afferents poorly penetrates the blood-brain barrier (BBB) and has a brain/plasma concentration ratio of less than 0.3.
[0065] The penetration level of compounds through the blood-brain barrier may be estimated by the following method.
[0066] A comparison is made between the maximal concentration of a drug in the blood and in the brain, and the brain/blood concentration ratio is calculated. The main advantage of this method of estimating BBB permeability for compounds is the extended period of time of measurement (up to 90 min, preferably 30-60 min) after systemic drug administration. Therefore, the brain/blood concentration ratio really shows penetration of the BBB by compounds at pike concentration in the blood after systemic administration.
[0067] For example, morphine which is an effective CNS drug has a brain/blood concentration ratio of 0.4-0.5. Compounds which poorly penetrate the BBB usually have a brain/blood concentration ratio of less than 0.3.
[0068] A description of the measurement of brain/plasma concentration ratio may be found in Fox, E. et al. (2002) Zidovudine Concentration in Brain Extracellular Fluid Measured by Microdialysis Steady - State and Transient Results in Rhesus Monkey Journal of Pharmacology And Experimental Therapeutics, 301:1003-1011.
[0069] Non limiting examples of a compound which stimulates peripheral osmoreceptors of vagal afferents include PVP, dextran, PEO, xylitol, mannitol, glycerinum, urea, sorbitol, or a combination of two or more stimulators.
[0070] In one embodiment of the invention, the compound which stimulates peripheral osmoreceptors of vagal afferents does not include osmotically active copolymers of N-vinyl-pyrrolidone with N,N,N,N, triethylmethacryloidoxyethylammonium iodide.
[0071] In one embodiment of the invention, when the compound which stimulates peripheral chemoreceptors of vagal afferents is an α-1-adrenomimetic such as phenylephrine or midodrine; a catecholamine such as epinephrine, norepinephrine and dopamine; or serotonin, the compound which stimulates peripheral osmoreceptors of vagal afferents is not PVP, dextran, PEO, xylitol, mannitol or sorbitol.
[0072] The composition of the invention is systemically administered to the subject (patient). Techniques of administration include systemic parenteral (e.g. intravenous, intramuscular, subcutaneous, inhalation) and systemic enteral (e.g. oral, sublingual, rectal) administration.
[0073] In a second aspect of the invention, there is provided a pharmaceutical composition for systemic administration comprising: (a) an effective dose of a drug which affects the central nervous system (CNS); and (b) a compound which stimulates peripheral chemoreceptors of vagal afferents; wherein the dose of the drug in the composition is less than the usual dose of the drug.
[0074] In this aspect of the invention, the “effective dose” of the drug is less than the usual, conventional dosage range of the drug. The usual dose of a CNS drug may be ascertained by reference to standard drug and pharmacological handbooks, such as Goodman & Gilman's The Pharmacological Basis of Therapeutics 9th ed. Hardman Paperback, McGraw-Hill Book Company, 1996, the Physician's Desk Reference, the Israel Drug Index, or drug product inserts provided by the drug manufacturer. This information is well known and available to the average skilled man of the art
[0075] A compound which stimulates peripheral chemoreceptors of vagal afferents is as defined above.
[0076] In the present invention, the term “composition” may be understood in its usual meaning, i.e. a product of mixing or combining the active ingredients, or the term may be understood as meaning that the active ingredients are administered separately but within a period of time which allows them to interact in the body. For example, in the second aspect of the invention, the compound which affects peripheral chemoreceptors and the CNS active drug may be administered either both parenterally or both orally or else one of them parenterally and the other orally. In the first aspect of the invention, the CNS active drug, the compound which affects peripheral chemoreceptors and the stimulator of osmoreceptors may be administered either all enterally or all parenterally, or else one of them parenterally and the other two enterally, or the reverse.
[0077] Preferred compositions according to the invention comprise α-1-adrenomimetic and PVP or dextran for intramuscular administration, and α-1-adrenomimetic and xylitol, PVP or dextran for oral administration.
[0078] In a third aspect of the invention, there is provided a method of potentiating the activity of a drug which affects the CNS comprising systemically administrating to a subject the drug together with an effective amount of a compound which stimulates peripheral chemoreceptors of vagal afferents and, optionally, with an effective amount of a compound which stimulates peripheral osmoreceptors of vagal afferents.
[0079] An “effective amount” of a compound which affects peripheral chemoreceptors or osmoreceptors as used in the method of the invention is an amount which results in a significant decrease of a minimal effective dose of the CNS drug administered together with these components. For example, the effective amount of a peripherical chemoreceptor stimulating component administered together with a CNS active drug may decrease by 10-100 fold the minimal effective dose of a CNS active drug required in order to elicit a maximal therapeutic effect (i.e. potentiates the effect of the CNS active drug threshold dose to give the effect of a maximal dose). The effective amount may also be an amount that potentiates the magnitude of the maximal effect of the CNS drug. Including the osmoreceptor stimulator into the composition results in a substantial additional decrease in the effective dose of the CNS active drug.
[0080] Preferred concentration ranges (in weight %) of the active ingredients in a composition according to the invention for systemic parenteral administration are as follows: for the CNS active drug: from 0.0005% to the upper limit of the usual dose for each drug; for α-1-adrenomimetic: from 0.0005% to 0.04%, and for stimulants of osmoreceptors from 0.1% to 10%. Compositions for oral administration preferably comprise each active ingredient in the amount of 0.0001% to 10% of the total weight of the composition. The remaining weight of the composition may comprise standard excipients.
[0081] In a fourth aspect of the invention, there is provided a method of treating a disease affecting the CNS comprising systemically administrating to a subject an effective dose of a drug which affects the CNS together with an effective amount of a compound which stimulates peripheral chemoreceptors of vagal afferents and an effective amount of a compound which stimulates peripheral osmoreceptors of vagal afferents.
[0082] In a fifth aspect of the invention, there is provided a method of treating a disease affecting the CNS comprising systemically administrating to a subject an effective dose of a drug which affects the CNS together with an effective amount of a compound which stimulates peripheral chemoreceptors of vagal afferents, wherein the dose of the drug in the composition is less than the usual dose of the drug.
[0083] In a sixth aspect of the invention, there is provided a method for preparing a pharmaceutical composition for systemic administration of a drug which affects the CNS, said method comprising adding to an effective dose of said drug a compound which stimulates peripheral chemoreceptors of vagal afferents; and a compound which stimulates peripheral osmoreceptors of vagal afferents.
[0084] In all of the aspects of the invention, the compound which stimulates peripheral chemoreceptors of vagal afferents and compound which stimulates peripheral osmoreceptors of vagal afferents are as defined in the first aspect above.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0000] Materials and Methods
[0085] The potentiation of the effect of CNS active drugs was studied in experiments on breedless white male rats having a mass of 180-200 g. For these studies, solutions of the composition of the invention were used, which were prepared using distilled water immediately before administration. The solutions were administered either orally (IG), by a rigid metal probe into the cardiac section of the stomach at a total amount of 0.8 ml, or intramuscularly (IM) at an amount of 0.2 ml, 30 min before testing.
[0086] To determine the potentiation effect of the composition on the CNS drug, a minimal effective dose of the CNS drug within the composition causing a maximal possible effect for a given model was determined. The potentiation degree was estimated by the magnitude of the decrease in the minimal effective dose of the CNS drug within the composition causing the given effect of CNS active drug.
[0087] The analgesic effect of the components was estimated by an extension of the latent period of the reflex of tail flicking in the “tail-flick” test [Woolf C. J., Barret G. D., Mitchel D., Myers R. A. (1977) Eur. J Pharmacol. 45(3):311-314] and of the reflex of hind leg flicking in the hyperalgesia test [Coderre T. J., Melzack R. Brain Res . (1987) 404(1-2):95-106].
[0088] For the “tail-flick” test, hyperalgesic rats were selected (latent period of tail flicking on placing into water with a temperature of 51° C. was 3-4 sec). To estimate the potentiation effect of Dipyrone or morphine, the minimal effective dose of these drugs in compositions causing a maximal analgesia was determined (latent period of the reflex above 30 s).
[0089] Hyperalgesia of a leg was developed by placing it into hot water (56° C.) for 20-25 sec under the conditions of ether anesthesia. Hyperalgesia was developed 30 min after the bum (latent period of leg flick reflex on its being placed into water at a temperature 47° C. was reduced from 15-20 s to 2-4 s). To estimate the potentiation effect of Dipyrone, the minimal effective dose of Dipyrone in the composition causing a maximal analgesic effect was determined (latent period of the leg-flick reflex above 30s).
[0090] Antidepressive effects was studied by Porsolt's test [Porsolt R. D., Anton G., Blavet N., Jalfre M. Eur. J. Pharmacol . (1978), 47(4):379-91]. For each rat under study, the total immobilization time was determined during 10 min of forced swimming in a glass vessel at a water temperature of 22° C. The animals were subdivided into three groups according to their immobilization time: highly-, medium- and low-active (immobilization time below 80 sec, 100-140 sec and above 150 sec, respectively). For a repeated study by Porsolt's test, on the second day low-active and highly active rats were selected.
[0091] A model of depression was created by administration to a group of highly active rats of the neurotoxin 1-methyl-4-phenyl-1,2,3,6-tetrahydropyridine (MPTP) [Krupina N. A., Orlova I. N., Kryzhanovskii G. N. Biull. Eksp. Biol. Med . (1995) 120(8):160-3] 30 min before testing at a dose of 15 mg/kg. In the 30 min after the administration of MPTP, MPTP depression was developed in 100% of the highly active rats, since they passed into the category of low-active “depressive” rats (immobilization time—above 150 sec). Antidepressants (amitriptyline or Fluoxetine), as well as their compositions were administered to highly active rats 30 minutes before MPTP administration (60 min before a repeated examination in Porsolt's test), and also to low-active rats 30 min before a repeated study in Porsolt's test.
[0092] To determine the degree of potentiation of the effect of antidepressants, their minimal effective dose within the compositions, which caused a maximal antidepressive effect (immobilization time—below 80 s) in low-active rats and in rats with MPTP-depression was determined.
[0093] In a forced swimming test, the ability of amitriptyline and its compositions to eliminate the effect of toxic doses of MPTP was studied. Single administration of high MPTP doses (30 mg/kg) causes acute suppression of motor activity (akinesis), catalepsy, and muscular rigidity. Antidepressants reduce behavioral depression caused by a single administration of toxic doses of MPTP. The behavioral depression was studied in a forced swimming test of a group of active rats after the administration of a toxic dose of MPTP (30 mg/kg IM). Swimming duration (maximal swimming duration—10 min) and the time of forced immobilization during the first 5 min of swimming (under the condition that swimming duration exceeds 5 min) was estimated in the forced swimming test 30 min after MPTP administration. Drugs were administered IM or IG 30 min before MPTP administration.
[0094] To estimate the potentiation of the effects of amitriptyline (its ability to reduce toxic effects of MPTP), the minimal effective dose of amitriptyline in the composition, which increased swimming time up to 9-10 min and reduced immobilization time during the first 5 min of swimming down to 20-30 sec was determined.
[0095] Haloperidol catalepsy is a test for selecting anti-parkinson agents [Campbell A., Baldessarini R. J., Cremens M. C. Neuropharmacology (1988), 27(11):1197-9; Ossowska K. J. Neural. Transm. Park. Dis. Dement. Sect . (1994) 8(1-2):39-71]. Catalepsy degree was estimated by the immobilization time (in sec) of a rat placed on a coarse-mesh grid at an angle of 45° during a 3-minute exposition [Campbell A., Baldessarini R. J., Cremens M. C. Neuropharmacology (1988) 27(11):1197-9] 30, 60, 90 and 120 minutes after haloperidol administration. Maximal catalepsy was attained in 40-60 minutes after haloperidol administration (immobilization time on the grid was 140-180 sec) and lasted from 2 to 6 hours depending on the dose of haloperidol (1 or 3 mg/kg). The minimal effective dose of the anti-parkinson agent memantine causing a maximal anticataleptic effect (immobilization time on an inclined grid less than 40 sec) 1 hour after haloperidol administration at a dose of 1 and 3 mg/kg was calculated.
[0096] To estimate the potentiation effect of memantine, the minimal effective dose of memantine in the composition causing a maximal anticataleptic effect was determined.
[0097] Anticonvulsive effects of drugs and their compositions was studied on the model of pentetrazole seizures [Parsons C. G., Quack G., Bresink I., Baran L., Przegalinski E., Kostowski W., Krzascik P., Hartmann S., Danysz W. Neuropharmacology (1995) 34(10):1239-1258). The capacity of the anticonvulsive drug diazepam and its compositions to prevent generalized clonico-tonic and clonic seizures in 80% of the rats 30 minutes after pentetrazole administration at a dose of 70 mg/kg IM (minimal effective dose) was estimated.
[0098] To estimate the potentiation of diazepam effect, its minimal effective dose in the composition preventing clonico-tonic and clonic seizures in 80% of rats was determined.
[0099] Antipsychotic effect of neuroleptics was studied using the model of behavioral toxicity “NK-toxicity” caused by a blocker of NMDA receptors MK-801 (Lapin I. P., Rogawski M. A. Behav. Brain Res . (1995) 70(2):145-151) and a model of phenaminic stereotypy caused by phenamine (Kuczenski R., Schmidt D., Leith N. Brain Res . (1977), 126(1):117-129).
[0100] The minimal effective dose of the neuroleptic haloperidol necessary to completely prevent the development of “MK-toxicity” (MK-801 at a dose of 0.4 mg/kg IM) and phenaminic stereotypy (phenamine at a dose of 10 mg/kg IM) in 80% of the rats was calculated. To estimate the potentiation of the antipsychotic effect of haloperidol, the minimal effective dose of haloperidol in compositions, which completely prevents the development of MK-toxicity and phenaminic stereotypy in rats, was determined.
[0101] The potentiation of the effect of psychostimulants was studied using the model of phenaminic stereotypy [Kuczenski R., Schmidt D., Leith N. Brain Res . (1977), 126(1):117-29]. Phenamine at a dose of 10 mg/kg IM, or 20 mg/kg IG, causes a marked behavioral stereotypy. To estimate the potentiation effect of phenamine, a phenamine dose in the IM or IG introduced composition was determined, which causes the same stereotypy as phenamine alone at a dose of 10 mg/kg, IM or 20 mg/kg, IG. The potentiation degree of the psychostimulating effect of phenamine was estimated by the magnitude of the decrease of an equally effective dose of phenamine in the composition.
EXAMPLES
Example 1
Potentiation of the Effect of Analgesics
[0000] a. Intramuscular Administration of Compositions
[0102] A non-narcotic analgesic named Dipyrone at a dose of 20 mg/kg and the narcotic analgesic morphine at a dose of 3 mg/kg completely eliminate algesia in the tail-flick test (latent period of tail-flicking reflex increases from 3 to 30 sec and more). In the hyperalgesia test Dipyrone does not cause 20 complete analgesia even in a limiting dose of 40 mg/kg (latent period of leg flicking reflex increases from 3-4 s to 12.6 s). The results of administrating compositions in accordance with the invention are summarized in Table I.
[0103] The α-1-adrenomimetics phenylephrine or midodrine at a threshold dose (0.008-0.01 mg/kg), which does not affect analgesia, in a composition with Dipyrone decrease the minimal effective dose of the drug 100 and 132 fold, respectively, causing maximal analgesia in the tail-flick test. In the hyperalgesia test, they potentiate the incomplete effect of the maximal dose of Dipyrone (30 mg/kg), which leads to the development of maximal analgesia in this model, that is more rigorous than the tail-flick model (the latent period of leg flicking reflex becomes longer than 30 s). An increase in α-1-adrenomimetic dose up to 0.02 mg/kg does not considerably increase the effect of Dipyrone in the tail-flick test, but decreases the minimal effective dose of Dipyrone causing a maximal analgesic effect in the hyperalgesia test 6-6.9 fold.
[0104] Inclusion of a stimulant of osmoreceptors, such as PVP, dextran or PEO, into the composition of Dipyrone with the α-1-adrenomimetics phenylephrine or midodrine at a dose that does not cause analgesia leads to an additional 2-3.5-fold decrease in the minimal effective dose of Dipyrone, as well as a 3.3-4-fold decrease of a dose of phenylephrine or midodrine in the composition.
[0105] Concentrations of the active ingredients in a solution of the composition of the invention potentiating the effect of Dipyrone were as follows: Dipyrone—from 0.005% to 3%, α-1-adrenomimetics—from 0.003% to 0.02%, and stimulants of osmoreceptors—from 0.25% to 2%. A decrease in the contents of α-1-adrenomimetics and stimulants of osmoreceptors in a composition with Dipyrone below the indicated limits leads to a dramatic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable intensification of the effect of the composition.
[0106] The minimal effective dose of morphine in the tail-flick test decreases 75-fold in a composition with threshold doses of phenylephrine, and 214-fold in a composition with threshold doses of phenylephrine and PVP.
[0000] b. Intragastric (Oral) Administration of Compositions
[0107] In the tail-flick test, Dipyrone at a dose of 20 mg/kg and morphine at a dose of 3 mg/kg cause a maximal analgesia (latent period of tail flicking reflex exceeds 30 s). In the hyperalgesia test, IG administration of Dipyrone at its maximal possible dose of 40 mg/kg causes a mild analgesic effect (latent period of tail flicking reflex—13 s).
[0108] Phenylephrine or midodrine at a threshold dose of 0.004-0.005 mg/kg in a composition with Dipyrone decreases its minimal effective dose, causing maximal analgesia in tail-flick test 133-167 times. In the hyperalgesia test they potentiate a mild analgesic effect of the maximal dose of Dipyrone (29 mg/kg) up to a complete analgesia (the latent period of leg flicking reflex becomes longer than 30 s).
[0109] A further increase in phenylephrine or midodrine dose up to 0.01 mg/kg in the hyperalgesia test causes not only a potentiation of the effect of Dipyrone, but also decreases 9 and 7.9 times, respectively, the minimal effective dose of Dipyrone in the composition.
[0110] Inclusion of stimulants of osmoreceptors such as PVP, dextran, PEO, xylitol or sorbitol into the composition of Dipyrone with α-1-adrenomimetics at a dose that does not cause analgesia leads to an additional 2.3-4.6-fold decrease in the minimal effective dose of Dipyrone and also to a 2.5-5-fold decrease in the threshold dose of phenylephrine or midodrine in the composition.
[0111] Concentrations of the active ingredients in a solution of the composition for potentiation were as follows: Dipyrone—from 0.003% to 3%, α-1-adrenomimetics—from 0.001% to 0.01%, and stimulants of osmoreceptors—from 0.1% to 0.8%. A decrease in the contents of α-1-adrenomimetics and stimulants of osmoreceptors in a composition with Dipyrone below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable potentiation of the effect of the composition.
[0112] The minimal effective dose of morphine in the tail-flick test decreases 100-fold in a composition with threshold doses of phenylephrine, and 300-fold—in a composition with threshold doses of phenylephrine and xylitol.
TABLE I Potentiation of analgesic effect of morphine and Dipyrone “Tail-flick” test Hyperalgesia test Drug or Way of Dose causing maximal Dose causing maximal composition administration analgesia* analgesia* Dipyrone IM*** 20 ± 2.2 mg/kg 40 mg/kg**** Dipyrone + phenylephrine IM 5.5 ± 0.6 mg/kg 31 ± 3.4 mg/kg IM 0.004 mg/kg 0.008 mg/kg Dipyrone + phenylephrine IM 0.20 ± 0.023 mg/kg 5.2 ± 0.56 mg/kg IM 0.01 mg/kg 0.02 mg/kg Dipyrone + midodrine IM 5.1 ± 0.55 mg/kg 29 ± 3.2 mg/kg IM 0.004 mg/kg 0.008 mg/kg Dipyrone + midodrine IM 0.15 ± 0.018 mg/kg 4.2 ± 0.46 mg/kg IM 0.01 mg/kg 0.02 mg/kg Dipyrone + phenylephrine + PVP IM 0.06 ± 0.007 mg/kg 1.6 ± 0.19 mg/kg IM 0.003 mg/kg 0.005 mg/kg IM 5 mg/kg 10 mg/kg Dipyrone + midodrine + PVP IM 0.05 ± 0.006 mg/kg 1.2 ± 0.15 mg/kg IM 0.003 mg/kg 0.005 mg/kg IM 5 mg/kg 10 mg/kg Dipyrone + phenylephrine + dextran IM 0.06 ± 0.007 mg/kg 1.9 ± 0.22 mg/kg IM 0.003 mg/kg 0.005 mg/kg IM 2.5 mg/kg 5 mg/kg Dipyrone + phenylephrine + PEO IM 0.09 ± 0.01 mg/kg 2.5 ± 0.29 mg/kg IM 0.003 mg/kg 0.005 mg/kg IM 10 mg/kg 20 mg/kg Dipyrone IG***** 20 ± 2.3 mg/kg 40 mg/kg****** Dipyrone + phenylephrine IG 7.1 ± 0.74 mg/kg 34.2 ± 3.6 mg/kg IG 0.002 mg/kg 0.004 mg/kg Dipyrone + phenylephrine IG 0.12 ± 0.014 mg/kg 3.8 ± 0.4 mg/kg IG 0.005 mg/kg 0.01 mg/kg Dipyrone + midodrine IG 6.5 ± 0.72 mg/kg 32.2 ± 3.6 mg/kg IG 0.002 mg/kg 0.004 mg/kg Dipyrone + midodrine IG 0.15 ± 0.018 mg/kg 4.1 ± 0.45 mg/kg IG 0.005 mg/kg 0.01 mg/kg Dipyrone + phenylephrine + PVP IG 0.05 ± 0.0068 mg/kg 1.2 ± 0.14 mg/kg IG 0.001 mg/kg 0.002 mg/kg IG 8 mg/kg 16 mg/kg Dipyrone + phenylephrine + dextran IG 0.04 ± 0.005 mg/kg 1.4 ± 0.16 mg/kg IG 0.001 mg/kg 0.002 mg/kg IG 4 mg/kg 8 mg/kg Dipyrone + phenylephrine + PEO IG 0.05 ± 0.0055 mg/kg 1.9 ± 0.23 mg/kg IG 0.001 mg/kg 0.002 mg/kg IG 16 mg/kg 32 mg/kg Dipyrone + phenylephrine + xylitol IG 0.03 ± 0.004 mg/kg 0.8 ± 0.09 mg/kg IG 0.001 mg/kg 0.002 mg/kg IG 4 mg/kg 8 mg/kg Dipyrone + midodrine + xylitol IG 0.05 ± 0.006 mg/kg 1.0 ± 0.12 mg/kg IG 0.001 mg/kg 0.002 mg/kg IG 4 mg/kg 8 mg/kg Dipyrone + phenylephrine + sorbitol IG 0.06 ± 0.07 mg/kg 2.5 ± 0.20 mg/kg IG 0.001 mg/kg 0.002 mg/kg IG 8 mg/kg 16 mg/kg Morphine IM 3.0 ± 0.37 mg/kg Morphine + phenylephrine IM 2.4 ± 0.028 mg/kg IM 0.004 mg/kg Morphine + phenylephrine IM 0.04 ± 0.0045 mg/kg IM 0.01 mg/kg Morphine + phenylephrine + PVP IM 0.014 ± 0.0017 mg/kg IM 0.003 mg/kg IM 5 mg/kg Morphine IG 3 ± 0.35 mg/kg Morphine + phenylephrine IG 0.8 ± 0.09 mg/kg IG 0.002 mg/kg Morphine + phenylephrine IG 0.03 ± 0.0035 mg/kg IG 0.005 mg/kg Morphine + phenylephrine + xylitol IG 0.01 ± 0.0012 mg/kg IG 0.001 mg/kg IG 4 mg/kg *Latent period of tail flicking reflex more than 30 sec. **Latent period of leg flicking reflex more than 30 sec. ***Hereinafter the IM administered volume is 0.2 ml. ****Latent period of leg flicking reflex 12.6 ± 1.4 sec. *****Hereinafter the IG administered volume is 0.8 ml. ******Latent period of leg flicking reflex 13.1 ± 1.6 sec.
Example 2
Potentiation of the Effect of Antidepressants
[0000] a. Intramuscular Administration of Compositions
[0113] IM administration of the antidepressant amitriptyline causes a maximal antidepressive effect in Porsolt's test (during 10 min of forced swimming, the immobilization time is below 80s) both in a group of low-active rats and in a group of highly active rats with MPTP depression (MPTP—15 mg/kg IM) at doses of 5.0 and 7.2 mg/kg, respectively. An increase of MPTP dose up to 30 mg/kg causes an acute suppression of motor activity and behavioral depression 15-30 min after IM administration. In a forced swimming test, the duration of swimming decreases from 550-600 s to 157-160 s.
[0114] Amitriptyline at a dose of 20 mg/kg does not influence the effects of toxic doses of MPTP. Amitriptyline at a maximal dose of 30 mg/kg only partially decreases the toxic effect of MPTP, increasing swimming duration up to 410 s. The total immobilization time after the administration of 30 mg/kg of amitriptyline with 30 mg/kg of MPTP during the first 5 min of swimming was equal to 61 s. This corresponds to the immobilization time of medium-active rats and testifies to a mild antidepressive effect of amitriptyline in the maximal dose in case of administration of toxic doses of MPTP. The results of administrating compositions in accordance with the invention are summarized in Tables II and III.
[0115] Phenylephrine or midodrine at a threshold dose (0.002-0.003 mg/kg) in a composition with amitriptyline decrease the minimal effective dose of amitriptyline causing maximal antidepressive effect in low-active rats and rats with MPTP-depression (MPTP 15 mg/kg IM) 87 and 70 times, respectively. Subsequent to the administration of a toxic dose of MPTP (30 mg/kg IM), phenylephrine at a threshold dose of 0.003 mg/kg in the composition with amitriptyline (30 mg/kg) potentiates a mild effect of amitriptyline in the maximal dose and eliminates completely the behavioral depression caused by the toxic dose of NPTP (swimming time increases up to 565 s, and the immobilization time is reduced from 61 s to 28 s). An increase of a dose of phenylephrine up to 0.006 mg/kg in the composition with amitriptyline makes it possible to decrease 3-fold the maximal effective dose of amitriptyline, which totally eliminates the effect of the toxic dose of MPTP.
[0116] Additional inclusion of a stimulant of osmoreceptors into the composition of amitriptyline with α-1-adrenomimetic allows decreasing both the minimal effective dose of amitriptyline (2.5-3.3-fold) and the dose of α-1-adrenomimetic (2-3.3-fold), which is observed in all the models under study.
[0117] Active ingredient contents in solution of the compositions for potentiation was as follows: amitriptyline—from 0.002% to 3%, α-1-adrenomimetics—from 0.0006% to 0.006%, and stimulants of osmoreceptors—from 0.5% to 2%. A decrease in the contents of α-1-adrenomimetics and stimulants of osmoreceptors in a composition with amitriptyline below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable potentiation of the effect of the composition.
[0118] IM administration of Fluoxetine causes a maximal antidepressive effect in low-active rats and rats with MPTP depression at a doses of 10.6 and 16.2 mg/kg, respectively. The minimal effective dose of Fluoxetine in Porsolts test in a composition with phenylephrine and PVP is decreased 46-63-fold.
[0000] b. Intragastric Administration of Compositions
[0119] IG administration of amitriptyline causes a maximal antidepressive effect in Porsolt's test (immobilization time below 80 s during 10 min of forced swimming) both in a group of low-active rats and in a group of highly active rats with MPTP depression (IM 15 mg/kg of MPTP) at a dose of 2-2.5 mg/kg, respectively. Amitriptyline at a dose of 30 mg/kg IG in the forced swimming test only partially eliminates the behavioral depression caused by a toxic dose of MPTP (30 mg/kg IM) (swimming time increased from 157 s to 340 s in comparison with reference group, and the immobilization time during 5 min of swimming amounted to 78 s).
[0120] Phenylephrine or midodrine at a threshold dose of 0.002-0.003 mg/kg) in a composition with amitriptyline decrease 25-33-fold the minimal effective dose of amitriptyline causing a maximal antidepressive effect in low-active rats and rats with MPTP-depression. On the administration of a toxic dose of MPTP (30 mg/kg IM), phenylephrine at a threshold dose of 0.004 mg/kg in the composition with amitriptyline (30 mg/kg) potentiates the incomplete effect of amitriptyline at the maximal dose and eliminates completely the behavioral depression caused by a toxic dose of MPTP (swimming time increases up to 560 s, and the immobilization time is reduced from 78 s to 30 s). An increase in phenylephrine dose up to 0.008 mg/kg in composition with amitriptyline makes it possible to decrease 3-fold the minimal effective dose of amitriptyline, eliminating completely the effect of the toxic dose of MPTP.
[0121] Addition of a stimulant of osmoreceptors to the composition of amitriptyline with α-1-adrenomimetic makes it possible to decrease both the minimal effective dose of amitriptyline (2.2-4-fold) and the dose of α-1-adrenomimetic (2-5-fold) in all the models under study.
[0122] Active ingredient contents in solutions of the compositions for potentiation was as follows: amitriptyline—from 0.001% to 3%, α-1-adrenomimetics—from 0.0005% to 0.008%, and stimulants of osmoreceptors—from 0.2% to 1%. A decrease in the contents of α-1-adrenomimetics and stimulants of osmoreceptors in a composition with amitriptyline below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable potentiation of the effect of the composition.
[0123] IG administration of Fluoxetine causes a maximal antidepressive effect in low-active rats and rats with MPTP depression at doses of 5.5 mg/kg and 10.7 mg/kg, respectively. The minimal effective dose of Fluoxetine in Porsolt's test in a composition with phenylephrine and PVP decreases 50-59-fold.
TABLE II Potentiation of antidepressive effect of amitriptyline and Fluoxetine in Porsolt's test Porsolt's test. Dose*. Porsolt's test. Group of highly-active Drug or Way of Dose*. rats*** with MPTP composition administration Group of low-active rats** depression**** Amitriptyline IM***** 5.2 ± 0.6 mg/kg 7.0 ± 0.8 mg/kg Amitriptyline + phenylephrine IM 2.1 ± 0.24 mg/kg 2.4 ± 0.27 mg/kg IM 0.001 mg/kg 0.0015 mg/kg Amitriptyline + phenylephrine IM 0.06 ± 0.0066 mg/kg 0.1 ± 0.013 mg/kg IM 0.002 mg/kg 0.003 mg/kg Amitriptyline + midodrine IM 3.1 ± 0.34 mg/kg 4.2 ± 0.47 mg/kg IM 0.001 mg/kg 0.0015 mg/kg Amitriptyline + midodrine IM 0.1 ± 0.012 mg/kg 0.12 ± 0.014 mg/kg IM 0.002 mg/kg 0.003 mg/kg Amitriptyline + phenylephrine + PVP IM 0.02 ± 0.0023 mg/kg 0.03 ± 0.0035 mg/kg IM 0.0006 mg/kg 0.001 mg/kg IM 10 mg/kg 10 mg/kg Amitriptyline + midodrine + PVP IM 0.03 ± 0. mg/kg 0.04 ± 0.005 mg/kg IM 0.0006 mg/kg 0.001 mg/kg IM 10 mg/kg 10 mg/kg Amitriptyline + phenylephrine + dextran IM 0.02 ± 0.0023 mg/kg 0.03 ± 0.0035 mg/kg IM 0.001 mg/kg 0.0015 mg/kg IM 5 mg/kg 5 mg/kg Amitriptyline + phenylephrine + PEO IM 0.025 ± 0.004 mg/kg 0.04 ± 0.005 mg/kg IM 0.001 mg/kg 0.0015 mg/kg IM 15 mg/kg 15 mg/kg Fluoxetine IM 10.6 ± 1.2 mg/kg 16 ± 2.1 mg/kg Fluoxetine + PVP IM 1.4 ± 0.17 mg/kg 1.9 ± 0.23 mg/kg IM 20 mg/kg 20 mg/kg Fluoxetine + phenylephrine + PVP IM 0.12 ± 0.015 mg/kg 0.17 ± 0.021 mg/kg IM 0.001 mg/kg 0.001 mg/kg IM 10 mg/kg 10 mg/kg Amitriptyline IG****** 2.0 ± 0.24 mg/kg 2.5 ± 0.5 mg/kg Amitriptyline + phenylephrine IG 0.92 ± 0.095 mg/kg 1.1 ± 0.25 mg/kg IG 0.001 mg/kg 0.0015 mg/kg Amitriptyline + phenylephrine IG 0.06 ± 0.0065 mg/kg 0.10 ± 0.012 mg/kg IG 0.002 mg/kg 0.003 mg/kg Amitriptyline + midodrine IG 1.2 ± 0.15 mg/kg 1.3 ± 0.15 mg/kg IG 0.001 mg/kg 0.0015 mg/kg Amitriptyline + midodrine IG 0.06 ± 0.0067 mg/kg 0.11 ± 0.013 mg/kg IG 0.002 mg/kg 0.003 mg/kg Amitriptyline + phenylephrine + xylitol IG 0.016 ± 0.0021 mg/kg 0.03 ± 0.0035 mg/kg IG 0.0005 mg/kg 0.001 mg/kg IG 8 mg/kg 8 mg/kg Amitriptyline + midodrine + xylitol IG 0.018 ± 0.0022 mg/kg 0.035 ± 0.0041 mg/kg IG 0.0005 mg/kg 0.001 mg/kg IG 8 mg/kg 8 mg/kg Amitriptyline + phenylephrine + PVP IG 0.022 ± 0.0026 mg/kg 0.04 ± 0.0045 mg/kg IG 0.0007 mg/kg 0.001 mg/kg IG 12 mg/kg 12 mg/kg Amitriptyline + phenylephrine + dextran IG 0.012 ± 0.0014 mg/kg 0.018 ± 0.0023 mg/kg IG 0.0005 mg/kg 0.001 mg/kg IG 8 mg/kg 8 mg/kg Amitriptyline + phenylephrine + PEO IG 0.025 ± 0.003 mg/kg 0.045 ± 0.0053 mg/kg IG 0.0007 mg/kg 0.0014 mg/kg IG 32 mg/kg 32 mg/kg Amitriptyline + phenylephrine + sorbitol IG 0.025 ± 0.0029 mg/kg 0.038 ± 0.0046 mg/kg IG 0.0006 mg/kg 0.0012 mg/kg IG 16 mg/kg 16 mg/kg Fluoxetine IG 5.5 ± 0.7 mg/kg 10.7 ± 1.1 mg/kg Fluoxetine + xylitol IG 1.8 ± 0.23 mg/kg 3.2 ± 0.36 mg/kg IG 20 mg/kg 20 mg/kg Fluoxetine + phenylephrine + xylitol IG 0.11 ± 0.013 mg/kg 0.18 ± 0.022 mg/kg IG 0.001 mg/kg 0.001 mg/kg IG 8 mg/kg 8 mg/kg *Minimal effective dose of drug causing a maximal antidepressive effect (immobilization time below 80 sec). **Total immobilization time more than 140 sec during 10 min of forced swimming in Porsolt's test. ***Total immobilization time below 80 sec during 10 min of forced swimming in Porsolt's test. ****MPTP in the dose of 15 mg/kg IM 30 min after its administration prolongs the immobilization time up to 150 and more seconds during 10 min of forced swimming in Porsolt's test. *****Hereinafter the IM administered volume is 0.2 ml. ******Hereinafter the IG administered volume is 0.8 ml.
[0124]
TABLE III
Potentiation of amitriptyline effect in a forced swimming test in
rats with behavioral depression caused by a toxic dose of MPTP
Total
immobilization
time during the
first 5 minutes of
Maximal duration of
forced
Way of
Dose
forced swimming*
swimming**
Drug
administration
mg/kg
sec
sec
Distilled water
IM***
—
160 ± 22
—
Amitriptyline
IM
20
220 ± 25
—
Amitriptyline
IM
30
410 ± 46
61 ± 6.3
Amitriptyline + phenylephrine
IM
30
560 ± 63
28 ± 3.0
IM
0.002
Amitriptyline + phenylephrine
IM
10
565 ± 61
25 ± 2.7
IM
0.006
Amitriptyline + phenylephrine + PVP
IM
5
590 ± 65
17 ± 1.9
IM
0.003
IM
20
Distilled water
IG****
—
157 ± 18
—
Amitriptyline
IG
30
340 ± 37
78 ± 8.5
Amitriptyline + phenylephrine
IG
30
565 ± 59
30 ± 3.4
IG
0.004
Amitriptyline + phenylephrine
IG
10
558 ± 64
28 ± 3.2
IG
0.008
Amitriptyline + phenylephrine + xylitol
IG
5
585 ± 61
20 ± 2.3
IG
0.004
IG
40
*Duration of forced swimming of rats in sec until drowning 30 min after MPTP administration in the dose of 30 mg/kg to active rats. Maximal recorded time of forced swimming 600 seconds.
**Immobilization time was recorded during the first 5 minutes of forced swimming, 30 min after MPTP administration in the dose of 30 mg/kg to active rats.
***Hereinafter the IM administered volume is 0.2 ml.
****Hereinafter the IG administered volume is 0.8 ml.
Example 3
Potentiation of the Effect of Antiparkinson Agents
[0000] a. Intramuscular Administration of Compositions
[0125] The anti-parkinson agent memantine at a dose of 7.5 mg/kg completely eliminates the catalepsy caused by haloperidol at a dose of 1 mg/kg (immobilization time of a rat on an inclined grid is below 40 s). However, even at a dose of 15 mg/kg, memantine eliminates the catalepsy caused by haloperidol at a dose of 3 mg/kg only partially (immobilization time—60-70 s). The results of administrating compositions in accordance with the invention are summarized in Table IV.
[0126] Phenylephrine or midodrine at a threshold dose (0.02 mg/kg) in a composition with memantine decrease its minimal effective dose causing a maximal effect (total elimination of catalepsy caused by haloperidol at a dose of 1 mg/kg) 18.8 and 17.9 times, respectively. They also potentiate an incomplete effect of memantine in the maximal dose (15 mg/kg) up to a complete elimination of catalepsy caused by haloperidol at a dose of 3 mg/kg. Further increase of a dose of phenylephrine or midodrine up to 0.04 mg/kg, which also does not cause an independent effect, not only potentiates the effect of memantine, but also decreases its maximal effective dose 4.5-4.8 times eliminating catalepsy caused by haloperidol at a dose of 3 mg/kg.
[0127] The inclusion of stimulants of osmoreceptors—PVP, dextran or PEO—into the composition with memantine and α-1-adrenomimetics causes an additional decrease in the minimal effective dose of memantine for both models of catalepsy 2.1-2.7 times and at a dose of α-1-adrenomimetic in a tertiary composition 3-4 times.
[0128] Active ingredient contents in solutions of the compositions for potentiation was as follows: memantine—from 0.015% to 1.5%, α-1-adrenomimetics—from 0.005% to 0.04%, and stimulants of osmoreceptors—from 1% to 4%. A decrease in the contents of α-1-adrenomimetics and stimulants of osmoreceptors in a composition with memantine below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable Potentiation of the effect of the composition.
[0000] b. Intragastric Administration of Compositions
[0129] Memantine at a dose of 11.5 mg/kg eliminates completely the catalepsy caused by haloperidol at a dose of 1 mg/kg (immobilization time of a rat on an inclined grid is below 40 s). However, at a dose of 16 mg/kg, memantine eliminates the catalepsy caused by haloperidol at a dose of 3 mg/kg only partially (immobilization time—60-70 s).
[0130] Phenylephrine or midodrine at a threshold dose of 0.02 mg/kg) in a composition with memantine decrease 10-11-fold its minimal effective dose causing a maximal effect (total elimination of catalepsy caused by haloperidol at a dose of 1 mg/kg). They also potentiate the incomplete effect of memantine in the maximal dose (16 mg/kg) up to a complete elimination of catalepsy caused by haloperidol at a dose of 3 mg/kg.
[0131] A further increase of a threshold dose of phenylephrine or midodrine up to 0.04 mg/kg causes both the potentiation of the effect of memantine and a 3.7-4-fold decrease of its minimal effective dose eliminating catalepsy caused by haloperidol at a dose of 3 mg/kg.
[0132] The inclusion of stimulants of osmoreceptors—PVP, dextran, PEO, xylitol or sorbitol—into the composition with memantine and α-1-adrenomimetic causes an additional decrease of the minimal effective dose of memantine in both models of catalepsy 2.1-4 times and the dose of α-1-adrenomimetic 4 times.
[0133] Active ingredient contents in solutions of the compositions for potentiation was as follows: memantine—from 0.02% to 1.6%, α-1-adrenomimetics—from 0.005% to 0.04%, and stimulants of osmoreceptors—from 1% to 10%. A decrease in the contents of α-1-adrenomimetics and stimulants of osmoreceptors in a composition with memantine below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable potentiation of the effect of the composition.
TABLE IV Potentiation of the effect of antiparkinson drugs Minimal effective dose of drug* eliminating catalepsy caused by: Way of a) haloperidol b) haloperidol Drug administration at a dose of 1 mg/kg** at a dose of 3 mg/kg** Memantine IM*** 7.5 ± 0.7 mg/kg 15.0 mg/kg**** Memantine + phenylephrine IM 5.7 ± 0.6 mg/kg 13.5 ± 1.5 mg/kg IM 0.01 mg/kg 0.02 mg/kg Memantine + phenylephrine IM 0.4 ± 0.045 mg/kg 3.1 ± 0.04 mg/kg IM 0.02 mg/kg 0.04 mg/kg Memantine + midodrine IM 6.2 ± 0.7 mg/kg 13.8 ± 1.5 mg/kg IM 0.01 mg/kg 0.02 mg/kg Memantine + midodrine IM 0.42 ± 0.05 mg/kg 3.3 ± 0.37 mg/kg IM 0.02 mg/kg 0.04 mg/kg Memantine + phenylephrine + PVP IM 0.15 ± 0.02 mg/kg 1.3 ± 0.17 mg/kg IM 0.005 mg/kg 0.01 mg/kg IM 10 mg/kg 20 mg/kg Memantine + midodrine + PVP IM 0.17 ± 0.021 mg/kg 1.4 ± 0.17 mg/kg IM 0.005 mg/kg 0.01 mg/kg IM 10 mg/kg 10 mg/kg Memantine + phenylephrine + dextran IM 0.18 ± 0.022 mg/kg 1.4 ± 0.16 mg/kg IM 0.005 mg/kg 0.01 mg/kg IM 10 mg/kg 20 mg/kg Memantine + phenylephrine + PEO IM 0.19 ± 0.023 mg/kg 1.5 ± 0.18 mg/kg IM 0.005 mg/kg 0.015 mg/kg IM 20 mg/kg 40 mg/kg Memantine IG***** 11.5 ± 1.2 mg/kg 16.0 mg/kg**** Memantine + phenylephrine IG 8.5 ± 0.9 mg/kg 15.0 ± 1.7 mg/kg IG 0.01 mg/kg 0.02 mg/kg Memantine + phenylephrine IG 1.0 ± 0.12 mg/kg 4.0 ± 0.046 mg/kg IG 0.02 mg/kg 0.04 mg/kg Memantine + midodrine IG 8.8 ± 0.9 mg/kg 15.2 ± 1.8 mg/kg IG 0.01 mg/kg 0.02 mg/kg Memantine + midodrine IG 1.1 ± 0.13 mg/kg 4.3 ± 0.05 mg/kg IG 0.02 mg/kg 0.04 mg/kg Memantine + phenylephrine + xylitol IG 0.24 ± 0.047 mg/kg 1.5 ± 0.18 mg/kg IG 0.005 mg/kg 0.01 mg/kg IG 80 mg/kg 120 mg/kg Memantine + midodrine + xylitol IG 0.26 ± 0.03 mg/kg 1.6 ± 0.19 mg/kg IG 0.005 mg/kg 0.01 mg/kg IG 80 mg/kg 120 mg/kg Memantine + phenylephrine + PVP IG 0.28 ± 0.034 mg/kg 1.8 ± 0.22 mg/kg IG 0.005 mg/kg 0.01 mg/kg IG 40 mg/kg 80 mg/kg Memantine + phenylephrine + dextran IG 0.2 ± 0.024 mg/kg 1.3 ± 0.15 mg/kg IG 0.005 mg/kg 0.01 mg/kg IG 40 mg/kg 80 mg/kg Memantine + phenylephrine + PEO IG 0.35 ± 0.044 mg/kg 2.0 ± 0.24 mg/kg IG 0.005 mg/kg 0.01 mg/kg IG 200 mg/kg 400 mg/kg Memantine + phenylephrine + sorbitol IG 0.32 ± 0.036 mg/kg 1.9 ± 0.23 mg/kg IG 0.005 mg/kg 0.01 mg/kg IG 160 mg/kg 320 mg/kg *Dose of the drug corresponding to the immobilization time of a rat on an inclined grid (at an angle of 45°) below 40 seconds. **Haloperidol in the doses of 1 mg/kg and 3 mg/kg IM causes after 60 minutes the immobilization of rats on an inclined grid for 140-180 seconds during 3 minutes of exposition. ***Hereinafter the IM administered volume is 0.2 ml. ****The immobilization time of rats on an inclined grid amounts to 60-70 seconds. *****Hereinafter the IG administered volume is 0.8 ml.
Example 4
Potentiation of the Effect of Anticonvulsive Agents
[0000] a. Intramuscular Administration of Compositions
[0134] Diazepam at a dose of 6.7 mg/kg completely eliminates the generalized (clonico-tonic) seizures caused by pentylenetetrazole at a dose of 70 mg/kg in 80% of rats. Diazepam at the maximal endurable dose of 10 mg/kg eliminates clonic seizures preceding the generalized seizures caused by pentylenetetrazole at a dose of 70 mg/kg only in 20% of rats. The results of administrating compositions in accordance with the invention are summarized in Table V.
[0135] Phenylephrine or midodrine at a threshold dose (0.012 mg/kg) in a composition with diazepam decrease its minimal effective dose causing a maximal anticonvulsive effect (elimination of clonico-tonic seizures caused by pentylenetetrazole at a dose of 70 mg/kg in 80% of rats) 74 and 85 times, respectively. They also potentiate a mild (only in 20% of rats) anticonvulsive effect of diazepam in the maximal dose (10 mg/kg) with respect to clonic pentylenetetrazole seizures (ensures a complete protection against clonic seizures in 80% of rats).
[0136] Further increase of a dose of phenylephrine or midodrine up to 0.024 mg/kg, which also does not cause an independent effect, not only potentiates the effect of diazepam, but also decreases 5.5-6.3 times its minimal effective dose eliminating clonic seizures in 80% of rats.
[0137] The inclusion of stimulants of osmoreceptors—PVP, dextran or PEO—into the composition with diazepam and α-1-adrenomimetics causes an additional decrease in the minimal effective dose of diazepam for both kinds of seizures 2.3-4.5 times and at a dose of α-1-adrenomimetic in a tertiary composition 2-2.4 times.
[0138] Active ingredient contents in solutions of the compositions for potentiation was as follows: diazepam—from 0.002% to 1%, α-1-adrenomimetics—from 0.005% to 0.024%, and stimulants of osmoreceptors—from 1% to 10%. A decrease in the contents of α-1-adrenomimetics and stimulants of osmoreceptors in a composition with diazepam below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable potentiation of the effect of the composition.
[0000] b. Intragastric Administration of Compositions
[0139] Diazepam at a dose of 2.5 mg/kg eliminates completely clonico-tonic seizures caused by pentylenetetrazole at a dose of 70 mg/kg in 80% of rats. Diazepam in the maximal dose of 10 mg/kg eliminates clonic seizures preceding the generalized seizures caused by pentylenetetrazole at a dose of 70 mg/kg only in 20% of rats.
[0140] Phenylephrine or midodrine at a threshold dose of 0.012 mg/kg) in a composition with diazepam decrease 42 and 50 times, respectively, its minimal effective dose causing a maximal effect with respect to clonico-tonic seizures. They also intensify the anticonvulsive effect of diazepam in the maximal dose (10 mg/kg) with respect to clonic pentylenetetrazole-induced seizures (the number of rats without clonic seizures increasing from 20% to 80%).
[0141] A further increase at a threshold dose of phenylephrine or midodrine up to 0.024 mg/kg causes both the potentiation of the effect of diazepam and a 5.0-5.9-fold decrease of its minimal effective dose eliminating clonic seizures in 80% of rats.
[0142] The inclusion of stimulants of osmoreceptors—PVP, dextran, PEO, xylitol or sorbitol—into the composition with diazepam and α-1-adrenomimetics causes an additional decrease of the minimal effective dose of diazepam in both kinds of seizures 2.3-4.6 times and a decrease at a dose of α-1-adrenomimetic 2.1-3 times.
[0143] Active ingredient contents in solutions of the compositions for potentiation was as follows: diazepam—from 0.0013% to 1%, α-1-adrenomimetics—from 0.004% to 0.024%, and stimulants of osmoreceptors—from 0.5% to 5%. A decrease in the contents of α-1-adrenomimetics and stimulants of osmoreceptors in a composition with diazepam below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable potentiation of the effect of the composition.
TABLE V Potentiation of anticonvulsive effect of diazepam. Minimal effective dose* eliminating seizures caused by pentylenetetrazole Way of (pentylenetetrazole dose 70 mg/kg IM) Drug administration clonico-tonic seizures clonic seizures Diazepam IM** 6.7 ± 0.7 mg/kg 10 mg/kg*** Diazepam + phenylephrine IM 1.2 ± 0.14 mg/kg 8.8 ± 0.9 mg/kg IM 0.006 mg/kg 0.012 mg/kg Diazepam + phenylephrine IM 0.09 ± 0.011 mg/kg 1.8 ± 0.23 mg/kg IM 0.012 mg/kg 0.024 mg/kg Diazepam + midodrine IM 0.78 ± 0.084 mg/kg 8.6 ± 0.95 mg/kg IM 0.006 mg/kg 0.012 mg/kg Diazepam + midodrine IM 0.08 ± 0.009 mg/kg 1.6 ± 0.20 mg/kg IM 0.012 mg/kg 0.024 mg/kg Diazepam + phenylephrine + PVP IM 0.03 ± 0.0033 mg/kg 0.5 ± 0.06 mg/kg IM 0.005 mg/kg 0.01 mg/kg IM 10 mg/kg 20 mg/kg Diazepam + midodrine + PVP IM 0.02 ± 0.0024 mg/kg 0.41 ± 0.05 mg/kg IM 0.005 mg/kg 0.01 mg/kg IM 10 mg/kg 20 mg/kg Diazepam + phenylephrine + dextran IM 0.02 ± 0.0026 mg/kg 0.45 ± 0.055 mg/kg IM 0.005 mg/kg 0.01 mg/kg IM 10 mg/kg 20 mg/kg Diazepam + phenylephrine + PEO IM 0.04 ± 0.045 mg/kg 0.70 ± 0.078 mg/kg IM 0.005 mg/kg 0.01 mg/kg IM 50 mg/kg 100 mg/kg Diazepam IG**** 2.5 ± 0.3 mg/kg 10 mg/kg*** Diazepam + phenylephrine IG 0.82 ± 0.089 mg/kg 8.6 ± 0.9 mg/kg IG 0.006 mg/kg 0.012 mg/kg Diazepam + phenylephrine IG 0.06 ± 0.007 mg/kg 2.0 ± 0.22 mg/kg IG 0.012 mg/kg 0.024 mg/kg Diazepam + midodrine IG 0.55 ± 0.062 mg/kg 8.5 ± 0.88 mg/kg IG 0.006 mg/kg 0.012 mg/kg Diazepam + midodrine IG 0.05 ± 0.006 mg/kg 1.7 ± 0.21 mg/kg IG 0.012 mg/kg 0.024 mg/kg Diazepam + phenylephrine + xylitol IG 0.02 ± 0.0024 mg/kg 0.65 ± 0.07 mg/kg IG 0.004 mg/kg 0.01 mg/kg IG 80 mg/kg 120 mg/kg Diazepam + midodrine + xylitol IG 0.015 ± 0.0017 mg/kg 0.62 ± 0.07 mg/kg IG 0.004 mg/kg 0.01 mg/kg IG 80 mg/kg 120 mg/kg Diazepam + phenylephrine + PVP IG 0.022 ± 0.0025 mg/kg 0.72 ± 0.082 mg/kg IG 0.004 mg/kg 0.01 mg/kg IG 40 mg/kg 80 mg/kg Diazepam + phenylephrine + dextran IG 0.013 ± 0.0016 mg/kg 0.6 ± 0.07 mg/kg IG 0.004 mg/kg 0.01 mg/kg IG 20 mg/kg 40 mg/kg Diazepam + phenylephrine + PEO IG 0.026 ± 0.003 mg/kg 0.82 ± 0.1 mg/kg IG 0.004 mg/kg 0.01 mg/kg IG 120 mg/kg 200 mg/kg Diazepam + phenylephrine + sorbitol IG 0.024 ± 0.028 mg/kg 0.80 ± 0.094 mg/kg IG 0.004 mg/kg 0.01 mg/kg IG 120 mg/kg 200 mg/kg *Minimal dose of diazepam preventing pentylenetetrazol seizures in 80% of rats. **Hereinafter IM administered volume of the solution is 0.2 ml. ***Prevents clonic pentylenetetrazole seizures in 20% of rats. ****Hereinafter IG administered volume of the solution is 0.8 ml.
Example 5
Potentiation of the Effect of Neuroleptics
[0000] a. Intramuscular Administration of Compositions
[0144] The neuroleptic haloperidol at a dose of 0.15 mg/kg completely prevents the development of phenaminic stereotypy in 80% of rats. At a dose of 1 mg/kg haloperidol only partially eliminates behavioral toxicity caused by MK-801 (completely eliminates ataxia in 80% of rats, but insignificantly reduces stereotypy and hyperactivity). The results of administrating compositions in accordance with the invention are summarized in Table VI.
[0145] Phenylephrine at a threshold dose (0.02 mg/kg) in a composition with haloperidol decrease its minimal effective dose causing a maximal antipsychotic effect (elimination of phenamine stereotypy in 80% of rats) times, respectively. They also potentiate an incomplete antipsychotic effect of haloperidol in the maximal dose (1 mg/kg) in MK-toxicity test (completely eliminates not only ataxia, but also hyperactivity and stereotypy in 80% of rats).
[0146] A further increase at a dose of phenylephrine up to 0.04 mg/kg, which also does not cause an independent effect, not only potentiates the effect of haloperidol, but also decreases 4.4 times its minimal effective dose, eliminating MK-toxicity.
[0147] The inclusion of a stimulant of osmoreceptors PVP into the composition with haloperidol and phenylephrine causes an additional decrease in the minimal effective dose of haloperidol in both tests of 3.0-3.1 times and at a dose of α-1-adrenomimetic in a tertiary composition by 4 times.
[0148] Active ingredient contents in solutions of the compositions for potentiation was as follows: haloperidol—from 0.0005% to 0.1%, alpha-1-adrenomimetic—from 0.005% to 0.04%, and stimulants of osmoreceptors—from 1% to 2%. A decrease in the contents of phenylephrine and PVP in a composition with haloperidol below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable potentiation of the effect of the composition.
[0000] b) Intragastric Administration of Compositions
[0149] Neuroleptic haloperidol at a dose of 0.18 mg/kg completely prevents the development of phenaminic stereotypy in 80% of rats. At a dose of 1 mg/kg haloperidol eliminates behavioral toxicity caused by MK-801 only partially (completely eliminates ataxia only).
[0150] Phenylephrine at a threshold dose of 0.02 mg/kg in a composition with haloperidol decrease 13 times its minimal effective dose causing a maximal antipsychotic effect (elimination of phenaminic stereotypy in 80% of rats). They also potentiate a partial antipsychotic effect of haloperidol in the maximal dose (1 mg/kg) in MK-toxicity test (completely eliminates not only ataxia, but also hyperactivity and stereotypy in 80% of rats).
[0151] A further increase at a threshold dose of phenylephrine up to 0.04 mg/kg causes both the potentiation of the effect of haloperidol and a 3.8-fold decrease of its minimal effective dose eliminating M-toxicity.
[0152] The inclusion of a stimulant of osmoreceptors PVP into the composition with haloperidol and phenylephrine causes an additional decrease of the minimal effective dose of haloperidol in both tests 3.2-3.3 times and a decrease at a dose of phenylephrine 4 times.
[0153] Active ingredient contents in solutions of the compositions for potentiation was as follows: haloperidol—from 0.0005% to 0.1%, α-1-adrenomimetics—from 0.005% to 0.04%, and stimulants of osmoreceptors—from 1% to 2%. A decrease in the contents of phenylephrine and PVP in a composition with haloperidol below the indicated limits leads to a drastic decrease in the composition activity, whereas an increase in their concentration does not lead to a considerable potentiation of the effect of the composition.
TABLE 6 Potentiation of antipsychotic effect of haloperidol Minimal dose of the drug Minimal dose of the drug preventing the preventing the development Way of development of phenamine of Mk-toxicity** in 80% of Drug administration stereotypy* in 80% of rats. rats. Haloperidol IM*** 0.15 ± 0.017 mg/kg 1 mg/kg**** Haloperidol + phenylephrine IM 0.09 ± 0.01 mg/kg 0.89 ± 0.093 mg/kg IM 0.01 mg/kg 0.02 mg/kg Haloperidol + phenylephrine IM 0.015 ± 0.0017 mg/kg 0.22 ± 0.026 mg/kg IM 0.02 mg/kg 0.04 mg/kg Haloperidol + phenylephrine + PVP IM 0.005 ± 0.0006 mg/kg 0.07 ± 0.0076 mg/kg IM 0.005 mg/kg 0.01 mg/kg IM 10 mg/kg 20 mg/kg Haloperidol IG**** 0.18 ± 0.022 mg/kg 1 mg/kg**** Haloperidol + phenylephrine IG 0.14 ± 0.016 mg/kg 0.88 ± 0.095 mg/kg IG 0.01 mg/kg 0.02 mg/kg Haloperidol + phenylephrine IG 0.016 ± 0.002 mg/kg 0.26 ± 0.029 mg/kg IG 0.02 mg/kg 0.04 mg/kg Haloperidol + phenylephrine + PVP IG 0.005 ± 0.00056 mg/kg 0.08 ± 0.01 mg/kg IG 0.005 mg/kg 0.01 mg/kg IG 40 mg/kg 80 mg/kg *Phenamine in the dose of 10 mg/kg IM causes a behavioral stereotypy after 30-60 minutes. **MK-801 (disocylpin) in the dose of 0.4 mg/kg IM causes a strong hyperactivity, stereotypy and ataxia after 20-30 minutes. ***Hereinafter IM administered volume of the solution is 0.2 ml. ****In the dose of 1 mg/kg (IM and IG) haloperidol eliminates ataxia in 80% of rats. *****Hereinafter IG administered volume of the solution is 0.8 ml.
Example 6
Potentiation of the Effect of Psychostimulants
[0154] The psychostimulant phenamine at a dose of 10 mg/kg IM and 20 mg/kg IG causes a marked behavioral stereotypy. IM or IG administration of phenamine in the composition with a threshold dose (0.02 mg/kg) of phenylephrine makes it possible to decrease the minimal effective dose of phenamine causing a maximally expressed stereotypy 4-5.3 times. The results of administrating compositions in accordance with the invention are summarized in Table VII.
[0155] Additional inclusion of a stimulant of osmoreceptors PVP (IM, IG) into the composition of phenamine with phenylephrine at a doses, which do not potentiate independently the effect of phenamine, decreases 2.3-2.4 times the minimal effective dose of phenamine and, at the same time, decrease 3.3-4 times the dose of phenylephrine in the composition.
[0156] A decrease at a dose of phenylephrine below 0.002 mg/kg and PVP below 20 mg/kg drastically decreases the activity of compositions with phenamine. An increase at a dose of phenylephrine above 0.02 mg/kg and PVP above 80 mg/kg does not considerably increase the activity of compositions with phenamine, but increases the risk of complications.
TABLE VII Potentiation of phenamine stereotypy in rats Minimal. dose of Way of phenamine causing Drugs administration a behavioral stereotypy* Phenamine + distilled IM 10.0 ± 1.1 mg/kg water Phenamine + PVP IM 8.5 ± 0.9 mg/kg 20 mg/kg Phenamine + phenylephrine IM 9.2 ± 0.97 mg/kg 0.01 mg/kg Phenamine + phenylephrine IM 2.5 ± 0.29 mg/kg 0.02 mg/kg Phenamine + phenylephrine IM 1.1 ± 0.13 mg/kg 0.005 mg/kg + PVP 10 mg/kg Phenamine + distilled IG 20.2 ± 2.3 mg/kg water Phenamine + PVP IG 17.8 ± 1.9 mg/kg 80 mg/kg Phenamine + phenylephrine IG 16.9 ± 1.8 mg/kg 0.01 mg/kg Phenamine + phenylephrine IG 3.8 ± 0.44 mg/kg 0.02 mg/kg Phenamine + phenylephrine IG 1.6 ± 0.14 mg/kg 0.005 mg/kg + PVP 40 mg/kg *Behavioral stereotypy caused by phenamine in the dose of 10 mg/kg IM. **Hereinafter IM administered volume of the solution is 0.2 ml. ***Hereinafter IG administered volume of the solution is 0.8 ml.
Example 7
Potentiation of CNS Drug by Cathecholamines
[0157] It may be concluded from Table VIII, below, that catecholamines (e.g. epinephrine, dopamine, serotonin) potentiate the anticonvulsive action of diazepam threshold doses, when administered i.m. in a double composition with diazepam or triple composition with diazepam and PVP.
TABLE VIII Potentiation of anticonvulsive effect of diazepam by cathecholamines Minimal effective dose* eliminating clonicotonic seizures caused by pentylenetetrazole Way of (pentylenetetrazole Drugs administration dose 70 mg/kg IM) Diazepame IM** 6.7 ± 0.7 mg/kg Diazepame + epinephrine IM 1.5 ± 0.18 mg/kg IM 0.01 mg/kg Diazepame + epinephrine IM 0.25 ± 0.3 mg/kg IM 0.02 mg/kg Diazepame + epinephrine+ IM 0.09 ± 0.01 mg/kg PVP IM 0.01 mg/kg IM 10 mg/kg Dizepame + dopamine IM 1.3 ± 0.15 mg/kg IM 0.01 mg/kg Dizepame + dopamine IM 0.12 ± 0.014 mg/kg IM 0.02 mg\kg Diazepame + dopamine + IM 0.04 ± 0.0046 mg/kg IM 0.01 mg\kg PVP IM 10 mg/kg Diazepame + serotonin IM 1.4 ± 0.16 mg\kg IM 0.006 mg\kg Diazepame + serotonin IM 0.17 ± 0.02 mg/kg IM 0.012 mg\kg Diazepame + serotonin + PVP IM 0.06 ± 0.007 mg/kg IM 0.005 mg\kg IM 10 mg\kg *Minimal dose of diazepam preventing pentylenetetrazol seizures in 80% of rats.. **Hereinafter IM administered volume of the solution is 0.2 ml
Example 8
Comparison of Prior Art Compositions and Composition of the Invention
[0158] Although it is known to potentiate CNS active drugs by osmoreceptor stimulators, the results obtained by combining the above two components together with a compound which affects peripheral chemoreceptors are significantly and unexpectedly improved, as illustrated in the following tables.
TABLE IX Comparative results of potentiation of analgesic effect of Dipyrone: “tail-flick” test Hyperalgesia test Drug or Way Of Dose causing maximal Dose causing maximal Composition Administration analgesia analgesia a Dipyrone IM 1.5 ± 0.18 mg/kg 20.2 ± 2.3 mg/kg PVP IM 20 mg/kg 40 mg/kg b Dipyrone IM 0.06 ± 0.007 mg/kg 1.6 ± 0.19 mg/kg PVP IM 5 mg/kg 10 mg/kg phenylephrine IM 0.003 mg/kg 0.005 mg/kg a Dipyrone IM 2.0 ± 0.24 mg/kg 24.5 ± 2.8 mg/kg dextran IM 10 mg/kg 20 mg/kg b Dipyrone IM 0.06 ± 0.007 mg/kg 1.9 ± 0.22 mg/kg Dextran IM 2.5 mg/kg 5 mg/kg phenylephrine IM 0.003 mg/kg 0.005 mg/kg a Dipyrone IM 2.5 ± 0.29 mg/kg 31.2 ± 3.5 mg/kg PEO IM 30 mg/kg 60 mg/kg b Dipyrone IM 0.09 ± 0.01 mg/kg 2.5 ± 0.29 mg/kg PEO IM 10 mg/kg 20 mg/kg phenylephrine IM 0.003 mg/kg 0.005 mg/kg a Dipyrone IG 6.2 ± 0.7 mg/kg 20.4 ± 2.2 mg/kg PVP IG 20 mg/kg 40 mg/kg b Dipyrone IG 0.05 ± 0.0068 mg/kg 1.2 ± 0.14 mg/kg PVP IG 8 mg/kg 16 mg/kg Phenylephrine IG 0.001 mg/kg 0.002 mg/kg a Dipyrone IG 3.9 ± 0.44 mg/kg 17.5 ± 1.9 mg/kg Dextran IG 10 mg/kg 20 mg/kg b Dipyrone IG 0.04 ± 0.005 mg/kg 1.4 ± 0.16 mg/kg Dextran IG 4 mg/kg 8 mg/kg phenylephrine IG 0.001 mg/kg 0.002 mg/kg a Dipyrone IG 6.5 ± 0.73 mg/kg 27.4 ± 2.9 mg/kg PEO IG 40 mg/kg 80 mg/kg b Dipyrone IG 0.05 ± 0.0055 mg/kg 1.9 ± 0.23 mg/kg PEO IG 16 mg/kg 32 mg/kg phenylephrine IG 0.001 mg/kg 0.002 mg/kg a Dipyrone IG 4.5 ± 0.5 mg/kg 14.6 ± 1.6 mg/kg xylitol IG 20 mg/kg 40 mg/kg b Dipyrone IG 0.03 ± 0.004 mg/kg 0.8 ± 0.09 mg/kg xylitol IG 4 mg/kg 8 mg/kg phenylephrine IG 0.001 mg/kg 0.002 mg/kg a Dipyrone IG 5.2 ± 0.5 mg/kg 18.5 ± 1.9 mg/kg sorbitol IG 40 mg/kg 80 mg/kg b Dipyrone IG 0.06 ± 0.007 mg/kg 2.5 ± 0.20 mg/kg sorbitol IG 8 mg/kg 16 mg/kg phenylephrine IG 0.001 mg/kg 0.002 mg/kg a) Dipyrone + osmoreceptor stimulant b) Dipyrone + osmoreceptor stimulant + peripheral α-1-adrenomimetic ingredient
[0159]
TABLE X
Comparative results of potentiation of anti-depressive
effect of amitryptiline
Porsolt's test. Dose.Group
Way of
Porsolt's test. Dose.
of highly-active rats with
Drug
Administration
Group of low-active rats
MPTP depression
a
Amitriptyline
IM
0.4 ± 0.045
mg/kg
0.6 ± 0.07
mg/kg
PVP
IM
20
mg/kg
20
mg/kg
b
Amitriptyline
IM
0.02 ± 0.0023
mg/kg
0.03 ± 0.0035
mg/kg
PVP
IM
10
mg/kg
10
mg/kg
phenylephrine
IM
0.0006
mg/kg
0.001
mg/kg
a
Amitriptyline
IM
0.3 ± 0.035
mg/kg
0.5 ± 0.06
mg/kg
Dextran
IM
10
mg/kg
10
mg/kg
b
Amitriptyline
IM
0.02 ± 0.0023
mg/kg
0.03 ± 0.0035
mg/kg
Dextran
IM
5
mg/kg
5
mg/kg
phenylephrine
IM
0.001
mg/kg
0.0015
mg/kg
a
Amitriptyline
IM
0.5 ± 0.07
mg/kg
0.8 ± 0.09
mg/kg
PEO
IM
30
mg/kg
30
mg/kg
b
Amitriptyline
IM
0.025 ± 0.003
mg/kg
0.04 ± 0.005
mg/kg
PEO
IM
15
mg/kg
15
mg/kg
phenylephrine
IM
0.001
mg/kg
0.0015
mg/kg
a
Amitriptyline
IG
0.5 ± 0.06
mg/kg
0.72 ± 0.084
mg/kg
PVP
IG
30
mg/kg
30
mg/kg
b
Amitriptyline
IG
0.022 ± 0.0026
mg/kg
0.04 ± 0.0045
mg/kg
PVP
IG
12
mg/kg
12
mg/kg
Phenylephrine + B57
IG
0.0007
mg/kg
0.001
mg/kg
a
Amitriptyline
IG
0.33 ± 0.037
mg/kg
0.52 ± 0.06
mg/kg
Dextran
IG
20
mg/kg
20
mg/kg
b
Amitriptyline
IG
0.012 ± 0.0014
mg/kg
0.018 ± 0.0023
mg/kg
Dextran
IG
8
mg/kg
8
mg/kg
phenylephrine
IG
0.0005
mg/kg
0.001
mg/kg
a
Amitriptyline
IG
0.55 ± 0.06
mg/kg
0.75 ± 0.09
mg/kg
PEO
IG
80
mg/kg
80
mg/kg
b
Amitriptyline
IG
0.025 ± 0.003
mg/kg
0.045 ± 0.0053
mg/kg
PEO
IG
32
mg/kg
32
mg/kg
phenylephrine
IG
0.0007
mg/kg
0.00014
mg/kg
a
Amitriptyline
IG
0.31 ± 0.035
mg/kg
0.45 ± 0.05
mg/kg
xylitol
IG
20
mg/kg
20
mg/kg
b
Amitriptyline
IG
0.016 ± 0.0021
mg/kg
0.03 ± 0.0035
mg/kg
xylitol
IG
8
mg/kg
8
mg/kg
phenylephrine
IG
0.0005
mg/kg
0.001
mg/kg
a
Amitriptyline
IG
0.63 ± 0.071
mg/kg
0.91 ± 0.1
mg/kg
sorbitol
IG
40
mg/kg
40
mg/kg
b
Amitriptyline
IG
0.025 ± 0.0029
mg/kg
0.038 ± 0.0046
mg/kg
sorbitol
IG
16
mg/kg
16
mg/kg
phenylephrine
IG
0.0006
mg/kg
0.0012
mg/kg
a) Amitriptyline + osmoreceptor stimulant
b) Amitriptyline + osmoreceptor stimulant + peripheral α-1 adrenomimetic stimulant
[0160]
TABLE XI
Comparative results of potentiation of antiparkinson
effect of memantine:
Minimal Effective dose of drug
Way of
eliminating catalepsy caused by
Drug
Administration
haloperidol at a dose of 1 mg/kg
a
Memantine
IM
1.4 ± 0.16 mg/kg
PVP
IM
20 mg/kg
b
Memantine
IM
0.15 ± 0.02 mg/kg
PVP
IM
10 mg/kg
phenylephrine
IM
0.005 mg/kg
a
Memantine
IM
1.8 ± 0.2 mg/kg
dextran
IM
20 mg/kg
b
Memantine
IM
0.18 ± 0.022 mg/kg
Dextran
IM
10 mg/kg
phenylephrine
IM
0.005 mg/kg
a
Memantine
IM
2.2 ± 0.24 mg/kg
PEO
IM
40 mg/kg
b
Memantine
IM
0.19 ± 0.023 mg/kg
PEO
IM
20 mg/kg
phenylephrine
IM
0.005 mg/kg
a
Memantine
IG
4.5 ± 0.5 mg/kg
PVP
IG
80 mg/kg
b
Memantine
IG
0.28 ± 0.034 mg/kg
PVP
IG
40 mg/kg
phenylephrine
IG
0.005 mg/kg
a
Memantine
IG
4.8 ± 0.54 mg/kg
dextran
IG
80 mg/kg
b
Memantine
IG
0.2 ± 0.024 mg/kg
Dextran
IG
40 mg/kg
phenylephrine
IG
0.005 mg/kg
a
Memantine
IG
4.9 ± 0.55 mg/kg
PEO
IG
400 mg/kg
b
Memantine
IG
0.35 ± 0.044 mg/kg
PEO
IG
200 mg/kg
phenylephrine
IG
0.005 mg/kg
a
Memantine
IG
5.2 ± 0.56 mg/kg
xylitol
IG
160 mg/kg
b
Memantine
IG
0.24 ± 0.047 mg/kg
xylitol
IG
80 mg/kg
phenylephrine
IG
0.005 mg/kg
a
Memantine
IG
5.7 ± 0.63 mg/kg
sorbitol
IG
320 mg/kg
b
Memantine
IG
0.32 ± 0.036 mg/kg
sorbitol
IG
160 mg/kg
phenylephrine
IG
0.005 mg/kg
a) memantine + osmoreceptor stimulant
b) memantine + osmoreceptor stimulant + peripheral α-1 adrenomimetic stimulant
[0161]
TABLE XII
Comparitive results of potentiation of anticonvulsive
effect of diazepam:
Minimal Effective dose
of drug eliminating
seizures caused by
Way of
pentylentetrazole
Drug
Administration
(D9 70 mg/kg I.M.)
a
diazepam
IM
1.5 ± 17 mg/kg
PVP
IM
20 mg/kg
b
diazepam
IM
0.03 ± 0.0033 mg/kg
PVP
IM
10 mg/kg
phenylephrine
IM
0.005 mg/kg
a
diazepam
IM
1.0 ± 0.12 mg/kg
dextran
IM
20 mg/kg
b
diazepam
IM
0.02 ± 0.0026 mg/kg
Dextran
IM
10 mg/kg
phenylephrine
IM
0.005 mg/kg
a
diazepam
IM
1.3 ± 0.16 mg/kg
PEO
IM
50 mg/kg
b
diazepam
IM
0.04 ± 0.0045 mg/kg
PEO
IM
25 mg/kg
phenylephrine
IM
0.005 mg/kg
a
diazepam
IG
0.4 ± 0.0045 mg/kg
PVP
IG
80 mg/kg
b
diazepam
IG
0.022 ± 0.0025 mg/kg
PVP
IG
40 mg/kg
phenylephrine
IG
0.004 mg/kg
a
diazepam
IG
0.2 ± 0.023 mg/kg
dextran
IG
40 mg/kg
b
diazepam
IG
0.013 ± 0.0016 mg/kg
Dextran
IG
20 mg/kg
phenylephrine
IG
0.004 mg/kg
a
diazepam
IG
0.53 ± 0.58 mg/kg
PEO
IG
240 mg/kg
b
diazepam
IG
0.026 ± 0.003 mg/kg
PEO
IG
120 mg/kg
phenylephrine
IG
0.004 mg/kg
a
diazepam
IG
0.38 ± 0.044 mg/kg
xylitol
IG
160 mg/kg
b
diazepam
IG
0.02 ± 0.0024 mg/kg
xylitol
IG
80 mg/kg
phenylephrine
IG
0.004 mg/kg
a
diazepam
IG
0.52 ± 0.055 mg/kg
sorbitol
IG
240 mg/kg
b
diazepam
IG
0.024 ± 0.0028 mg/kg
sorbitol
IG
120 mg/kg
phenylephrine
IG
0.004 mg/kg
a) diazepam + osmoreceptor stimulant
b) diazepam + osmoreceptor stimulant + peripheral α-1-adrenomimetic stimulant
[0162]
TABLE XIII
Comparative results of potentiation of antipsychotic
effect of haloperidol:
Minimal dose of
Minimal dose of
the drug preventing
the drug preventing
Way of
the development of
the development of MK-
Drug
Administration
phenamine stereotypy
toxicity in 80% of rats
a
haloperidol
IM
0.07 ± 0.008 mg/kg
0.45 ± 0.05 mg/kg
PVP
IM
20 mg/kg
40 mg/kg
b
haloperidol
IM
0.005 ± 0.0006 mg/kg
0.07 ± 0.008 mg/kg
PVP
IM
10 mg/kg
20 mg/kg
phenylephrine
IM
0.005 mg/kg
0.01 mg/kg
a
haloperidol
IG
0.05 ± 0.006 mg/kg
0.48 ± 0.055 mg/kg
PVP
IG
80 mg/kg
160 mg/kg
b
haloperidol
IG
0.005 ± 0.00056 mg/kg
0.08 ± 0.01 mg/kg
PVP
IG
40 mg/kg
80 mg/kg
phenylephrine
IG
0.005 mg/kg
0.01 mg/kg
a) haloperidol + osmoreceptor stimulant
b) haloperidol + osmoreceptor stimulant + peripheral α-1-adrenomimetic stimulant
[0163]
TABLE XIV
Comparative results of potentiation of psychostimulant
effect of phenamine:
Minimal dose of
Way Of
phenamine causing
Drug
Administration
behavioral stereotypy
a
phenamine
IM
8.5 ± 0.9 mg/kg
PVP
IM
20 mg/kg
b
phenamine
IM
1.1 ± 0.13 mg/kg
PVP
IM
10 mg/kg
phenylephrine
IM
0.005 mg/kg
a
phenamine
IG
17.8 ± 1.9 mg/kg
PVP
IG
80 mg/kg
b
phenamine
IG
1.6 ± 0.14 mg/kg
PVP
IG
40 mg/kg
phenylephrine
IG
0.005 mg/kg
a) phenamine + osmoreceptor stimulant
b) phenamine + osmoreceptor stimulant + peripheral α-1-adrenomimetic stimulant | A method of potentiating the activity of a drug which affects the central nervous system (CNS) comprising systemically administrating to a subject said drug together with an effective amount of a compound which stimulates peripheral chemoreceptors of vagal afferents and, optionally, with an effective amount of a stimulator of peripheral osmoreceptors of vagal afferents. Also disclosed are pharmaceutical compositions for systemic administration comprising a CNS drug together with the aforementioned compounds. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for treating fibrous material and more particularly to such a method and apparatus which have particular utility in pretreating fibrous material such as cotton fiber for the more effective removal of foreign matter therefrom without damage to the fiber and without capture of minute particles of the foreign matter within the fiber as experienced with conventional methods and apparatuses.
2. Description of the Prior Art
The manufacture of finished products using natural and synthetic fibers involves a multiplicity of steps. In the case of natural fibers, these steps are directed toward converting the natural fiber from its native state into a fabric from which the finished product can be manufactured. With natural fibers such as cotton, wool, and the like, the fiber must first be harvested and then processed for the removal of foreign matter prior to being further processed and woven into fabric.
Cotton fiber, for example, is first harvested using mechanical harvesters which employ mechanical picking heads to extract the cotton fiber from the bolls of the plants and collect it for subsequent processing. The picking heads typically employ rotary members mounting a multiplicity of spindles and doffers which ensnare and remove cotton from the bolls of the plants passing in relative motion through the picking head. However, this process also pulls seed from the bolls with the cotton fiber. Furthermore, the operation inherently crushes other portions of the cotton plant causing fragments of leaves, bolls, seeds, stems, dirt and other foreign matter to become entrapped in the cotton fiber during the harvesting operation. This foreign matter is known as "trash" and the cotton fiber containing such trash is known as "seed cotton" or untreated cotton. Thus, the seed cotton is collected in the harvester with such trash intimately associated therewith.
Subsequent to such harvesting, present practice calls for the seed cotton to be deposited in a device known as a "module maker" which compresses the seed cotton into a large block known as a "cotton module". The cotton module ultimately is delivered to a cotton gin for the removal of the trash from the cotton fiber and thereafter for compression of the ginned cotton into cotton bales. The ginning of seed cotton for removal of the seed and other trash is a process which has been known, in at least rudimentary forms, for about two hundred (200) years. A plethora of specific ginning processes have been developed more efficiently and dependably to remove trash from the cotton fiber. Notwithstanding the lengthy period of development of technology directed to this specific purpose, a number of problems continue to plague ginning operations which have not satisfactorily been overcome. In a multiplicity of specific embodiments, it has been known to apply heat, moisture, and mechanical manipulation to the cotton fiber in an effort to extract the trash therefrom. However, such conventional processes have had to operate in an environment in which competing considerations required a compromise of the objectives involved. As a relative matter, the more the cotton fiber is processed, the more trash is removed therefrom. Conversely, the more the cotton fiber is processed, the more damage is done to the fiber itself and the more intimately entrapped in the cotton fiber become finely divided particles of the trash. Present technology calls for an exceedingly complex and expensive series of steps in the ginning of the cotton fiber in an effort to balance these considerations more closely to achieve the desired result. However, even the most successful conventional processes have failed to resolve these problems.
Therefore, it has long been known that it would be desirable to have a method and apparatus for treating fibrous material which has application to a wide variety of both natural and synthetic fibers, which is operable to permit removal of foreign matter from the fiber without damage to the fiber and without more intimately entrapping foreign matter within the fiber, which has application to a wide variety of conventional processes adapted to achieve specific operational goals, and which can be installed and operated without considerable adaptation and expense.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an improved method and apparatus for treating fibrous material.
Another object is to provide such a method and apparatus which cooperate dependably to remove a higher percentage of foreign matter from fibrous material such as cotton than has heretofore been possible while avoiding damage to the fiber itself.
Another object is to provide such a method and apparatus which are particularly well suited to the removal of foreign matter, commonly known as "trash", from cotton fiber and which handle the cotton fiber in such a fashion that the trash is not inextricably capture within the matrix of the fiber.
Another object is to provide such a method and apparatus which operate to pretreat fibrous material and the foreign matter therewithin so as to dissipate the natural adhesion between the fibrous material and the foreign matter.
Another object is to provide such a method and apparatus which can be employed to pretreat the intermixed cotton fiber and trash prior to the ginning operation so that the conventional steps in the ginning operation can be preformed more successfully to remove the trash from the cotton fiber.
Another object is to provide such a method and apparatus which can be utilized in virtually any conventional ginning operation at one or more points throughout the ginning operation so as more successfully to achieve removal of the trash from the cotton fiber being fully compatible with such conventional ginning processes and equipment.
Another object is to provide such a method and apparatus which can be installed and operated in conventional cotton gins and the like to achieve their most effective result at nominal expense.
Another object is to provide such a method and apparatus which can be employed in the ginning of cotton fiber more efficiently and immediately to remove trash from the cotton fiber so that fewer steps are required in the ginning process to achieve a substantially enhanced result over conventional practice without in any way detracting from the ginning operation.
Another object is to provide such a method and apparatus which can be employed to produce a higher grade of cotton fiber than has heretofore been possible.
Further objects and advantages are to provide improved elements and arrangements thereof in an apparatus for the purpose described which is dependable, economical, durable and fully effective in accomplishing its intended purpose.
These and other objects and advantages are achieved in the preferred embodiment of the method and apparatus of the present invention by passing fibrous material containing matter to be separated therefrom and having a given temperature along a path of travel and a fluid stream; and directing a jet of fluid, having a temperature substantially greater than that of the fibrous material and matter, against the fibrous material and matter to release the matter from the fibrous material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary vertical section showing the apparatus for treating fibrous material of the present invention for practicing the method hereof shown in a typical operative environment beneath a module feeder in a cotton gin.
FIG. 2 is a somewhat enlarged, fragmentary vertical section of the apparatus of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, the apparatus for treating fibrous material of the present invention is generally indicated by the numeral 10 in FIG. 1. The apparatus is shown in FIG. 1 in a typical operative environment where it is employed in the treating of seed cotton for the removal of trash therefrom. It will be understood that the method and apparatus of the present invention have application to the treating of fibrous material of the wide variety of types, both naturally occurring and synthetic, for the removal of foreign substances therefrom.
As shown in FIG. 1, a cotton gin 11 has a concrete foundation 12 having a concrete floor 13. A pit 14 is formed in the concrete foundation bounded by concrete walls 15. Suspended on the concrete walls are main support beams 16 interconnected by cross beams 17. Two of the cross beams 17 define a passage 18 therebetween leading into the pit 14.
Mounted on the concrete floor 13, main support beam 16 and cross beam 17 above the passage 18 is a module feeder 25. Module feeders are conventional devices which are employed to receive untreated cotton compressed to form cotton modules and to break the seed cotton therefrom on a continuous, gradual basis so that the seed cotton is delivered into the cotton gin in a free flowing and therefore more easily processed form. The module feeder 25 has a main housing 26 with an entrance 27 facing to the left, as viewed in FIG. 1. The entrance 27 is defined by an upper internal wall 28 leading to an oblique internal wall 29 and to a lower internal wall 30. The entrance 27, upper internal wall 28, oblique internal wall 29 and lower internal wall 30 define an internal chamber 31 for the housing of the module feeder.
Mounted within the internal chamber 31 of the module feeder 25 is a plurality of doffers 36. The doffers are individually adapted for rotation about individual axes of rotation disposed substantially parallel to each other and arranged in a plane substantially parallel to the oblique internal wall 29, as shown in FIG. 1. Each of the doffers consists of a doffer cylinder 37 mounting a plurality of doffer spikes 38. The module feeder operates in the conventional fashion to rotate the doffer cylinders about their individual axes of rotation.
The cotton gin 11 has a moving floor 45 upon which is rested untreated cotton in the form of a cotton module 46. The cotton module has a leading surface 47 and is, in accordance with conventional practice, progressively fed by the moving floor 45 against the doffers 36 which break away cotton fiber intermixed with trash 48 from the cotton module. The cotton fiber 48 is delivered by gravity and the application of vacuum pressure downwardly in the module feeder and out the bottom thereof through the passage 18.
The structure of the cotton gin 11 heretofore described is essentially conventional. In such a conventional cotton gin, the cotton fiber 48, having passed through the passage 18, is delivered by vacuum pressure along ducting, not shown, into the cotton gin for ginning. The apparatus 10 of the present invention is, in accordance with the method and apparatus hereof, mounted in position in place of such ducting.
The apparatus 10 has a main housing 60 mounted in the pit 14 beneath the passage 18 in receiving relation to the cotton fiber 48. The main housing has flange plates 61 which are disposed for facing engagement with the concrete walls 15 and through which bolts 62 are extended and into the concrete walls to mount the housing 60, and thus the apparatus 10, in the operational position shown in FIGS. 1 and 2.
The main housing 60 has a receiving trough 63 disposed in receiving relation to the passage 18 and extending downwardly in converging relation therefrom and from the cross beams 17 to a cylinder chamber 64 leading to a discharge passage 65. The main housing has a hot air chamber 66. These portions of the main housing are defined by a forward wall 70 composed of a trough portion 71 and a lower discharge duct portion 72. The discharge duct portion of the front wall has a duct mounting flange 73 at the lower end thereof. The main housing has a rearward wall 74 which extends downwardly from the cross beam 17 on the right as viewed in FIGS. 1 and 2 in converging relation upon the trough portion 71 and to a curved lower lip 75 immediately above the cylinder chamber 64.
The hot air chamber 66 is housed within the main housing 60 by a hot air plenum 80 constituting part of the main housing. The hot air plenum is defined by an upper wall 81 connected to the upper edge of the rearward wall 74 and extending rearwardly therefrom along the under side of the main support beams 16. The hot air plenum has a rearward wall 82 extending downwardly from the upper wall and communicating at its lower edge with a lower wall 83. The hot air plenum has a forward wall 84 extending from the lower wall to a position roughly in alignment with the lower edge of the trough portion 71 of the forward wall 70, as best shown in FIG. 2.
The main housing 60 has a cylinder chamber wall 90 composed of a main arcuate portion 91 constituting the lower boundary of the cylinder chamber 64. The cylinder chamber wall includes a forward arcuate portion 92 which is connected to the forward wall 84 extending in concentric relation to the discharge duct portion 72 of the forward wall 70 to a rearwardly facing duct mounting flange 93. It will be understood that the main housing has opposite lateral walls disposed in spaced, substantially parallel relation to each other and interconnected by the walls heretofore described extending in substantially normal relation therebetween. The walls of the main housing thus form a substantially airtight housing.
The cylinder chamber wall 90 has an adjustable portion 94 extending upwardly from the main arcuate portion 91 for adjustment, as will hereinafter be described, from a pivot line 95 extending transversely of the main housing 60. The adjustable portion 94 has an upper curved portion 96 conforming to the curved lower lip 75 of the rearward wall 74 and extending rearwardly therefrom. The opposite lateral ends of the adjustable portion 94 and upper curved portion 96 individually mount adjustment plates 97 individually disposed in slidably facing relation to the opposite lateral walls of the housing 60. Each of the adjustment plates has an opening 98 therein bounded by oval cam surfaces 99 and aligned along an axis substantially parallel to the adjustable portion 94 of the cylinder chamber wall 90. An eccentric 100 extends through and interconnects the openings 98 of the adjustment plates. The eccentric includes a shaft 101 mounting a cam lobe 102 within each opening 98. The eccentric 100 is positioned by any suitable manual or mechanical mechanism, not shown, externally of the main housing 60. Thus, by such adjustment of the eccentric 100, the adjustment portion 94 and the upper curved portion 96 thereof can be moved toward or from the curved lower lip 75 of the rearward wall 74. The area between the curved lower lip 75 and the upper curved portion 96 and adjustable portion 94 constitutes a nozzle or a throat 103 adjustable as to area by the eccentric 100 in the manner heretofore described. As will hereinafter be described, the throat 103 passes a jet of heated air along a path indicated by arrow 104 into the cylinder chamber 64. The area immediately bounded by the cylinder chamber wall 90 extending from the curved lower lip 75 to the duct mounting flange 93 constitutes a separation zone 105.
A suitable source of heated air, not shown, is connected to the main housing 60 at a hot air inlet 110 which communicates directly with the hot air plenum 80. The source of heated air can be, for example, a heater and blower unit preferably capable of forcing air heated to a temperature such as to produce a jet of heated air at the throat 103 having a temperature of substantially about 210 degrees Fahrenheit at a velocity of substantially about eight (8) thousand feet per minute to about twelve (12) thousand feet per minute. The heater and blower unit is preferably adjustable as to both temperature and velocity. A discharge duct 111 is mounted on the duct mounting flanges 73 and 93 and extends into the operative portion of the cotton gin 11 for processing of the cotton fiber passing therethrough.
A cylindrical drum 120 is mounted in the cylinder chamber 64 of the main housing 60 extending transversely thereof substantially concentric to the cylinder chamber wall 90 and between the opposite lateral walls of the main housing. The cylindrical drum is mounted for rotational movement on a main shaft 121 and is driven by any suitable drive mechanism, not shown. Preferably, although not necessarily, the drive mechanism is operable to rotate the main shaft and the cylindrical drum borne thereby throughout a range of rotational velocities. The preferred range of velocities includes from forty (40) revolutions to eighty (80) revolutions per minute.
The cylindrical drum 120 mounts a plurality of pins or spikes 122 positioned substantially evenly upon the cylindrical drum extending in radial extension therefrom to terminal ends 123. As can be seen in FIGS. 1 and 2, the terminal ends 123 extend into juxtaposition to the cylinder chamber wall 90 when passing thereby. The spikes are preferably steel and of cylindrical configuration having smooth outer surfaces and being of approximately 21/2 inches to 3 inches in length. Preferably, although not necessarily, the spikes are arranged in what is known as a "chevron pattern" on the cylindrical drum. Within this chevron pattern one-half of the surface of the cylindrical drum has spikes arranged in a helical pattern operable to urge cotton toward one end of the cylindrical drum and the other half of the surface of the cylindrical drum has spikes arranged in a helical pattern operable to urge cotton toward the opposite end of the cylindrical drum.
OPERATION
The operation of the described embodiment of the present invention is believed to be readily apparent and is briefly summarized at this point.
As previously noted, the method and apparatus of the present invention have application to a wide variety of operative environments, but are described herein in a typical operative environment in the cotton gin 11. The cotton gin 11 operates in the normal fashion wherein the cotton module 46 of untreated cotton is fed by the moving floor 45 into the internal chamber 31 of the module feeder 25 and against the doffers 36 thereof. The doffers are rotated to break away cotton fiber from the leading surface 47 of the cotton module. The cotton fiber intermixed with trash 48 then is passed by gravitational and vacuumatic attraction downwardly from the internal chamber 31 of the module feeder and through the passage 18.
The untreated cotton consisting of cotton fiber intermixed with trash 48 passes into the receiving trough 63 of the main housing 60 wherein it is contacted by the cylindrical drum 120 and the radial spikes 122 thereof rotating in a clockwise direction as shown in FIGS. 1 and 2. The cylindrical drum is rotated at a relatively slow speed, that being substantially about forty (40) revolutions to about eighty (80) revolutions per minute. Normally for untreated cotton of average or normal moisture content, the speed of rotation of the cylindrical drum is preferably about eighty (80) revolutions per minute. However, where the moisture content of the untreated cotton is greater, the speed of rotation of the cylindrical drum may preferably be less and perhaps as low as forty (40) revolutions per minute depending upon the specific moisture content. The relationship is such that the slower the speed of rotation, the longer the exposure of the cotton fiber and trash to the heated air since movement of the cotton fiber and trash is further retarded thereby.
At this time the eccentric 100 is adjusted so that the thickness of the throat 103 is somewhere in the range of from one-eighth (1/8) of an inch to one (1) inch to produce the jet desired. The source of heated air directs heated air through the hot air inlet 110 to the hot air plenum 80 at a velocity such that the heated air is discharged through the throat 103 at a velocity of substantially about eight (8) thousand feet per minute to about twelve (12) thousand feet per minute. Preferably the temperature of the heated air supplied is such that the temperature of the heated air at the throat 103 is substantially about 210 degrees Fahrenheit. The heated air is discharged along the path indicated by arrow 104 through the cylinder chamber 64 and into the discharge duct 111 through the discharge passage 65. Because of the vacuum applied to the apparatus by the discharge duct 111 and the high velocity jet of heated air passing along the path indicated by arrow 104, the natural velocity of the cotton fiber intermixed with trash 48 would be relatively great. However, the cylindrical drum 120 and the spikes 122 thereof retard such passage of the cotton fiber intermixed with trash so that the heated air is passed through and about the cottom fiber and trash at great velocity causing the cotton fiber to attenuate. It has been discovered that this "slippage" of the heated air passed the cotton fiber and trash prior to passage of the cotton fiber and trash into the gin greatly facilitates drying and removal of the trash by normal ginning procedures while eliminating the complex and expensive drying towers employed in conventional gins. It is believed that such slippage of heated air passed the cotton fiber and the trash causes the moisture within the trash and cotton fiber to flash from the outer surfaces of the cottom fiber and trash, or conversely, to be forced inwardly of the cotton fiber and trash from the outer surfaces thereof. In any case, the moisture content in the outer surfaces of the cotton fiber and trash is temporarily substantially reduced. Over time, moisture beneath the outer surfaces will be absorbed into those outer surfaces to again establish a certain uniformity. However, this takes time and in the meantime the outer surfaces of the cotton fiber and trash retain substantially reduced moisture content.
In any case, this operation breaks the surface adhesion caused by the moisture in the outer layers of cotton fiber and trash thereby freeing the trash for removal from the cotton fiber with significantly less ginning than has heretofore been possible employing conventional technology. Similarly, since this adhesion is temporarily effectively removed, the trash is free to fall from or be released outwardly by virtue of such forces as gravity, centrifugal force and the like which would otherwise not be sufficient to overcome the adhesive character of the surface tension of the moisture within the outer surfaces of the cotton fiber and trash.
Since the trash is thereby free to be released from the cotton fiber during the ginning operation, the aggressive application of forces to the cotton fiber itself characteristic of conventional ginning technology is not required and therefore is not performed. As a consequence, the natural and preferred character of the cotton fiber is preserved through the ginning operation. Still further, since the aggressive manipulation of the cotton fiber is not required in the ginning operation in order to release the trash, the trash is not ground into the cotton fiber during the ginning operation so as to become intimately and inextricably captured within the fiber as occurs in conventional processes. Thus, a higher grade of cotton fiber is produced simultaneously with a greater removal of trash therefrom all with significantly less ginning. Therefore, the expensive and complex equipment required in conventional ginning operations is obviated while simultaneously producing a better a result.
As previously noted, the method and apparatus of the present invention are compatible with virtually all types of ginning operations. Similarly, the method and apparatus can be adapted to the particular ginning process employed and to the desired result. Thus, a plurality of the apparatuses 10 can be employed in a practice of the method in staged sequence and at any desired points throughout the ginning operation. Since the application of the heated air in passage at high velocity through and about the cotton fiber and trash achieves the desired result, a variety of variations can be employed in the method and apparatus to achieve the desired result. As can best be seen upon reference to FIG. 2, the hot air plenum 80 can be so configured as to apply and maintain the temperature conducive to the elimination of the adhesion previously referred to by extension of the hot air plenum further along the path of the movement of the cotton fiber and trash. The hot air plenum can be seen in FIG. 2 to extend entirely about the cylinder chamber wall 90. Since the heated air is employed to pressurize the interior of the hot air plenum, the heat is transferred through the cylindrical chamber wall 90 entirely about the cylinder chamber 64. If desired, the hot air plenum can be extended further along the path of movement of the cotton fiber and trash, or, conversely, a shorter distance along the path of movement of the cotton fiber and trash. In the embodiment of the apparatus of the present invention shown in FIGS. 1 and 2, it has been found that if the temperature of the heated air at the throat 103 is 210 degrees Fahrenheit, the temperature of the heated air by the time it reaches the discharge duct 111 is about 150 degrees Fahrenheit.
Therefore, the method and apparatus for treating fibrous material of the present invention permits a more effective and dependable removal of foreign matter from fibrous material such as cotton than has heretofore been possible in the art, substantially enhances the effectiveness of conventional ginning techniques so as to eliminate the need for the complex methods and apparatuses required in conventional ginning techniques, preserve the natural character of the fibrous material through the process of removing such foreign matter therefrom by eliminating the need for aggressive manipulation of the fibrous material for the removal of the foreign matter, avoids the inextricable intermixing of minute particles of foreign matter within the fibrous material which characterizes conventional techniques, and is otherwise fully effective in achieving the desired result of producing natural and synthetic fibrous material substantially free of foreign matter and in an operation which is substantially less expensive and more dependable than heretofore achieved in the art.
Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of the invention which is not to be limited to the illustrative details disclosed. | A method for treating fibrous material containing matter to be separated therefrom, the method including the steps of passing fibrous material containing the matter and having a given temperature along a path of travel in a fluid stream; and directing a jet of fluid, having a temperature substantially greater than that of the fibrous material and matter, onto the fibrous material and matter to release the matter from the fibrous material.
An apparatus for treating fibrous material containing matter to be separated, the apparatus having a housing with a path of fluid movement therethrough; a system for passing fibrous material containing the matter to be separated along the path through the housing; and a system for discharging a gas, having a temperature substantially greater than that of the fibrous material and matter, onto the fibrous material and matter during passing thereof along the path to release the matter from the fibrous material. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2009-238557, filed Oct. 15, 2009; the entire contents of which are incorporated herein by reference.
FIELD
Embodiments described herein relate generally to a device and a method for humidity estimation that estimate an indoor humidity value to be used for calculating air-conditioning parameters in an air-conditioner that controls air-conditioning within a building such as a hospital.
BACKGROUND
Generally, energy consumption relating to air-conditioning occupies a half of energy consumption for all building equipments. Therefore, promotion of energy saving for air-conditioning highly contributes to energy saving for entire of building equipments.
Meanwhile, it is required to satisfy sensation of warmth (i.e. comfort) of persons in an amenity space such as a room in a business building. Though ensuring comfort has aspects opposing against energy saving, energy waste can be saved by restraining excessive energy consumption beyond a range where persons in a room feel comfortable.
Therefore, a control using a comfort index called as PMV is widely adopted for contamination of comfort and energy saving. Hereinafter, the comfort index “PMV” will be explained.
The PMV is a comfort index calculated by use of parameters (a) air temperature, (b) relative humidity, (c) mean radiant temperature, (d) airflow speed, (e) activity index value [index of heat generation within human body], and (f) amount of clothing that affects a human sensation of warmth with respect to heat and cold.
An amount of heat generation in a human is a sum of an amount of convective radiation, an amount of heat radiation in heat radiation, an amount of evaporative heat, an amount of heat radiation through breathings, and an amount of stored heat. When an equation of thermal equilibrium with respect to these is satisfied, a human body is thermally neutral and in a comfortable state that is not too hot and too cold. On the other hand, a human body feels heat and cold when the equation of thermal equilibrium becomes invalid.
Professor Fanger at the Technical University of Denmark released an introduction of a comfort equation in 1967. This being as a start point, a thermal load to a human body and a human sensation for heat and cold were associated each other through statistical analyses of questionnaires to many European and American examinees, so that the PMV (Predicted Mean Vote) was proposed. This was got into the ISO standard and then frequently used in recent days.
The PMV as an index of sensation of heat and cold is presented with a value using next seven-grade evaluation scale.
+3 Hot
+2 Warm
+1 Slightly warm
0 Neutral
−1 Slightly cool
−2 Cool
−3 Cold
Among the above-mentioned parameters, the activity index value that represents work intensity is generally used with a unit of a metabolism amount “met”, and the amount of clothing is used with a unit “clo”.
The unit “met” represents a metabolism amount and 1 met is defined with a following equation (1) based on a metabolism amount under resting condition in a thermally comfort state.
1 met=58.2 W/m 2 =50 kcal/m 2 ·h (1)
In addition, the unit “clo” represents a thermally insulation property of clothing and 1 clo is a value such that an amount of heat radiation from a surface of a human body in a room (21° C. of air temperature, 50% of relative humidity and not more than 5 cm/s of airflow speed) equilibrates with a metabolic amount of 1 met. It is defined with a following equation (2) based on a conversion to a normal thermal resistance value.
1 clo=0.155 m 2 ·° C./W=0.18 m 2 ·h·° C./kcal (2)
An air-conditioning load can be reduced to save energy by setting a PMV target value within a comfortable range (−0.5<PMV<+0.5) using a following equation (3) so that it is set toward a hot side when cooling or toward a cold side when heating.
PMV=(0.352 e −0.042M/A +0.032)· L (3)
M: activity index value [kcal]
A: surface area of human body [m 2 ]
L: thermal load to human body [kcal/m 2 ·h] (calculated from the Fanger's comfort equation)
e: base of natural logarithm
A patent document 1 (Japanese Patent Application Laid-opened No. 2006-331372) discloses environmental energy management system that achieves energy saving while ensuring comfort of persons in a room using the PMV and so on. The system is configured with an apparatus to which an agent technique is applied. The system achieves both of optimization of indoor thermal environment and minimization of energy consumption according to a control function for air-conditioning equipments based on functions of the agent apparatus (i.e. an autonomous control function, a logical group function, and a hierarchization function) and functions of a management apparatus (i.e. a data acquisition function from the agent apparatus, an integrated management/control function for the agent apparatus, and a calculation function of the thermal environment and the energy optimization).
SUMMARY
Although many parameters that affect human comfort exist, such as temperature, humidity, airflow speed or the like, both of optimization of indoor thermal environment and minimization of energy consumption are achieved in the above-mentioned environmental energy management system disclosed in the patent document 1 by the control function for air-conditioning equipments that utilizes the agent function based on the calculation function of the thermal environment and the energy optimization, and their calculation results.
However, since comfort that a person feels depends not only on the thermal environment but also on humidity, a control of humidity environment is also desired. But no humidity measurement instrument is equipped in many buildings. Therefore, it is hard to perform a control of humidity environment.
An object of embodiments is to provide a device and a method for humidity estimation that can estimate an indoor humidity value to be used for air-conditioning even in a building where no humidity measurement instrument is equipped.
A first aspect of the present invention provides a humidity estimation device connected with an air-conditioner that includes a charge airflow rate estimation unit, a charge air absolute humidity estimation unit, an indoor generated vapor amount estimation unit, and an indoor absolute humidity estimation unit. The charge airflow rate estimation unit acquires operation control information of a charge fan of the air-conditioner and calculates an estimated charge airflow rate of the air-conditioner based on the operation control information of the charge fan and a preset fan differential pressure. The charge air absolute humidity estimation unit acquires a charge air temperature value of the air-conditioner and calculates an estimated charge air absolute humidity of the air-conditioner based on the charge air temperature value and a preset charge air relative humidity. The indoor generated vapor amount estimation unit that acquires an indoor temperature value of a room that is an object controlled by the air-conditioner and calculates an estimated indoor generated vapor amount based on the indoor temperature value, the number of persons in the room and activity index values of the persons that are input. The indoor absolute humidity estimation unit that calculates an estimated absolute humidity in the room based on the estimated charge airflow rate calculated by the charge airflow rate estimation unit, the estimated charge air absolute humidity calculated by the charge air absolute humidity estimation unit and the estimated indoor generated vapor amount calculated by the indoor generated vapor amount estimation unit.
A second aspect of the present invention provides a humidity estimation method for estimating humidity in a room in which an air-conditioner is equipped. The method includes: acquiring operation control information of a charge fan of the air-conditioner; calculating an estimated charge airflow rate of the air-conditioner based on the operation control information of the charge fan and a preset fan differential pressure; acquiring a charge air temperature value of the air-conditioner; calculating an estimated charge air absolute humidity of the air-conditioner based on the charge air temperature value and a preset charge air relative humidity; acquiring an indoor temperature value of the room; calculating an estimated indoor generated vapor amount based on the indoor temperature value, the number of persons in the room and activity index values of the persons that are input; and calculating an estimated absolute humidity in the room based on the estimated charge airflow rate, the estimated charge air absolute humidity and the estimated indoor generated vapor amount.
According to the above aspects of the present invention, an indoor humidity value to be used for air-conditioning can be estimated even in a building where no humidity measurement instrument is equipped.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram of a device for humidity estimation according to an embodiment;
FIG. 2 is a flowchart showing operations of the device for humidity estimation;
FIG. 3 is a graph showing information of a charge airflow rate table stored in a charge airflow rate estimation unit of the device for humidity estimation;
FIG. 4 is a graph showing information of a charge air humidify table stored in a charge air absolute humidity estimation unit of the device for humidity estimation; and
FIG. 5 is a graph showing information of a generated vapor amount table stored in an indoor generated vapor amount estimation unit of the device for humidity estimation.
DETAILED DESCRIPTION OF EMBODIMENTS
(Configuration of Device for Humidity Estimation)
Hereinafter, configuration of an embodiment of a humidity estimation device 10 will be explained with reference to FIG. 1 .
The humidity estimation device 10 is provided in an air-conditioner for a room in a building. The humidity estimation device 10 includes a charge airflow rate estimation unit 11 , a charge air absolute humidity estimation unit 12 , an indoor generated vapor amount estimation unit 13 , and an indoor absolute humidity estimation unit 14 . Plural (n number of) air-conditioners 1 to n are provided in a room that is a controlled object for air-conditioning.
The charge airflow rate estimation unit 11 acquires each controlled rotational speed of charge fans as operation control information from DDCs (Direct Digital Controllers: not shown) or the like in the air-conditioners 1 to n. Then, the charge airflow rate estimation unit 11 calculates each charge airflow rate of the air-conditioners 1 to n based on the rotational speed and a preset fan differential pressure.
The charge air absolute humidity estimation unit 12 acquires each controlled charge air temperature value from the DDCs or the like in the air-conditioners 1 to n. Then, the charge air absolute humidity estimation unit 12 calculates each estimated charge air absolute humidity value of the air-conditioners 1 to n based on the charge air temperature value and a preset charge air relative humidity value.
The indoor generated vapor amount estimation unit 13 acquires an indoor temperature value from a temperature sensor provided in the room of the controlled object for air-conditioning. Then, the indoor generated vapor amount estimation unit 13 calculates an estimated indoor generated vapor amount based on the indoor temperature value and the number of persons in the room and their activity index values that are input.
The indoor absolute humidity estimation unit 14 calculates an estimated humidity value of the room based on the charge airflow rate of each of the air-conditioners 1 to n calculated by the charge airflow rate estimation unit 11 , the estimated charge air absolute humidity value of each of the air-conditioners 1 to n calculated by the charge air absolute humidity estimation unit 12 and the estimated indoor generated vapor amount calculated by the indoor generated vapor amount estimation unit 13 .
(Operation of Device for Humidity Estimation)
Next, operation of the embodiment of the humidity estimation device 10 will be explained with reference to FIG. 2 .
First, each controlled rotational speed of the charge fans as the operation control information from the DDCs or the like in the air-conditioners 1 to n by the charge airflow rate estimation unit 11 . The rotational speed is indicated by its percentage when its maximum rotational speed is defined as 100%. Then, the charge airflow rate estimation unit 11 calculates each charge airflow rate of the air-conditioners 1 to n based on the rotational speed and the preset fan differential pressure (step S 1 ).
In the charge airflow rate estimation unit 11 , stored is a charge airflow rate table as shown in FIG. 3 in which relationship between the fan differential pressure and the charge airflow rate are defined in association with variation of the rotational speeds of the charge fan (e.g. rotational speeds 35%, 50% and 100% when the maximum speed is defined as 100%). For example, when the acquired rotational speed of the charge fan is 50% and the preset differential pressure takes a value p, the estimated charge airflow rate is determined as a charge airflow rate q based on the charge airflow rate table shown in FIG. 3 . The charge airflow rate table is preliminarily prepared for each charge fan of the air-conditioners 1 to n based on its fan property.
In addition, each controlled charge air temperature value is acquired from the DDCs or the like in the air-conditioners 1 to n by the charge air absolute humidity estimation unit 12 . Then, the charge air absolute humidity estimation unit 12 calculates each estimated charge air absolute humidity value of the air-conditioners 1 to n based on the charge air temperature value and the preset charge air relative humidity value (step S 2 ).
In the charge air absolute humidity estimation unit 12 , stored is a charge air relative humidity table as shown in FIG. 4 in which relationship between the charge air temperature value and the charge air absolute humidity value in association with variation of the charge air relative humidity values (e.g. relative humidity values 50%, 70% and 90%). For example, when the acquired charge air temperature value is r ° C. and the preset charge air relative humidity value is 90%, the estimated charge air absolute humidity value is determined as an absolute humidity value s based on the charge air relative humidity table shown in FIG. 4 . The charge air relative humidity table is a part of the Psychrometric Chart and fixed information that doesn't change according to conditions.
In addition, the indoor temperature value is acquired from the temperature sensor provided in the room of the controlled object for air-conditioning by the indoor generated vapor amount estimation unit 13 . Then, the indoor generated vapor amount estimation unit 13 calculates the estimated indoor generated vapor amount based on the indoor temperature value and the number of persons in the room and their activity index values that are input (step S 3 ).
In the indoor generated vapor amount estimation unit 13 , stored is a generated vapor amount table as shown in FIG. 5 in which relationship between the indoor temperature value and a generated vapor amount to be generated from one person in association with variation of the activity index values (e.g. met=1.0, 1.2 and 2.6). For example, when the acquired indoor temperature value is t ° C. and the preset activity index value “met” according to the activity state of the persons in the room is 1.2, an estimated generated vapor amount per one person is determined as an generated vapor amount u based on the generated vapor amount table shown in FIG. 5 . Then the indoor estimated generated vapor amount in the room for the controlled object for air-conditioning is calculated by multiplying the determined estimated generated vapor amount per one person by the number of persons in the room.
Next, the estimated humidity value H r of the room is calculated by the indoor absolute humidity estimation unit 14 based on a following equation (4) to which the charge airflow rate of each of the air-conditioners 1 to n calculated by the charge airflow rate estimation unit 11 , the estimated charge air absolute humidity value of each of the air-conditioners 1 to n calculated by the charge air absolute humidity estimation unit 12 and the estimated indoor generated vapor amount calculated by the indoor generated vapor amount estimation unit 13 are applied (step S 4 ).
H r =(( lw /ρ)+ F 1 sa H 1 sa + . . . +F n sa H n sa )/( F 1 sa + . . . +F n sa ) (4)
ρ: density of air [kg/m 3 ]
F 1 sa , F 2 sa . . . F n sa : each estimated charge airflow rate of the air-conditioners 1 to n [m 3 /h]
H 1 sa , H 2 sa . . . H n sa : each estimated charge air humidity of the air-conditioners 1 to n [kg/kgDA]
lw: estimated indoor generated vapor amount [kg/h]
Based on the above equation (4), the estimated humidity value H r is presented by a vapor amount per unit of a charge airflow rate by dividing a sum of the vapor amount generated from the persons in the room of the controlled object for air-conditioning and the vapor amount included in the charge air by a sum of the charge airflow.
Then, the PMV is calculated for each of the air-conditioned 1 to n using the estimated humidity value of the room estimated in this manner and thereby the calculated PMV is utilized for air-conditioning for the room of the controlled object for the air-conditioning.
According to the above embodiment, the indoor absolute humidity value can be estimated even in a building in which where no humidity measurement instrument is equipped. Therefore, air-conditioning control in the light of not only indoor temperature but also indoor humidity can be achieved by utilizing the estimated indoor absolute humidity value. As a result, the humidity estimation device 10 contributes to the achievement of both of optimization of indoor thermal environment and minimization of energy consumption.
In the above embodiment, the charge airflow rate table with the rotational speeds 35%, 50% and 100% is shown in FIG. 3 . When the rotational speed takes another value other than these rotational speeds 35%, 50% and 100%, the charge airflow rate can be estimated by a value calculated through a compensation process based on given values of these rotational speeds 35%, 50% and 100%.
In addition, in the above embodiment, the charge air relative humidity table with the relative humidity values 50%, 70% and 90% is shown in FIG. 4 . When the relative humidity takes another value other than these relative humidity value 50%, 70% and 90%, the charge air humidity value can be estimated by a value calculated through a compensation process based on given values of these relative humidity values 50%, 70% and 90%.
In addition, in the above embodiment, the generated vapor amount table with the activity index values (met=1.0, 1.2 and 2.6) is shown in FIG. 5 . When the input activity index value takes another value other than these activity index values (met=1.0, 1.2 and 2.6), the generated vapor amount can be estimated by a value calculated through a compensation process based on these given activity index values (met=1.0, 1.2 and 2.6).
Further, in the above embodiment, each rotational speed of the charge fans are used as the operation control information when calculating the estimated charge airflow rate. However, the estimated charge airflow rate may be calculated based on frequency values for controlling the charge fans each driven with an inverter. In this case, relationship between the fan differential pressure and the charge airflow rate are defined in the charge airflow rate table in association with variation of the frequency values for controlling the charge fans each driven with an inverter.
Alternatively, the estimated charge airflow rate may be calculated based on information that indicates operation modes (e.g. “high mode”, “medium mode” or “low mode”) of the charge fans. In this case, relationship between the fan differential pressure and the charge airflow rate are defined in the charge airflow rate table in association with variation of the operation modes. | A humidity estimation device connected with an air-conditioner includes a charge airflow rate estimation (CARE) unit, a charge air absolute humidity estimation (CAAHE) unit, an indoor generated vapor amount estimation (IGVAE) unit, and an indoor absolute humidity estimation (IAHE) unit. The CARE unit calculates an estimated charge airflow rate (ECAR) of the air-conditioner based on operation control information of the charge fan and a preset fan differential pressure. The CAAHE unit calculates an estimated charge air absolute humidity (ECAAH) of the air-conditioner based on a charge air temperature and a preset charge air relative humidity. The IGVAE unit calculates an estimated indoor generated vapor amount (EIGVA) based on an indoor temperature, the number of persons in the room and activity index values of the persons. The IAHE unit calculates an estimated absolute humidity in the room based on the ECAR, the ECAAH and the EIGVA. | 5 |
[0001] The present invention relates to a process for producing electrochromic optical lenses, and also to the lenses obtained.
BACKGROUND OF THE INVENTION
[0002] Electrochromic devices produced by depositing a composition containing a crosslinkable polymer onto a suitable support (for example one of the electrodes), followed by in situ crosslinking, are known. EP-0 850 920 describes the production of an electrochromic device via a process that consists in applying a polymerizable composition onto a glass plate coated with a layer of WO 3 and a tin oxide conductive sublayer, in photopolymerizing by UV irradiation to obtain a membrane that is optically transparent in the visible range and adherent to the support, and then in assembling this membrane with a counterelectrode formed from a glass plate bearing a layer of hydrogenated iridium oxide H x IrO 2 and a tin oxide sublayer. In this process, the polymerizable composition is formed from the lithium salt of trifluoromethanesulfonyl(1-acryloyl-2,2,2-tri-fluoroethanesulfonyl)imide, poly(ethylene glycol) dimethacrylate, silica particles and xanthone. However, xanthone has coloring properties, and its presence in the electrolyte reduces the transparency. In addition, silica dissolves very poorly in a polymer without solvent, it increases the porosity of the material and it also contributes toward reducing the transparency.
[0003] WO 97/26661 describes an electrochromic device comprising an assembly that is formed by two electrochromic layers separated by a film of ion-conducting material and which is placed between two convex lenses. Each electrochromic layer is borne by a substrate coated with a conductive oxide of the ITO type. The ion-conducting material forms an ion-conducting polymer electrolyte and it is formed by a proton-conducting polymer, for example a 2-acrylamido-2-methylpropanesulfonic acid homopolymer. The polymer film is produced by depositing onto one of the electrodes a liquid reaction mixture containing the polymer precursor dissolved in a liquid solvent, for example a mixture of water and NMP. The presence of the liquid solvent in the composition intended to form the solid electrolyte necessitates removal of the liquid solvent, the result of which is that the film of polymer electrolyte resulting therefrom is porous. However, the porosity of a layer of an electrochromic device harms the optical quality of the electrochromic device.
SUMMARY OF THE INVENTION
[0004] The aim of the invention is to provide a process for producing an electrochromic device with a nonporous polymer electrolyte, which may be used as an electro-chromic lens for spectacles, which does not have the drawbacks of the prior art.
[0005] The process according to the present invention is intended for the production of an electrochromic lens comprising an electrode and a counterelectrode separated by a solid polymer electrolyte, the electrode being formed by a transparent substrate bearing an electronically conductive film coated with a film of a cathode active material with electrochromic properties, the counterelectrode being formed by a transparent substrate bearing an electronically conductive film coated with a film of an anode active material with electrochromic properties, the electrolyte being formed by an ion-conducting material comprising a salt dissolved in a solvating solid polymer.
[0006] The process according to the invention comprises the steps consisting in preparing said electrode and said counterelectrode, and in assembling them via their faces bearing the electrochromic material, by intercalating between said faces an electrolyte membrane, and it is characterized in that the electrolyte membrane is intercalated in the form of a composition of low viscosity free of volatile liquid solvent and comprising a polymer or a polymer precursor and a salt. The term “low viscosity” means either a liquid composition, or a composition whose dynamic viscosity μ is between 100 and 10 6 Pa.s.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0007] When the composition intended to form the electrolyte comprises a polymer precursor and is intercalated in liquid form, it is applied to the electrochromic face of at least one of the transparent substrates, and the precursor is then subjected to polymerization or crosslinking. Applying the composition intended to form the electrolyte layer in liquid form has the result that said composition penetrates the porosity of the electrode and the counterelectrode, which creates a very good interface and provides an electrochemical bridge. The device thus has a lower impedance. In addition, the use of a solvent-free composition eliminates the need to remove said solvent and thus prevents the formation of porosity in the electrolyte film, given that porosity of the electrolyte film harms the performance of the device.
[0008] When the composition intended to form the electrolyte comprises a polymer and has a viscosity of between 100 and 10 6 Pa.s, the process comprises an additional step that consists in applying to an auxiliary film a liquid composition containing a polymer precursor and a salt, in subjecting to crosslinking or polymerization, and then in depositing the film obtained by crosslinking or polymerization onto the face bearing the electrochromic material of one of the substrates, by applying a pressure with heat to bring the film obtained by polymerization or crosslinking to a viscosity of between 100 and 10 6 Pa.s. Next, the auxiliary film is removed and the electrochromic face of the other substrate is applied to the face of the polymerized or crosslinked film freed by removal of the auxiliary film.
[0009] The auxiliary film is advantageously made of a polypropylene, a polyethylene, a polyethylene terephthalate or a polytetrafluoroethylene.
[0010] In a first embodiment, the liquid composition containing the polymer precursor is applied to the face bearing the electrochromic material of one of the transparent substrates, and then subjected to polymerization or crosslinking, after which the electrochromic face of the other substrate is applied to the polymer membrane obtained after crosslinking. In one particular embodiment of this first embodiment:
an electronically conductive film and a film of a cathode active material with electrochromic properties are successively deposited onto one of the surfaces of a 1 st transparent substrate, to form the electrode, an electrically conductive film and a film of an anode active material with electrochromic properties are successively deposited on one of the surfaces of a 2 nd transparent substrate, to form the counterelectrode; a liquid composition intended to form the polymer electrolyte is applied to the film of electrochromic active material of one of the substrates and said composition is subjected to crosslinking or polymerization; the electrochromic face of the other substrate is applied to the membrane formed by crosslinking or polymerization of the composition.
[0015] In a second embodiment, the liquid composition containing the polymer precursor is injected into a space delimited by the free face of the film of electrochromic material of each of the preassembled substrates, and then subjected to polymerization or crosslinking. In one particular embodiment of this second embodiment:
an electrically conductive film and a film of a cathode active material with electrochromic properties are successively deposited on one of the surfaces of a 1 st transparent substrate, to form the electrode, an electrically conductive film and a film of an anode active material with electrochromic properties are successively deposited on one of the surfaces of a 2 nd transparent substrate, to form the counterelectrode; a liquid composition intended to form the polymer electrolyte is applied to the film of electrochromic active material of one of the substrates; the film of electrochromic material of the other substrate is applied to the layer of said composition; said composition is subjected to crosslinking or polymerization.
[0021] The materials constituting the various layers of an electrochromic lens according to the invention are all materials that are transparent in the visible region of the light spectrum.
[0022] The ion-conducting material forming the electrolyte of the electrochromic lens is formed by a salt dissolved in a solvating solid polymer. It is obtained from a liquid composition that contains a liquid polymer precursor, a salt and optionally a diluent.
[0023] The solid polymer is a crosslinked polymer formed by solvating polymer chains connected via crosslinking nodes. The solvating polymer chains are especially of the polyether type or of the polyimine type. Chains of an ethylene oxide homopolymer (POE), a propylene oxide homopolymer (POP) and a copolymer of ethylene oxide or of propylene oxide with 2,3-epoxy-1-propanol are preferred in particular.
[0024] The liquid solvating polymer precursor used in the liquid composition intended to form the electrolyte may be chosen from liquid monomers and liquid polymers of low mass, which are precursors for the solvating polymer chains defined above.
[0025] The monomers are preferably chosen from ethylene oxide, propylene oxide and 2,3-epoxy-1-propanol.
[0026] The liquid polymers are preferably chosen from POE, POP and copolymers of ethylene oxide or of propylene oxide with 2,3-epoxy-1-propanol, the mass of which is low enough for them to be in the liquid state and in which certain repeating units bear reactive groups enabling subsequent crosslinking, for example acrylate groups. A mixture of a polymer of low molecular mass and a polymer of high molecular mass may also be used.
[0027] The electrolyte salt is preferably a salt of lithium and of an anion of delocalized electronic charge. Examples of anions that may be mentioned in particular include Br − , ClO 4 − , AsF 6 − , R F SO 3 − , (R F SO 2 ) 2 N − and (R F SO 2 ) 3 C − , R F representing a perfluoroalkyl or perfluoroaryl group containing from 1 to 4 carbon atoms, and diaminocyclohexane-N,N′-tetraacetate (DCTA − ). The preferred ionic compounds are (CF 3 SO 2 ) 2 N − Li + and CF 3 SO 3 − Li + , more particularly (CF 3 SO 2 ) 2 N − Li + . The salt concentration of the liquid composition intended to form the electrolyte is preferably from 0.1 M to 2 M.
[0028] The liquid composition intended to form the electrolyte may contain a diluent chosen from nonvolatile organic solvents of low viscosity and of high boiling point. Mention may be made in particular of a dipropylene glycol (DPG) dimethyl ether. Mention may also be made of low-viscosity acrylate monomers that are compatible with the polymers and salts used. The diluent is intended to remain in the electrolyte after crosslinking.
[0029] The application of the precursor composition of the electrolyte membrane is advantageously performed by spin coating. The application is preferably performed under a nitrogen atmosphere. In this mode of application, the liquid composition preferably contains a diluent.
[0030] The application of the precursor composition of the electrolyte membrane may also be performed using an applicator of scraper type, generally known as a doctor blade.
[0031] In one particular embodiment, a plastic film, for example a poly(ethylene terephthalate) film, may be interposed between the transparent substrate and the electronically conductive layer adjacent thereto.
[0032] The polymerization and crosslinking may be performed via a suitable technique, for example by irradiation with UV radiation or an electron beam, thermally or via
[0033] UV irradiation combined with a heat treatment.
[0034] The crosslinking is performed in the presence of a suitable photoinitiator, for example Esacure KT046® sold by the company Lamberti, or the photoinitiators sold under the name Irgacure® by the company Ciba Specialty Chemicals. The content of photoinitiator in the liquid composition intended to form the electrolyte is preferably from 0.1% to 3%. The photoinitiator is not necessary when the crosslinking is performed using an electron beam.
[0035] In the first embodiment of the process, it is preferable to perform the photocrosslinking under an inert atmosphere, for example under a nitrogen atmosphere, to avoid inhibiting the radical polymerization with O 2 . In the second embodiment, the presence of the transparent substrates prevents O 2 from diffusing in the liquid composition intended to form the electrolyte.
[0036] The UV radiation may be obtained with the aid of a UV lamp of the mercury lamp type, for example having a light energy of 1480 mJ over its entire emission spectrum.
[0037] The electrode and the counterelectrode each comprise a transparent substrate bearing a suitable electrochromic active material.
[0038] The transparent substrates are formed by any mineral, organic or composite material that is electronically conductive, and they are preferably chosen from the materials used for making ophthalmic lenses. The two transparent substrates are preferably formed from the same material.
[0039] Mineral glass with an index of 1.5 is the traditional material of ophthalmic optics. It is formed from 60-70% silicon oxide, the remainder being various components such as calcium, sodium and boron oxides. Mineral glass of index 1.6 is now tending to become the new standard in ophthalmic optics. Its higher index is obtained by adding to the mixture a significant proportion of titanium oxide.
[0040] “Sodocalcic” materials contain significant proportions of sodium and calcium and they constitute the traditional materials of optics; their refractive index is not particularly high (n d =1.523) and their chromatic dispersion is low (constringence of about 60). “Borosilicate” materials have a high boron content and are materials that have been more recently used for the manufacture of medium-index glasses; they have a higher refractive index than that of sodocalcic materials (n d =1.600).
[0041] Other mineral materials have a higher index. Mention may be made especially of titanium glasses (index 1.7 and constringence 41), lanthanum glasses (index 1.8 and constringence 34) and niobium glasses (refractive index 1.9 and constringence 30). A higher refractive index allows thinner glasses to be made.
[0042] In addition, the organic materials used in optics and in ophthalmie may be used as transparent substrate for an electrochromic lens of the invention. Nonlimiting examples that may be mentioned include polycarbonates; polyamides; polyimides; polysulfones; polymethyl methacrylates; copolymers of ethylene terephthalate and of carbonate; polyolefins, especially polynorbornenes; diethylene glycol bis(allyl carbonate) polymers and copolymers; (meth)acrylic polymers and copolymers, especially (meth)acrylic polymers and copolymers derived from bisphenol-A; thio(meth)acrylic polymers and copolymers; urethane and thiourethane polymers and copolymers; epoxy polymers and copolymers, and episulfide polymers and copolymers. These materials have a refractive index of between 1.50 and 1.80 with an Abe number (or constringence) of between 30 and 60. Advantageously, in the context of the invention, substrates formed from organic materials such as, for example, diethylene glycol bis(allyl carbonate) polymers and copolymers (more commonly known under the name CR39 and sold by the company PPG), (meth)acrylic copolymers, especially (meth)acrylic polymers and copolymers derived from bisphenol-A (such as Orma® and Ormus® sold by the company Essilor International), urethane and thiourethane polymers and copolymers, epoxy polymers and copolymers, episulfide polymers and copolymers, polycarbonates, polyamides and polymethyl methacrylates are preferably chosen.
[0043] The active material of the electrochromic electrode is a material that is capable of reversibly passing from a colored state to a colorless state under the effect of polarization, during oxidation. It may be chosen especially from WO 3 , Li 4 Ti 5 O 12 and substituted polythiophenes [for example poly(3,4-ethylenedioxythiophene) known as PEDOT].
[0044] The active material of the electrochromic counterelectrode is a material that is capable of reversibly passing from a colored state to a colorless state under the effect of polarization, during reduction. It may be chosen especially from Prussian blue, LiFePO 4 , NiO x , conductive polymers of the polyaniline, polythiophene or polypyrrole type, and H x IrO 2 .
[0045] The material forming the conductive layers is a semiconductive material. It is advantageously chosen from tin oxide, indium oxide and zinc oxide derivatives. Mention may be made in particular of fluorine-doped tin oxide, tin-doped indium oxide (ITO), antimony-doped tin oxide and aluminum-doped zinc oxide. Indium titanium oxide (ITO) is particularly preferred.
[0046] The present invention is described in greater detail with the aid of the examples that follow, to which it is not, however, limited.
[0047] The products used are:
Baytron M®: 3,4-ethylenedioxythiophene (EDOT) sold by the company HC Starck; Baytron C®: Fe III p-toluenesulfonate sold by the company HC Starck; E6311-A: ethylene glycol dimethacrylate oxide polymer of molar mass Mw 2500 sold under the name EG-2500 by the company DKS (Japan); E6311-B: ethylene oxide polymer of molar mass Mw 5000 sold under the name EG-5000 by the company DKS (Japan); E6311-C: glyceryl tris[poly(oxyethylene(oxypropylene)]triacrylate of molar mass Mw 8000, sold under the name TA by the company DKS (Japan); POE 10 6 : poly(ethylene oxide) of mass 10 6 sold by the company Aldrich; Esacure KTO46: photoinitiator sold by the company Sartomer Company, Inc., and formed by a mixture of phosphine oxide, α-hydroxy ketone and a benzophenone derivative; DPG: dipropylene glycol dimethyl ether, solvent of high boiling point, sold by Clariant; Torr Seal®: epoxy resin seal sold by the company Varian Inc.; CR39: polycarbonate plate, sold by the company Essilor International.
EXAMPLE 1
Preparation of an Electrode
[0057] ITO was deposited by cathodic sputtering onto a CR-39 plate. The layer of ITO obtained has a layer resistance of 50 Ω/□. Next, a composition containing 8 g of Baytron M and 33 g of Baytron C was deposited by spin coating onto the CR39 plate coated with an ITO film, followed by a heat treatment at 60° C. for 1 hour to crosslink the thiophene monomer. The excess Baytron C was removed by washing with n-butanol. The electrode thus obtained has a PEDOT-substituted polythiophene electrochromic layer and it was electrochemically reduced to obtain the maximum coloration.
EXAMPLE 2
Preparation of the Counterelectrode
[0058] ITO was deposited by cathodic sputtering onto a CR-39 plate with a layer resistance of 50 Ω/□. Next, Prussian blue was deposited electrochemically onto the CR39 plate coated with an ITO film, to a thickness giving a capacitance of 3 mC/cm 2 .
EXAMPLE 3
Preparation of Precursor Compositions of the Electrolyte Membrane
[0059] Various precursor compositions (CME) of the electrolyte membrane containing one of the liquid polymers E6311, LiTFSI, KTO46 and DPG were prepared via the following process:
optional addition of DPG as diluent to E6311, and stirring for 5 minutes, addition of LiTFSI to E6311, and stirring for 20 minutes, addition of KTO46, and stirring of the mixture for 20 minutes before use.
[0063] The content of the constituents, expressed as weight %, is given in the following table for four compositions.
[0000]
E6311
LiTFSI
KTO46
DPG
CME1
E6311-A
65
0.6
2
32.4
CME2
E6311-B
65
0.6
2
32.4
CME3
E6311-C
96
1
3
—
CME4
E6311-B
96
1
3
—
EXAMPLE 4
[0064] Deposition of an Electrolyte Film onto a Substrate
[0065] Composition CME1 was deposited by spin coating onto a CR-39 plate, with a first step of 30 seconds at 600 rpm and a second step of 120 seconds at 1500 rpm. Next, the plate thus coated was introduced into a closed chamber purged beforehand for 10 seconds with a stream of nitrogen to remove the oxygen, followed by irradiation using a mercury lamp with the following energy: UVA 780 mJ, UVB 60 mJ, UVC 60 mJ, UVV 580 mJ. The membrane obtained after polymerization is transparent and non-tacky, and has a thickness of 6 μm. The degree of transmission is 92% in the visible range. The polymerized membrane consequently absorbs only a very small amount of visible light.
[0066] It is noted that the same result was obtained by using the composition CME1 after storage for one month.
EXAMPLE 5
Assembly of an Electrochromic Cell, After Crosslinking of the Electrolyte
[0067] An electrochromic cell was assembled according to the following procedure.
[0068] The composition CME1 was deposited by spin coating onto a counterelectrode prepared according to the process of Example 2, with a first step of 30 seconds at 600 rpm and a second step of 120 seconds at 1500 rpm. Next, the counterelectrode thus coated was introduced into a closed chamber purged beforehand for 10 seconds with a stream of nitrogen to remove the oxygen, followed by irradiation using a mercury lamp with the following energy: UVA 780 mJ, UVB 60 mJ, UVC 60 mJ, UVV 580 mJ. The membrane obtained after polymerization is transparent and non-tacky, and has a thickness of 6 μm.
[0069] An electrode, obtained according to the process of Example 1, was deposited onto the surface of the polymer membrane obtained after UV irradiation, and the assembly thus formed was placed in a press system and compressed for 1 hour at 70° C., and then at room temperature for 12 hours.
[0070] The electrochromic cell thus formed was subjected alternately to a potential of −1 V and of +1 V. It was found that the color changed from pale blue to dark blue and reciprocally in less than 10 seconds.
[0071] However, it was found that the contact between the membrane forming the electrolyte and the adjacent layer of the electrode is not homogeneous.
[0072] Two other electrochromic cells were assembled according to the same process, but using, respectively, the composition CME2 and the composition CME4 instead of the composition CME1. In these cells, the thickness of the membrane forming the electrolyte is 6 μm for composition CME2 and 25 μm for composition CME4. In both cases, a color change was observed at the same speed as that observed for the device obtained using composition CME1. In the two cells, the same phenomenon of poor homogeneity between the layer of electrolyte and the layer d is observed.
EXAMPLE 6
[0073] An electrochromic cell was produced according to the procedure of Example 1, with the following differences:
The composition intended to form the electrolyte, referred to herein as CME5, was prepared from 150 g of the polymer E6311-C, 32.62 g of LiTFSI and 0.15 g of KTO46, by mixing the constituents until the dissolution of the LiTFSI and the KTO46 in the polymer is complete. The thickness of the layer of CME5 before crosslinking is 30 μm. The crosslinking is performed by irradiation with a UV lamp (0.2 A, λ=365 nm) for 5 seconds. After assembling the counterelectrode bearing the crosslinked polymer electrolyte membrane and the electrode, and pressurizing, the assembly is sealed using a Torr Seal® seal to form an electrochromic lens.
[0078] The lens thus obtained is dark blue at +1 V and light gray at −1 V. The color change takes place in 3 seconds.
EXAMPLE 7
[0079] An electrochromic lens was produced according to the procedure of Example 5, with the difference that composition CME5 was applied to the electrode, and the counterelectrode was applied to the polymer membrane borne by the electrode.
[0080] The same colors and speeds of color change were observed.
EXAMPLE 8
[0081] The procedure of Example 5 was repeated, but using a composition CME6 prepared from 197 g of polymer E6311-C, 49.3 g of polymer POE 10 6 , 53.56 g of LiTFSI and 0.24 g of KTO46.
[0082] It was found that the presence of a polymer of very high molecular weight substantially improved the adhesion between the electrolyte membrane and the electrochromic layers adjacent thereto.
[0083] The color changes as a function of polarization of the electrochromic lens obtained are similar to those observed for the lens of Example 7.
[0084] A similar result was obtained by applying composition CME6 to the electrode, and then the counterelectrode to the electrode bearing the electrolyte membrane.
EXAMPLE 9
Crosslinking of the Electrolyte Polymer After Assembly of the Electrochromic Cell
[0085] An electrochromic cell was assembled according to the following procedure.
[0086] Composition CME3 was deposited by spin coating onto a counterelectrode prepared according to the process of Example 2, with a first step of 30 seconds at 600 rpm and a second step of 120 seconds at 1500 rpm. Next, an electrode obtained according to the process of Example 1 was deposited on the surface of the layer of composition CME3, taking care to avoid short circuits between the electrode and the counterelectrode.
[0087] Irradiation of the layer CME3 with a UV lamp similar to that used in Example 4 was performed through the electrode, to photopolymerize said layer CME3. The thickness of the electrolyte membrane after polymerization is 20 μm.
[0088] Taking into account the absorption spectrum of the photoinitiator, the transmission window of the working electrode (CR39+ITO+PEDOT) and the emission spectrum of the mercury lamp used, the irradiation was able to be performed through the electrode.
[0089] The electrochromic cell thus formed was subjected alternately to a potential of −1 V and of +1 V. It was found that the color changed from pale blue to dark blue and reciprocally in less than 20 seconds.
[0090] The contact between the membrane forming the electrolyte and the adjacent layers is homogeneous.
EXAMPLE 10
[0091] Comparison of an electrolyte prepared without solvent and of an electrolyte prepared with solvent
[0000] Electrolyte Prepared without Solvent
[0092] An electrolyte composition was prepared as follows: 150 g of polymer based on polyethylene oxide (E6311C) with a molecular weight of 8000 was mixed with 32.6 g of salt LiTFSI, with stirring on a roll system for 12 hours. An amount of 1000 ppm of photoinitiator (KT46) relative to the weight of polymer was added, and the composition was then applied to a polypropylene (PP) support, by pressure at 10 psi with heat (t=80° C.), followed by crosslinking using a UV lamp at 365 nm for one minute. The 50-micron film obtained is free of porosity.
[0093] This film is used as an electrolyte film in a configuration:
[0094] PET/ITO/PEDOT/electrolyte/Prussian blue/ITO/PET.
[0095] The coloration time of this window is less than 5 seconds.
[0000] Electrolyte Prepared with Solvent (Counterexample)
[0096] An electrolyte composition was prepared as follows: 49 g of the polymer POE 10 6 were mixed with 122 ml of acetonitrile, 30 ml of acetone and 10 g of the salt LiTFSI, with stirring on a roll system for 12 hours. Next, an amount of 1000 ppm of photoinitiator (KT46) relative to the weight of the polymer was added, and the composition was then applied to a polypropylene (PP) support and the solvent was evaporated off at 40° C., followed by crosslinking using a UV lamp at 365 nm for one minute. The 30-micron film obtained is porous.
[0097] This film is used as an electrolyte film in a configuration:
[0098] PET/ITO/PEDOT/electrolyte/Prussian blue/ITO/PET.
[0099] The coloration time of this window is greater than 10 seconds. | The invention relates to an electrochromic optical lens and a method for the preparation thereof. The lens includes an electrode and a counter-electrode bearing an electrochromic material separated by a solid polymer electrolyte. The method consists of preparing the electrode and the counter-electrode and the assembly thereof by the surfaces thereof bearing the electrochromic material by interleaving an electrolyte membrane between said surfaces. The electrolyte membrane is interleaved in the form of a composition free of volatile liquid solvent, including a precursor of the polymer and a salt, which is liquid or which has a dynamic viscosity [mu] between 100 and 106 Pa.s. | 8 |
FIELD OF THE INVENTION
This invention relates to wool-synthetic blend fabrics and more particularly to flame-resistant, dimensionally stable wool-synthetic blend fabrics suitable for use in aircraft and other transport interiors.
BACKGROUND OF THE INVENTION
Upholstery fabrics made from wool are known to have an attractive appearance and feel to the touch. Due to the tendency of wool to shrink after washing in water, however, attempts have been made to substitute wool fabrics with fabrics made from synthetic materials such as polyester. The appearance and feel of fabrics made from synthetic materials, however, has been found to be inferior to that of fabrics made from wool. Fabrics made from blends of wool fibers with certain synthetic fibers retain some of the aesthetic features of wool as well as some of the cost benefits and potential property advantages of synthetics.
In the aircraft industry, seat cover fabrics are subject to specifications provided by aircraft manufacturers such as Airbus and Boeing. The relevant Airbus technical specification, for example, is TL 25/5092/83. The relevant flammability, smoke and toxicity portions of the standard are FAR 25.853 (b), appendix F, amended 32, JAR 25853 (b), appendix change 10, and ABD 0031 (previously numbered ATS 1000.001). These specifications include standards for abrasion resistance including resistance to abrasion simulated by a Martindale tester. Resistance to stains resulting from spills, and to loss of color and shrinkage due to washing, is also specified. Seat cover fabrics may be required to meet specifications after a minimum of 10 washings. An areal weight below 470 g/m 2 is specified. It is desirable that shrinkage during service life, including shrinkage due to cleaning processes, be minimized. Resistance to pilling, corrosion and color loss may also be specified.
The relevant Boeing specification is BMS 8-236, for general upholstery interior applications. The flammability standard is provided by BSS7230, a twelve second vertical burn test, in which the sample is required to self extinguish within fifteen seconds, with a burn length of less than eight inches. Drips, if any, are required to extinguish in less than five seconds. Smoke emissions of less than 200 are specified according to BSS7238. Prescribed limits for individual toxic components in toxic gas emissions are tested according to BSS 7239. Dimensional stability is evaluated after prescribed cleaning, whether dry cleaning or water washing methods are used. While zero shrinkage is ideal, shrinkage levels of less than 6%, in both warp and fill directions, are acceptable. Standards for appearance, snag resistance, pilling resistance, color fastness and strength are part of the overall specification.
Wool fabrics are typically cleaned using a dry-cleaning process, including immersion in a solvent such as perchloroethylene, in order to maintain the dimensional stability of the fabric. Due to environmental and cost considerations, it would be desirable to clean wool-based fabrics without the use of perchloroethylene or other organic solvents. Water containing surfactants or detergents is highly effective in cleaning such fabrics, however, use of water-based cleaning solutions has been limited by the tendency of wool based fabrics to shrink after being subjected to such solutions. Synthetic fibers, on the other hand, are typically highly resistant to shrinkage following washing in water. Synthetic fibers, however, tend to be highly flammable.
Because of the nature of the constituent parts of the above mentioned wool-synthetic blends, such blends in the prior art are typically neither flame resistant, nor shrink resistant when washed in water. There is a need for fabrics made from wool-synthetic blends that will meet the special requirements for aircraft interiors.
BRIEF DESCRIPTION OF THE INVENTION
In one embodiment of the invention, a method of producing a dimensionally stable, fire-resistant fabric suitable for use on aircraft includes the steps of providing a yarn having a blend of wool fibers and fire-resistant synthetic fibers, the wool fibers comprising approximately 30% to 70% of the blend, weaving the yarn to form a fabric, and dimensionally stabilizing the fabric to achieve a washable woven structure resistant to shrinkage. The synthetic fibers may include polyester fibers produced or treated to enhance fire resistance. The fabric may be dimensionally stabilized by heat setting or by applying a coating such as neoprene or polyurethane.
In another embodiment a method is provided for producing a dimensionally stable, fire-resistant fabric by spinning wool and fire-resistant polyester fibers to form a yarn, weaving the yarn to a form a fabric, and heat-setting the fabric to produce a finished material that passes Airbus and/or Boeing specifications.
In a further embodiment a method is provided for producing a fire-resistant wool-based yarn by spinning shortened wool fibers with fire-resistant polyester fibers in a vortex spinning apparatus. The yarn is woven into a fabric that passes aircraft manufacturer specifications. The fabric is stabilized dimensionally, to prevent or substantially reduce shrinkage during use, by heat-setting the fabric in a stenter apparatus or by applying a coating such as neoprene or polyurethane. In one embodiment, the fabric is dimensionally stabilized such that it resists shrinkage after water washing. In a further embodiment, the method includes treating the yarn or fabric with zirconium to augment the fire-resistant properties.
In yet another embodiment a method is provided for producing a dimensionally stable fabric by providing wool fibers, an effective percentage thereof cut or broken to fall within a selected length range, providing fire-resistant synthetic fibers, spinning the wool and synthetic fibers to produce a wool-synthetic blend yarn, wherein the wool fibers comprise approximately 30% to 70% of the blend, weaving the yarn to form a fabric, and providing dimensional stabilization by application of a polymer coating or by heat setting the fabric to produce a final product that passes aircraft manufacturer specifications.
Wool fibers having a typical length of no greater than approximately five centimeters may be prepared by stretch-breaking. The synthetic fibers may include polyester fibers. Fibers may be spun by delivering the fibers to a ring spinning, air-jet spinning or vortex spinning apparatus for spinning the fibers into a yarn. The fabric may be heat-set by securing and heating the fabric within a stenter. When passing the fabric through a stenter, sufficient heat is applied to set the fabric and produce a dimensionally stabilized fabric resistant to shrinkage. Further steps may include applying zirconium fire retardant to the fabric and applying a coating to bind the zirconium fire retardant to the fabric.
DETAILED DESCRIPTION
In one embodiment, wool fibers are first prepared by reducing their length. Wool tops, consisting of fibers that are approximately 5.5 to 8 cm in length, are passed through a stretch-breaking machine to reduce their lengths to approximately 2 to 5 cm. It is advantageous if the fibers are approximately 3 to 4 cm in length. It is advantageous if the wool fibers have diameters in the range of 13 to 25 microns, and particularly advantageous if the wool fibers have diameters in the range of approximately 22 to 25 microns.
After stretch breaking, the wool fibers are combined with flame retardant (FR) synthetic fibers (such as polyester) having a length of approximately 2 to 5 cm and a compatible denier such as 1 to 4.5, and the resulting combined fiber bundles are passed through one or more draw frames. The drafted wool and FR fiber bundles are introduced into a spinning machine at such relative rates as to achieve wool contents in the range of approximately 30 to 70 percent. It is advantageous to the properties of the resulting fabric if the wool content is in the range of approximately 40 to 60 percent.
Spinning Technology
Typically, carding occurs prior to, or as an initial step in, the spinning process. Through carding, fibers are straightened and made relatively parallel to one another. After carding the fibers form a thin layer called a web. The web is gathered into a loose rope called a sliver. The sliver is typically wound into a large can and then moved to a draw frame. In the drawing process, multiple cans of sliver are drawn together to form a combined sliver.
Ring spinning is a relatively slow spinning technology that typically yields a high quality yarn. During ring spinning, sliver is fed into the drafting zone of the ring spinning frame. The drafting zone has one roller that turns relatively slowly and feeds the sliver and another roller that turns relatively fast. The faster roller pulls out a few fibers at a time forming a fine stream of fibers that are fed to a rotating spindle inside a ring. As the spindle rotates, it drags a slower moving traveler on the ring. The ring twists the fibers as they are wound onto a bobbin that rides on the spindle. After spinning, the yarn may then be used for weaving, perhaps after being further transferred to other holding structures. Ring spinning has been the preferred method of producing high quality wool yarns that demonstrate superior feel to the touch and abrasion resistance.
The air-jet spinning method uses air currents to twist fibers together, resulting in higher throughput and productivity than ring spinning. Air-jet spinning may be used to spin blends of wool and synthetic FR fibers, but yields yarns with reduced abrasion resistance in comparison with ring and vortex spinning.
The air vortex spinning method is a particularly efficient spinning method that is a capable of spinning yarns at very high speeds and that yields a yarn having a relatively smooth texture and increased abrasion resistance. A vortex spinning apparatus typically takes drawn sliver and drafts it to the desired yarn count via a four-roller drafting unit. The drafted fibers are then sucked into a nozzle where a high speed air vortex wraps the fibers around the outside of a hollow stationary spindle. Yarn twist is then imparted as the fibers are pulled down a shaft that runs through the middle of the spindle.
An example of a vortex spinning apparatus is described in the patent to Mori, U.S. Pat. No. 6,370,858, hereby incorporated by reference. Mori discloses a Murata vortex spinning method in which a drafted fiber bundle is supplied to a nozzle block and then to a hollow guide shaft. A core fiber is also fed to the nozzle block and then to the hollow guide shaft. Vortex air currents ejected from spinning nozzles in the nozzle block cause inversely turned fibers to wrap the fiber bundle and core fiber to create core yarn. The core fiber may be multi-filament in which case the vortex air currents balloon the multiple filaments, resulting in the filaments being partially separated from one another. The vortex air currents insert the front ends of the fibers into the clearances between the separated filaments, and cause the other ends of the fibers to wrap around the multi-filament core fiber, resulting in the creation of the core yarn.
In another embodiment, the fiber bundle, comprising a blend of shortened wool and synthetic fibers, is delivered to the vortex spinner and spun without use of core fiber. In this embodiment, vortex nozzle apertures and build pressures are optimized for spinning such that a percentage of the fibers delivered to the spinner tend to form a core. Remaining fibers are simultaneously spun or wrapped around this core thereby causing the core of the yarn to build as the yarn strand itself is formed.
The spinning speed of a vortex spinner is much faster than that provided by ring spinning with the ring method typically producing yarn at the rate of 20 meters per minute and the vortex method typically producing yarn at the rate of 400 meters per minute. The vortex method does not readily accommodate the longer fibers typically used in wool spinning, however, and it has been found to be advantageous to reduce the fiber lengths as illustrated in the various embodiments of the invention disclosed herein.
Preparation of the Fabric
In the various embodiments contained herein, the spinning process used to produce the yarn may include ring spinning, air-jet spinning, air vortex spinning or other appropriate means. It is advantageous, however, to spin the yarn using a vortex spinning method and apparatus.
After spinning, the yarn is typically dyed to a selected color and then woven into a fabric. The particular weave is typically determined by the requirements of the eventual use of the fabric. Appropriate weaves include those known for use by American Airlines and United Airlines.
After weaving, the fabric is heat-set to increase dimensional stability of the fabric. It is advantageous if the heat setting includes the step of affixing the fabric within a stenter frame so that a given dimension may be controlled during the heat-setting process. The fabric is heat set within the stenter by heating the fabric to a temperature in excess of 100° C. The actual temperature used is primarily dependent upon the chemical nature of the synthetic fiber being used. Multiple heating bays may be used, each successive bay typically providing increased heat. In the case where a polyester fiber is used, the maximum temperature is typically set between approximately 170° C. and 220° C. Dwell time, the time period in which heat is applied to the fabric in the stenter may be adjusted according to temperatures used and composition of the fabric. The fabric is typically heated by provision of dry heat using appropriate means such as a gas fired burner and heat exchanger. In one embodiment, dimensional stability results from incipient melting of polyester (or other synthetic) fibers and subsequent bonding of the fibers to form a continuous or semi-continuous polyester network or lattice within the fabric.
In an embodiment directed to vortex spun yarn, wool tops are passed through a stretch-breaking apparatus and the fiber length is thereby reduced to approximately 3 to 4 cm. The wool fibers are then combined with synthetic FR staple (such as polyester) having an approximate length of 3 cm, at a ratio of one part wool fiber to one part synthetic FR fiber, to form an intimate blend. The combined fibers (“intimate blend”) are drafted on a drawframe and then spun in a vortex spinner.
Portions of the yarn are dyed to a desired color or colors and then woven into a fabric suitable for use in aircraft such as for seat upholstery. The fabric is heat set in a stenter at an appropriate temperature (approximately 190° C. if the synthetic primarily comprises polyester) for approximately 30 seconds. As a result of this process the fabric meets airline interior fabric test specifications, including those for fire resistance, abrasion and shrinkage after water washing. By way of example, a fabric may be produced in accordance with the above embodiment to pass Airbus specification TL 25/5092/83 and Boeing specification BMS 8-236. Fabric meeting these specifications may be produced without heat setting if the fabric is to be dry-cleaned rather than subjected to water washing.
Representative passing test results include the following for flame resistance, abrasion resistance and relaxation and felting shrinkage (dimensional stability).
TABLE 1
Flame Resistance
(Federal Aviation Regulation § 25.853(a))
Average Dripping
Average Burn Time
Average Burn
Flame Time
Specimen
After Flame (seconds)
Length (mm)
(seconds)
Warp
8.7
83
Nil
Weft
7.3
77
Nil
TABLE 2
Abrasion Resistance
(Martindale Method)
No. Cycles to Grey
No. Cycles to
Average No.
Scale 3
Unacceptable
Total
Cycles to Mechanical
Color Change
Appearance
Loading
End Point
End Point
Change End Point
12 Kpa
46,500
Not reached
Not reached
TABLE 3
Dimensional Stability
(Wool/Polyester, American Airlines Weave,
No. of Cycles: 7A × 1, 5A × 2)
Width
Length
% Relaxation shrinkage
−2.1
−3.5
% Felting shrinkage
−1.5
−2.1
% Total shrinkage
−3.6
−5.5
% Area shrinkage
−3.6
As an alternative to fabric produced from a blend of wool and synthetic FR fiber, yarn may be spun from a blend of wool and non-fire resistant synthetic fiber or from wool alone. Fabric woven from such yarn may then be treated with zirconium fire retardant. Such treatment typically includes a coating to bind the zirconium fire retardant to the fabric. If woven from yarn spun from wool and without the addition of synthetic fibers, fabric would typically not be heat set but would retain dimensional stability during use through dry-cleaning rather than washing with water.
Additionally, yarn spun from a blend of wool and synthetic fibers, the wool fibers comprising between approximately 30 to 70 percent of the blend, may be treated with zirconium-based fire retardants prior to weaving to augment the fire-resistant qualities of the resulting fabric. Zirconium treatment may be applied to any of the fabrics set forth above to enhance fire-resistance.
To resist dislodging of the zirconium fire retardant from the fabric during washing, the fabric may be treated with polyurethane or other appropriate material to coat the zirconium and bind it to the fabric.
It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto except insofar as such limitations are included in the following claims and allowable equivalents thereof. | A method of producing a dimensionally stable, fire-resistant fabric including the steps of spinning yarn from wool and fire-resistant synthetic fibers, weaving the yarn to form a fabric, and dimensionally stabilizing the fabric to produce a textile that passes aircraft manufacturer specifications. | 3 |
FIELD OF THE INVENTION
This invention relates generally to optical frequency measurement devices and interferometry, and more specifically to measurement of frequency separation between two monochromatic sources, which can have applications in optical metrology, spectroscopy, and other optical instrumentation.
BACKGROUND OF THE INVENTION
Instruments for optical measurement of distances are of great importance in manufacturing processes which require precise distance measurements. They are being used in the manufacture of automobiles, airplanes, and other goods. These measurement instruments use laser light sources and often require precise knowledge of emission frequency.
Several gage tools which use interferometric techniques have been proposed. An example of one using two-wavelength interferometry is found in Williams et al., "Absolute Optical Ranging with 200 nm Resolution," Optical Letters, vol. 14, no. 11, pp. 542-544. The proposed tools require precise knowledge of the frequency separation of light from two laser sources, typically with a rapid update, absolute measurement accuracies on the order of 0.05 GHz, and an operational range of over 150 GHz. In some cases, the measurement must be made while the lasers are being rapidly tuned in frequency at rates greater than 250 GHz per second. The instrument for performing this measurement should be compact, inexpensive, and ruggedly packaged for use on the factory floor.
The object of the invention, therefore, is to provide a compact, inexpensive means for determining the frequency separation between two monochromatic sources with rapidity and a high degree of accuracy, capable of being ruggedized for use in practical applications such as manufacturing.
Such a device would also have application for absolute frequency measurement when calibrated against a known frequency, and to analysis of multiple spectral lines, where such lines are sequentially analyzed.
SUMMARY OF THE INVENTION
The invention provides a method and apparatus for determining the frequency separation between lasers or other monochromatic light sources with a high degree of accuracy and great rapidity. The invention is based on amplitude-division interferometry having three parallel beams, each with a different optical path length. The differences in interferometric phase corresponding to the two frequencies are measured for each of the three beams, and the frequency difference is then calculated.
In a preferred embodiment of the claimed invention, the frequency separation between two light signals, one having a first and the other having a second frequency, is determined by first forming three light beams, each including both frequencies; directing the three beams through an interferometer in which they traverse three optical paths having three different known optical path lengths; determining the interferometric phases for each of the three optical paths at both frequencies; and determining the difference between the first and second frequencies from the interferometric phases and known optical path lengths. The light signals may be light from two lasers operating at different frequencies. The optical path lengths can be predetermined by calibration using two light sources of know frequencies.
A preferred embodiment of an apparatus for carrying out this method is also disclosed. This apparatus includes beam splitter means for splitting an input light beam which includes light from each source into three parallel beams; a stationary object mirror; a movable reference mirror; an interference signal detector, which is preferably a three-element detector array; an optical assembly for splitting each of the three beams into parallel reference beams and object beams directed to the object mirror and reference mirror, respectively. This assembly also directs light returning from said object and reference mirrors to the detector array.
BRIEF DESCRIPTION OF THE DRAWINGS
The features set forth above and other features of the invention are made more apparent in the ensuing Detailed Description of the Preferred Embodiment when read in conjunction with the attached Drawings, wherein:
FIG. 1 is a schematic illustration showing the principle of operation of the invention;
FIG. 2 shows the optical layout of a preferred embodiment of the invention;
FIG. 3 is a detailed view of the 1- to 3-beam spatial multiplexing prism of the FIG. 2 embodiment;
FIG. 4 is a detailed view of the amplitude division optical assembly of the FIG. 2 embodiment;
FIG. 5 is a cross-sectional view taken along line A--A of FIG. 2;
FIGS. 6 and 7 show the FIG. 2 embodiment as used with alternative phase detection systems;
FIG. 8 is a side view of the mechanical packaging of the FIG. 2 embodiment; and
FIG. 9 is a plan view of the packaging of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
To facilitate understanding, the underlying theory of operation of the invention will be explained first. Referring to FIG. 1, there is shown a schematic of an interferometer 9 for measuring frequency. The interferometer includes a beam splitter 16 which directs the incoming light beams 10a, 10b, 10c to an object mirror 17 and a movable reference mirror 18, affixed to a piezoelectric transducer (PZT) 19 which oscillates the reference mirror 18 in a manner known to those skilled in the art. The beams 10a, 10b, 10c follow three parallel optical paths, each having its own optical path length x, y, z respectively between the reference arm 12 and the object arm 14. By comparison of the interferometric phases for the three optical path lengths at two frequencies, the frequency separation can be determined as explained below.
The following symbols will be used in this discussion:
______________________________________υ.sub.1,υ.sub.2 optical frequencies of two laser sources (speed of light/wavelength)υ average of υ.sub.1 and υ.sub.2Δυ difference between υ.sub.1 and υ.sub.2Δυ'Δυ" first and second estimates of Δυx,y,z phase-velocity path lengthsx,y,z phase-velocity path lengths at a frequency υ = υX,Y,Z group-velocity path lengths for frequencies near υ = υθ.sub.1x,θ.sub.2x interferometric phases at υ.sub.1,υ.sub.2 at a distance x.Φ.sub.x synthetic phase, equal to θ.sub.1x - θ.sub.2xΦ".sub.x estimate of synthetic phase Φ.sub.x, based on Δυ"Φ.sub.x synthetic phase modulo 2πΨ.sub.xy difference in synthetic phases Φ.sub.x and Φ.sub.yΨ'.sub.xy estimate of difference in synthetic phases Φ.sub.x and Φ.sub.y, based on Δυ"Ψ.sub.xy synthetic phase difference modulo 2πm.sub.x ##STR1##______________________________________
The interferometric phases θ 1x , θ 2x are dependent upon the frequencies υ 1 , υ 2 according to
θ.sub.1x =(2πx/c)υ.sub.1 and θ.sub.2 =(2πx/c)υ.sub.2 (1a, 1b)
Similar equations can be written for the y and z phase velocity path lengths. The difference in phase, referred to here as the "synthetic phase," for a frequency separation Δυ=υ 1 -υ 2 is
Φ.sub.x =θ.sub.1x -θ.sub.2x =(2πX/c)Δυ(2)
where
X=x+υdx/dυ (3)
is the group-velocity path length associated with x=x at an average frequency υ. The phase difference Φ x can be divided into two parts, the first part being an integer m x multiplied by 2π and a second part Φ x that is commonly called the fractional phase. Normally, it is only the fractional phase that can be determined directly from an interference effect with a single optical path difference, and the integer part is not known. Thus it is not ordinarily possible to measure Δυ without ambiguity by inverting Equation (2). However, with three path differences x, y, z there results a system of three equations
Δυ=(c/2πX) (2πm.sub.x +Φ.sub.x) (4a)
Δυ=(c/2πY) (2πm.sub.y +Φ.sub.y) (4b)
Δυ=(c/2πZ) (2πm.sub.z +Φ.sub.z) (4c)
which for a well-chosen set of path differences X<Y<Z can be solved exactly for Δυ. The method for solving this system of equations is similar to that taught in an article entitled "Three Color Laser Diode Interferometer," by P. de Groot (Applied Optics, vol. 30, pp. 3612-3616) which is incorporated herein by reference.
For some range of possible frequency differences, the apparatus can be designed so that Z-Y is known to be less than c/Δυ. Then Equation 4c minus Equation 4b can be used for a first estimate Δυ of the frequency difference without ambiguity: ##EQU1## where
Ψ.sub.zy =Φ.sub.z -Φ.sub.y. (6)
Then using the fact that m x and m y are integers, Equation 4b minus Equation 4a yields a second estimate Δυ" of higher accuracy: ##EQU2## where the function Int { } is equal to the nearest integer of its argument, and the approximation ##EQU3## is free of phase ambiguities. Finally, a third and final calculation Δυ'" of the frequency difference uses Equation 4a alone, ##EQU4## where ##EQU5## In practice, the path lengths X,Y,Z may be calibrated using a known frequency difference Δυ and inverted forms of Equations 5, 8 and 10.
FIG. 2 shows a practical implementation of an interferometer 19 which utilizes this theory of operation. Incoming light from two monochromatic sources, such as lasers or laser diodes operating at different frequencies, travels through a fiber 20 to a collimating lens 22, and is then split into three parallel beams by a 1- to 3-beam spatial multiplexing prism 24, which is shown in greater detail in FIG. 3. The 1- to 3-beam prism 24 includes a rhombohedron 26 abutting a right angle prism 28. The surface 30 between their abutting sides is partially reflective. Preferably, it is 50% reflective. The exact size and geometry of the rhombohedron 26 and prism 28 are as chosen so as to form three exit beams 32x, 32y and 32z. These three beams are in a plane perpendicular to the plane of FIG. 2.
Referring again to FIG. 2, the three beams 32x,y,z enter an amplitude division optical assembly 34, shown in greater detail in FIG. 4. This assembly 34 comprises two right angle prisms 36, 38 abutting opposite sides of a beam splitter 40. Referring again to FIG. 2, the assembly 34 serves several functions. It splits the incoming set of three beams 32x,y,z into a set of three reference beams 42x,y,z and three object beams 44x,y,z and directs the reference and object beams in a direction opposite the incoming direction toward a reference mirror 46 and an object mirror 48, respectively. The reference mirror 46 is mounted to a PZT 45. Appropriate mounting means are well-known to those skilled in the art.
The assembly 34 also directs the reflected beams 42' and 44' returning from the mirrors 46, 48 to a detector array 49, which detects the interference signals.
The geometry of the assembly 34 is chosen so that the input beams 32x,y,z, the reference beams 42x,y,z and the object beams 44x,y,z are parallel and remain parallel even when the assembly 34 is rotated within the plane of FIG. 2. This greatly reduces the sensitivity of the device to alignment errors, and also allows the assembly 34 to be rotated through small angles to reduce the effects of secondary reflections from the prism surfaces. It will be appreciated that the design of the assembly 34 also allows for a compact and rugged apparatus.
The assembly 34 also directs an exit beam 43 out of the interferometer 19. This exit beam 43 can be used to check alignment, or for a spectroscopic technique described in connection with FIG. 7 below.
Achromatic lenses 50, 52 are disposed in the path of the reference beams 42x,y,z and object beams 44x,y,z, and positioned so as to focus the beams on the reference mirror 46 and object mirror 48, respectively. As will be apparent to those skilled in the art, the alignment of the interferometer 19 is thus rendered insensitive to a first order, to rotation of these mirrors. Also, due to the focusing property of these lenses 50, 52, the PZT-actuated reference mirror 46 can be made very small and light.
Path-change optics 54 of a type which may be chosen from those well-known in the interferometry art lie in the path of the object beams 44 between the assembly 34 and the achromatic lens 56. As shown in FIG. 5, these path change optics 54 are positioned so that two of the three beams 44x, 44y, 44z pass through the path change optics 54.
The interferometer 19 shown in FIG. 2 can be used with a variety of well-known phase detection systems. Such systems include:
1. Sequential measurement of phases with first one laser then the other, using the PZT 45 and standard PMI techniques, or frequency-tunable lasers and pseudo-heterodyne techniques, both known in the art. This time-multiplexed approach can be used for several lasers in sequence;
2. Direct measurement of phase differences for two simultaneously operating tunable lasers, using chirped-synthetic wavelength detection methods such as that described in our copending patent application Ser. No. 07/879,836, filed May 6, 1992 for Chirped Synthetic Wavelength Radar, which is incorporated herein by reference;
3. Direct measurement of phase differences for two simultaneously operating lasers, using amplitude or frequency modulation to encode the signals. Appropriate encoding apparatus and electronic post-processing are taught, for example, in an article by O. Sosaki, et al. in Applied Optics, vol. 30 pp. 4040-4044, which is incorporated herein by reference;
4. Direct measurement of phase differences for two simultaneously operating lasers, using electric field polarization to encode the signals. Use of polarization to encode signals from two different lasers is taught in an article by A. J. den Boef in Applied Optics, vol. 27, pp 306-311, which is incorporated herein by reference. As shown in FIG. 6, application to the present invention can be easily achieved by introducing a polarization beam splitter 58 and a second detector array 60 in an alternative embodiment, which is otherwise identical to the FIG. 2 embodiment; and
5. Simultaneous measurement of phases for two or more lasers, using separation of wavelengths by spectral analysis at the interferometer output. This approach is appropriate if the approximate wavelengths of the lasers are known, and if their frequency separation is greater than 50 GHz, so that they may easily be resolved with a 2.5 cm diffraction grating. An optical geometry for achieving this is shown in FIG. 7. It includes an interferometer 19 as described above, with cylindrical expansion optics 62 which direct exit beam 43 to a diffraction grating 64. The diffracted beam 66 travels through cylindrical telescopic optics 68 to a pair of 3-element detector arrays 70, 72.
Referring now to FIGS. 8 and 9, a rugged mechanical package 74 for the preferred embodiment includes a base plate 78 and a mounting block 80 for the PZT which is affixed to the base plate 78. These pieces are preferably machined from aluminum, stainless steel, or Invar. The base plate 78 includes mounting brackets for the various optical components, which are affixed thereto by any well-known means. In operation, optical path lengths of X=40 mm, Y=41.5 mm, Z=41.75 mm, and lasers operating at wavelengths near 780 nm have been found to be preferable.
Although the invention has been described with respect to a particular preferred embodiment, it will be understood that variations and modifications are possible in light of the above teachings. Such variations or modifications may be within the scope of the claims. | The frequency separation between two light signals, one having a first and the other having a second frequency, is determined by first forming three light beams, each including both frequencies; directing the three beams through an interferometer in which they traverse three optical paths having three different known optical path lengths; determining the interferometric phases for each of the three optical paths at both frequencies; and determining the difference between the first and second frequencies from the interferometric phases and known optical path lengths. The light signals may be light from two lasers operating at different frequencies. The optical path lengths can be predetermined by calibration using two light sources of know frequencies. An apparatus for carrying out this method is also disclosed. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to embedding media for the preparation of thin sections of embedded biological materials. The thin sections are of the type which may be employed for light or electron microscopic study of the embedded biological materials.
U.S. Pat. No. 4,424,329 describes producing embedding media by admixing several methacrylates, a free radical polymerisation initiator, one or more co-initiators and--optionally--a plasticizer. The use of a complex initiator system instead of a simple compound is, however, a disadvantage. Apart from this, the described initiator system is not optimal for polymerisation at low temperature.
Described in J. Electron Microscopy 28, (1979) pp. 53-55, is that tree cell walls can be best observed by embedding tree cells in a medium consisting of methyl and n-butyl methacrylate and polymerizing the embedding medium. However, polymerisation is carried out only at elevated temperature with 2,2'-azobisisobutyronitrile as an initiator. Furthermore, the two-component embedding medium lacks variability.
Finally, a method of producing an embedding medium which comprises admixing several methacrylates and a free radical polymerisation initiator is described in DE-A No. 27 48 938. However, this embedding medium is likewise polymerised at elevated temperature and additionally admixing the monomer mixture with a further component of polymer powder is required Furthermore, the preparation of biological specimens with available embedding media by the thin sectioning technique, although usually adequate for general cytological work, has severe limitations for high resolution electron microscopy as in the molecular region.
In order to improve the amount of useful information retrievable, a number of deleterious effects must be minimised, including the effects of molecular denaturation, supramolecular disordering, damage by sectioning, and other factors related to observation, such as staining, and beam damage due to irradiation in the electron microscope.
Most attempts to improve embedding techniques in the past have involved the consideration that a water-soluble resin renders dehydration essentially unnecessary and that use of such resins will not lead to solvent-induced denaturation. What does not appear to have been properly observed or considered is that the liquid resin itself can be a solvent which leads to solvent denaturation. Furthermore, the fact that a liquid resin may be water-soluble does not ensure that the initial polar environment of cell structures would be maintained.
Procedures for the preparation of thin sections of embedded biological materials are in general characterized by the inability to independently alter several parameters, including particularly:
the effect on biological materials such as proteins and lipoproteins when water is replaced by organic fluids employed in the embedding procedure,
the effect of polarity of the organic solvent and embedding medium,
effects of temperature,
effects of water content remaining after dehydration,
effects of the type and duration of fixation,
effect of the nature of heavy metal staining.
It is an object of the present invention to provide new embedding media enabling parameters such as above to be varied independently. This enables determination of the influence of each parameter on the different structural aspects in biological materials such as proteinaceous complexes and protein-rich lipoprotein membranes. The parameters are extremely interdependent or intercorrelated, as for example illustrated by the fact that aminoacid residues at the surface of proteins as well as polar heads of lipids are firmly associated with a layer of water, the hydration shell, and the fact that the binding of this water on proteins is different for different molecular surfaces and can "melt away" at different temperatures. Thus, the higher this "melting temperature", the "firmer" is the water bound. This phenomenon is involved in the formation of the hydrophobic bond, which becomes established only upon raising of temperature. Such bonds are entropy driven, i.e. the disorder associated with "melting" of the hydration water increases the entropy more than the association (ordering) proteins does decrease it. Many believe that the hydration shell is an important factor in establishing the tertiary structure of a protein. Pertubing or removing it, would lead to the conformational changes associated with denaturation. Therefore, the fate of the hydration shell during embedding must be considered. Similarly, with highly polar organic solvents or embedding media, in which water is soluble, the possibility of competitive effects between these liquids and the biological material for the remaining water of hydration must be considered. Particularly in a polar resin, a sort of composition might occur which removes the hydration shell, if water has a higher affinity to the resin. Since no experimental data are as yet available, this question has to be solved empirically for the embedding. Non-polar solvents or embedding media on the contrary have no affinity for water and it can be envisaged that the hydration shell is not removed, provided obviously that this was maintained during dehydration. This returns the consideration to those related to polar solvents.
Two embedding medium compositions, which take into account the considerations discussed above are described in U.S. Pat. No. 4,424,329. However, the viscosity of these compositions is a limiting factor for application at lower temperatures. To avoid these disadvantages, three new compositions two polar and one non-polar, have been developed, which enable embedding at a substantially lower temperature range.
SHORT DESCRIPTION OF THE INVENTION
The new compositions of the present invention, similar to the previous compositions, may be employed in the "PLT technique" (Progressive Lowering of Temperature), but at lower temperature of embedding. They have been more specifically designed for freeze-substitution and similar techniques. In this freeze-substitution technique, rapid freezing is effected with e.g. liquid propane or helium and cell components are stabilized and immobilized with alterations of cell structures kept to a minimum; in a second step, the substitution, the frozen water is replaced in cells by an organic solvent. Usually the frozen material is fixed (osmiumtetroxide at -90° C., or glutaraldehyde down to -50° C.) before infiltration and polymerisation. Chemical fixation modifies the cell constituents chemically and thus has an influence on their detectability by cytochemical technique, when applied directly on sections. The new compositions have been specifically designed to overcome this problem. Frozen biological materials are infiltrated and polymerized at low temperatures(-78° C. for the non-polar composition; -60° to -65° C. for the polar compositions) after the substitution step to keep the cell structures and diffusable substances immobilized by cryofixation without the introduction of a chemical fixative.
In accordance with the invention there are provided methods of producing non-polar and polar embedding media and multicomponent package comprising the components of the media for carrying out the methods. There are provided non-polar and polar embedding medium components for admixture with a cross-linking agent and a small amount of polymerisation initiator. A variety of components may be suitable for preparing non-polar and polar embedding media and similarly a variety of cross-linking agents may be suitable.
In the case of the polymerisation initiator, practically any substance capable of providing a free radical with sufficient reactivity for free radical polymerisation would be suitable for use in preparing embedding media of the present invention. At the same time, the nature of the polymerisation initiator and the amount employed in the preparation of the embedding would in general be chosen so that polymerisation is not too rapid which can cause perturbation of the cellular structures such as by "polymerisation explosion" or so that no significant amount of heat is generated, which can also lead to perturbation or distortion of cellular structures. Any benzoin would in essence be suitable for use as the polymerisation initiator, benzoin monomethylether being exemplary. The amount of polymerisation initiator employed in preparing the embedding media of the present invention is not critical, but would be at least 0.2% by weight based on the total weight of the embedding medium prepared. More than 1% of polymerisation initiator would not provide any benefit. This is true for the new polar compositions in all cases. However, as the non-polar compositions show less polymerisation reactivity than the polar compositions at embedding temperatures below -50° C., it is recommended to employ a more effective initiator, e.g. benzyldimethylacetal.
The cross-linking agent should be present in a sufficient amount in each of the embedding media of the present invention, since it is probable that the gelling effect of the cross-linking agent on the medium will lower or exclude monomer flow from one region to another in embedded cellular structure which can result in "polymerisation explosion" of the nature mentioned above, or rupture of sensitive membranes defining cell structures.
With the same considerations as above related to polymerisation rate in mind, the energy for polymerisation initiation, for example UV irradiation with 360 nm wavelength should be such that polymerisation is not too rapid.
DETAILED DESCRIPTION OF THE INVENTION
Discussing now first the non-polar embedding medium of the present invention, two non-polar monomers for admixture, or already admixed, have been established to be suitable. These are ethyl methacrylate and n-butyl methacrylate, although it is to be understood that other non-polar monomers could be employed without departing from the essential characteristics of the present invention. In view of the very extensive experimentation necessary to establish suitable ratios, effects of specific cross-linking agents on other non-polar monomers, the non-polar embedding medium of the present invention will only be described and claimed in relation to ethyl methacrylate and n-hexyl methacrylate monomers. Similarly, in the case of the cross-linking agent, only 1,3-butanediol dimethacrylate will be described and claimed as a cross-linking agent actually known and established to be suitable for this purpose at the ratios indicated.
In the case of the two polar embedding media of the present invention, two polar monomers for admixture, or already admixed, have been established to be suitable. These are 2-hydroxyethyl acrylate and 2-hydroxypropyl methacrylate. These two polar monomers are also admixed with an amount of a mixture of non-polar monomers, which for similar reasons as discussed above are identified as n-butyl methacrylate, methoxyethyl methacrylate and ethoxyethyl methacrylate. 1,3-eutanediol dimethacrylate is employed as cross-linking agent in the preparation of the polar embedding media.
As already indicated, the ratios of the components employed in the preparation of the embedding media needs to be established, and upper and lower limits determined outside of which unsatisfactory results would be obtained.
The following Table I shows the components and parts by weight which are employed for the preparation of a non-polar embedding medium:
TABLE I______________________________________component parts by weight typical parts by weight______________________________________ethyl methacrylate 52 to 70 60.7n-butyl methacrylate 26 to 42 33.91,3-butanediol dimeth- 4 to 7 5.4acrylatepolymerisation ini- 0.20 to 1 0.50tiator above-50° C. use:benzoin methylether-50 to -70° C. use: 0.20 to 1 0.50benzyldimethylacetalbelow -70° C. use: 0.50 to 1.25 0.60benzyldimethylacetal______________________________________
The following Table II shows the components and parts by weight which are employed for the preparation of a polar embedding medium:
TABLE II______________________________________component parts by weight typical parts by weight______________________________________n-butyl methacrylate 10 to 15 12.2methoxyethyl meth- 7 to 13 10.2acrylateethoxyethyl meth- 8 to 14 11.2acrylate2-hydroxyethyl 16 to 24 20.6acrylate2-hydroxypropyl 36 to 46 41methacrylate1,3-butanediol dimeth- 3.5 to 6 4.8acrylatepolymerisation ini- 0.20 to 1 0.50tiator benzoinmethylether______________________________________
The methylethyl methacrylate may be eliminated from the above composition in accordance with the following Table III.
TABLE III______________________________________component parts by weight typical parts by weight______________________________________n-butyl methacrylate 10 to 20 15.3ethoxyethyl meth- 10 to 20 17.0acrylate2-hydroxyethyl 26 to 34 26.6acrylate2-hydroxypropyl 35 to 45 36.2methacrylate1,3-butanediol dimeth- 2.5 to 3.5 4.9acrylatepolymerisation ini- 0.20 to 1 0.5tiator benzoinmethyleter______________________________________
As will be recognized from Table I above, the ratio by weight of ethyl methacrylate:n-btuyl methacrylate can lie between the two extreme limits of 52:42 and 70:26. This is equivalent to a ratio of ethyl methacrylate:n-butyl methacrylate of 1.24 to 2.70:1. Similarly, the ratio by weight of the combined ethyl methacrylate and n-butyl methacrylate:1,3-butanediol dimethacrylate can lie between the two extreme limits of 52+26:7 and 70+42:4. This is equivalent to a ratio of the combined ethyl methacrylate and n-butyl methacrylate:1,3-butanediol dimethacrylate of 11.14 to 16:1. The amount of polymerisation initiator shown in the Table I corresponds to 0.2 to 1% of the total weight of the embedding medium above -70° C. and to 0.5 to 1,25% of the total weight of the embedding medium below -70° C.
Most conveniently, the ethyl methacrylate and n-butyl methacrylate are provided in combined form in a single container at said ratio of 1.24 to 2.70:1, and the 1,3-butanediol dimethacrylate cross-linking agent is provided in a separate container. In preparing a non-polar embedding medium 11.14 to 16 parts by weight of the combined ethyl methacrylate and n-butyl methacrylate are then admixed with the 1,3-butanediol dimethacrylate and the small amount of polymerisation initiator which is conveniently provided in a further separate container. A three component package for preparing the non-polar embedding medium is therefore a convenient means for making available the non-polar embedding medium components.
In the same fashion as above, and turning now to Table II concerning the polar embedding medium, it will be recognized that the ratio by weight of the 2-hydroxyethyl acrylate:2-hydroxypropyl methacrylate can lie between the two extreme limits of 16:46 and 24:36. This is equivalent to a ratio of 2-hydroxyethyl acrylate:2-hydroxypropyl methacrylate of 0.35 to 0.67:1. Similarly, the ratio by weight of the combined 2-hydroxyethyl acrylate and 2-hydroxypropyl methacrylate:n-butyl methacrylate can lie between the two extreme limits of 16+36:15 and 24+46:10. This is equivalent to a ratio by weight of the combined 2-hydroxyethyl acrylate and 2-hydroxypropyl methacrylate:n-butyl methacrylate of 3.47 to 7:1.
The ratio by weight of the combined 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate and n-butyl methacrylate: methoxyethyl methacrylate can lie between the extreme limits of 16+36+10:13 and 24+46+15:7, which is equivalent to a ratio by weight of combined 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate and n-butyl methacrylate : methoxyethyl methacrylate of 4.77 to 12.15:1.
The ratio by weight of the combined 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate and methoxyethyl methacrylate:ethoxyethyl methacrylate can lie between the extreme limits of 16+36+10+7:14 and 24+46+15+13:8, which is equivalent to a ratio by weight of combined 2-hydroxyethyl acrylate, 2hydroxypropyl methacrylate, n-butyl methacrylate and methoxyethyl methacrylate:ethoxyethyl methacrylate of 4.93 to 12.25:1.
The ratio by weight of the combined 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate, methoxyethyl methacrylate and ethoxyethyl methacrylate:1,3-butanediol dimethacrylate can lie between the extreme limits of 16+36+10+7+8:6 and 24+46+15+13+14:3.5, which is equivalent to a ratio by weight of combined 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate, methoxyethyl methacrylate and ethoxyethyl methacrylate:1,3-butanediol dimethacrylate of 12.83 to 32:1.
The 2-hydroxyethyl acrylate and 2-hydroxypropyl methacrylate may be provided in combined form in a single container at said ratio of 0.35 to 0.67:1. In this case, the n-butyl methacrylate, ethoxyethyl methacrylate and 1,3-butanediol dimethacrylate are provided in separate containers. Alternatively, the 2-hydroxyethyl acrylate and n-butyl methacrylate are provided in combined admixed form in a single container at a ratio by weight of between 16:15 and 24:10, which is equivalent to a ratio by weight of 2-hydroxyethyl acrylate:n-butyl methacrylate of 1.07 to 2.40:1. The 2-hydroxypropyl methacrylate, methoxyethyl methacrylate, ethoxyethyl methacrylate and 1,3-butanediol dimethacrylate are then provided in separate containers. Yet a further alternative is to provide the 2-hydroxypropyl methacrylate and the n-butyl methacrylate in combined admixed form in a single container at a ratio by weight of between 36:15 and 46:10, which is equivalent to a ratio by weight of 2-hydroxypropyl methacrylate:n-butyl methacrylate of 2.40 to 4.60:1. In this further alternative, the 2-hydroxyethyl acrylate, methoxyethyl methacrylate, ethoxyethyl methacrylate and the 1,3-butanediol dimethacrylate are provided in separate containers.
As already indicated, the 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate, methoxyethyl methacrylate (where included) and ethoxyethyl methacrylate are most conveniently provided in admixed form in a single container. In this case 12.83 to 32 parts by weight of the admixed form are simply admixed with 1 part by weight of the 1,3-butanediol dimethacrylate and the polymerisation initiator added.
In the same fashion as above, and turning now to Table III concerning the polar embedding medium, it will be recognized that the ratio by weight of the 2-hydroxyethyl acrylate:2-hydroxypropyl methacrylate can lie between the two extreme limits of 26:40 and 34:35. This is equivalent to a ratio of 2-hydroxyethyl acrylate:2-hydroxypropyl methacrylate of 0.58 to 0.97:1. Similarly, the ratio by weight of the combined 2-hydroxyethyl acrylate and 2-hydroxypropyl methacrylate:n-butyl methacrylate can lie between the two extreme limits of 26:35:20 and 34+45:10. This is equivalent to a ratio by weight of the combined 2-hydroxyethyl acrylate and 2-hydroxypropyl methacrylate:n-butyl methacrylate of 3.05 to 7.9:1. The ratio by weight of the combined 2-hydroxyethyl ethyl acrylate, 2-hydroxypropyl methacrylate and n-butyl methacrylate:ethoxyethyl methacrylate can lie between the extreme limits of 26+35+10:20 and 34+45+20:10, which is equivalent to a ratio by weight of combined 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate and methoxyethyl methacrylate:ethoxyethyl methacrylate of 3.55 to 9.90:1.
The ratio by weight of the combined 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate and ethoxyethyl methacrylate:1,3-butanediol dimethacrylate can lie between the extreme limits of 26+35+10+10:3.5 and 34+45+20+20:2.5, which is equivalent to a ratio by weight of combined 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate and ethoxyethyl methacrylate:1,3-butanediol dimethacrylate of 23.14 to 47.6:1.
The 2-hydroxyethyl acrylate and 2-hydroxypropyl methacrylate may be provided in combined form in a single container at said ratio of 0.58 to 0.97:1. In this case, the n-butyl methacrylate, ethoxyethyl methacrylate and 1,3-butanediol dimethacrylate are provided in separate containers. Alternatively, the 2-hydroxyethyl acrylate and n-butyl methacrylate are provided in combined admixed form in a single container at a ratio by weight of between 26:20 and 34:10, which is equivalent to a ratio by weight of 2-hydroxyethyl acrylate:n-butyl methacrylate of 1.30 to 3.40:1. The 2-hydroxypropyl methacrylate, ethoxyethyl methacrylate and 1,3-butanediol dimethacrylate are then provided in separate containers. Yet a further alternative is to provide the 2-hydroxypropyl methacrylate and the n-butyl methacrylate in combined admixed form in a single container at a ratio by weight of between 35:20 and 45:10, which is equivalent to a ratio by weight of 2-hydroxypropyl methacrylate:n-butyl methacrylate of 1.75 to 4.50:1. In this further alternative, the 2-hydroxyethyl acrylate, methoxyethyl methacrylate, ethoxyethyl methacrylate and the 1,3-butanediol dimethacrylate are provided in separate containers.
As already indicated, the 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate and ethoxyethyl methacrylate are most conveniently provided in admixed form in a single container. In this case 23.14 to 47.6 parts by weight of the admixed form are simply admixed with 1 part by weight of the 1,3-butanediol dimethacrylate and the polymerisation initiator added.
Depending on the ratios chosen within the limits indicated above, the hardness and hence adaptability to sectioning can be adjusted. Thus, for example, in the non-polar embedding medium of the present invention higher proportions of ethyl methacrylate (within the limits indicated) inclines the embedding medium composition to produce an embedding having harder properties, whereas higher proportions of n-butyl methacrylate (within the limits indicated) inclines the embedding medium composition to produce an embedding having softer properties. A balance between the two properties can be achieved as desired by chosing the ratios of admixture. Similarly, if too much cross-linking agent, i.e. 1,3-butanediol dimethacrylate is employed, the resulting embedding medium will form an embedding which would be too brittle for sectioning.
The embedding media of the invention are capable of polymerisation at low temperature of -60° to -65° C. (polar medium) and to -80° C. (non-polar medium). A further characteristic of the embedding media of the present invention is their capability to absorb ultraviolet light of a wavelength which does not act on embedded biological materials such as proteins, nucleic acids and hemoglobin. It will be appreciated that if energy sources are employed which involve wavelength emissions which are absorbed by the embedded materials, the energy would not be available for activation of the polymerisation initiator. Also, it will be appreciated that on would not wish transmitted energy to act on the biological materials since this might act to destroy cellular structures.
As indicated above, a variety of components may be suitable for preparing non-polar and polar embedding media. Further exemplary monofunctional monomers which could be suitable for preparing embedding media have proper ties equivalent to those of the invention are 2-hydroxyethyl methacrylate, n-propyl methacrylate, hexyl methacrylate, ethyl acrylate, and acrylic and methacrylic esters of 2-ethylhexanol, and of methanol and methylstyrene. Other cross-linking agents which could prove suitable include ethyleneglycol dimethacrylate and divinyl benzene.
Exemplary polymerization initiators suitable for low temperature UV light polymerization and which possess the necessary activity are benzoin, benzoin ethylether, benzoin monomethylether, benzoin isopropylether, 2,2-dimethoxy-2-phenylacetophenone (benzyldimethylacetal) and 2-hydroxy-2-methyl-1-phenylpropan-1-one.
The following preparation schemes shown in Tables IV and V below are examples of two embedding procedures employing the embedding media of the present invention which have provided entirely satisfactory results at low temperatures.
TABLE IV______________________________________(Steps 1. to 7.) polar embedding medium______________________________________1. Desired aldehyde fixa- tion at 0° C. to 20° C.2. 65% ethyleneglycol 60 min 0° C.3. 80% ethanol 120 min -50° C.4. 100% polar medium 60 min -60° C. typical of Table II diluted 1:1 with ethanol5. 100% polar medium 60 min -60° C. diluted 2:1 with ethanol6. 100% polar medium 60 min -60° C.7. 100% polar medium overnight -60° C. or longer______________________________________
TABLE V______________________________________(Steps 1. to 8.) non-polar embedding medium______________________________________1. Desired aldehyde fixa- tion at 0° C. to 20° C.2. 65% ethyleneglycol 60 min 0° C.3. 70% ethanol 60 min -50° C.4. 90% ethanol 120 min -70° C.5. 100% non-polar medium 60 min -80° C. typical of TABLE I diluted 1:1 with ethanol6. 100% non-polar medium 60 min -80° C. diluted 2:1 with ethanol7. 100% non-polar medium 60 min -80° C.8 100% non-polar medium overnight or longer______________________________________
(The schemes can be adapted for any other temperature or non-polar or polar solvent as long as solubility allows it).
Polymerization: Both resins are polymerized by indirect UV--irradiation 360 nm (2 x Philips TLAD 15W/05 or equivalent) at -80° C. to -60° C. at a distance of 30-40 cm, 48 to 72 hours. Sectioning quality improves when the blocks are further hardened at room temperature for 2-3 days. Polymerization can also be carried out at room temperature.
Sectioning and Staining: The embedding media, easily yield silver to grey sections on diamond or glass knives. Optimal sectioning requires a moderate cutting speed. Poststaining is easily effected with uranyl acetate; Reynold's lead citrate appears acceptable for low magnification work. The polar embedding medium provides excellent results with immunostaining on sections with the known protein A-gold complex technique.
In the case of Epon 812 (epoxy resin, condensation product of epichlorohydrin and bisphenol A), it is impossible to gain the advantages offered by low temperature embedding procedures, which is typical of any epoxy resins which cannot be cured at low temperature. In the case of the Leduc embedding media (HPMA Leduc=hydroxypropyl methacrylate, HEM Leduc=hydroxyethyl methacrylate), which do have polar properties, these partly prepolymerized preparations resulting in too high viscosity which again eliminates possibilities to gain the advantages offered by low temperature embedding procedures.
The polar embedding medium of the present invention is water compatible and provides rapid, but uniform, infiltration and UV-polymerization without sacrifying quality. The medium maintains the low viscosity and water-miscible characteristics of previous methacrylate formulations, but does not suffer from the "melting" phenomenon during irradiation in the microscope. The inherent low viscosity of the liquid medium allows for the exploitation of a broad temperature range for specimen preparation, and can easily infiltrate a specimen and be hardened at temperatures as low as -60° to -65° C. (polar medium) and -80° C. (non-polar medium). Thus an embedding procedure for sensitive structure can be easily designed to take advantage of the stabilizing effects of the low temperatures. The polar medium also provides excellent results with immuno-staining techniques on sections.
The non-polar embedding medium of the invention is a hydrophobic medium which produces blocks of excellent sectioning quality. The medium retains the properties of low viscosity and uniform polymerization, but adds the capability of embedding material at very low temperatures. The non-polar medium can be used routinely at temperatures as low as -80° C. At these low temperatures, biological material is stabilized and may even retain its bound water. The medium also provides excellent results under conventional conditions.
The media of the invention should be prepared in brown glass containers or otherwise protected from direct light. All the components are readily miscible with each other. Excessive stirring should be avoided. Methacrylates and acrylates do cause eczema on sensitive persons, so that it is strongly recommended to use gloves when there is risk of skin contact. Polypropylene or polyethylene are suitable but not gloves made from other plastic material.
Typical dehydration and infiltration preparation schemes for embedding media at low temperatures are given in Table VI below:
TABLE VI______________________________________(Steps 1. to 9.)______________________________________ polar medium1. Desired aldehyde fixa- tion at 0° C. to 20° C.2. 30% ethanol with water 30 min 0° C.3. 50% ethanol with water 60 min -20° C.4. 70% ethanol with water 60 min -35° C.5. 90% ethanol with water 120 min -50° C.6. 100% polar medium 60 min -60° C. diluted 1:1 with ethanol7. 100% polar medium 60 min -60° C. diluted 2:1 with ethanol8. 100% polar medium 60 min -60° C.9. 100% polar medium overnight -60° C. non-polar medium1. Desired aldehyde fixa- tion at 0° C. to 20° C.2. 30% ethanol with water 30 min 0° C.3. 50% ethanol with water 60 min -20° C.4. 70% ethanol with water 60 min -50° C.5. 90% ethanol with water 120 min -70° C.6. 100% non-polar medium 60 min -80° C. diluted 1:1 with ethanol7. 100% non-polar medium 60 min -80° C. diluted 2:1 with ethanol8 100% non-polar medium 60 min -80° C.9. 100% non-polar medium overnight -80° C.______________________________________
At all temperatures below 0° C. care must be taken not to allow the residual water in the specimen to freeze during the dehydration steps.
Both resins can be hardened at room temperature with direct irradiation. However, it is recommended that the original initiator be exchanged for the same amount of benzoin ethylether. Room temperature polymerized blocks can be ready for sectioning after a few hours.
General characteristics: Specimens embedded with the media of the present invention show that excellent ultrastructural preservation is feasible without heavy metal fixation. Enough contrast for observation may be subsequently introduced through section staining or by dark-field microscopy. The non-polar medium is particularly suitable for dark-field observation due to its low density as compared to conventional embedding media.
A further practical application for the embedding media of the present invention is embedding of biological, archeological and other artifacts for preservation purposes. | The invention concerns methods and embedding media components for producing essentially non-polar and polar embedding media. The non-polar embedding medium comprises ethyl methacrylate, n-butyl methacrylate, 1,3-butanediol dimethylacrylate, and a small amount of polymerization initiator. The polar embedding medium comprises 2-hydroxyethyl acrylate, 2-hydroxypropyl methacrylate, n-butyl methacrylate, optionally methoxyethyl methacrylate, ethoxyethyl methacrylate, 1,3-butanediol dimethacrylate, and a small amount of polymerization initiator. The embedding media of the invention are particularly suitable for the preparation of a polymer embedded biological material for light or electron microscopic study of thin sections thereof. The embedding media can be polymerized at low temperature and UV light employed for initiating polymerization. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a metallocene catalyst for preparing vinyl aromatic polymers and a method for polymerizing styrene using the same, and more particularly to a multinuclear transition metal half metallocene catalyst with a noble structure for preparing syndiotactic polystyrenes having high activity, superior stereoregularity, high melting point and broad molecular weight distribution and a method for polymerizing styrene using the same.
2. Background of the Related Art
Syndiotactic polystyrenes can be generally prepared using a metallocene catalyst composed of a Group 4 transition metal, such as titanium, zirconium and hafnium, and one or two cycloalkandienyl groups. The cycloalkandienyl group includes cyclopentadienyl, indenyl, fluorenyl group and their derivatives.
Such metallocene catalyst can produce syndiotatic polystyrenes exhibiting high activity and having high syndiotacticity when it is used together with alkylaluminum oxane, (for example metylamuminum oxane) which is a reaction product of water and alkylaluminum compound.
As described above, it is known that olefin or styrene polymers having such high stereoreguality can be synthesized by using a catalyst composed of a transition metal compound and alkylaluminum oxane. Examples are as follows.
EP 210,615 has disclosed a method for synthesizing syndiotactic polystyrene having superior stereoregularity in high yield by combining a metallocene catalyst such as cyclopendienyltitanium trichloride (CpTiCl 3 ) or pentametylchclopentadienyltitanium trichloride (Cp*TiCl 3 ) as a main catalyst with metylaluminoxane as a cocatalyst.
Japanese Patent Laid-Open No. 314790/1992 has described that syndiotactic polystyrene can be obtained in much higher yield when pentamethylcyclopentadienyltitanium trimethoxide (CpTi(OMe) 3 ) and methylaluminoxane are used together as a main catalyst and a cocatalyst, respectively.
On the other hand, only a few cases of using a multinuclear metallocene catalyst system to synthesize polystyrene have been reported. Examples are as follows.
U.S. Pat. No. 6,010,974 has disclosed preparation of di-nuclear half metallocene catalyst in which two cycloalkandienyl groups are connected to both nuclei—through alkylene or sillylene bridge and styrene polymerization using the same.
EP 964,004 has disclosed preparation of a metallocene catalyst in which two or more half metallocenes are connected through coligand bridge having dialkoxy group or diaryloxy group and styrene polymerization using the same.
WO 03/006473 A1 has disclosed preparation of di-nuclear half metallocene catalyst system using bridge ligands simultaneously containing functional groups directedly connected to cycloalkandienyl groups and styrene polymerization using the same.
However, there was a difficulty in commercializing the disclosed catalysts due to high production cost and insufficient catalytic activity, or because they exhibit high catalytic activity only in the presence of a large amount of alkylamuminoxane serving as a cocatalyst. Accordingly, there is a need for a catalyst that can be produced at low cost and exhibit high catalytic activity, particularly in the presence of only a small amount of alkylaluminoxane serving as a cocatalyst.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a new multinuclear half metallocene catalyst with high activity, a method for preparing the catalyst, and a method for homopolymerizing styrene or copolymerizing styrene with olefin suing the same catalyst, where the catalyst includes at least two metal compounds containing transition metals of Groups 3 to 10 in the periodic table, a cycloalkandienyl group and a phenol amine or phenol compound lignad, and is capable of producing syndiotatic polystyrenes having superior stereoreguality, high melting point and broad molecular weight distribution in high yield using a small amount of cocatalyst.
To achieve the objects of the present invention, there is provided a multinuclear half metallocene catalyst having the structure represented by the following formula 1, 2 or 3. The catalyst includes a transition metal of Groups 3 to 10 in the periodic table, a cycloalkandienyl group or its derivative forming η 5 binding and a phenolamine or phenol compound in which two or more phenolamine or phenol groups are bounded to a nitrogen atom:
wherein, in the formulas 1, 2 and 3, M 1 , M 2 and M 3 are transition metals, respectively, and each is selected from the group consisting of atoms in Groups 3, 4, 5, 6, 7, 8, 9, 10 on the Periodic Table, and L 1 , L 2 and L 3 are cycloalkanedienyl ligands, respectively and each is represented by the following formula 4, 5, 6, 7 or 8:
wherein, in the formulas 4, 5, 6, 7 and 8, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , and R 13 are respectively or independently hydrogen atom, halogen, alkyl, C 3-20 cycloalkyl, C 2-20 alkenyl, alkylsilyl, haloalkyl, alkoxy, alkylsiloxy, amino, alkoxyalkyl, thioalkoxyalkyl, alkylsiloxyalkyl, aminoalkyl, alkylphosphinoalkyl, aryl, arylalkyl, alkylaryl, arylsilyl, arylalkylsilyl, haloaryl, aryloxy, aryloxoalkyl, thioaryloxoalkyl, aryloxoaryl, arylsiloxy, arylalkylsiloxy, arylsiloxalkyl, arylsiloxoaryl, arylamino, arylaminoalkyl, arylaminoaryl or arylphosphinoalkyl group (here, the alkyl group is C 1-20 hydrocarbon group having either the straight or the branch structure and the aryl group is C 6-40 aromatic or heteroaromatic group) and each of m and n is an integer of 1 or more;
X 1 , X 2 , X 3 , X 4 , X 5 , and X 6 , which are σ-ligand functional groups, are respectively or independently hydrogen atom, halogen, hydroxyl, alkyl, C 3-20 cycloalkyl, alkylsilyl, C 2-20 alkenyl, alkoxy, alkenyloxy, thioalkoxy, alkylsiloxy, amide, alkoxyalcohol, alcoholamine, carboxyl, sulfonyl, aryl, alkylaryl, arylalkyl, arylsilyl, haloaryl, aryloxy, arylalkoxy, thioaryloxy, arylsiloxy, arylalkylsiloxy, arylamide, arylalkylamide, aryloxoalcohol, alcohoarylamine, or arylaminoaryloxy group (here, the alkyl group is C 1-20 hydrocarbon group having the straight or branch structure and the aryl group is C 6-40 aromatic or hetero aromatic group);
A 1 , A 2 , and A 3 , which are σ-ligand functional groups respectively, are independently oxygen atom, sulfur atom, carboxyl group, sulfonyl group, N—R 14 and P—R 15 ;
B 1 , B 2 , B 3 , B 4 and B 5 are respectively or independently alkyl, C 3-20 cycloalkyl, C 2-20 alkenyl, alkylsilyl, haloalkyl, alkoxy, alkylsiloxy, amino, dialkylether, dialkyltioether, alkylsiloxyalkyl, alkylaminoalkyl, alkylphosphinoalkyl, aryl, arylalkyl, alkylaryl, arylsilyl, arylalkylsilyl, haloaryl, aryloxy, aryloxoalkyl, thioaryloxoalkyl, aryloxoaryl, arylsiloxy, arylalkylsiloxy, arylsiloxalkyl, arylsiloxoaryl, arylamino, arylaminoalkyl, arylaminoaryl, or arylphosphinoalkyl group (here, the alkyl group is C 1-20 hydrocarbon group having either the straight or the branch structure and the aryl group is C 6-40 aromatic or heteroaromatic group);
D 1 , D 2 , D 3 , D 4 , D 5 and D 6 , which are functional groups respectively, are independently hydrogen atom, halogen, alkyl, C 3-20 cycloalkyl, C 2-20 alkenyl, alkylsilyl, haloalkyl, alkoxy, alkylsiloxy, amino, alkoxyalkyl, thioalkoxyalkyl, alkylsiloxyalkyl, aminoalkyl, alkylphosphinoalkyl, aryl, arylalkyl, alkylaryl, arylsilyl, arylalkylsilyl, haloaryl, aryloxy, aryloxoalkyl, thioaryloxoalkyl, aryloxoaryl, arylsiloxy, arylalkylsiloxy, arylsiloxalkyl, arylsiloxoaryl, arylamino, arylaminoalkyl, arylaminoaryl, or arylphosphinoalkyl group (here, the alkyl group is C 1-20 hydrocarbon group having either the straight or the branch structure and the aryl group is C 6-40 aromatic or heteroaromatic group);
Q 1 , and Q 2 are respectively or independently nitrogen, phosphorous, C—R 16 , Si—R 17 or Ge—R 18 ; and
R 14 , R 1 , R 16 , R 17 and R 18 are respectively or independently hydrogen atom, halogen, alkyl, C 3-20 cycloalkyl, C 2-20 alkenyl, alkylsilyl, haloalkyl, alkoxy, alkylsiloxy, amino, alkoxyalkyl, thioalkoxyalkyl, alkylsiloxyalkyl, aminoalkyl, alkylphosphinoalkyl, aryl, arylalkyl, alkylaryl, arylsilyl, arylalkylsilyl, haloaryl, aryloxy, aryloxoalkyl, thioaryloxoalkyl, aryloxoaryl, arylsiloxy, arylalkylsiloxy, arylsiloxalkyl, arylsiloxoaryl, arylamino, arylaminoalkyl, arylaminoaryl or arylphosphinoalkyl group (here, the alkyl group is C 1-20 hydrocarbon group having the straight or branch structure and the aryl group is C 6-40 aromatic or heteroaromatic group).
The present invention further provides a method for preparing styrene polymers by homopolymerizing or copolymerizing styrene monomers and/or styrene derivative monomers or copolymerizing with olefins in the presence of a catalyst system which includes the multinuclear half metallocene compound described above and a cocatalyst composed of one or more ones selected from the group consisting of alkylaluminum oxane having a repeating unit represented by the following formula 29, alkylaluminum represented by the following formula 30 and weak coordinate Lewis acid,
wherein R 19 is a hydrogen atom, substituted or unsubstituted alkyl, C 3-20 substituted or unsubstituted cycloalkyl, aryl, alkylaryl or arylalkyl group; R 20 , R 21 , and R 22 are respectively or independently are hydrogen atom, halogen, substituted or unsubstituted alkyl, substituted or unsubstituted C 3-20 cycloalkyl, aryl, alkylaril or arylalkyl group, where at least one of the R 20 , R 21 , and R 22 is alkyl group (here, the alkyl group is C 1-20 hydrocarbon group having the straight or branch structure and the aryl group is C 6-40 aromatic or heteroaromatic group); and n is an integer from 1 to 100.
The metallocene catalyst represented by the formula 1, 2 or 3 may be preferably the compound represented the following formula 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27 or 28.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawing, in which;
FIG. 1 illustrates an X-ray single crystal structure of a ligand [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(Me)CH 2 ] 2 included in half metallocene catalysts of the formulas 9 and 10 according to the present invention, and the structure was obtained by using an X-ray diffractometer; and
FIG. 2 illustrates an X-ray single crystal structure of a ligand Me 2 NCH 2 CH 2 N{CH 2 Ph(3,5-Me) 2 (4-OH)} 2 included in half metallocene catalyst of the formulas 27 and 28 and the structure was obtained by using an X-ray diffractometer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be explained in detail.
The present invention provides a multinuclear half metallocene catalyst satisfying the above formula 1, 2 or 3 for synthesizing styrene polymers by polymerization and a process for preparing styrene polymers using the same as a main catalyst.
The metallocene catalyst satisfying the above formula 1, 2 or 3 is a multinuclear half metallocene compound including a transition metal selected from the group consisting of Groups 3 to 10 in the periodic table, a cycloalkandienyl group, and one or more ligand of phenolamine compound or phenol compound. Therefore, since each central metal (transition metal) makes cationic polymerization active species during polymerization, styrene polymers having high polymerization activity, superior stereoreguality and high melding point can be produced using the metallocene catalyst of the present invention. Further, molecular weight of polymers can be easily controlled by using the metallocene catalyst of the present invention because molecules with molecular weights in a wide range are distributed in uniform in the polymers which are produced using the metallocene catalyst of the present invention. Accordingly, it is possible to overcome a disadvantage of the conventional metallocene catalysts, which generally produce polymer with narrow molecular weight distribution, meaning that the polymer produced using the conventional metallocene catalyst has low processability.
The multinuclear half metallocene catalyst of the present invention can be prepared by i) introducing a cycloalkandienyl group to a transition metal, thereby obtaining a half metallocene compound, and then iia) converting a phenolamine or phenol compound ligand to its alkali metal salt and reacting the salt with the half metallocene compound prepared in step i). Alternatively, The multinuclear half metallocene catalyst of the present invention can be prepared by i) introducing a cycloalkandienyl group to a transition metal, thereby obtaining a half metallocene compound, and then iib) reacting a neutral phenolamine or phenol ligand with the half metallocene compound prepared in step i).
The phenolamine or phenol ligand may be prepared by i) an organic reaction of phenol with a substituting group, hexametyl tetraamin and p-toluene sulfonic acid or ii) a reaction among phenol with a substituting group, substituted amine and formaldehyde.
In a process for preparation of the multinuclear half metallocene catalyst above, the alkali metal salt of a cycloalkandienyl group includes cyclopentadienyl lithium, cyclopentadienyl sodium, cyclopentadienyl potassium, cyclopentadienyl magnesium, methylcyclopentadienyl lithium, methyl cyclopent adienyl sodium, methyl cyclopentadienyl potassium, tetramethylcyclopentadienyl lithium, tetramethylcyclopentadienyl sodium, tetramethylcyclopentadienyl potassium, indenyl lithium, indenyl sodium, indenyl potassium, fluorenyl lithium, etc. The salts above can be prepared by reacting a ligand having cycloalkandienyl backbone with n-butyl lithium, sec-butyl lithium, tert-butyl lithium, methyl lithium, sodium methoxide, sodium ethoxide, potassium tert-butoxide, potassium hydroxide, methylmagnesium chloride, methylmagnesium bromide, dimethylmagnesium, lithium, sodium, potassium, or etc.
Examples of the phenol compound having a substituting group include o-cresol, 2-ethylphenol, 2-propylphenol, 2-isopropylphenol, 2-sec-butylphenol, 2-tert-butylphenol, 2-cyclopentylphenol, 2-fluorophenol, α,α,α-trifluoro-o-cresol, 2-chlorophenol, 2-bromophenol, guaiacol, 2-ethoxyphenol, 2-isopropoxyphenol, 2,3-dimethylphenol, 5,6,7,8-tetrahydro-1-naphthol, 2,3-dichlorophenol, 2,3-dihydro-2,2-dimethyl-7-benzofuranol, 2,3-dimethoxyphenol, 2,6-dimethylphenol, 2,6-diisopropylphenol, 2-tert-butyl-6-methylphenol, 2,6-di-tert-butylphenol, 2-allyl-6-methylphenol, 2,6-difluorophenol, 2,3-difluorophenol, 2,6-dichlorophenol, 2,6-dibromophenol, 2-fluoro-6-methoxyphenol, 2,6-dimethoxyphenol, 3,5-dimethylphenol, 5-isopropyl-3-methylphenol, 3,5-di-tert-butylphenol, 3,5-bis(trifluoromethyl)phenol, 3,5-difluorophenol, 3,5-dichlorophenol, 3,5-dimethoxyphenol, 3-chloro-5-methoxyphenol, 2,5-dimethylphenol, thymol, carvacrol, 2-tert-butyl-5-methylphenol, 2,4-difluorophenol, 2-tert-butyl-4-methylphenol, 2,4-di-tert-butylphenol, 2,4-di-tert-amylphenol, 4-fluoro-2-methylphenol, 4-fluoro-3-methylphenol, 2-chloro-4-methylphenol, 2-chloro-5-methylphenol, 4-chloro-2-methylphenol, 2-bromo-4-methylphenol, 4-iodo-2-methylphenol, 4-chloro-2-fluorophenol, 2-bromo-4-fluorophenol, 4-bromo-2-fluorophenol, 2,4-dichlorophenol, 2-bromo-4-chlorophenol, 2-chloro-4-fluorophenol, 2,4-dibromophenol, 2-methoxy-4-methylphenol, 2-methoxy-4-propylphenol, 4-ethylguaiacol, 2,3,6-trimethylphenol, 2,4-dichloro-3-methylphenol, 2,3,4-trifluorophenol, 2,3,6-trifluorophenol, 2,3,4-trichlorophenol, 2,4,5-trifluorophenol, 2-chloro-4,5-dimethylphenol, 2-bromo-4,5-difluorophenol, 2,4,5-trichlorophenol, 2,3,5,6-tetrafluorophenol, etc.
Examples of the phenolamine compound includes methylamine, ethylamine, hexylamine, propylamine, isopropylamine, decylamine, n-butylamine, tert-butylamine, 2-butylamine, amylamine, isoamylamien, tert-amylamine, 1-methylbutylamine, 2-methylbutylamine, 2-ethylbutylamine, 1-ethylpropylamine, neopentylamine, 1,2-dimethylpropylamine, octylamine, 1,3-dimethylbutylamine, heptylamine, nonylamine, undecylamine, 1,5-dimethylhexylamine, 2-aminoheptane, 3,3-dimethylbutylamine, dodecylamine, tridecylamine, 1-tetradecylamine, pentadecylamine, 1-hexadecylamine, octadecylamine, 2-amino-3,3-dimethylbutane, 3-aminoheptane, 1-methylheptylamine, 2-ethylhexylamine, 1,3-diaminopropane, tert-octylamine, ethylenediamine, 1,2-diaminopropane, 1,4-diaminobutane, 1,2-diamion-2-methylpropane, 2,2-dimethyl-1,3-propanediamine, 2-methyl-1,5-pentanediamine, 1,6-hexanediamine, 1,7-diaminoheptane, 1,8-diaminooctane, 2,5-dimethyl-2,5-hexanediamine, 1,9-diaminononane, 1,10-diaminodecane, methylhydrizine, 1,2-dimethylhydrazine, 1,1-dimethylhydrazine, 1,12-diaminododecane, N-propylethylenediamine, N-methylethylenediamine, N-ethylethylenediamine, N-isopropylethylenediamine, N,N-diethylethylenediamine, N,N′-diethylethylenediamine, N,N-diethylethylenediamine, N,N-dibutylethylenediamine, N-isopropyl-2-methyl-1,2-propanediamine, N-methyl-1,3-propanediamine, N-propyl-1,3-propanediamine, N-isopropyl-1,3-propanediamine, 3-dimethylaminopropylamine, 3-diethylaminopropylamine, 3-(dibutylamino)propylamine, N,N′-dimethyl-1,3-propylamine, N,N′-diethyl-1,3-propanediamine, N,N′-diisopropyl-1,3-propanediamine, N,N,2,2-tetramehtyl-1,3-propanediamine, 2-amino-5-diethylaminopentane, N,N′-dimethyl-1,6-hexanediamine, diethylenetriamine, N-(2-aminoethyl)-1,3-propanediamine, 3,3′-diamino-N-methyldipropylamine, 3,3′-iminobispropylamine, spermidine, triethylenetetramine, tris(2-aminoethyl)amine, tetraethylenepentamine, cyclobytylamine, cyclohexylamine, cyclopentylamine, cyclopropylamine, (aminoethyl)cyclopropane, 5-amino-2,2,4-trimethyl-1-cyclopentanemethylamine, 2-methylcyclohexylamine, 3-methylcyclohexylamine, 4-methylcyclohexylamine, 4,4-methylenebis(cyclohexylamine), 4,4′-methylbis(2-methylcyclohexylamine, 1,2-diaminocyclohexane, 1,4-diaminocyclohexane, cyclohexanemethylamine, cyclohexylethylamine, 1,3-cyclohexanebis(methylamine), cycloheptylamie, cyclooctylamine, cyclododecylamine, exo-2-aminonorbornene, bornylamine, 3-noradamantanamine, 1-adamantanemethylamine, 1,3-adamantanediamine, allylamine, oleylamine, 2-(1-cyclohexenyl)ethylamine, 2,2,2-trifluoroethylamine, 2,2,2-trifluoroethylhydrazine, 2-methoxyethylamine, 3-methoxypropylamine, 3-ethoxypropylamine, 3-butoxypropylamine, 2-amino-1-methoxypropane, 3-isopropoxypropylamine, 4,9-dioxa-1,12-dodecanediamine, 4,7,10-trioxa-1,13-tridecanediamine, tetrahydrofurfurylamine, ethanolamine, aminoacetaldehyde diethylacetal, 2-hydroxyethylhydrazine, 3-amino-1-propanol, 2-amino-1-propanol, 4-amino-1-butanol, 2-amino-1-butanol, 2-amino-2-methyl-1-propanol, 5-amino-1-pentanol, 2-amino-1-pentanol, 6-amino-1-hexanol, 2-amino-1-hexanol, isoleucinol, leucinol, 2-(2-aminoethoxy)ethanol, 3-aminomethyl-3,5,5-trimethylcyclohexanol, 2-(methylamino)ethanol, 2-(ethylamino)ethanol, 2-(propylamino)ethanol, 4,4′-trimethylenedipiperidine, 4,4′-trimethylenebis(1-methylpiperidine, 1-aminopiperidine, 1-aminohomopiperidine, piperazine, 2,6-dimethylpiperazine, 2,5-dimethylpiperazine, 1,4-diaminopiperazine, homopiperazine, 1,4,7-triazacyclononane, 1,5,9-triazacyclododecane, cyclone, 1,4,8,11-tetraazacyclotetradecane, 1,4,8,12-tetraazacyclopentadecane, 4-aminomorpoline, 1,4,10,13-tetraoxa-7,16-diazacyclooctadecane, aniline, 1,2-dianilinbethane, o-toluidine, 2-ethylaniline, 2-propylaniline, 2-isopropylaniline, 2-tert-butylaniline, 2-fluoroaniline, 2-aminobenzotrifluoride, 2-chloroaniline, 2-bromoaniline, 2-iodoaniline, o-anisidine, o-phenetidine, m-toluidine, 3-ethylaniline, 3-fluoroaniline, 3-aminobenzotrifluoride, 3-chloroaniline, 3-bromoaniline, 3-iodoaniline, m-anisidine, m-phenetidine, 3-(trifluoromethoxy)aniline, 3-(1,1,2,2-tetrafluoroethoxy)aniline, p-toluidine, 4,4′-ethylenedianiline, 4-ethylaniline, 4-propylaniline, 4-isopropylaniline, 4-butylaniline, 4-sec-butylaniline, 4-tert-butylaniline, 4-pentylaniline, 4-hexylaniline, 4-heptylaniline, 4-octylaniline, 4-decylaniline, 4-tetradecylaniline, 4-hexadecylaniline, 4-cyclohexylaniline, 3,3′-methylenedianiline, 4,4′-methylenedianiline, 4,4′-diaminostilbene, 4-fluoroaniline, 4-aminobenzotrifluoride, 4-chloroaniline, 4-bromoaniline, 4-iodoaniline, p-phenetidine, 4-butoxyaniline, 4-pentyloxyaniline, 4-hexyloxyaniline, 4-(trifluoromethoxy)aniline, 4-aminophenylether, 4-(methylmercapto)aniline, 4-aminophenyl disulfide, 2,3-dimethylaniline, 1-amino-5,6,7,8-tetrahydronaphthalene, 2,6-dimethylaniline, 6-ethyl-o-toluidine, 2,6-diethylaniline, 2-isopropyl-6-methylaniline, 2,6-diisopropylaniline, 3-fluoro-2-methylaniline, 2-chloro-6-methylaniline, 2,6-difluoroaniline, 2,3-difluoroaniline, 2,6-dichloroaniline, 2,3-dichloroaniline, 2,6-dibromoaniline, 2-methoxy-6-methylaniline, 3-fluoro-o-anisidine, 2,3-dihydro-2,2-dimethyl-7-benzofuranamine, 3,4-dimethylaniline, 5-aminoindan, 2,5-dimethylaniline, 2,4-dimethylaniline, 4,4′-ethylenedi-m-toluidine, 2,5-di-tert-butylaniline, 3-fluoro-4-methylaniline, 2-fluoro-4-methylaniline, 5-fluoro-2-methylaniline, 2-fluoro-5-methylaniline, 4-fluoro-2-methylaniline, 2,5-bis(trifluoromethyl)aniline, α,α,α,6-tetrafluoro-o-toluidine, α,α,α,2-tetrafluoro-m-toluidine, 2,4-difluoroaniline, 3-chloro-4-fluoroaniline, 3,4-difluoroaniline, 2,5-difluoroaniline, 4-chloro-2-fluoroaniline, 2-chloro-4-fluoroaniline, 2-bromo-4-fluoroaniline, 4-bromo-2-fluoroaniline, 2-fluoro-4-iodoaniline, 2-chloro-4-methylaniline, 2-chloro-5-methylaniline, 5-chloro-2-methylaniline, 4-chloro-2-methylaniline, 3,4-dichloroaniline, 2,4-dichloroaniline, 2,5-dichloroaniline, 4-bromo-2-methylaniline, 4-bromo-3-methylaniline, 3-bromo-4-methylaniline, 2-bromo-4-methylaniline, 4-bromo-2-chloroaniline, 2,4-dibromoaniline, 2,5-dibromoaniline, α,α,α,4-tetrafluoro-o-toluidine, α,α,α,4-tetrafluoro-m-toluidine, 5-amino-2-chlorobenzotrifluoride, 2-amino-5-chlorobenzotrifluoride, 4-bromo-α,α,α-tetrafluoro-m-toluidine, 4-methoxy-2-methylaniline, 2-methoxy-5-methylaniline, 5-methoxy-2-methylaniline, 3-amino-4-chlorobenzotrifluoride, 6-bromo-α,α,α-tetrafluoro-m-toluidine, 6-methoxy-α,α,α-tetrafluoro-m-toluidine, 6-chloro-m-anisidine, 3,4-(methylenedioxy)aniline, 1,4-benzodioxan-6-amine, 2,4-dimethoxyaniline, 2,5-dimethoxyaniline, 5-chloro-o-anisidine, 3-fluoro-p-anisidine, 3,5-dimethylaniline, 3,5-di-tert-butylaniline, 3,5-difluoroaniline, 3,5-dichloroaniline, 3,5-dimethoxyaniline, 5-methoxy-α,α,α-tetrafluoro-m-toluidine, 2,4,6-trimethylaniline, 4,4′-methylenebis(2,6-dimethylaniline), 4,4′-methylenebis(2,6-diethylaniline), 4,4′-methylenebis(2,6-diisopropylaniline), 2,4,6-tri-tert-butylaniline, 2,6-dichloro-3-methylaniline, 2,3,4-trichloroaniline, 2,3,4-trifluoroaniline, 2,3,6-trifluoroaniline, 2,4,6-trifluoroaniline, 2,6-dibromo-4-methylaniline, 3-chloro-2,6-diethylaniline, 4-bromo-2,6-dimethylaniline, 2-chloro-3,5-difluoroaniline, 4-bromo-2,6-difluoroaniline, 2-bromo-4-chloro-6-fluoroaniline, 2,4-dibromo-6-fluoroaniline, 2,6-dibromo-4-fluoroaniline, 4-chloro-2,6-dibromoaniline, 3,4,5-trichloroaniline, 3,4,5-trimethoxyaniline, 3,3′,5,5′-tetramethylbenzidine, 2,4,6-trichloroaniline, 2,4,6-tribromoaniline, 2-bromo-3,5-bis(trifluoromethyl)aniline, 2-chloro-4-fluoro-5-methylaniline, 2,4,5-trifluoroaniline, 2,4,5-trichloroaniline, 4-chloro-2-methoxy-5-methylaniline, 2,5-diaminotoluene, 2,3,5,6-tetrachloroaniline, 2,3,5,6-tetrafluoroaniline, 2,3,4,5-tetrachloroaniline, 2,3,4,5-tetrafluoroaniline, 1,4-phenylenediamine, 2,3,4,6-tetrafluoroaniline, 2-bromo-3,4,6-trifluoroaniline, 2-bromo-4,5,6-trifluoroaniline, 2,3,4,5,6-pentafluoroaniline, 4-bromo-2,3,5,6-tetrafluoroaniline, 2-aminobiphenyl, N,N-dimethyl-1,4-phenylenediamine, N,N-diethyl-1,4-phenylenediamine, N,N′-diphenyl-1,4-phenylenediamine, 2,5-dimethyl-1,4-phenylenediamine, 2-chloro-1,4-phenylenediamine, 2,5-dichloro-1,4-phenylenediamine, 2,6-dichloro-1,4-phenylenediamine, benzylamine, 2,3,5,6-tetramethyl-1,4-phenylenediamine, 2-benzylaniline,
4,4′-(hexafluoroisopropylidene)dianiline, 2-phenoxyaniline, 3-phenoxyaniline, 3,3′-dimethoxybenzidine, 4-benzyloxyaniline, 3,3′-dimethylnaphthidine, 2,7-diaminofluorene, 9-fluorenone hydrazone, O-tritylhydroxylamine, α-methylbenzylamine, tritylamine, triphenylmethanesulfenamide, aminodiphenylmethane, 1,2-diphenylethylamine, 2,2-diphenylethylamine, 2,2-diphenylpropylamine, phenethylamine, 3-phenyl-1-propylamine, 1-methyl-3-phenylpropylamine, 1-methyl-2-phenoxyethylamine, 3,3-diphenylpropylamine, 4-phenylbutylamine, N,N′dibenzylethylenediamine, β-methylphenethylamine, 2-methylbenzylamine, 1-aminoindan, 2-aminoindan, 2-(trifluoromethyl)benzylamine, 2-fluorobenzylamine, 2-fluorophenethylamine, 3-(trifluoromethyl)benzylamine, 2-chlorobenzylamine, 2-(2-chlorophenyl)ethylamine, 1,2,3,4-tetrahydro-1-naphthylamine, 3-fluorophenethylamine, 2-methoxybenzylamine, 2-ethoxybenzylamine, 3-methylbenzylamine, m-xylylenediamine, 3-fluorobenzylamine, 3-chlorobenzylamine, 2-(3-chlorophenyl)ethylamine, 3-bromobenyzlamine, 3-iodobenzylamine, 3-methoxybenzylamine, N,N′-dimethyl-1,2-bis(3-(trifluoromethyl)phenyl)-1,2-ethanediamine, 4-fluorophenethylamine, p-xylylenediamine, 3-aminobenzylamine, 3-methoxyphenethylamine, 4-methylbenzylamine, 4-methoxybenzylamine, 4-(trifluoromethyl)benzylamine, 4-fluorobenzylamine, 2-(p-tolyl)ethylamine, 4-chlorobenzylamine, 3,5-bis(trifluoromethyl)benzylamine, 4-bromophenethylamine, 2-(4-chlorophenyl)ethylamine, 4-methoxyphenethylamine, 2,5-difluorobenzylamine, 4-(trifluoromethoxy)benzylamine, 4-aminobenzylamine, 3-fluoro-5-(trifluoromethyl)benzylamine, 2-(4-aminophenyl)ethylamine, 2,6-difluorobenzylamine, 2,4-difluorobenzylamine, 3,4-difluorobenzylamine, 2,4-dichlorobenzylamine, 3,4-dichlorobenzylamine, 2,4-dichlorophenethylamine, 2,3-dimethoxybenzylamine, 3,5-di-methoxybenzyl-amine, 2,4-dimethoxybenzylamine, 2,5-dimethoxyphenethylamine, veratrylamine, piperonylamine, 3,4-dimethoxyphenethylamine, 1-(1-naphthyl)ethylamine, 9-aminofluorene, 4-amino-1-benzylpiperidine, etc.
Examples of the half metallocene compound includes cyclopentadienyltitanium trichloride, (η 5 -C 5 H 5 )TiCl 3 ), cyclopentadienylmethoxytitanium dichloride, (η 5 -C 5 H 5 )TiCl 2 (OMe), cyclopentadienyldimethoxytitanium monochloride, (η 5 -C 5 H 5 )TiCl(OMe) 2 , cyclopentadienyltitanium trimethoxide, (η 5 -C 5 H 5 )Ti(OMe) 3 , methylcyclopentadienyltitanium trichloride, (η 5 -C 5 H 4 Me)TiCl 3 , methylcyclopentadienylmethoxytitanium dichloride, (η 5 -C 5 H 4 Me)TiCl 2 (OMe), methylcyclopentadienyldimethoxytitanium monochloride, (5-C 5 H 4 Me)TiCl(OMe) 2 , methylcyclopentadienyltitanium trimethoxide, (η 5 -C 5 H 4 Me)Ti(OMe) 3 , pentamethylcyclopentadienyltitainium trichloride, (η 5 -C 5 Me 5 )TiCl 3 , pentamethylcyclopentadienylmethoxytitainium dichloride, (η 5 -C 5 Me 5 )TiCl 2 (OMe), pentamethylcyclopentadienyldimethoxytitainium monochloride, (η 5 -C 5 Me 5 )TiCl(OMe) 2 , pentamethylcyclopentadienyltitainium trimethoxide, (η 5 -C 5 Me 5 )Ti(OMe) 3 , indenyltitanium trichloride, (η 5 -C 9 H 7 )TiCl 3 , indenylmethoxytitanium dichloride, (η 5 -C 9 H 7 )TiCl 2 (OMe), indenyldimethoxytitanium monochloride, (η 5 -C 9 H 7 )TiCl(OMe) 2 , indenyltitanium trimethoxide, (η 5 -C 9 H 7 )Ti(OMe) 3 , etc.
Examples of the alkylsily and the alkytin that can be substituted for the cycloalkandienyl group include trimethylsilyl, triethylsilyl, tert-butyldimethylsilyl, phenyldimethylsilyl, trimethyltin, triethyltin, tributyltin, etc.
In the multinuclear half metallocene catalyst represented by the formula 1, 2 or 3 for preparation of styrene polymers, M 1 , M 2 or M 3 is preferably a Group 4 transition metal, and more preferably titanium, zirconium or hafnium.
Examples of the ligand having cycloalkandienyl backbone include cycloalkandieynl, indenyl, fluorenyl, 4,5,6,7-tetrahydroindenyl, 2,3,4,5,6,7,8,9-octahydrofluorenyl group, etc.
Examples of the halogen group include fluoro group, chloro group, bromo group and iodine group. Further, examples of the C 1-20 alkyl, cycloalkyl, alkenyl, alkylsillyl, haloalkyl, alkoxy, alkylsilloxy, amino, alkoxyalkyl, thioalkoxyalkyl, alkylsilloxyalkyl, aminoalkyl, and alkylphosphinoalkyl group preferably include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, allyl, 2-butenyl, 2-pentenyl, methylsillyl, dimethylsillyl, trimethylsillyl, ethylsillyl, dietylsillyl, triethylsillyl, propylsillyl, dipropylsillyl, tripropylsillyl, butylsillyl, di-butylsillyl, tri-butylsillyl, butyldimethylsillyl, trifluoromethyl, methoxy, ethoxy, propoxy, butoxy, pentoxy, hexyloxy, methylsilloxy, dimethylsilloxy, trimethylsilloxy, ethylsilloxy, dietylsilloxy, triethylsilloxy, butyldimethylsilloxy, dimethylamino, diethylamino, dipropylamino, dibutylamino, pyrrolidine, piperidine, methoxyethyl, methoxypropyl, methoxybutyl, thiomethoxyethyl, thiomethoxybutyl, trimethylsilloxyethyl, dimethylaminoethyl, diethylphosphinobutyl groups, etc.
Examples of the C 6-40 aryl, arylalkyl, alkylaryl, arylsillyl, arylalkylsillyl, haloaryl, aryloxy, aryloxoalkyl, thioaryloxoalkyl, aryloxoaryl, arylsilloxy, arylalkylsilloxy, arylsilloxoalkyl, arylsilloxoaryl, arylamino, arylaminoalkyl, arylaminoaryl, and arylphosphinoalkyl group preferably include phenyl, biphenyl, terphenyl, naphtyl, fluorenyl, benzyl, phenylethyl, phenylpropyl, tollyl, xylyl, butylphenyl, phenylsillyl, phenyldimethylsillyl, diphenylmethylsillyl, triphenylsillyl, chlorophenyl, pentafluorophenyl, phenoxy, naphthoxy, phenoxyethyl, biphenoxybutyl, thiophenoxyethyl, phenoxyphenyl, naphthoxyphenyl, phenylsilloxy, triphenylisiloxy, phenyldimethylsilloxy, triphenylsilloxethyl, diphenylsilloxphenyl, aniline, toluidine, benzylamino, phenylaminoethyl, phenylmethylaminophenyl, diethylphosphinobutyl group, etc.
Syndiotactic styrene polymer and styrene copolymer with various physical properties can be obtained by styrene homopolymerization or copolymerization with olefin, using the multinuclear half metallocene catalyst represented by the above formula 1, 2 or 3 as a main catalyst together with a cocatalyst
Examples of the cocatalyst used together with the multinuclear half metallocene catalyst include alkylaluminoxane having a repeating unit of the following formula 29 and week coordinate Lewis acid, and they are typically used together with alkylaluminum represented by the following formula 30.
In the formula 29, R 19 is a hydrogen atom, substituted or unsubstituted C 1-20 alkyl, substituted or unsubstituted C 3-20 cycloalkyl, C 6-40 aryl, alkylaryl or arylalkyl group, and n is an integer from 1 to 100.
In the formula 30, R 20 , R 21 and R 22 are independently hydrogen atom, halogen, substituted or unsubstituted C 1-20 alkyl, substituted or unsubstituted C 3-20 cycloalkyl, C 6-40 aryl, alkylaryl or arylalkyl group, where at least one of the R 20 , R 21 and R 22 includes an alkyl group.
The compound of the formula 29 may be linear, circular or network structure, and specifically, the examples thereof include methylaluminoxane, modified methylaluminoxane, ethylaluminoxane, butylaluminoxane, hexylaluminoxane, decylaluminoxane, etc.
Examples of the compound of the formula 30 include trimethylaluminum, dimethylaluminum chloride, dimethylaluminum methoxide, methylaluminum dichloride, triethylaluminum, diethylaluminum chloride, diethylaluminum methoxide, ethylaluminum dichloride, tri-n-propylaluminum, di-n-propylaluminum chloride, n-propylaluminum chloride, tri-isopropylaluminum, tri-n-butylaluminum, tri-isobutylaluminum, di-isobutylaluminum hydride, etc.
The weak coordinate Lewis acid cocatalyst may be ionic or neutral type, and specifically, the examples include trimethylammonium, tetraphenylborate, tributylammonium, tetraphenylborate, trimethylammonium tetrakis(pentafluorophenyl)borate, tetramethylammonium tetrakis(pentafluorophenyl)borate, N,N-dimethylanilinium tetraphenylborate, dimethylanilinium tetrakis(pentafluorophenyl)borate, pyridinium tetraphenylborate, pyridinium tetrakis(pentafluorophenyl)borate, silver tetrakis(pentafluorophenyl)borate, ferrocerium tetrakis(pentafluoropehnyl)borate, triphenylcarbenium tetrakis(pentafluorophenyl)borate, triphenylcarbenium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, sodium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, tris(pentafluorophenyl)borane, tris(2,3,4,5-tetrafluorophenyl)borane, tris(3,5-bis(trifluoromethyl)phenyl)borane, tris(2,4,6-trifluorophenyl)borane, etc.
In styrene polymerization or copolymerization with olefin using the metallocene catalyst, the amount of the cocatalyst used together is not specifically limited but may vary according to the kinds.
The mole ratio of alkylaluminoxane to metallocene catalyst is in the range of from 1:1 to 10 6 :1, and preferably from 10:1 to 10 4 :1. The mole ratio of alkylaluminum that can be used together with alkylaluminoxane to metallocene catalyst is in the range of from 1:1 to 10 4 :1.
The mole ratio of week coordinate Lewis acid and metallocene catalyst is in the range of from 0.1:1 to 50:1, and the mole ratio of alkylaluminum and metallocene catalyst is in the range of from 1:1 to 3000:1, and preferably from 50:1 to 1000:1.
The monomers that can be polymerized by the catalyst system of the present invention include styrene, styrene derivatives, and olefins. Among them, styrene or styrene derivatives can be homopolymerized, respectively. Further, styrene and styrene derivatives can be compolymerized. Still further, styrene or styrene derivatives can be copolymerized with olefins.
The styrene derivatives have substituents on a benzene ring, and examples of the substituents include halogen, alkyl, alkoxy, ester, thioalkoxy, sillyl, tin, amine, phosphine, halogenated alkyl, C 2-20 vinyl, aryl, vinylaryl, alkylaryl, aryl alkyl group, etc. More detailed examples of the styrene derivatives include chlorostyrene, bromostyrene, fluorostyrene, p-methylstyrene, m-methylstyrene, ethylstyrene, n-butylstyrene, p-t-butylstyrene, dimethylstyrene, methoxystyrene, ethoxystyrene, butoxystyrene, methyl-4-styrenylester, thiomethoxystyrene, trimethylsillylstyrene, triethylsillylstyrene, tert-butyldimethylsillylstyrene, trimethyltin styrene, dimethylaminostyrene, trimethylphosphinostyrene, chloromethylstyrene, bromomethylstyrene, 4-vinylbiphenyl, p-divinylbenzene, m-divinylbenzene, trivinylbenzene, 4,4′-divinylbiphenyl, vinylnaphthalene, etc.
Examples of the olefins that can be used in copolymerization with styrene or styrene derivatives include C 2-20 olefin, C 3-20 cycloolefin or cyclodiolefin, C 4-20 diolefin, etc., and detailed examples thereof include ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, cyclopentene, cyclohexene, cyclopentadiene, cyclohexadiene, norbonene, methyl-2-norbonene, 1,3-butadiene, 1,4-pentadiene, 2-methyl-1,3-butadiene, 1,5-hexadiene, etc.
Polymerization using the catalyst system of the present invention can be conducted in slurry phase, liquid phase, gas phase or massive phase. When polymerization is conducted in slurry phase or liquid phase, solvent can be used as a polymerization medium, and examples of the solvent include C 4-20 alkane or cycloalkane such as butane, pentane, hexane, heptane, octane, decane, dodecane, cyclopentane, methylcyclopentane, cyclohexane, etc.; C 6-20 aromatic arene such as benzene, toluene, xylene, mesitylene, etc.; and C 1-20 halogen alkane or halogen arene such as dichloromethane, chloromethane, chloroform, tetrachloromethane, chloroethane, 1,2-dichloroethane, 1,1,2,2-tetrachloroethane, chlorobenzene, 1,2-dichlorobenzene, 1,2,4-trichlorobenzene, etc. Mixtures of these with a predetermined mixing ratio can be used as the solvent. Polymerization in gas phase can be conducted when an inner pressure of a reactor is in the range of from 0.01 to 20 atm under solvent-free condition.
Polymerization temperature is −80 to 200° C., and preferably 0 to 150° C., and polymerization pressure is suitably 1 to 1000 atm including the pressure of comonomers for styrene homopolymerization or copolymerization with olefin.
According to the present invention, polymer can be prepared by i) introducing a solvent and monomers or monomers only into a reactor, elevating a temperature of the reactor, and then introducing alkylaluminum, cocatalyst and main catalyst (metallocene compound) into the reactor in this order, or ii) activating main catalyst with alkylaluminum and cocatalyst, and then introducing the activated main catalyst into a reactor containing monomers, or iii)-adding alkylaluminum to monomers before the monomers are introduced into a reactor, introducing the monomers with the alkylaluminum into the reactor, and then introducing main catalyst activated with a cocatalyst to the reactor. And, the activation by bringing main catalyst into contact with cocatalyst is preferably conducted at 0 to 150° C. for 0.1 to 240 minutes, and more preferably for 0.1 to 60 minutes.
The amount of the main catalyst (metallocene compound) is not specifically limited, but is suitably 10 −8 to 1.0 M on the basis of concentration of central metal in reaction system, and ideally 10 −7 to 10 −2 M.
Syndiotactic styrene polymers and copolymers obtained by polymerization using the catalyst system of the present invention can be controlled in a molecular weight range of 1000 to 10,000,000 and in a molecular weight distribution range of from 1.1 to 100 by controlling the kinds and the amounts of a main catalyst and a cocatalyst, reaction temperature, reaction pressure and concentration of monomers.
Hereinafter, the present invention will be described in more detail through examples and comparative examples. Examples are presented on the exemplary purpose but can not be construed to limit the scope of the present invention.
EXAMPLES
Example 1
Synthesis of Catalyst 1
Preparation of Ligand N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 3
3.80 g (27 mmol) of hexamethylenetetramine, 23 ml (124 mmol) of 2.6-diisopropylphenol and 0.1 g of p-toluenesulfonic acid are put into a 100 ml Shlenk flask without solvent, and heated up to 110° C. As the temperature rises, solids are melted and homogenized, thereby turning into a dark brown solution. 12 hours later, 7 ml (37.8 mmol) of 2,6-diosoprppylphenol is trickled into a reaction vessel containing the dark brown solution using a syringe, and then reaction is continued for 12 hours more at 110° C. After the reaction is completed and the reaction vessel is cooled down to a room temperature, it is observed that the solution is turned into solid. The solid is dissolved in a small amount of acetone and then a solution in which all the solid is completely dissolved is maintained in a refrigerator to obtain colorless precipitate. Then, the solution is filtered and dried under vacuum, thereby obtaining 15 g (yield 94%) of N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 3 . 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=7.02 (s, 6H, Ph-H), 3.74 (s, 6H, NCH 2 ), 3.15 (m, 6H, CHMe 2 ), 1.26 (d, J=6.9 Hz, 36H, CHMe2) 13 C{ 1 H} NMR(75.47 MHz, CDCl 3 , ppm): δ=148.9(Ph), 133.7(Ph), 132.0(Ph), 123.3(Ph), 53.13(NCH 2 ), 27.18(CHMe 2 ), 22.77(CHMe 2 )
Preparation of Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 3 N] (Catalyst 1)
0.71 g (1.20 mmol) of the ligand N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 3 synthesized according to the method above is dissolved in 30 ml of toluene to obtain a ligand solution. On the other hand, a separate solution is prepared by dissolving Cp*Ti(OMe) 2 in 30 ml of toluene. The ligand solution is slowly trickled to the separate solution drop by drop at a room temperature. Every when one drop of the ligand solution was added to the separate solution, the separate solution becomes darker yellow. After the ligand solution is completely added to the separate solution, the solution mixture is agitated for 12 hours at a room temperature. 12 hours later, solvent is removed under decompression from the solution mixture to obtain a yellowish orange reaction product which is abstracted with 30 ml of normal hexane. Then resultant material is filtered using a celite filter to obtain a yellow clear solution. Solvent is removed under vacuum from the yellow clear solution, and then the solution-free material is dried to produce yellowish orange solid, catalyst-1 of the formula 9 by 1.74 g (yield 92%). 1 H NMR (300, 13 MHz, CDCl 3 , ppm): δ=6.95 (s, 6H, Ph-H), 4.08 (s, 18H, OMe), 3.73 (s, 6H, NCH 2 ), 3.23 (m, 6H, CHMe 2 ), 2.04 (s, 45H, C 5 Me 5 ), 1.21 (d, J=6.9 Hz, 36H, CHMe2). 13 C{ 1 H} NMR (75.47 MHz, CDCl 3 , ppm): δ=157.9(Ph), 136.7(Ph), 130.9(Ph), 123.1(Ph), 122.5(C 5 Me 5 ), 62.32(OMe), 53.63 (NCH 2 ), 25.86(CHMe 2 ), 23.87 (CHMe 2 ), 10.87(C 5 Me 5 ).
Example 2
Synthesis of Catalyst 2
1.00 g (1.70 mmol) of the ligand N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 3 synthesized according to the example 1 method above is introduced into a 250 ml Shlenk flask and dissolved by 30 ml of diethylether, thereby obtaining a ligand solution. Then, the reaction vessel is lowered to −78° C. 2.2 ml (5.61 mmol) of normal butyl(n-BuLi, 2.5M solution hexane) is injected to the reaction vessel to be added to the ligand solution using a syringe and then the reaction vessel is gradually raised to a room temperature. The reaction solution is agitated for 4 hours, and then the reaction vessel is lowered to −78° C. again and a separate solution prepared by dissolving 5.61 mmol(1.62 g) of Cp*TiCl 3 in 30 ml of diethylether using a cannula is added to the reaction solution in the reaction vessel. The solution mixture is agitated for 30 minutes, raised to a room temperature and then reagitated overnight. Solvent is removed from the reaction product in the reaction vessel under vacuum and then reddish orange product is abstracted using 30 ml of toluene. The reddish orange product is filtered using a 545 celite filter and then lithium chloride salt is separated from the reddish orange product to obtain a clean reddish orange solution. Solvent is removed from the clean reddish orange solution under vacuum and the resultant material is dried for a long time. As a result, 1.79 g (yield 78%) of reddish orange solid, Cp*TiCl 2 [{(4-0)(3,5-i-Pr) 2 PhCH 2 } 3 N], that is catalyst 2 of the formula 10, is obtained. 1 H NMR (300, 13 MHz, CDCl 3 , ppm): δ=7.26 (s, 6H, Ph-H), 3.79 (s, 6H, NCH 2 ), 3.07 (m, 6H, CHMe 2 ), 2.10 (s, 45H, C 5 Me 5 ), 1.14 (d, J=7.1 Hz, 36H, CHMe 2 ). 13 C{ 1 H} NMR (75.47 MHz, CDCl 3 , ppm) δ=159.7(Ph), 140.1(Ph), 132.7(Ph), 125.3(Ph) 125.0(C 5 Me 5 ), 99.45(NCH 2 ), 26.92(CHMe 2 ), 23.90(CHMe 2 ), 12.97(C 5 Me 5 ).
Example 3
Synthesis of Catalyst 3
Preparation of Ligand N{CH 2 Ph(3,5-Me) 2 (4-OH)} 3
Ligand N{CH 2 Ph(3,5-Me) 2 (4-OH)} 3 is prepared by the same method as in Example 1 except that 2,6-dimethylphenol is used instead of 2,6-diisopropylphenol. Yield 42%. 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=6.78 (s, 6H, Ph-H), 4.46(br s, 3H, OH), 3.69 (s, 6H, NCH 2 ), 2.16 (s, 18H, Me). 13 C{ 1 H} NMR (75.47 MHz, CDCl 3 , ppm): δ=150.3(Ph), 133.4(Ph), 128.9(Ph), 122.9(Ph), 40.26(NCH 2 ), 15.90 (Me).
Preparation of Cp*Ti(OMe) 2 [{(4-O)(3,5-Me) 2 PhCH 2 } 3 N] (Catalyst 3)
Catalyst 3, Cp*Ti(OMe) 2 [{(4-O)(3,5-Me) 2 PhCH 2 } 3 N] is prepared by the same method as to prepare the catalyst 1, Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 3 N], as in Example 1 except that N{CH 2 Ph(3,5-Me) 2 (4-OH)} 3 is used instead of N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 3 . Yield 88%. 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=6.65 (s, 6H, Ph-H), 3.96 (s, 18H, OMe), 2.12 (s, 6H, NCH 2 ), 2.08 (s, 18H, Me), 2.04 (s, 45H, C 5 Me 5 ). 13 C{ 1 H} NMR (75.47 MHz, CDCl 3 , ppm): δ=156.3(Ph), 128.2(Ph), 126.3(Ph), 125.6(Ph), 123.0(C 5 Me 5 ), 62.29(OMe), 55.63(NCH 2 ), 26.78(Me) 10.95(C 5 Me 5 ).
Example 4
Preparation of Catalyst 4
Catalyst 4 having the formula 12, Cp*TiCl 2 [{(4-0)(3,5-Me) 2 PhCH 2 } 3 N], is prepared by the same method to prepare the catalyst 2, Cp*TiCl 2 [{(4-1)(3,5-i-Pr) 2 PhCH 2 } 3 N], as in Example 2 except that N{CH 2 Ph(3,5-Me) 2 (4-OH)} 3 is used instead of N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 3 . Yield (71%). 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=7.13 (s, 6H, Ph-H), 3.12 (s, 6H, NCH 2 ), 2.19 (s, 18H, Me), 2.11 (s, 45H, C 5 Me 5 ).
Example 5
Synthesis of Catalyst 5
Preparation of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2
25 ml (50 mmol) of methylamine (2M solution in MeOH), 17.8 g (100 mmol) of 2.6-diisopropylphenol and 8.05 g (100 mmol) of formaldehyde (37 wt % in H 2 O) were dissolved in 30 ml of methanol in a 250 ml Shlenk flask (reaction vessel). After the reaction for 12 hours, temperature of the reaction vessel was lowered to a room temperature, and then the reaction product was washed with water. Organic solution component in the reaction product were extracted with 30 ml of carbon dichloride (CH 2 Cl 2 ) and moisture in the organic solution was removed with anhydrate magnesium sulphate (MgSO 4 ). The organic solution was filtered, solvent in the organic solution was removed in a rotary evaporator, and then the resultant solution was dried under vacuum to obtain 18.9 g of yellow solid compound MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 in yield of 92%. 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=7.04 (s, 4H, Ph-H), 3.41 (s, 4H, NCH 2 ), 3.15 (m, 4H, CHMe 2 ), 2.16 (s, 3H, NMe), 1.27 (d, J=6.9 Hz, 24H, CHMe2). 13 C{ 1 H} NMR (75.47 MHz, CDCl 3 , ppm): δ=148.7(Ph), 133.2(Ph), 131.0(Ph), 124.0(Ph), 61.41(NCH 2 ), 42.37(NCH 3 ), 27.16(CHMe 2 ), 22.81(CHMe 2 ).
Preparation of Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 3 NMe] (Catalyst 5)
0.52 g (1.27 mmol) of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 obtained according to the method above is dissolved in 30 ml of toluene to obtain a first solution. On the other hand, 0.70 g (2.53 mmol) of Cp*Ti(OMe) 3 is dissolved in 30 ml of toluene in a different flask to obtain a second solution. The first solution is slowly dropped to the second solution at a room temperature. Every when one drop of the first solution was added to the second solution, the solution becomes darker yellow. After the first solution is completely added to the second solution, orange solution is obtained. The orange solution is agitated for 12 hours at a room temperature, and then solvent is removed under reduced pressure. After removing solvent, obtained orange products were extracted with 30 ml of normal hexane. The products were filtered to obtain clear orange solution. Solvent is removed again under vacuum and the clear orange solution is dried for a long time to obtain 0.67 g (yield 85%) of orange precipitate, which is catalyst 5 of the formula 13. 1 H NMR (300, 13 MHz, CDCl 3 , ppm): δ=6.92 (s, 4H, Ph-H), 4.07 (s, 12H, OMe), 3.36 (s, 4H, NCH 2 ), 3.20 (m, 4H, CHMe 2 ), 2.18 (d, J=7.4 Hz, 3H, NMe), 2.07 (s, 30H, C 5 Me 5 ), 1.19 (d, J=6.7 Hz, 24H, CHMe 2 ).
Example 6
Synthesis of Catalyst 6
30 ml of diethylether is introduced into a 250 ml Shlenk flask charged with 0.52 g (1.27 mmol) of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 synthesized in Example 5 to completely dissolve the compound MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 , and temperature of the Shlenk flask is lowered to −78° C. 1.12 ml (2.79 mmol) of n-butyllithium (2.5M) in hexane solution were slowly injected to the Shlenk flask with a syringe. Temperature of the Shlenk flask was slowly elevated to a room temperature to obtain reaction solution. A separate solution is prepared by dissolving 2.79 mmol (0.808 g) of Cp*TiCl 3 in 30 ml of diethylether in a different flask. This separate solution is dropped to the reaction solution using a cannula and the solution mixture is agitated for 30 minutes at −78° C. The solution mixture is further agitated overnight after temperature of the solution mixture is raised to a room temperature. After removing solvent under reduced pressure, the obtained reddish orange product is extracted with 30 ml of toluene. It is filtered through celite 545 filter and LiCl slat and solution were separated to obtain clear light reddish orange solution. Solvent was removed from the solution under vacuum and the solution was dried for a long time to obtain 0.86 g (yield 74%) of reddish orange product Cp*TiCl 2 [{(4-0)(3,5-i-Pr) 2 PhCH 2 } 2 NMe] of the formula 14 (catalyst 6). 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=7.19 (s, 4H, Ph-H), 3.78 (s, 4H, NCH 2 ), 2.42 (d, J=7.4 Hz, 3H, NMe), 2.11 (s, 30H, C 5 Me 5 )
Example 7
Synthesis of Catalyst 7
Preparation of Ligand MeN{CH 2 Ph(3,5-Me) 2 (4-OH)} 2
Ligand MeN{CH 2 Ph(3,5-Me) 2 (4-OH)} 2 is prepared by the same method for preparing MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 as in Example 5, except that 2.6-dimethylphenol is used instead of 2.6-diisopropylphenol. Yield 67%. %. 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=6.92 (s, 4H, Ph-H), 3.34 (s, 4H, NCH 2 ), 2.22 (s, 12H, PhMe), 2.12 (s, 3H, NMe). 13 C{ 1 H} NMR (75.47 MHz, CDCl 3 , ppm): δ=151.1(Ph), 130.6(Ph), 129.4(Ph), 122.6(Ph), 61.29 (NCH 2 ), 41.99(PhMe), 15.90(NCH 3 ).
Preparation of Cp*Ti(OMe) 2 [{(4-O)(3,5-Me) 2 PhCH 2 } 3 NMe] (Catalyst 7)
Catalyst 7 of the following formula 17 is prepared by the same method for preparing the catalyst 5, Cp*Ti(OMe) 2 , [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe], as in Example 5, except that MeN{CH 2 Ph(3,5-Me) 2 (4-OH)} 2 is used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 89%. 1 H NMR (300, 13 MHz, CDCl 3 , ppm): δ=6.88 (s, 4H, Ph-H), 4.10 (s, 12H, OMe), 3.51 (s, 4H, NCH 2 ), 2.31 (s, 12H, PhMe), 2.28 (s, 3H, NMe), 2.08 (s, 30H, C 5 Me 5 ).
Example 8
Synthesis of Catalyst 8
Catalyst 8 of the following formula 16, Cp*TiCl 2 [{(4-0)(3,5-Me) 2 PhCH 2 } 2 NMe], was prepared by the same method for preparing the catalyst 6, Cp*TiCl 2 [{(4-0)(3,5-i-Pr) 2 PhCH 2 } 2 NMe] as in the Example 6, except that ligand MeN{CH 2 Ph(3,5-Me) 2 (4-OH)} 2 is used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 76%. 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=7.07 (s, 4H, Ph-H), 3.55 (s, 4H, NCH 2 ), 2.39 (s. 12H, PhMe), 2.32 (s, 3H, NMe), 2.14 (s, 30H, C 5 Me 5 ).
Example 9
Synthesis of Catalyst 9
Preparation of Ligand [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(Me)CH 2 ] 2
Ligand [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(Me)CH 2 ] 2 was prepared by the same method for preparing the ligant MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 as in Example 5, except that N,N′-dimethylethylenediamine is used instead of methylamine. Yield 74%. %. 1 H NMR (300.13 MHZ, CDCl 3 , ppm): δ=6.94 (s, 4H, Ph-H), 3.43 (s, 4H, NCH 2 Ph), 3.12 (m, 4H, CHMe 2 ), 2.51 (s, 4H, MCH 2 CH 2 N), 2.19 (s, 6H, NMe), 1.24 (d, J=8.8 Hz, 24H, CHMe 2 ). 13 C{ 1 H} NMR (100.62 MHz, CDCl 3 , ppm): δ=148.9(Ph), 133.3(Ph), 130.4(Ph), 124.3(Ph), 62.7(NCH 2 Ph), 54.6(NCH 3 ), 42.6(NCH 2 CH 2 N), 27.2(CHMe 2 ), 22.8(CHMe 2 ).
Preparation of [Cp*Ti(OMe) 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }N(Me)CH 2 ] 2 (Catalyst 9)
Catalyst 9 of the following formula 17, [Cp*Ti(OMe) 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }N(Me)CH 2 ] 2 , was prepared by the same method for preparing the catalyst 5, Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe], as in the Example 5, except that [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(Me)CH 2 ] 2 is used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 85%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=6.90 (s, 4H, Ph-H), 4.13 (s, 12H, OMe), 3.45 (s, 4H, NCH 2 Ph), 3.22 (m, 4H, CHMe 2 ), 2.54 (s, 4H, NCH 2 CH 2 N) 2.19 (s, 6H, NMe), 2.08 (s, 30H, C 5 Me 5 ), 1.24 (d, J=8.8 Hz, 24H, CHMe 2 ).
Example 10
Synthesis of Catalyst 10
Catalyst 10 of the following formula 18, [Cp*TiCl 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }N(Me) CH 2 ] 2 was prepared by the same method for preparing the catalyst 6, Cp*TiCl 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe] as in Example 6, except that ligand [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(Me)CH 2 ] 2 is used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 71%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.16 (s, 4H, Ph-H), 3.59 (s, 4H, NCH 2 Ph), 3.34 (m, 4H, CHMe 2 ), 2.66 (s, 4H, NCH 2 CH 2 N), 2.22 (s, 6H, NMe), 2.12 (s, 30H, C 5 Me 5 ), 1.31 (d, J=9.1 Hz, 24H, CHMe 2 ).
Example 11
Synthesis of Catalyst 11
Preparation of [{(4-HO)(3,5-Me) 2 PhCH 2 }N(Me) CH 2 ] 2
[{(4-HO)(3,5-Me) 2 PhCH 2 }N(Me)CH 2 ] 2 was prepared by the same method for preparing the ligand MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 as in the Example 5, except that 2,6-dimethylphenol and N,N′-dimethylethylenediamine are used instead of 2,6-diisopropylphenol and methyl amine, respectively. Yield 81%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=6.87 (s, 4H, Ph-H), 4.79 (s, 2H, OH), 3.35 (s, 4H, NCH 2 Ph), 2.52 (s, 4H, NCH 2 CH 2 N), 2.18 (s, 12H, PhMe), 1.17 (s, 6H, NMe). 13 C{ 1 H} NMR (100.62 MHz, CDCl 3 , ppm): δ=151.2(Ph), 130.2(Ph), 129.4(Ph), 122.8(Ph), 62.2(NCH 2 Ph), 55.1(NCH 3 ), 42.5(NCH 2 CH 2 N), 15.9 (PhCH 3 ).
Preparation of [Cp*Ti(OMe) 2 {(4-O)(3,5-Me) 2 PhCH 2 }N(Me) CH 2 ] 2
Catalyst 11 of the following formula 19, [Cp*Ti(OMe) 2 {(4-O)(3,5-Me) 2 PhCH 2 }N(Me)CH 2 ] 2 was prepared by the same method for the catalyst 5, Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe] as in the Example 5, except that [{(4-HO)(3,5-Me) 2 PhCH 2 }N(Me)CH 2 ] 2 is used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 88%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=6.84 (s, 4H, Ph-H), 4.13 (s, 12H, OMe), 3.33 (s, 4H, NCH 2 Ph), 2.55 (s, 4H, NCH 2 CH 2 N), 2.21 (s, 12H, PhMe), 2.08 (s, 30H, C 5 Me 5 ), 1.21 (s, 6H, NMe).
Example 12
Synthesis of Catalyst 12
Catalyst 12 of the following formula 20, [Cp*TiCl 2 {(4-O)(3,5-Me) 2 PhCH 2 }N(Me)CH 2 ] 2 , was prepared by the same method for preparing the catalyst 6, Cp*TiCl 2 [{(4-0)(3,5-i-Pr) 2 PhCH 2 } 2 NMe] as in the Example 6, except that [{(4-HO)(3,5-Me) 2 PhCH 2 }N(Me)CH 2 ] 2 is used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 73%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.15 (s, 4H, Ph-H), 3.49 (s, 4H, NCH 2 Ph), 2.71 (s, 4H, NCH 2 CH 2 N), 2.30 (s, 12H, PhMe), 2.15 (s, 30H, C 5 Me 5 ), 1.29 (s, 6H, NMe).
Example 13
Synthesis of Catalyst 13
Preparation of Ligand [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2
Ligand [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2 was prepared by the same method for preparing the ligand MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 as in the Example 5, except that N, —N′-dibenzylethylenediamine is used instead of methylamine. Yield 70%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.33-6.94 (m, 14H, Ph-H), 3.47 (s, 4H, NCH 2 Ph(i-Pr) 2 ), 3.36 (s, 4H, NCH 2 Ph), 3.16 (m, 4H, CHMe 2 ), 2.55 (s, 4H, NCH 2 CH 2 N), 1.22 (d, J=7.0 Hz, 24H, CHMe 2 ).
Preparation of [Cp*Ti(OMe) 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }N(CH 2 Ph) CH 2 ]
Catalyst 13 of the following formula 21, [Cp*Ti(OMe) 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2 was prepared by the same method for preparing the catalyst 5 (Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe]) as in the Example 5, except that [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2 is used instead of the ligand compound MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 Yield 81%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.22-6.87 (m, 14H, Ph-H), 4.15 (s, 12H, OMe), 3.42 (s, 4H, NCH 2 Ph(i-Pr) 2 ), 3.29 (s, 4H, NCH 2 Ph), 3.19 (m, 4H, CHMe 2 ), 2.53 (s, 4H, NCH 2 CH 2 N), 2.05 (s, 30H, C 5 Me 5 ), 1.22 (d, J=8.8 Hz, 24H, CHMe 2 ).
Example 14
Synthesis of Catalyst 14
Catalyst 14 of the following formula 22, [Cp*TiCl 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2 was prepared by the same method for preparing the catalyst 6(Cp*TiCl 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe]) as in the Example 6, except that [{(4-HO)(3,5-i-Pr) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2 was used instead of the ligand MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 66%. 1 H NMR (400.13 Mhz, CDCl 3 , ppm): δ=7.41-7.15 (m, 14H, Ph-H), 3.59 (s, 4H, NCH 2 Ph(i-Pr) 2 ), 3.46 (s, 4H, NCH 2 Ph), 3.28 (m, 4H, CHMe 2 ), 2.61 (s, 4H, NCH 2 CH 2 N), 2.11 (s, 30H, C 5 Me 5 ), 1.27 (d, J=8.5 Hz, 24H, CHMe 2 ).
Example 15
Synthesis of Catalyst 15
Preparation of Ligand [{(4-HO)(3,5-Me) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2
Ligand [{(4-HO)(3,5-Me) 2 PhCH 2 }N(CH 2 Ph) CH 2 ] 2 was prepared by the same method for preparing the ligand MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 as in the Example 5, except that 2,6-dimethylphenol and N,N′-dibenzylethylenediamine are used instead of 2,6-diisopropylphenol and methylamine, respectively. Yield 74%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.23-7.10 (m, 14H, Ph-H), 3.44 (s, 4H, NCH 2 Ph(Me) 2 ), 3.34 (s, 4H, NCH 2 Ph), 2.50 (s, 4H, NCH 2 CH 2 N), 2.18 (s, 12H, PhMe).
Preparation of [Cp*Ti(OMe) 2 {(4-O)(3,5-Me) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2
Catalyst 15 of the following formula 23 was prepared by the same method for preparing the catalyst Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe] as in the Example 5, except that [{(4-HO)(3,5-Me) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2 is used instead of the ligand MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 80%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.19-7.01 (m, 14H, Ph-H), 4.11 (s, 12H, OMe), 3.40 (s, 4H, NCH 2 Ph(Me) 2 ), 3.25 (s, 4H, NCH 2 Ph), 2.48 (s, 4H, NCH 2 CH 2 N), 2.18 (s, 12H, PhMe), 2.06 (s, 30H, C 5 Me 5 ).
Example 16
Synthesis of Catalyst 16
Catalyst 16 of the following formula 24, [Cp*TiCl 2 {(4-O)(3,5-Me) 2 PhCH 2 }N(CH 2 Ph) CH 2 ]2, was prepared by the same method for preparing the catalyst 6(Cp*TiCl 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe]) as in the Example 6, except that [{(4-HO)(3,5-Me) 2 PhCH 2 }N(CH 2 Ph)CH 2 ] 2 was used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 61%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.33-7.14 (m, 14H, Ph-H), 3.52 (s, 4H, NCH 2 Ph(Me) 2 ), 3.40 (s, 4H, NCH 2 Ph), 2.57 (s, 4H, NCH 2 CH 2 N), 2.23 (s, 12H, PhMe), 2.12 (s, 30H, C 5 Me 5 ).
Example 17
Synthesis of Catalyst 17
Preparation of Ligand Me 2 NCH 2 CH 2 N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2
Ligand Me 2 NCH 2 CH 2 N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 was prepared by the same method for preparing the ligand MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 as in the Example 5, except that N,N-dimethylethylenediamine was used instead of methylamine. Yield 77%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.03 (s, 4H, Ph-H), 3.49 (s, 4H, NCH 2 Ph), 3.13 (m, 4H, CHMe 2 ), 2.52 (m, 2H, NCH 2 CH 2 NMe 2 ), 2.43 (m, 2H, NCH 2 CH 2 NMe 2 ), 2.15 (s, 6H, NMe 2 ), 1.25 (d, J=6.8 Hz, 24H, CHMe 2 ) 13 C{ 1 H} NMR (100.62 MHz, CDCl 31 ppm): δ=148.7(Ph), 133.3(Ph), 131.5(Ph), 123.7(Ph), 58.6(NCH 2 Ph), 57.7(NCH 2 CH 2 NMe 2 ), 51.3 (NCH 2 CH 2 NMe 2 ), 45.8 (NMe 2 ), 27.2 (CHMe 2 ), 22.9 (CHMe 2 ).
Preparation of [Cp*Ti(OMe) 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }] 2 NCH 2 CH 2 NMe 2 (Catalyst 17)
Catalyst 17 of the following formula 25, [Cp*Ti (OMe) 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }] 2 NCH 2 CH 2 NMe 2 was prepared by the same method for preparing the catalyst 5(Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe]) as in the Example 5, except that Me 2 NCH 2 CH 2 N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 was used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 89%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=6.92 (s, 4H, Ph-H), 4.14 (s, 12H, OMe), 3.44 (s, 4H, NCH 2 Ph), 3.10 (m, 4H, CHMe 2 ), 2.50-2.38 (m, 4H, NCH 2 CH 2 NMe 2 ), 2.16 (s, 6H, NMe 2 ), 2.05 (s, 30H, C 5 Me 5 ), 1.24 (d, J=8.4 Hz, 24H, CHMe 2 ).
Example 18
Synthesis of Catalyst 18
Catalyst 18 of the following formula 26, [Cp*TiCl 2 {(4-O)(3,5-i-Pr) 2 PhCH 2 }] 2 NCH 2 CH 2 NMe 2 was prepared by the same method for preparing the catalyst 6(Cp*TiCl 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe]) as in the Example 6, except that Me 2 NCH 2 CH 2 N{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 was used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . Yield 64%. 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.32 (s, 4H, Ph-H), 3.54 (s, 4H, NCH 2 Ph), 3.27 (m, 4H, CHMe 2 ), 2.66-2.49 (m, 4H, NCH 2 CH 2 NMe 2 ), 2.17 (s, 6H, NMe 2 ), 2.11 (s, 30H, C 5 Me 5 ), 1.22 (d, J=8.8 Hz, 24H, CHMe 2 ).
Example 19
Synthesis of Catalyst 19
Preparation of Ligand Me 2 NCH 2 CH 2 N{CH 2 Ph(3,5-Me) 2 (4-OH)} 2
Ligand Me 2 NCH 2 CH 2 N{CH 2 Ph (3,5-Me) 2 (4-OH)} 2 was prepared by the same method for preparing the ligand MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 as in the Example 5, except that 2,6-dimethylphenol and N,N-dimethylethylenediamine was used instead of 2,6-diisopropylphenol and methylamine. (Yield 78%) 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=6.90 (s, 4H, Ph-H), 3.42 (s, 4H, NCH 2 Ph), 2.54 (m, 2H, NCH 2 CH 2 NMe 2 ), 2.42 (m, 2H, NCH 2 CH 2 NMe 2 ), 2.18 (s, 12H, PhMe), 2.15 (s, 6H, NMe 2 ). 13 C{ 1 H} NMR (100.62 MHz, CDCl 3 , ppm): δ=151.2(Ph), 130.7(Ph), 129.1(Ph), 122.9(Ph), 57.9(NCH 2 Ph), 57.4(NCH 2 CH 2 NMe 2 ), 50.8(NCH 2 CH 2 NMe 2 ), 45.7(NMe 2 ), 16.0(PhMe 2 ),
Preparation of [Cp*Ti (OMe) 2 {(4-O)(3,5-Me) 2 PhCH 2 }] 2 NCH 2 CH 2 NMe 2 (Catalyst 19)
Catalyst 19 of the following formula 27, [Cp*Ti (OMe) 2 {(4-O)(3,5-Me) 2 PhCH 2 }] 2 NCH 2 CH 2 NMe 2 was prepared by the same method for preparing the catalyst 5(Cp*Ti(OMe) 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe]) as in the Example 5, except that Me 2 NCH 2 CH 2 N{CH 2 Ph(3,5 Me) 2 (4-OH)} 2 was used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . (Yield 82%) 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=6.88 (s, 4H, Ph-H), 4.11 (s, 12H, OMe), 3.39 (s, 4H, NCH 2 Ph), 2.50-2.38 (m, 4H, NCH 2 CH 2 NMe 2 ), 2.13 (s, 12H, PhMe), 2.10 (s, 6H, NMe 2 ), 2.04 (s, 30H, C 5 Me 5 ).
Example 20
Synthesis of Catalyst 20
Catalyst 20 of the following formula 28, [Cp*TiCl 2 {(4-O)(3,5-Me) 2 PhCH 2 }] 2 NCH 2 CH 2 NMe 2 was prepared by the same method for preparing the catalyst 6(Cp*TiCl 2 [{(4-O)(3,5-i-Pr) 2 PhCH 2 } 2 NMe]) as in the Example 6, except that Me 2 NCH 2 CH 2 N{CH 2 Ph(3,5-Me) 2 (4-OH)} 2 was used instead of MeN{CH 2 Ph(3,5-i-Pr) 2 (4-OH)} 2 . (Yield 68%) 1 H NMR (400.13 MHz, CDCl 3 , ppm): δ=7.15 (s, 4H, Ph-H), 3.52 (s, 4H, NCH 2 Ph), 2.71-2.49 (m, 4H, NCH 2 CH 2 NMe 2 ), 2.34 (s, 12H, PhMe), 2.26 (s, 6H, NMe 2 ), 2.12 (s, 30H, C 5 Me 5 ).
Example 21
Preparation of Styrene Homopolymers (Solution Phase Polymerization)
Solution phase styrene homopolymerization was conducted using each of the multinuclear half metallocene catalysts synthesized according to Examples 1 to 20.
To a polymerization reactor under high purity nitrogen atmosphere, 70 ml of purified heptane was introduced and temperature of the reactor was elevated to 50° C. 30 ml of styrene, 0.5 ml (1.0 M toluene solution) of triisobutylaluminum, and 0.44 ml of methylaluminoxane (2.1 M toluene solution, Akzo Company product) were sequentially introduced into the reactor. 0.75 ml (3.75 μmol of Ti) of toluene solution in which each of the metallocene catalysts was dissolved was added thereto, while vigorously agitating the reaction mixture in the reactor. After agitating for 1 hour, 10 wt % of chloric acid-ethanol solution was added to terminate the reaction, and the reactant was filtered to obtain white solid precipitate. The precipitate was washed with ethanol and dried in a vacuum oven heated to 50° C. overnight to obtain final styrene polymer. Results of polymerization and physical properties of polymers for each catalyst are shown in Table 1. In addition, each of the polymers was refluxed in methylethylketone for 12 hours and extracted to obtain polymers that remain undissolved. As result of analyzing the polymers by carbon atom nuclear magnetic resonance spectroscopy, they were confirmed to have syndiotactic structure.
Comparative Examples 1 and 2
Solution phase styrene homopolymerization was conducted by the same method as in Example 21, except that well known catalysts Cp*Ti(OMe) 3 and Cp*TiCl 2 (OPh(2.6-i-Pr) 2 were used as a catalyst.
TABLE 1
Results of styrene homopolymerization in solution phase
Molecular
Weight
Yield
Activity
Syndiotacticity
Molecular
Distribution
Melting Point
Catalyst
(g)
(kgS/molTi · hr)
(%)
Weight (Mw)
(Mw/Mn)
(° C.)
Exam. 1
4.58
611
91
310,000
2.1
271
Exam. 2
3.31
120
94
278,000
2.4
272
Exam. 3
6.93
923
90
295,000
2.2
270
Exam. 4
2.09
278
92
290,000
2.2
273
Exam. 5
6.65
887
91
302,000
2.3
269
Exam. 6
1.76
234
93
296,000
2.1
270
Exam. 7
8.24
1097
92
298,000
2.4
270
Exam. 8
2.22
296
92
292,000
2.5
271
Exam. 9
5.73
768
93
307,000
2.2
271
Exam. 10
1.43
191
94
304,000
2.4
272
Exam. 11
8.59
1147
90
310,000
2.5
269
Exam. 12
2.31
309
93
298,000
2.2
273
Exam. 13
6.95
931
92
293,000
2.1
271
Exam. 14
1.41
188
94
295,000
2.5
272
Exam. 15
9.33
1244
91
300,000
2.4
272
Exam. 16
1.93
258
93
306,000
2.2
272
Exam. 17
6.57
878
93
310,000
2.3
270
Exam. 18
1.42
190
93
299,000
2.4
271
Exam. 19
9.22
1229
90
261,000
2.3
270
Exam. 20
2.21
295
91
250,000
2.4
272
Comparative 1
9.30
1240
91
297,000
2.5
269
Cp*Ti(OMe) 3
Comparative 2
0.57
76
90
299,000
2.3
271
Cp*TiCl 2 (OPh(2,6-i-
Pr) 2 )
Example 22
Preparation of Styrene Homopolymer (Bulk Phase Polymerization)
Bulk polymerization of styrene was conducted using the catalysts of Examples 3, 7, 11, 15, and 19.
To a polymerization reactor under high purity nitrogen atmosphere, 100 ml of purified styrene were introduced and temperature of the reactor was elevated to 50° C. Then, 5 ml of triisobutylaluminum (1.0 M toluene solution) and 5 ml of methylaluminoxane (2.1 M toluene solution, Akzo Company product) were sequentially introduced to the reactor. 5 ml (50 μmol of Ti) of toluene solution in which the metallocene is dissolved were added thereto while vigorously agitating. After agitating for 1 hour, 10 wt % of chloric acid-ethanol solution was added to terminate the reaction, and the reactant was filtered, washed with ethanol, and dried in a vacuum oven of 50° C. to obtain a final styrene polymer. Results of polymerization and physical properties of produced polymers for each catalyst are shown in Table 2. And, each polymer was refluxed in methylethylketone for 12 hours and extracted to obtain polymers that remained undissolved. As results of analyzing the polymers with carbon atom nuclear magnetic resonance spectroscopy, they were confirmed to have syndiotactic structures.
Comparative Examples 3 and 4
Bulk phase homopolymerization of styrene was conducted by the same method as in Example 22, except that well known catalysts Cp*Ti(OMe) 3 and Cp*TiCl 2 (OPh(2.6-i-Pr) 2 were used as a catalyst.
TABLE 2
Results of Styrene Homopolymerization in Bulk Phase
Molecular
Activity.((Kg
Weight
Melting
polymer/
Molecular
Distribution
Point
Catalyst
Yield (g)
mol Ti hr)
Weight (Mw)
(Mw/Mn)
(° C.)
Exam. 3
58.2
1164
310,000
2.6
269
Exam. 7
63.1
1262
299,000
2.4
270
Exam. 11
63.6
1272
305,000
2.8
268
Exam. 15
62.9
1258
289,000
2.3
267
Exam. 19
63.9
1278
291,000
2.4
269
Comp. 3
64.0
1280
298,000
2.5
269
Cp*Ti(OMe) 3
Comp. 4
30.5
610
287,000
2.2
268
Cp*TiCl 2 (OPh(2.6-i-
Pr) 2
Example 23
Preparation of Styren/Ethylene Copolymer
Styrene/ethylene copolymerization was conducted using the catalysts of even-numbered Examples out of the multinuclear half metallocene catalysts of Examples 1 to 20.
To a polymerization reactor under high purity nitrogen atmosphere, 10 ml of purified styrene and 20 ml of toluene were introduced and reaction temperature was controlled to 50° C. Ethylene of 4 atm was added to saturate and then 5 ml of methylaluminoxane (2.1 M toluene solution, Akzo Company product) were introduced. 0.44 ml (3.75 mmol of Ti) of toluene solution in which one of the metallocene catalysts is dissolved was added while vigorously agitating. After agitating the reaction mixture for 1 hour, 10 wt % of chloric acid-ethanol solution was added to terminate a reaction, the reactant was filtered, washed with ethanol and dried in a vacuum oven of 50° C. to obtain a final styrene/ethylene copolymer. Polymerization results and physical properties of polymers for each catalyst are shown in Table 3.
Comparative Example 5
Styrene/ethylene copolymerization was conducted by the same method as in Example 23, except that well known catalyst Cp*TiCl 2 (OPh(2.6-i-Pr) 2 was used as a catalyst.
TABLE 3
Results of Styrene/Ethylene Copolymerization
Molecular
Activity
Styrene
Glass
Weight
(Kg polymer/
Concentration
transition
Molecular
Distribution
Catalyst
mol Ti hr)
(mol %)
temp.(° C.)
Weight(Mw)
(Mw/Mn)
Exam. 2
4100
37.6
18.3
150,000
2.20
Exam. 4
5070
26.1
−2.5
172,000
1.78
Exam. 6
2900
41.4
24.9
140,000
1.69
Exam. 8
3350
39.7
21.1
175,000
1.92
Exam. 10
3100
28.9
7.2
110,000
1.88
Exam. 12
3500
25.5
5.6
135,000
1.93
Exam. 14
2510
44.5
28.9
151,000
1.95
Exam. 16
2890
41.2
24.5
165,000
1.88
Exam. 18
4190
58.6
38.9
235,000
2.15
Exam. 20
4980
65.1
45.5
251,000
2.50
Comparative 5
2450
56.9
38.2
99,000
1.99
Example 24
Preparation of Styrene/p-Methylstyrene Copolymer
Styrene/p-methylstyrene copolymerization was conducted using the catalysts of Examples 3, 7, 11, 15, and 19.
To a polymerization reactor under high purity nitrogen atmosphere, 100 ml of purified styrene and 5 ml of p-methylstyrene were introduced and temperature was elevated to 50° C. 5 ml of triisobutylaluminum (1.0 M toluene solution) and 5 ml of methylaluminoxane (2.1 M toluene solution, Akzo Company product) were sequentially introduced. 5 ml (50 μmol of Ti) of toluene solution in which the metallocene catalyst is dissolved was added while vigorously agitating. After agitating for 1 hour, 10 wt % of chloric acid-ethanol solution was added to terminate a reaction, the reactant was filtered, washed with ethanol and dried in a vacuum oven of 50° C. overnight to obtain a final styrene/p-methylstyrene copolymer. Polymerization results and physical properties of polymers for each catalyst are shown in Table 4.
TABLE 4
Results of Styrene/p-methylstyrene Copolymerization
p-Methyl-
Glass
Activity.((Kg
styrene
transition
Melting
polymer/
content
temperature
Point
Catalyst
Yield(g)
mol Ti hr)
(mol %)
(° C.)
(° C.)
Exam. 3
50.5
1010
7.1
100
246
Exam. 7
55.7
1110
7.4
95
237
Exam. 11
59.2
1180
6.8
101
251
Exam. 15
54.8
1100
7.0
99
243
Exam. 19
58.1
1160
7.0
91
229
Example 25
Preparation of Styrene/1.3-butadiene Copolymer
Styrene/1,3-butadiene copolymerization was conducted using the catalysts of even-numbered Examples out of the multinuclear half metallocene catalysts of Examples 1 to 20.
To a polymerization reactor under high purity nitrogen atmosphere, 50 ml of purified styrene and 50 ml of 1,3-butadiene were introduced and reaction temperature was controlled to 25° C. Then, 5 ml of triisobutylaluminum (1,0 M toluene solution) and 5 ml of methylaluminoxane (2.1 M toluene solution, Akzo Company product) were sequentially introduced. 5 ml (50 μmol of Ti) of toluene solution in which the metallocene catalyst is dissolved was added while vigorously agitating. After agitating for 2 hours, 10 wt % of chloric acid-ethanol solution was added to terminate a reaction the reactant was filtered, washed with ethanol and dried in a vacuum oven of 50° C. to obtain a final styrene/1,3-butadiene copolymer. Polymerization results and physical properties of polymers for each catalyst are shown in Table 5.
TABLE 5
Results of styrene/1,3-butadiene
Activity.
Glass
((Kg
1,3-butadien
transition
Melting
polymer/
content
temperature
Point
Catalyst
Yield (g)
mol Ti hr)
(mol %)
(° C.)
(° C.)
Exam. 2
19.8
198
15
73
246
Exam. 4
20.7
207
12
82
260
Exam. 6
23.5
235
8
85
266
Exam. 8
24.6
246
7
86
267
Exam. 10
21.2
212
9
84
262
Exam. 12
22.9
229
10
81
259
Exam. 14
18.5
185
13
77
253
Exam. 16
19.3
193
12
79
255
Exam. 18
22.7
227
7
84
265
Exam. 20
24.1
241
6
86
266
Referring to tables 1 and 5, it is found that the multinuclear half metallocene catalyst constitutes a catalyst system with high activity together with a cocatalyst such as alkylamuminoxame, so that polymers including sindiotatic styrene homopolymer, styrene/styrene derivate copolymer and styrene/olefin copolymer, produced using the catalyst system have superior sterioreguality, high melting point and broad molecular weight distribution.
The group 3 to 10 transition metal multinuclear half metallocene catalyst of the present invention using a bridge ligand simultaneously containing n-ligand cycloalkandienyl group and σ-ligand functional group comprises a catalyst system with high activity together with a cocatalyst such as alkylaluminoxane. Accordingly, syndiotactic styrene polymers and copolymers with olefins having superior stereoregularity, high melting temperature and broad molecular weight distributions can be prepared using the catalyst system above. Polymers prepared according to the present invention have superior heat resistance, chemical resistance, drug resistance and processability and thus can be diversely applied for engineering plastics, etc.
In concluding the detailed description, those skilled in the art will appreciate that many variations and modifications can be made to the preferred embodiments without substantially departing from the principles of the present invention. Therefore, the disclosed preferred embodiments of the invention are used in a generic and descriptive sense only and not for purposes of limitation. | Disclosed is a multinuclear transition metal half metallocene catalyst having a multinuclear half metallocene structure in which a transition metal of groups 3 to 10 on periodic table is connected to a cycloalkandienyl group or its derivative group on a side and also connected to phenol or phenolamine compound having a plurality of binding sites on another side. The metallocene catalyst is useful to produce syndiotatic styrene polymer having superior steroreguality, high melting point and broad molecular weight distribution with high activity together with a small amount of a cocatalyst. Further disclosed is a method for preparing styrene polymers using the same catalyst. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an internal weld joint cleaner, and more particularly, to a weld joint cleaner designed to travel within an internally coated pipeline and clean the interior of said pipeline in the cutback area which surrounds the weld joint and extends up to a point where previously applied internal coating ceases, such area being filled with flux and residue from welding two pipe joint sections together.
2. Prior Art
The present invention relates to a pipeline which is made up from pipe sections which have been previously coated at the mill except for the ends thereof which are left uncoated so that the sections can be welded together in the field in an end-to-end relation. In this particular case, we are concerned with a pipeline which is internally coated; that is each pipe section is previously internally coated except for a band extending about 4-8 inches back from the end of each pipe section. This band is sometimes referred to as the cut-back area. Thereafter, the pipe sections are welded together in the field which means that there will be a total area of 8-16 inches of bare or uncoated pipe around each weld joint which must be cleaned prior to the application of a coating over the weld joint. The added coating will overlap with the internal coating which has been previously applied at the mill.
A machine for coating the uncoated weld joints in an otherwise internally coated pipeline is disclosed in Hart U.S. Pat. No. 4,092,950 issued on June 6, 1978; however, in order to effectively employ the apparatus of Hart U.S. Pat. No. 4,092,950, the weld joints must be thoroughly cleaned to provide a proper surface for receiving the coatings.
The basic method of cleaning the internal weld joints of an internally coated pipeline, of the type described above, has previously involved a spinning wire brush of the type shown in Hasegawa et al U.S. Pat. No. 3,967,584 issued on July 6, 1976; this method, however, is difficult to control, the operation generally affects the previously applied mill coating and the cleaning itself is inferior to the cleaning effected by sand blasting or grit blasting. Attempts have been made and proposed to abrasively blast the internal weld joints manually, and sometimes automatically but these attempts so far have met with little success. As far as sand blasting or grit blasting itself is concerned, a device for abrasive-blast cleaning of the end of a pipe prior to welding is shown in Hart U.S. Pat. No. 3,972,149 issued on Aug. 3, 1976.
In the present invention, after the grit blast weld cleaner has been properly located over the weld joint, and after the grit blast cleaning operation has continued for a period of time, the weld joint cleaner is caused to oscillate longitudinally with respect to the weld joint. The present inventors are not aware of any prior art device which involves an oscillation of the weld joint cleaner with respect to the weld joint.
SUMMARY OF THE INVENTION
The present invention relates to an internal weld joint cleaner designed to travel within an internally coated pipeline and clean the interior of said pipeline in the uncoated cutback area which surrounds the weld joints in the pipeline. The weld joint cleaner of the present invention is a machine adapted to travel along the interior of a pipeline whose weld joints must be cleaned preparatory to the coating of these joints. The machine is composed of a plurality of modules which are segmentally connected, similar to cars on a train. It is designed to travel within a pipeline and to clean areas adjacent to the field girth weld. These areas, referred to as cut-back areas since they extend up to a point where previously applied internal coating ceases, are filled with flux and residue from welding two pipe sections together.
The various modular components which make up this machine or system are: (1) a Cleaning Head Module; (2) a Grit Supply Module; (3) a Prime Mover/Battery Pack Module; and (4) a Generator Module. The configuration of the modular units can be rearranged simplistically because of the bulkhead/rod type of construction used in this invention. The modules described above include a plurality of spaced bulkheads which generally divide the machine into a series of articulated sections. Certain of the bulkheads connect with each other by a plurality of circumferentially arranged rods which are bolted at their ends to these bulkheads. Also, certain of adjacent bulkheads are connected to each other by means of universal joint connections to provide the articulation referred to herein.
The cleaning head module comprises a throwing wheel hub connected to a plurality of radially mounted, spoke-like hollow tubes which are commonly connected to a hollowed out cavity in the hub. The cleaning head also includes a pair of cleaning cavity seals. The first seal is mounted on a forward plate and the second seal is mounted on a rear plate located on the opposite side of the throwing wheel. These seals and fit up against the pipeline wall thereby creating a cleaning chamber capable of completely containing all of the grit dispensed from throwing wheel tubes. A snorkel-shaped breathing port passes through the front seal and plate where it is downwardly baffled at its lower end to prevent grit from bouncing out. A vacuum head projects downwardly through the rear plate into the cleaning chamber where it reaches to within a close proximity of the bottom of the inner pipeline wall. The vacuum head picks up grit and blasted-off material from the cleaning chamber and passes it through the rear plate where it then attaches to a pair of flexible hoses which carry the grit back to the grit supply module.
The grit supply module contains a reservoir vat consisting of a pair of side-by-side grit supply hoppers, a vacuum chamber, three fans, a pair of side by side air compressors, an air storage tank plus attendant electrical switching terminal plates. A corrugated flexible hose connects the vacuum pickup head in the cleaning head module with a grit return tube which passes into the grit supply hoppers. The hoppers are separated by a vat divider wall which the grit return tube ultimately continues through before reaching a final deposit site in rear hopper. The grit deposit or reservoir end of the grit return tube is L-shaped to provide access to both grit supply hoppers for the purpose of depositing returning or reclaimed grit. Each opening of this L-shaped tube is covered by a free-suspended flapper valve. The "straight" portion of the tube which carries one flapper valve passes into the rear hopper; the right angled end of the return tube which carries the other flapper valve terminates within the forward hopper. The function of these aforementioned flapper valves is to allow the vacuum in one chamber to open its respective flapper valve and thus close the other hopper' s flapper valves thus allowing grit to return to the hopper under vacuum as determined by the LOGIC to be discussed later.
The grit supply hoppers have small discharge ports at their bottoms and a pair of rod valves mounted within the hoppers are operated together or alternately by a pair of air cylinders which control the opening or closure of the discharge ports. A pair of suction tubes closeable at their outer ends within the vacuum chamber pass into the rear hopper and the forward hopper, respectively. A pair of disc valves operated by a pair of pneumatic cylinders alternately open and close the suction tubes. A trio of vacuum fans are mounted externally of the vacuum chamber. The intake inlets of these fans are formed by openings through the bulkhead which forms one of the outer walls of the vacuum chamber. Also, in the grit supply module are a pair of electrically operated air compressors and an air storage tank which attach to bulkheads within this module. Compressed air, which is provided at 40-60 psi by these compressors, is utilized to provide air power to many solenoid-operated valves which control the various cylinder-operated functions throughout the present invention and to provide actuating power for these cylinders. A hopper vent valve at the top of the grit supply hoppers communicates with the hoppers on opposite sides of the divider wall and connects to an actuating rod which is operated by a pneumatic cylinder to alternately vent the hopper chambers to atmosphere according to the LOGIC to be described later.
Below the two grit storage hoppers is a single tube which is open at its left end. This open-ended pipe (open to take in outside air and to receive grit via the discharge ports) carries grit forward towards the central cavity of the throwing hub via a hose. The open-end provides a continuous air flow because of the vacuum created by the rotation of throwing wheel through said hose, thus creating a dynamic force which propels the grit in the air current towards the throwing wheel.
The prime mover/battery pack module contains a pair of power drive units, a battery pack supply section, a brake mechanism and a stabilization mechanism or assembly. Each of the power drive units consists of a pair of drive wheels, a pair of drive motors and a pair of reducing gear boxes. The two pairs of wheels are located one above the other in the same vertical plane. The wheels are tapered at a 22° angle to provide maximum contact with the pipeline wall. A pair of cylinders are mounted within the power drive section for urging the upper pair of drive wheels away from the lower drive wheels and, hence, into forced contact with the upper portion of the pipeline wall. The cylinders are used to provide extra traction force through the upper power wheels especially during periods when the lower wheels encounter mud, rusty water, and/or oil or other debris within the pipeline wall. The prime mover/battery pack module also contains a battery portion including three pairs of batteries which make up the battery power pack. This series of batteries allows the present cleaning machine to be used until the engine is able to generate its own power within the pipeline or for bringing the unit out of the pipeline in case of engine failure.
The prime mover/battery pack module further contains a locking brake mechanism consisting of a curved, locking brake shoe which is curved to fit a variety of pipe diameters. An air-actuated cylinder forces the brake shoe against the pipeline wall when the cleaning process is running and serves to release and retract the brake shoe when the process is not running or when the machine needs to travel down the pipe to the next weldment site. Finally, the prime mover/battery pack module includes a stabilization mechanism or assembly which consists of a pair of high friction, rubber roller-castors or wheels attached to a stabilizer bar. One wheel is canted 2° toward the left of the longitudinal axis of the pipeline; the other wheel is positioned 2° toward the right of the longitudinal axis of the pipeline. The stabilizer bar is mounted on the vertical section of an L-shaped arm which is further connected to and activated by a spring-centered pneumatic cylinder which is triggered by a pair of mercury limit switches (not shown). For example, one switch is tripped when the machine rotates left more than 10° from its vertical axis. This causes the stabilizer bar to pivot or rotate thereby pushing the appropriate castor up against the pipe wall until an upright position is achieved. If the machine would over-correct and rotate 10° to the right, the other mercury limit switch would activate causing the other castor to be pushed up against the pipe wall thereby righting the cleaner. The mounting of the wheels at a 2° angle off center from the horizontal axis of the pipe allows the machine to assume a correct upright position slowly. So long as the machine remains within 10° of a normally upright position within the pipeline, the mercury switches are both de-energized thereby causing the stabilizing bar to remain level thus preventing both castor wheels from making contact with the pipe.
The generator module broadly includes an extra large capacity fuel storage tank, a gasoline or diesel engine, a pair of alternators and a pair of electronic controller boxes. The extra large capacity gasoline tank is located between a pair of bulkheads and is separately walled and sealed off from the rest of the system. The engine is mounted adjacent a pair of alternators or generators. A pair of pulley wheels connected to a spin input shaft coming from the engine are drive by a pair of pulley belts which are further connected over a pair of generator pulley wheels which, in turn, are mounted on a pair of generator output shafts. The electrical power produced by the alternators drives the motors of the prime mover drive assembly.
The electronics LOGIC connected with the present invention is also mounted on the generator module; this LOGIC provides for several functional unit operations throughout the modules. The unit cycle operating sequence and timing are controlled by such equipment as that manufactured by General Electric Corporation and International Test Equipment Company. The electronics LOGIC is centered within a pair of conroller modules mounted on the terminal bulkhead of the generator module, except for the isotope sensing unit which is mounted on a plate located in the cleaning head module.
One of the novel features of the present invention involves the oscillation of the cleaning unit. The oscillation of the cleaning head unit occurs because of its attachment to an oscillation unit which is located in the cleaning head module but which connects with the universal joint which articulates the cleaning head module to the adjacent grit supply module. The oscillation unit includes an oscillating motor which is mounted on a bulkhead within the cleaning head module and which drives a gear box having an output shaft connecting to a rotatable disc. The disc connects with one end of a connector rod, the other end of which connects with one pair of ends of a pair of rigid rods which are slidably mounted within a pair of linear bushings. The linear bushings extend through the terminal bulkhead in the cleaning head module. The other ends of the rigid rods connect with a universal joint which, in turn, connects with the initial bulkhead on the grit supply module. The rigid shafts remain stationary while the entire forward cleaning head module oscillates along them. Two linear bushings are used to provide rigidity and stability so the cleaning head module cannot rotate sideways or ride up the pipe wall. When the process controller (located in the generator module) signals the cleaning head unit, the linear bushings allow the entire cleaning head module to move back and forth along a longitudinal axis as the bushings move back and forth on the rigid rods reciprocated (relatively) by the circular disc, thereby causing the forward cleaning head module to oscillate back and forth. Therefore, an area on either side of the weldment gets cleaned as well as the weld itself.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation, in two broken parts, of a grit blast welding machine constructed in accordance with the present invention, showing the machine within a pipeline which is in cross-section;
FIG. 2 is a front elevation, on a larger scale than FIG. 1, showing the cleaning module appearing at the lower right hand end of FIG. 1;
FIG. 3 is a front elevation, partly in secion and on a larger scale than FIG. 2, showing details of the throwing wheel hub and its associated bearing assembly taken from FIG. 2;
FIG. 4 is a plan view taken along line 4--4 of FIG. 2 showing details of the linear bushings and associated elements;
FIG. 5 is a front elevation, taken from FIG. 1 in similar fashion to FIG. 2, but showing the grit supply module and associated elements appearing to the left of the cleaning module of FIG. 1;
FIG. 6 is a plan view of the elements shown in FIG. 5;
FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 5 through the housings for the fan motors, but with the fans and fan motors removed;
FIG. 8 is a front elevation, on a larger scale than FIG. 1, of the prime mover section shown at the upper right in FIG. 1;
FIG. 9 is a plan view of the elements shwon in FIG. 8;
FIG. 10 is an end view of the elements shown in FIG. 8 as taken along line 10--10 of FIG. 1;
FIG. 11 is a front elevation, on a larger scale than FIG. 1, of the gasoline tank, the internal combustion engine and alternators shown adjacent the upper left hand end of FIG. 1;
FIG. 12 is a plan view of the elements shown in FIG. 11;
FIG. 13 is a schematic showing the sequence of operation of the hopper select vents and the hopper feeds;
FIG. 14 is a flow chart illustrating the sequence of operations of the cleaning cycle and relative timing;
FIG. 15 is a schematic diagram illustrating how the radio-active signal (from outside of the pipe) triggers a programmed sequence of events to begin and what various components of the invention are involved at specific times.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The internal grit blast weld joint cleaner of the present invention is segmentally connected, similar to cars on a train. It is designed to travel within a pipeline and to clean areas adjacent to the field girth weld W. These areas, referred to as cut-back areas since they extend up to a point where previously applied internal coating ceases, are filled with flux and residue from welding two pipe sections together.
The over-all operation of the present invention is best described by reference to the various modular components (see FIG. 1) which make up this system. They are: (1) the Cleaning Head Module A; (2) the Grit Supply Module B; (3) the Prime Mover/Battery Pack Module C; and (4) the Generator Module D. The configuration of the modular units can be rearranged simplistically because of the bulkhead/rod type of construction used in this invention.
The modules described above include a plurality of spaced bulkheads which generally divide the invention into a series of articulated sections as will appear hereinafter. For example, the Cleaning Module A includes bulkheads B0, B1, and B2. The Grit Supply Module B includes bulkheads B3, B4, and B5. The Prime Mover/Battery Pack Module C includes bulkheads B6, B7, and B8. The Generator Module D includes bulkheads B9, B10, B11, and B12. Bulkheads B0, B1, and B2 connect with each other by a plurality of circumferentially arranged rods 28 (two of which are shown in FIG. 2) which are bolted at their ends to these bulkheads. Bulkheads B3, B4, and B5 connect with each other by means of similar rods which pass through the bulkheads and are bolted at their ends to bulkheads B3 and B5. Similarly, bulkheads B6, B7, and B8 and bulkheads B9, B10, B11, and B12 are connected to each other, respectively, in the same manner. In order to provide the articulation, bulkhead B2 is connected to bulkhead B3 by means of a universal joint connection 154 as will be described hereinafter. The same considerations hold true for the connection of bulkhead B5 to bulkhead B6 and for the connection of bulkhead B8 to B9.
I. Cleaning Head Module A
The cleaning head unit 30 comprises one part of the Cleaning Head Module A. The cleaning head 30 (see now FIGS. 2, 3, and 4) contains a throwing wheel hub 32 consisting of radially mounted, spoke-like hollow tubes 34 which are commonly connected to a hollowed out cavity 36 in the hub. Said tubes 34 ar also welded to a pair of metal windbreaker plates 35 which, as mounted, allow the cleaning head 30 to more evenly distribute grit particles. The cleaning head 30 also includes a pair of rubber cleaning cavity seals 38 and 40. The first seal 38 is mounted on a forward plate 42 and the second seal 40 is mounted on a plate 44 (also known as B0) located on the opposite side of the throwing wheel. These seals 38 and 40 fit up against the pipeline wall 50 thereby creating a cleaning chamber 46 capable of completely containing all of the grit dispensed from throwing wheel tubes 34. Both seals 38 and 40 are located on the cleaning chamber side of their mounting plates in order to reduce abrasion. A snorkel-shaped breathing port 48 passes through the front seal 38 and plate 42 where it is downwardly baffled at its lower end 52 to prevent grit from bouncing out.
A vacuum head 54 projects downwardly through plate 44 (B0) and rear seal 40 into the cleaning chamber 46 where it reaches to within a close proximity of the bottom of the inner pipeline wall 50. The head 54, shaped in a shallow cure to allow maximum suction, picks up grit from the inner cleaning cavity 46 and passes it through the rear seal 40 and plate 44 where it then attaches to a pair of flexible hoses 56 which carry the grit back to a central line hose 58 which is located between the B2 and B3 bulkheads as will be described later.
The hoses 56 pass through bulkhead B1 and on toward bulkhead B2 where they curve upward and attach to a Y-coupling 60 which passes through bulkhead B2. The Y-coupling 60 reduces to a single fitting as it passes through bulkhead B2 thus further connecting with another section of flexible corrugated hose 58 which attaches to the next module. The hose 58 carries the suctioned grit to the return supply vat 62 (which is in Module B, later to be described).
Also, in the rear cavity seal plate 44 (B0) is a ventilation port valve or disc 64 (although only one is shown, there may be as many as three) disposed over a ventilation port 65 in the plate 44. Disc 64 is opened and closed by a small pneumatic cylinder 66 attached to a cylinder rod 68. The ventilation port valve 64 mounts at the front end of the cylinder rod 68 and is secured thereto by a lock nut 70 and a washer 72. The cylinder 66 is connected to the rear plate 44 via a mounting bracket 76. Two air hoses (not shown) connect the cylinder 66 with the rest of the solenoid-operated system to be described later in the LOGIC in FIGS. 13, 14, and 15. When air is supplied to the cylinder 66, the valve or disc 64 will move to the right to permit air to pass through the plate 44.
A pair of wheels 78, located at the bottom of the cleaning unit 30, are the first of a series to be found throughout the length of the present invention. They are radially mounted at a 45° angle so as to more capably bear the weight of each section to which they are attached. This first pair of wheels 78 connect to the cleaning head by suitable axles and brackets (not shown) in a conventional manner.
The throwing wheel hub 32 (see also FIG. 3) is attached to one end of a hollow tubular shaft 80 which rotates around a hollow non-rotatable tube 82 of smaller diameter than the shaft 80. The right hand end of the tube 82 is welded to the left end of a split support shaft 84 whose right hand section passes through the front rubber seal 38 and plate 42. The right end of 84 is welded to a spring 92 before continuing on forward through front plate 42. The shaft 84 is attached to the plate 42 by a clamp 86 which is held in place with a set screw 88. The left section of shaft 84 passes through a pilot bearing 90 mounted in the forward section of the throwing wheel hub 32. The spring 92, welded between the sections of the split shaft 84 (between the throwing wheel hub 32 and front seal 38) allows greater flexibility to the forward seal plate 42, especially when the whole cleaning modular unit travels around a curve in the pipeline.
The right end of the rotary 80 ends in a central tapered cavity 36 within the hub 32 where the shaft and the cavity both taper outward at a 21° angle before connecting with the spoke-like throwing tubes 34. The tubes receive grit from the 21° tapered central cavity 36 which communicates with the interior of the non-rotatable tube 82 through four oval-shaped, grit emission ports 94 thereby allowing grit to be evenly propelled via gravity and centrifugal force out of the throwing arms 34 into the cleaning cavity 46.
The shaft 80 for rotating the throwing wheel hub assembly 32 passes through plate 44 (B0), which acts as a backing for the rear rubber seal 40 and into a bearing assembly 96 which includes two pairs of bearings 98 and 100. Bearings 98 abut against a shoulder 81 on the shaft 80. The bearing assembly 96 is bolted to plate 44 (bulkhead B0) by a plurality of nuts 102 and bolts 104. The rotating shaft 80 terminates in close proximity to bulkhead B1 within 1/32 inch, but not touching bulkhead B1. This close proximity (not shown) allows small amounts of air to be pulled by the suction of the rotating hub assembly 32 into the annular space formed by the rotating shaft 80 and stationary feed tube 82.
The throwing flywheel (hub) 32 rotates at approximately 3200 RPM's, causing the radial tubes 34 to become an air pump, creating a partial vacuum in the cavity 36 and a decreased pressure on a grit access hose 106 connected to the left-hand end of the tube 82 and leading from the bottom of grit supply hoppers (later to be described) which are in Module B. When grit enters through hollow intake feed tube 82, it is pulled into the conically-shaped, centrally-walled cavity 36, and is thrown out of the four emission port holes 94. Since the throwing wheel is centered within the pipe at the weld W and is surrounded by rubber seals 38 and 40, the high velocity grit impinges against the inner pipe surface thus cleaning the weldment area.
After a specific, programmable period of time of cleaning the weld joint W itself, the entire Cleaning Head Module A begins oscillating longitudinally a specific distance on either side of the weld W as will be described hereinafter. Because the wheel 32 is still throwing grit, the area adjacent to the weld W is cleaned up to the edge of the previously applied mill coating.
The shaft 80 passes through the bearing assembly 96 and attaches to a double pulley 108 mounted thereon. Two V-belts 110, connect the double pulley on the shaft 80 to two lower single pulleys 112 which are mounted on the output shafts 114 respectively of two side-by-side motors 116 (only one of which is shown in FIG. 2). Thus each V-belt 110 connects the output shaft of each motor 116 separately with one of the pulleys of the double pulley on the shaft 80.
The oscillation of the cleaning head unit 30 occurs because of its attachment to the oscillation unit 118, which is oscillated in a manner to be described below. An oscillating motor 120 is mounted through the bulkhead B1 and drives a gear box 122 which has an output shaft 124 connecting it to a rotatable disc 126. Disc 126 connects with one end of a connector rod 128 by means of a bolt 130 and a nut 132. The rod 128 further connects with a common ear 134 (see now FIG. 4) wich is formed as the center section of a face plate 136. Together they receive another bolt 138 which passes therethrough and fastens these two together with a nut 140. Another end face plate 142 connects to the first face plate 136 by means of a pair of parallel rigid shafts 144 which are held in place by a pair of bolts 146 on one end and a second pair of bolts 148 on the other end.
The rigid shafts 144 reciprocate through a pair of linear bushings 150. The bushings 150 are attached to a housing 156 which in turn is flange mounted to bulkhead B2. Plate 142 further connects with a post 152 which receives a Universal-joint 154 (hereinafter referred to as U-joint). Shafts 144 remain stationary while the entire forward Cleaning Head Module A oscillates along them. The left end of the U-joint 154 connects with bulkhead B3 (as shown in FIG. 1). Two linear bushings 150 are used to provide rigidity and stability so the Cleaning Head Module A cannot rotate sideways or ride up the pipe wall.
When the process controller 352 (located in the Generator Module D to be described later) signals the cleaning head unit 30, the linear bushings 150 allow the entire Cleaning Head Module A to move back and forth along a longitudinal axis as it is reciprocated by the circular disc 126, thereby causing the forward Cleaning Head Module A to oscillate back and forth. Therefore, an area on either side of the weldment gets cleaned as well as the weld W itself.
A pin 159 is attached to the periphery of the disc 126 and comes in contact with a lever arm 160 which is attached to a normally closed electrical limit switch 162. When the machine is signaled to move to the next weld joint W and has run the stationary cleaning process (to be later described in the LOGIC in FIGS. 13, 14, and 15), a latching relay is activated which starts the rotation of disc 126 which is then free to continue until an electronic signal from the process controller 352 turns it off. When the limit switch 162 is activated by the pin 159 located on disc 126, a circuit is opened thus halting the oscillation in mid-position. In other words, the pin 159 is located in such a position that the cleaning head 30 always stops right at the central point of the weld W, never at a position to either the left or right side of it.
All sections of the train are connected by universal joints 154 which allow the unit flexibility as it travels through any standard field bends. Each U-joint 154 is bolted together with a pin 158 which can be pulled to release one module from the next for repair work or other purposes.
II. Grit Supply Module B
The Grit Supply Module B itself (see now FIGS. 5, 6 and 7) is located between bulkheads B3 and B5. It broadly contains a reservoir vat 62, a vacuum chamber 164, three fans 166, a pair of side by side air compressors 168 (only one visible in FIG. 5), an air storage tank 170 plus attendant electrical switching terminal plates (not shown). The vacuum chamber 164 is formed by a cylindrical housing 161 which extends across the space between bulkhead B4 and intermediate bulkhead B4'. Vat chamber 62 is anchored between bulkheads B3 and B4 which are connected by rods 28 as previously mentioned. Rods 28 further connect bulkheads B4 and B5 to each other.
The corrugated flexible hose 58, which connects the vacuum pickup head 54, coming from Cleaning Head Module A to the adjacent Grit Hopper Module B, has sufficient compressible length to prevent damage during the oscillation cycle. This section of flexible hose 58 connects over a grit return tube 172 which passes through bulkhead B3 and then enters the uppermost portion of the first of a pair of grit supply hoppers 174 (front) and 176 (rear) mounted side-by-side as one. Together they comprise reservoir vat 62.
The hoppers 174 and 176 are separated by a vat divider wall 178 which the tube 172 ultimately continues through before reaching a final deposit site (via an L-shaped fitting) in rear hopper 176. The grit deposit or reservoir end of tube 172 is L-shaped to provide access to both separately-walled chambers 174 and 176. Access is necessary for the purpose of depositing returning or reclaimed grit. Each opening of this L-shaped tube 172 is covered by a free-suspended flapper valve 173 and 175. The "straight" portion of the tube which carries the flapper valve 175 passes through the wall 178 and terminates within the hopper 176; the right angled end of the tube 172 which carries the flapper valve 173 terminates within the hopper 174. The details of the flapper valves 173 and 175 are not illustrated because they are considered to be more or less conventional; in FIG. 6 these valves are merely shown as broadly pivoted to the right angled ends of the tube 172. However, it should be understood that these flapper valves are mounted at their upper ends over the openings in the tube 172 for pivoting about their upper ends on horizontal pivot axes (not shown) for movement away from or against the openings at the end of the tube 172. It should be further understood that these flapper valves will normally close by gravity in the absence of any pressure differential on the opposite sides of the flapper. The function of these aforementioned flapper valves is to allow the vacuum in one chamber to open it's respective flapper valve and thus close the other hopper's flapper valves thus allowing grit to return to the hopper under vacuum as determined by the LOGIC to be discussed later. (LOGIC alternates chambers every other cycle.) The reverse occurs when the LOGIC dictates need of a vacuum in the other hopper. For example, when chamber 176 is under vacuum, flapper valve 175 is open and flapper valve 173 is closed; when chamber 174 is under vacuum, the condition of the valves is reversed.
The reservoir chambers 174 and 176 are hopper-shaped on the bottom and have small discharge ports 180 and 182 therein. Within each chamber and leading to these flow control discharge ports 180 and 182 are a pair of inclined baffles 184 and 186 which further direct the grit flow to said port openings. In other words, there are V-shaped walls surrounding the ports shaped thusly to permit a better flow of grit out of each supply chamber. Were the port walls to be cylindrical, the grit might tend to stack up thereby occluding the opening.
The ports 180 and 182 receive a pair of rod valves 188 and 190 which are operated by a pair of air cylinders 192 and 194 which control the opening or closure thereof. These valves, which form V-shape points at their ends, are nose-mounted directly above each respective port on a pair of angle arm brackets 196 and 198 which connect centrally to the vat divider wall 178. However, when hose 58 is returning grit from the vacuum pickup head 54 in the Cleaning Head Module A through tube 172 in the uppermost portion of the grit supply hopper section 62, one port will be open and the other one will be closed unless they are both closed as during time of transport from one weldment site to another. (See LOGIC in FIGS. 13, 14, and 15.)
FIGS. 5 and 6 show a pair of suction tubes 200 (shorter) and 202 (longer) which pass through the top of bulkhead B4. A pair of pneumatic cylinders 204 and 206 alternately open and close the tubes 200 and 202 as will appear below. Tube 200 from the vacuum chamber 164 passes through bulkhead B4 and terminates within the rear hopper chamber 176. Tube 202, which also passes through B4 from the vacuum chamber 164, extends on through hopper chamber 176, hopper divider wall 178, and opens into the forward hopper chamber 174.
Tubes 200 and 202, which allow suction to pass from chamber 164 into the rear and forward grit storage hoppers 176 and 174, respectively, are sealed from chamber 164 by a pair of discs 208 and 210 (constituting disc valves) upon which are mounted a pair of rubber seals 212 and 214. These discs and seals are mounted on a pair of actuating rods 216 and 218 which extend through B4 where they attach to said pneumatic cylinders 204 and 206 which control the alternate opening and closing thereof according to the LOGIC as diagrammed in FIGS. 13, 14 and 15. Also, located in the vacuum chamber 164 is a four-sided, closed box type, bottom open only, baffle deflector 220 which prevents occasional particles of grit from entering the inlets of fans 166 as will appear hereinafter.
A trio of vacuum fans 166 are located between bulkheads B4 and B5. Each fan comprises a motor portion (not shown) covered by motor housing 163 and a fan portion (not shown) covered by a fan housing 165. The intake inlets 222 of these fans (see also FIG. 7) pass through bulkhead B4' and communicate with the vacuum-sealed chamber 164. (FIG. 7 is a cross-sectional view through the motor housings 163, but with the fan motors and fans removed.) These three fans 166 draw the suction intake air through the openings 222 thus creating the vacuum in compartment 164. Cylinders 204 and 206, which are threadedly received into appropriate openings cut in the top of bulkhead B4' and which are located above these fans, open alternately to allow suction to build up in vat chambers 174 and 176 alternately, which causes grit to be pulled in via tube 172, via connecting hose 58, via cleaning compartment hoses 56, and ultimately from the vacuum pickup nozzle 54 located in the Cleaning Head Module A.
Fans 166 are held in place against the rear wall bulkhead B4' by means of a metal fan clamping plate 224 which is positioned behind the fan housings 165 and attached to the bulkhead by a threaded rod 226 and a nut (not shown). The plate 224 is somewhat in the form of a clover leaf and is provided with three arcuate openings 225 which are slightly more than 180° and which are adapted to receive the housings 163 for the fan motors. The right surface (FIGS. 5 and 6) of the plate 224 bears against the left hand ends of the fan housings 165. A stabilizing rod 223 connects the upper end of plate 224 to bulkhead B4' to prevent rotation of the plate. A series of bolts 227 anchor B4' to B4 by clamping the circular housing 161 which forms the walls of vacuum chamber 164 together therebetween. The circular housing 161 of chamber 164 fits over a shoulder (not shown) on the right peripheral edge of B4' and into a groove (not shown) in the chamber side of bulkhead B4. All vacuum fan intake ports 222 open through B4' as do cylinders 204 and 206 via threaded mounting holes (not shown).
Also, in the Grit Supply Module B are a pair of electrically operated air compressors 168 and an air storage tank 170 which attach to bulkheads B3 and B4 as necessary. (These compressors may be located in other positions depending on available space in other size models of this present invention.) Compressed air, which is provided at 40-60 psi, is utilized to provide air power to many solenoid-operated valves which control the various cylinder-operated functions throughout the present invention and to provide actuating power for these cylinders.
Also, located in the top of the grit storage chambers 174 and 176 are a pair of grit access fill holes 228 and 229 through which cleaning grit is introduced into the hoppers. Said fill holes are further sealed off by a pair of filler caps 230 and 232. A hopper vent valve 234 (diagrammatically shown) communicates with the chambers 174 and 176 at the top on opposite sides of the divider wall 178 and connects to an actuating rod 236 which is operated by a pneumatic cylinder 238 (diagrammatically shown) to alternately vent hopper chambers 174 and 176 to atmosphere according to the LOGIC to be described later.
Below the two grit storage hoppers 174 and 176 is a single tube 240 which is open at its left end 241. This open-ended pipe 240 (open to take in outside air and to receive grit via ports 180 and 182) carries grit forward towards the central cavity 36 of the throwing hub 30 via hose 106. The open-end 241 provides a continuous air flow because of the vacuum created by the rotation of throwing wheel 30 through said hose 106, thus creating a dynamic force which propels the grit in the air current towards the throwing wheel 30.
The two air cylinder-operated rod valves 192 and 194, which alternately allow grit to drop from supply vats 174 and 176 into the flow control orifices as per the LOGIC flow chart in FIGS. 13, 14, and 15, both close, however, when the cleaning cycle is off. (The two chambers alternately drop grit into this air stream based on the above described vacuum controlled suction sequence which is described in the LOGIC illustrated later in FIGS. 13, 14, and 15.)
III. Prime Mover/Battery Pack Module C
The Grit Supply Hopper Module B is connected by another universal-joint 154 (see FIGS. 1, 8, 9, and 10) to the Prime Mover/Battery Pack Module C which broadly contains the following: (1) a pair of power drive units 242 (upper) and 244 (lower), (2) a battery pack supply section 246, (3) a brake mechanism 248, and (4) a stabilization mechanism or assembly 250.
Each of the power drive units 242 and 244 shown in FIGS. 8, 9, and 10, consists of a pair of drive wheels 252 and 254, a pair of drive motors 256 and 258, and a pair of reducing gear boxes 260 and 262. The two pairs of wheels 252 and 254 are located one above the other in the same vertical plane. FIG. 10 shows an end view of the Prime Mover portion of the Module C. A pair of upper wheels 252, tapered at a 22° angle to provide maximum contact with the pipeline wall 50, make up one set of the Prime Mover power wheels which allow the present invention to travel from one weldment to another within the pipeline. These upper power wheels 252 are mounted on a pair of hubs 264 which fit over an output shaft 266 thus connecting them to the upper gear box 260 which is flange mounted by a series of bolts 268 to the upper drive motor 256.
The lower portion of the upper gearbox 260 connects by a series of bolts 270 to an A-frame yolk assembly 272 which attaches to a bracket 274 by means of a pivot bolt 276 passing therethrough. The bracket 274 attaches to bulkhead B7 by a pair of bolts 278.
The lower pair of drive wheels 254 are mounted on a pair of hubs 280 which fit over an output shaft 282 which passes through lower gear box 262. The upper portion of this lower gear box 262 is attached by a series of bolts 284 to a mounting bracket 286 which has an upper spine 288 down the center thereof; this gearbox 262 is further flange mounted to the lower drive motor 258 by a series of bolts 290. The mounting bracket 286 is further attached by a series of bolts 292 to bulkhead B6.
A pair of cylinders 296 having lower lug portions 298 are mounted to the upper spine 288 by bolts 294. (The lug is part of the cylinder.) A pair of actuating rods 300 at the other end of cylinders 296 connect by a pair of lugs 302 to the unattached end 303 of the A-frame yolk assembly 272.
The rods 300 plus the cylinders 296 are used to provide extra traction force through the upper power wheels 252 especially during periods when the lower wheels 254 encounter mud, rusty water, and/or oil or other debris within the pipeline walls 50. Therefore, these two sets of tapered wheels 252 and 254, mounted above each other in a vertical plane, and the two cylinders 296 help pre-load the workforce and keep the grit cleaning unit traveling down the pipeline.
The Prime Mover unit is connected together by a plurality of rods 28 (not here shown) which are bolted to bulkheads B6, B7, and B8; B7 and B8 form the beginning and end bulkheads encompassing the battery portion 246 of the Prime Mover Module C. FIG. 1 shows a side view of section 246 which contains three pairs of batteries 304 which make up the battery power pack. This series of batteries 304 allows the present cleaner invention to be used until the engine is able to generate its own power within the pipeline or until the unit can be brought out of the pipeline in case of engine failure.
FIG. 1 also shows a side view of the locking brake mechanism 248. A curved, locking brake shoe 306 is mounted on a lever arm 308 which attaches to a bracket 310 which is flange mounted to bulkhead B8 near the upper surface of the grit cleaner unit in close proximity to the upper inside surface of the pipeline wall 50. The brake shoe 306 is curved to fit a variety of pipe diameters.
The brake mounting bracket 310 is connected at its lower end to an air-actuated cylinder 312 which forces the lever arm 308 to set and lock the brake shoe 306 in place against the pipeline wall 50 when the cleaning process is running and to release and retract the brake shoe 306 when the process is not running and when the machine needs to travel down the pipe to the next weldment site. The sequencing is automatically controlled by the process controller timer 352.
A circuit in the process timer 352 controls the operation of the brake shoe 248. A relay contact is normally open when the machine is traveling through the pipeline from one weldment to another. The relay contact closes when the cleaning process starts and triggers the solenoid-operated air cylinder 312 to push the brake shoe 306 up against the pipeline wall 50. When the cleaning process ends, another signal causes the pneumatic cylinder 312 to release from its locked position thereby allowing the brake shoe 306 to disengage from pipeline wall contact.
At the front end of the battery compartment 246 and mounted on the upper edge of bulkhead B7 is the stabilization mechanism or assembly 250. A pair of high friction, rubber roller-castors or wheels 314 and 316 are attached to a stabilizer bar 318. One wheel (314) is canted 2° toward the left of the longitudinal axis of the pipeline; the other wheel (316) is positioned 2° toward the right of the longitudinal axis of the pipeline.
The stabilizer bar 318 is mounted on the vertical section of an L-shaped arm 320 which is further connected to and activated by a spring-centered pneumatic cylinder 322 which is triggered by a pair of mercury limit switches (not shown). For example, one switch is tripped when the machine rotates left more than 10° from it's vertical axis. This causes the stabilizer bar 318 to pivot or rotate thereby pushing the appropriate castor up against the pipe wall until an upright position is achieved. If the machine would over-correct and rotate 10° to the right, the other mercury limit switch would activate causing the other castor to be pushed up against the pipe wall thereby righting the cleaner.
The mounting of the wheels 314 and 316 at a 2° angle off center from the horizontal axis of the pipe allows the machine to assume a correct upright position slowly. So long as the machine remains within 10° of a normally upright position within the pipeline, the mercury switches are both de-energized thereby causing the stabilizing bar to remain level thus preventing both castor wheels from making contact with the pipe.
IV. Generator Module D
The Generator Module D (see now FIGS. 1, 11, and 12) broadly includes an extra large capacity fuel storage tank 324, an engine 326, a pair of alternators 328 and 330, and a pair of electronic controller boxes 352 and 354.
At the rear end of this Battery Pack Module section 246 is bulkhead B8 which connects via a universal joint 154 to bulkhead B9, thus beginning the Generator Module D. The extra large capacity gasoline tank 324 is located between bulkheads B9 and B10 and is separately walled and sealed off therefrom. The gasoline or diesel engine 326 is mounted between bulkheads B11 and B12 adjacent the generators 328 and 330, which are found between the confines of bulkhead walls B10 and B11. The engine shown in FIGS. 1, 11, and 12 is mounted on and bolted to a metal plate 332 which extends across B11 and B12.
A pair of pulley wheels 334, connected to a spin input shaft 338 coming from the engine 326, are driven by a pair of pulley belts 340 and 342 which are further connected over a pair of generator pulley wheels 344 and 346 which are mounted on a pair of generator output shafts 348 and 350. These two belts, one coming from the engine and one coming from each of the two 24 volt alternators, operate one pair at a time by predetermined signal. For example, if one alternator would fail, controller 354 would be signaled which, in turn, would trigger the device to activate the other alternator. The electrical power produced by the alternators 328 and 330 drives the motors 256 and 258 of the Prime Mover drive assembly.
The electronics LOGIC connected with the present invention provides for several functional unit operations throughout the modules. (See now FIGS. 1, 2, 13, 14, and 15.) The unit cycle operating sequence and timing are controlled by such equipment as that manufactured by General Electric Corporation and International Test Equipment Company.
The electronics LOGIC center is disposed within a pair of controller modules 352 and 354 mounted to the left of bulkhead B12 in the Generator Module D, except for the isotope sensing unit 356 (see FIG. 2) which is mounted on a plate 358 located in the Cleaning Head Module A. Plate 358 is bolted in a suitable fashion to the rear end of gear box 122 located within the oscillation unit 118 and also to connecting rods 28 which hold various modular units of the grit cleaner together.
LOGIC: THE SEQUENCE OF FLOW OF A BASIC CYCLE
After a field weld W has been detected, an ITE (International Test Equipment Company, Tulsa, locating detector assembly--no model number assigned) standard isotope sensing unit 356 senses, receives, and translates a radio-active signal emitted by a low energy isotope source outside of the pipe 50. (The isotope sensing unit can be located anywhere along the grit cleaning unit's entire length. It merely bolts on as an electronic unit.) It is usually positioned along the cleaner a certain distance from the center of the throwing wheel hub 32 so that its exact location can be accurately measured to coincide with a manual placement of the isotope source outside of the pipeline wall 50.
An independent container 360 (see now FIG. 15), which holds a radio-active isotope within an inner, sealed lead box (not shown), is placed manually above the outside of the pipeline wall 50 a predetermined distance from at the center of the weld joint W. The grit cleaner engine 326 provides power to the unit as it travels down the pipe 50 until the isotope sensor 356 senses the transmitted radio-active signal coming from container 360. This signal, which then collapses the circuit to a grounded condition and electronically notifies the Prime Mover controller 354 and the human operator that the throwing wheel hub 32 in the Cleaning Module A is properly positioned at the center of the weldment, also causes the Prime Controller 354 (ITE's Control Module Model #316SC) to electronically command the power wheels 252 and 254 of the Prime Mover Module C to stop or reverse direction so as to be in the exact center of the weldment area. So the sensor 356 performs two functions: (1) it positions the unit, and (2) it gives a trigger signal to the automatic cycle controllers.
Once this trigger signal has been given, the cleaning cycle is then activated by the unit's process controller/timer 352. [ITE's Automatic Timing Control Model #410AC. Other models of electronic controllers are commercially available from companies such as General Electric.] Controller/timer 352 programs the cleaning sequence which tells the grit cleaner when to move, when to run the throwing wheel process, when to oscillate, and when to stop.
Once in the proper position, the controller/timer 352 gives the signal for the cleaning cycle to start. When one grit hopper supply tank, for example hopper 174, is open to the vacuum chamber created by the three intake fans, it is closed to the atmosphere thus creating a pull on the other tank's (176) flapper valve 175. [One flapper valve 173 is open, the other one 175 is pulled shut.] Also, the vat valve 180, located in the bottom of the grit supply hopper 174 that is under the vacuum, is closed. The other chamber 176 is open to the atmosphere by virtue of the position of valve 234, and although its flapper valve 175 is closed, its vat valve 182 is open. This arrangement allows the feeding of spent grit and blasted-off material to the hopper 174 and the flow of recovered grit from the hopper 176 to the grit supply tube 240. By means of a flip-flop, the controller reverses these conditions.
The machine of the present invention may require an external fan (not shown) to be placed at the end of the pipe 50 to provide additional "breathing air" for the engine 326 when the machine is moving along the pipeline. For example, when the machine is stopped and the cleaning process is in operation, the vacuum fans 166 are pulling some air through the port 48 in the forward rubber seal disc 38 and plate 42 to provide "breathing air" for the engine 326 while the process is running. However, when the cleaning process is over, the fans 166 are off and this source of "breathing air" is no longer available, and, thus, there would be a tendency for the engine to shut down as the machine commences to move along the pipeline. Therefore, another air source, the ventilation port 65, is cut in the rear seal 40 and plate 44. The number of ventilation ports may be increased depending on the size of engine to be used. If sufficient air does not pass through the port or ports 65 as the machine travels along the pipeline, it may be necessary or desirable to place an external fan (not shown) at one end of the pipeline (as suggested above) to increase the flow of air through these ports 65 so as to provide the amount of oxygen necessary to support combustion in the engine 326.
FIGS. 13, 14, and 15 are diagrammatic representations which have been added for a fuller understanding of the present invention. FIG. 13, for example, illustrates, in diagrammatic fashion, the disposition or more of the forward hopper 174 and the rear hopper 176 during a given cleaning cycle; FIG. 3 also illustrates the mode of the various valves associated with these two hoppers. A portion of the process controller/timer 352 is employed to control the various valves associated with the two hoppers. This portion of the process controller/timer is diagrammatically designated as 352A on FIG. 13. It should be also mentioned that FIG. 13 represents the condition where the rear hopper 176 is receiving returned grit from the hose 58 while the forward hopper 174 is forwarding grit to the grit supply tube 240 through the port 180. Thus, the hopper select 352A sends a signal to a solenoid operated valve (not shown) to operate the pneumatic cylinder 204 to open the disk valve 208; this opens the tube 200 to the vacuum chamber 164. At the same time, the hopper select 352A sends a signal to the vent valve 234 so as to close the rear hopper's vent to the atmosphere and open the forward hopper's portion of this vent to the atmosphere. The suction on the tube 200 will cause the flapper 175 to open and the flapper 173 to close as indicated on FIG. 13. The hopper select 352A also sends a signal to actuate the two needle valves 188 and 190. In the case of FIG. 13, the needle valve 188 is open for the purposes of that cleaning cycle but can be further opened and closed as will be explained further in connection with the description of FIG. 14. The signal sent by the hopper select 352A to the needle valve 190 is such that this needle valve is closed during the entire cleaning cycle represented by FIG. 13. For the next cleaning cycle however, the conditions shown in FIG. 13 will be reversed. That is, the forward hopper 174 is adapted to receive grit from the hose 58 while the rear hopper 176 is adapted to feed grit to the supply tube 240 through the valve 190.
Turning now to FIG. 14, this figure shows the dispositions of the fans 166 ("FANS"), the cleaning wheel 32 ("CLEANING WHEEL"), the grit feed valve 188 or 190 ("GRIT FEED"), the oscillator motor 120 (OSCILLATOR"), the vent valve 64 ("CAVITY VENT") and the brake 248 ("UNIT BRAKE") during an entire cleaning cycle. The horizontal lines opposite the above legends represent "on" or "off" or "open" or "closed" as the case might be. For an up condition of the line the corresponding item is on or open; when the line drops down, the item is turned off or closed. It will be assumed that the machine is presently positioned in the pipeline and that the machine is waiting for the next signal from the LOGIC controller to "Start Cleaning Cycle". At this point, the brake 248 is fully engaged, the forward vent 64 is fully closed and the fans 166 are turned on to commence the cleaning cycle.
At the commencement of the cleaning cycle, the condition shown in FIG. 13 will also obtain except that the valve 188 will be momentarily closed so that there is suction to the cleaning cavity 46 before the cleaning wheel commences to rotate and before grit or abrasive particulate material is supplied to the grit supply tube. After the fans 166 have been operating for a predetermined period of time, the forward motor 116 will be powered to rotate the cleaning wheel 32 as represented by the first rise in the line corresponding to "CLEANING WHEEL". When the cleaning wheel gets up to speed, the suction created within the cavity 36 inside the hub 32 will cause suction to be transmitted through the hose 106 back to the grit supply tube 240 and through the open end 241. After the wheel has been rotating a predetermined period of time, then the "GRIT FEED" (which is in the mode of FIG. 13) is actuated to the extent that the valve 188 is now opened to permit grit to drop through the port 180 into the tube 240 as represented by the first rise in the line corresponding to "GRIT FEED". The grit is sucked into the cavity 36 and is propelled outwardly through the tubes 34 against the weld W. Both the grit feed and cleaning wheel are turned off in anticipation of the reversal of rotation of the cleaning wheel. The grit feed is actually turned off a few seconds before the cleaning wheel is turned off so that there will be no grit from the open end 241 to the chamber 36 at the time the cleaning wheel actually stops rotating. After a pause long enough for the cleaning wheel to cease rotation or nearly so, a signal is sent to the motor 116 to rotate the cleaning wheel in the reverse direction and, at the same time, a signal is sent to the motor 120 to cause oscillation of the entire cleaning unit 30 in the manner previously described. This oscillation, as indicated by the first rise in the line corresponding to "OSCILLATOR", will continue to the end of the given cleaning cycle. In the interim, however, the cleaning wheel is stopped or slowed down and reversed while the grit feed is off. This will allow the cleaning wheel to fully dispense any abrasive material remaining in the grit feed lines and, of course, the suction will remove all grit and blasted-off material and return it to the rear hopper 176. The feed unit oscillates back and forth so that the vacuum tube 54 will suck up whatever grit and blasted-off material is left in the cleaning area.
The times broadly referred to above, as represented by the rises and falls on FIG. 14, can be varied depending upon the cleaning requirements of the given pipeline. For example, the fans start first. It is not desirable to turn the fans and the wheel motor on at the same time because of the initial amperage draw. When the fans get up to speed, after about five seconds, the wheel motor is energized. The wheel motor takes about twenty-seven seconds to get up to speed. After about forty-five seconds, the grit valve 188 (or 190) is opened. The cleaning wheel will blast grit directly over the weld seam itself for approximately a minute to a minute and a half. The grit feed and cleaning wheel are then turned off in that order and the oscillation mode begins. The wheel has been spinning at approximately 3200 RPM's so it is given approximately thirty seconds to slow down after which the wheel motor is given an opposite rotational signal and the wheel starts spinning in the opposite rotary direction. Twenty seconds after that, the grit feed turns back on again. After about another minute to a minute and a half the grit feed and the cleaning wheel are turned off in that order and the grit feed remains off for the remainder of the cycle. After about thirty seconds the cleaning wheel is turned back on for rotation in a rotary direction opposite to its last rotary movement and the wheel continues to spin for approximately a minute while the cleaning unit continues to oscillate. The spinning wheel provides turbulence in the cleaning cavity while the cleaning unit oscillates back and forth to suck up all of the grit in the cleaning cavity. Just prior to the end of the cleaning cycle, the process controller/timer 352 sends a signal to the micro-switch 162 so that, on the final revolution of the disk 126, the pin 159 will contact the lever arm to open the limit switch 162 and shut off the motor 120 causing the wheel 32 to come to rest directly over the weld W.
FIG. 15 is a diagrammatic representation of the major components of the overall system. After the machine has been placed in the pipeline with the engine 326 operating, the alternators 328 will be supplying current to the batteries 304 which, in turn will be supplying electrical power to all of the various units requiring electrical power, although the time when the power is supplied to such units may be determined by the process controller/timer 352. Electrical power will be immediately applied to the compressor 168 which supplies compressed air to the air reservoir 170. Air under pressure is supplied from the reservoir 170 to all air operated units through various solenoid valves which are controlled by the prime controller 354 and/or the process controller/timer 352 with the exception of cylinder 296 which is manually operated at the time the machine is inserted in the pipeline.
At the time that the machine is inserted in the pipeline, it is generally disposed on a trough sufficiently long to contain the machine and having a curvature corresponding to the lower curvature of the pipeline. The trough is brought up against the pipeline so that the curvature of the trough is in abutting alignment with the lower end of the pipeline. The engine 326 is started and the machine is "jogged" into the pipeline by intermittently actuating the motors 256 and 258. When both sets of wheels 252 and 254 are within the pipeline, a manual valve (not shown) is opened to actuate the cylinder 296 at which time the upper wheels 252 are urged upwardly into firm engagement with the upper portion of the pipeline wall. The control can now be switched to automatic and the remaining operations can be controlled by the radio-active isotope in the hand held container 360.
As shown in FIG. 2, the isotope sensor 356 is located a predetermined distance away from the center of the wheel 32. If this distance is, for example, eighteen inches, then the hand held isotope source 360 should be placed eighteen inches to the left of the weld W, assuming that the cleaning machine shown in FIGS. 1 and 2 is moving to the left in proceeding from one weld joint to the next. Returning now to a further consideration of FIG. 15 and assuming that the hand held isotope source 360 has been placed at the proper location on the pipeline, the machine will have moved and stopped with the isotope sensor 356 located physically directly below the hand held source 360. The brakes will have been engaged and the system is waiting for a signal from the process controller/timer 352 to commence the cleaning cycle. Although the system could be set up in such a way that the cleaning cycle would commence automatically upon the stopping of the machine at the proper location, preferably the machine, as in the present case, is designed for a further signal to be given prior to the commencement of the cleaning cycle. This signal is given merely by removing the hand held source 360 from the pipeline. At this time the isotope sensor 356 (which was actuated by the isotope source 360 and which sent a signal to the prime controller 352) sends a reverse signal (upon removal of the source 360) to the prime controller 354. In effect, the isotope sensor 356 actuates a stepping switch (not shown) in the prime controller 354; the placement of the source 360 over the sensor 356 causes this stepping switch to move half-way to the next step. The subsequent removal of the source 360 from its influence over the sensor 356 causes this stepping switch to remove all the way to the next step. Assuming that this next step is the commencement of the cleaning cycle, then the machine will commence to clean the pipe weld W in the manner described previously. However, should the operator of the machine desire some alternate action, such as movement of the machine in a reverse direction back to the previous weld joint, then alternate placement and removal of the source 36 over the sensor 356 will cause the stepping switch within the prime controller 354 to move to whatever position this operator desires consistent with the demands at the time.
Purely by way of example, the stepping switch (not shown) referred to above has four main positions or steps. The first position is "Forward"; the second position is "Reverse"; the third position is "Stop"; and the fourth position is "Process", or, in other words, the cleaning cycle itself. In the "Forward" position, the brake 248 will be off (by de-energizing the cylinder 312) and the motors 256 and 258 will be actuated to move in a "Forward" direction which, of course, is arbitrary with respect to the machine unless and until it is established which end of the machine is the "Forward" end. For the purposes of this application, the end containing the control elements 352 and 354 mounted on bulkhead B12 will be considered the "Forward" end of the machine. Therefore, in relation to FIGS. 1, 2 and 8, energizing the motors 256 and 258 to move in a "Forward" direction will mean that the machine moves towards the left with respect to the above mentioned figures. Since it is necessary to back the machine out, in numerous instances, a "Reverse" condition must be available to allow the machine to move towards the right with respect to FIG. 1 et seq. In the "Reverse" and "Forward" modes, the motors 256 and 258 are energized, the engine 326 is on, the alternators are charging the batteries 304, the stabilizing mechanism 320 is on, the vent valve 64 is open, the air compressor 168 is running, the cylinder 296 is pressurized and everything else is either off or closed. In the "STOP" position, the power is removed from the motors 256 and 258, the cylinder 312 is pressurized to engage the brake 248 and the remainder of the system is the same as in the forward or reverse mode. When the stepping switch is in the "Process" mode, the machine operates as previously described with particular reference to FIGS. 13, 14 and 15.
There are three specific conditions where the machine is stopped: first, whenever the radio-active isotope 360 is disposed on the pipeline 50 directly above the sensor 356; secondly, when the stepping switch is in the "Stop" mode; and thirdly, at the completion of the "Process" mode. Assuming that the machine has completed a cleaning cycle at a given weld joint W, the machine will be at the end of the process mode, the operator will then place the radio-active source 360 on the pipe over the sensor 356 and the sensing switch will move halfway to the next step. The operator will then remove the source 360 and the stepping switch will move all the way to the next step which is the "Forward" position. Now the machine will commence moving towards the left and towards the next weld joint. The operator will have marked a position eighteen inches to the left of the next weld joint for the proper placement of the source 360 for the cleaning operation at that weld joint. However, it is necessary to take the stepping switch through the "Reverse" mode and through the "Stop" mode before the "Process" mode can commence. Accordingly, the operator will place the source 360 some three feet, for example, to the left of the proper position for this source as referred to immediately above. When the machine moves such that the sensor 356 is below the actuator 360, the machine will stop some three feet plus eighteen inches beyond this second weld joint. By virtue of the fact that the sensor 356 is now below the source 360, the stepping switch will have stepped halfway towards the next step. Now the operator again removes the source 360 from the pipe and the stepping switch moves all the way to the next position which is the "Reverse" position. Immediately thereafter, the operator moves the isotope source to the mark 18 inches to the left of the second weld joint and the machine will travel in a reverse direction to this point at which time it will stop and the stepping switch will move halfway to the next position. When the operator now removes the source 360, the machine will be in the "Stop" position. If it is desired to leave the machine at this point for a period of time, it can be done conveniently. If the operator wishes to initiate the cleaning cycle, he merely places the isotope source 360 over the sensor 356 and thereafter removes it to cause the stepping switch to move to the "Process" mode and the cleaning cycle begins as described above.
At the conclusion of a cleaning cycle, the machine will generally sound a horn (not shown) at which time the operator will place the hand held unit 360 over the isotope sensor 356 and remove it to actuate the prime controller for the next step, preferably "Forward" to the next weld. At the same time, the operator will place the same or another hand held source 360 eighteen inches to the left of the next weld joint (or three feet beyond this point, if it is necessary to take the machine through the "Reverse" mode and the "Stop" mode, as described above).
In FIG. 15, the air compressor 168 and the unit stabilization system 320 are not controlled directly or indirectly by the prime controller 354; these units operate whenever the engine (or batteries) are "on". The other instrumentalities connected to the prime controller 354 or the process controller/timer 352 are dependent upon signals initiated by the radio-active isotope source 360. For safety purposes, a toggle switch (not shown) is located at each end of the machine; in the event that the machine proceeds out of either end of the pipeline, the toggle switch at that end can be thrown to stop the movement of the machine immediately. A further safety feature (not shown) can be incorporated into the machine to stop the same automatically after a predetermined distance of movement, say fifty feet, in the event that the machine "gets away" from the operator and travels beyond the next weld joint which would normally be about forty feet away.
Whereas the present invention has been described in particular relation to the drawings and diagrams attached hereto, it should be understood that other modifications, apart from those shown or suggested herein may be made within the spirit and scope of this disclosure. | A machine for cleaning the interior uncoated surfaces surrounding the weld joints in an otherwise internally coated pipeline comprising a first plate mounted on the machine and extending transversely across the pipeline when the machine is disposed within the pipeline, a second plate mounted on the machine in spaced parallel relation with the first plate, a first resilient member mounted on the first plate and having a circular periphery for engaging the inner periphery of the pipeline wall, a second resilient member mounted on the second plate and having a circular periphery for engaging the inner periphery of the pipeline wall, the first and second plates with their attached resilient members forming a closed cleaning chamber sealed at its ends with respect to the pipeline, a hollow rotatable hub mounted on the machine and within the cleaning chamber and rotatable on an axis substantially co-axial with the longitudinal central axis of the pipeline, a plurality of hollow tubes extending radially outward from the hub and in communication with the interior of the hub, a motor for rotating the hub whereby air is forced outwardly through the tubes to create a partial vacuum within the interior of the hub, arrangement for supplying particulate abrasive material to the interior of the hub whereby the vacuum created upon rotation of the hub will cause the particulate material to be propelled outwardly against the interior of the pipeline wall, wheels for moving the machine so as to position the radial tubes in alignment with a weld joint whereby, upon rotation of the hub and upon supplying the hub with particulate abrasive material, the tubes will propel the particulate material against the weld joint to clean the same by a sand blasting effect, a rotary disc and linkage acting in timed response to the initial rotation of the hub for oscillating the plates and hub as a unit longitudinally with respect to weld joint whereby the tubes will move alternately back and forth across the weld joint to clean the entire weld joint area, and a vacuum head for removing accumulated spent particulate material and blasted-off material continuously from the cleaning chamber. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. §120 to and is a divisional application of U.S. patent application Ser. No. 12/889,032, filed on Sep. 23, 2010, hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention is related to a multi-purpose catheter that is used to deliver dose, measure the dose and remove human waste while providing an easy connection module.
BACKGROUND
[0003] In medicine, a catheter is a tube that can be inserted into a body cavity, duct, or vessel. Catheters thereby allow drainage, injection of fluids, or access by surgical instruments. The process of inserting a catheter is catheterization. In most uses, a catheter is a thin, flexible tube (“soft” catheter), though in some uses, it is a larger, solid (“hard”) catheter. A catheter left inside the body, either temporarily or permanently, may be referred to as an indwelling catheter. A permanently inserted catheter may be referred to as a permcath.
[0004] The ancient Syrians created catheters from reeds. “Katheter— ” originally referred to an instrument that was inserted such as a plug. The word “katheter” in turn came from “kathiemai—καθíεμα ” meaning “to sit”. The ancient Greeks inserted a hollow metal tube through the urethra into the bladder to empty it and the tube came to be known as a “katheter”.
[0005] Prior catheters were used only for single functions, such as removing human remains and enlarging an area inside the human body. The single functioning catheters require that medical personnel remove one catheter and insert another catheter into the patient when multiple functions are required to be performed on the patient. This removal and insertion process creates much discomfort to the patient, because the removal of one catheter and insertion of another catheter creates pain. Also, when multiple catheters need to be inserted into a patient, each catheter is inserted into the patient. However, the catheter's excessive length can cause confusion and the medical personnel may perform a function on the wrong catheter.
[0006] Thus, the need exists to have a catheter that can provide multiple functions and which is less traumatic than current procedures involving insertion and removal. The present invention meets that need without the risk of causing damage or producing pain.
SUMMARY OF THE INVENTION
[0007] According to one general aspect, there is a medical device including a locking mechanism that is used to connect a plurality of catheters, a multi-balloon inflator that inflates multiple balloons on a single catheter, an extraction point used to remove bodily fluids, e.g. human fluids from the human body, and a connecting point that allows a syringe or a machine to insert air or a liquid, such as a liquid saline solution, or to insert radioactive isotopes into the multi-balloon inflator. Also, a multi-balloon catheter for medical applications is provided that includes a multi-balloon inflator that inflates multiple balloons on a single catheter, an extraction point used to remove human fluids from the human body, and a connecting point that allows a syringe or a machine to insert air or any other liquid, such as a liquid saline solution, for inflation of a corresponding balloon of the multiple balloons. By allowing each balloon to have its respective connection, an advantage of such connection is that it will allow medical personnel to control the size of each balloon independently. Further, by having multiple balloons on a single catheter the shape of each balloon can be changed relative to the location of the catheter in the human body to allow for a proper fixture, such as in a body cavity.
[0008] The medical device that contains the locking mechanism can be affixed to any male or female connection attached to any type of catheter.
[0009] The medical device of the multi-balloon catheter that contains the multi-balloon inflator is connected to each individual connecting point to allow a volume for inflation.
[0010] The medical device that contains the said locking mechanism when affixed to another catheter creates a vacuum seal that does not allow the fluids or any air to pass through any said connecting point.
[0011] The medical device that contains the extraction point contains an inner seal within the opening that only allows for a single direction flow for only removal of fluids which does not allow for fluids to be inserted into the human body.
[0012] The medical device that contains the extraction point is large enough to contain a measuring device used to measure the amount of dose radiated to human tissue while said extraction point is removing fluids from the human body.
[0013] The medical device contains a multi-balloon inflator that includes a plurality of connections, wherein at least one connection of the multi-balloon inflator contains radioactive isotopes while the remaining one or more connections of the multi-balloon inflator contain air or any other liquid, such as a liquid saline solution, for inflation of the corresponding balloon.
[0014] The medical device that contains a plurality of catheters can be inserted into both the rectum and the urethra with a plurality of measuring devices to take dose measurements while applying dose therapy through the multi-balloon inflator.
[0015] According to another general aspect, there is a method of operating a multi-functional catheter, wherein said method comprises connecting a plurality of catheters, inflating multiple balloons on a single catheter, removing human fluids from the human body, and pumping liquid saline solution or radioactive isotopes into said multi-balloon inflator.
[0016] The connecting includes affixing any male or female connection to the catheter.
[0017] The inflating is provided to each individual connecting point to allow the volume for inflation.
[0018] The affixing to another catheter creates a vacuum seal that does not allow the fluids or any air to pass through any said connecting point.
[0019] The removing fluids by an inner seal within the opening that only allows for a single direction flow for only removal of fluids which does not allow for fluids to be inserted into the human body.
[0020] The removing includes a measuring device used to measure the amount of dose radiated to human tissue while the extraction point is removing bodily fluids, such as from the human body.
[0021] The radiating includes providing by a multi-balloon inflator through a corresponding connection radioactive isotopes, while the other one or more of the connections of the multi-balloon inflator contains air or any other liquid, such as a liquid saline solution, for inflation of the corresponding balloon on a medical device that contains a multi-balloon inflator having a plurality of connections.
[0022] A plurality of said medical devices can be inserted into both the rectum and urethra with a plurality of said measuring devices take dose measurements while applying dose therapy through said multi-balloon inflator.
DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an illustration of a first position rectum balloon attached to a rectum catheter and a first position urethra catheter balloon attached to a urethra catheter.
[0024] FIG. 2 is an illustration of a rectum catheter including a first position rectum balloon and a measuring device, such as a metal-oxide-semiconductor field-effect transistor (MOSFET), attached to a urethra catheter that includes a measuring device and a first position urethra catheter balloon.
[0025] FIG. 3 is an illustration of a rectum catheter including a first position rectum balloon and a second position rectum balloon attached to a urethra catheter that includes a first position urethra catheter balloon.
[0026] FIG. 4 is an illustration of a rectum catheter including a first position rectum balloon, a second position rectum balloon and a measuring device, such as a metal-oxide-semiconductor field-effect transistor (MOSFET), attached to a urethra catheter that includes a measuring device and a first position urethra catheter balloon.
[0027] FIG. 5A is an illustration of a rectum catheter including a first position rectum balloon, a second position radiation balloon and a third position rectum balloon attached to a urethra catheter that includes a first position urethra catheter balloon. FIG. 5B is a sectional view of the rectum catheter 1 - 11 taken at the section A-A of FIG. 5A .
[0028] FIG. 6A is an illustration of a rectum catheter including a first position rectum balloon, a second position radiation balloon, a third position rectum balloon and a measuring device, such as a metal-oxide-semiconductor field-effect transistor (MOSFET), attached to a urethra catheter that includes a measuring device and a first position urethra catheter balloon. FIG. 6B is a sectional view of the rectum catheter 1 - 11 taken at the section A-A of FIG. 6A .
[0029] FIG. 7 is an illustration of a first position rectum balloon and a second position rectum balloon in the human body and a first position urethra catheter balloon in the human body.
[0030] FIG. 8 is an illustration of a rectum catheter including a first position rectum balloon and a second position rectum balloon attached to a urethra catheter that includes a first position urethra catheter balloon.
[0031] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.
DETAILED DESCRIPTION
[0032] The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses and/or systems described herein. Accordingly, various changes, modifications, and equivalents of the systems, apparatuses, and/or methods described herein will likely suggest themselves to those of ordinary skill in the art. Also, descriptions of well-known functions and constructions are omitted to increase clarity and conciseness.
[0033] FIG. 1 shows an exemplary medical device including a rectum catheter 1 - 11 that includes a first position rectum balloon 1 - 2 , as well as a balloon inflator 1 - 20 having connections 1 - 7 and 1 - 8 ; the rectum catheter 1 - 11 being attached to a urethra catheter 1 - 10 , the urethra catheter 1 - 10 including a urethra catheter balloon 1 - 1 , as well as a balloon inflator 1 - 30 having connections 1 - 5 and 1 - 6 . The rectum catheter 1 - 11 that includes the rectum balloon 1 - 2 has multiple uses and features. The rectum balloon 1 - 2 can be used to deliver radiation, such as by radioactive isotopes that can be inserted via the connection 1 - 7 , and a measuring device, e.g., a sensor, (not shown in FIG. 1 ), as can be associated with the rectum catheter 1 - 11 or with the urethra catheter 1 - 10 , that can simultaneously measure the radiation that is being delivered to the abnormal growth and a connection of the rectum catheter 1 - 11 can remove bodily fluids, e.g., human waste. The rectum catheter 1 - 11 has a female or a male connection 1 - 8 of a balloon inflator 1 - 20 that is used to insert any form of a sensor for dose measurement and simultaneously remove human waste by an extraction opening 1 - 12 in the rectum catheter 1 - 11 . The extraction opening 1 - 12 contains an inner seal 1 - 17 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the rectum. The human waste removed travels through a tube 1 - 3 that is associated with the male or female connection 1 - 8 . Furthermore, the rectum catheter 1 - 11 has a luer lock connection 1 - 7 of the balloon inflator 1 - 20 that is used to inflate the rectum balloon 1 - 2 to a predetermined size. The balloon inflation of the rectum balloon 1 - 2 may be used as a locking mechanism for the rectum catheter 1 - 11 in the patient or can be used to push internal organs in a certain direction. The rectum catheter 1 - 11 may be attached by a locking mechanism 1 - 9 to the urethra catheter 1 - 10 . The locking mechanism 1 - 9 may be attached by either a male or a female connection, and the locking mechanism 1 - 9 is associated with the balloon inflator 1 - 20 and the balloon inflator 1 - 30 . The locking mechanism 1 - 9 allows for medical personnel to have an easier control of the rectum catheter 1 - 11 and the urethra catheter 1 - 10 to provide delivery and extraction guidance for the catheters within a single area. The urethra catheter 1 - 10 has a urine or bodily fluid extraction opening 1 - 4 that communicates with a tube 1 - 15 that is used to remove fluids in the bladder that are taken out by an extraction opening connection 1 - 5 of the balloon inflator 1 - 30 and by the associated tube 1 - 15 . The extraction opening 1 - 4 contains an inner seal 1 - 18 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the bladder. Furthermore, a measuring device (not shown in FIG. 1 ) may be inserted into the extraction opening connection 1 - 5 and into the tube 1 - 15 while removing the urine or bodily fluid. The advantage allows for simultaneously measuring a dose and removing urine by the urethra catheter 1 - 10 . The urethra catheter balloon 1 - 1 is an inflatable balloon. The balloon inflation can be performed via a male or a female luer lock connection 1 - 6 of the balloon inflator 1 - 30 of the urethra catheter 1 - 10 . Further drawings will show modifications to both the urethra catheter 1 - 11 and the rectum catheter 1 - 10 .
[0034] FIG. 2 shows an exemplary medical device, similar to that shown in FIG. 1 , including a rectum catheter 1 - 11 attached to a urethra catheter 1 - 10 . Upon further review, the rectum catheter 1 - 11 allows for a measuring device 2 - 1 for dose measurement, such as a metal-oxide-semiconductor field-effect transistor (MOSFET), to be inserted into a center valve of a connection 1 - 8 of a balloon inflator 1 - 20 of the rectum catheter 1 - 11 . The rectum catheter 1 - 11 may be attached by a locking mechanism 1 - 9 to the urethra catheter 1 - 10 , as described. The advantage for inserting the measuring device 2 - 1 will allow medical personnel to measure the dose simultaneously while delivering the radiation to the tumor region. Furthermore, a second measuring device 2 - 2 may be inserted into the urethra catheter 1 - 10 through an extraction opening connection 1 - 5 of a balloon inflator 1 - 30 and into an associated tube 1 - 15 of the extraction opening connection 1 - 5 . Inflating the rectum balloon 1 - 2 allows for determining the organ region and for providing a fixing or locking mechanism. The inflating rectum balloon 1 - 2 on the rectum catheter 1 - 11 can also be filled with a radioactive material, e.g., radioactive isotopes, via the connection 1 - 7 of the balloon inflator 1 - 20 that delivers dose while being measured by the measuring device 2 - 1 . This is a big advantage since the dose can be measured and the volume of radioactive isotopes can be reduced depending on the inflating size of the inflating rectum balloon 1 - 2 . Next, the second measuring device 2 - 2 can also be inserted into the urethra catheter 1 - 10 through the extraction opening connection 1 - 5 of the balloon inflator 1 - 30 into the associated tube 1 - 15 and, along with the measuring device 2 - 1 in the rectum catheter 1 - 11 , can allow medical personnel to measure the dose from two different locations at the same time. Also, as described, the urethra catheter 1 - 10 has a urine extraction opening 1 - 4 that communicates with the tube 1 - 15 and is used to remove fluids in the bladder that are taken out by the extraction opening connection 1 - 5 of the balloon inflator 1 - 30 and by the associated tube 1 - 15 . The extraction opening 1 - 4 contains an inner seal 1 - 18 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the bladder. The rectum catheter 1 - 11 has a female or a male connection 1 - 8 of a balloon inflator 1 - 20 , that can be used to insert any form of a sensor for dose measurement and simultaneously remove human waste by an extraction opening 1 - 12 in the rectum catheter 1 - 11 . The extraction opening 1 - 12 contains an inner seal 1 - 17 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the rectum. The human waste removed travels through a tube 1 - 3 associated with the male or female connection 1 - 8 .
[0035] FIG. 3 shows an exemplary medical device that includes a rectum catheter 1 - 11 attached to a urethra catheter 1 - 10 . The rectum catheter 1 - 11 includes a first position rectum balloon 1 - 2 and second position rectum balloon 4 - 1 , as well as a balloon inflator 1 - 20 , as a multi-balloon inflator, having connections 1 - 7 , 1 - 8 and 4 - 2 ; and the urethra catheter 1 - 10 includes a first position urethra catheter balloon 1 - 1 , as well as a balloon inflator 1 - 30 having connections 1 - 5 and 1 - 6 . The rectum catheter 1 - 11 may be attached by a locking mechanism 1 - 9 to the urethra catheter 1 - 10 , as described. The rectum catheter 1 - 11 contains two balloons, which allows for the first position rectum balloon 1 - 2 to be used for fixing or locking. The second position rectum balloon 4 - 1 can be filled with a radioactive material, e.g. radioactive isotopes, via the connection 4 - 2 . The second position rectum balloon 4 - 1 can deliver the radiation after the first position rectum balloon 1 - 2 has been inflated via the connection 1 - 7 . Another advantage for double inflatable balloons can be the first position rectum balloon 1 - 2 can be used to move sensitive organs out of the region, and the second position rectum balloon 4 - 1 can deliver the dose. Each balloon has the ability to be filled up via its male or female connection. Specifically, the second position rectum balloon 4 - 1 is enlarged via the male/female connection 4 - 2 ; and, the first position rectum balloon 1 - 2 is enlarged via the male/female connection 1 - 7 . By allowing each balloon to have its respective connection, an advantage of such connection is that it will allow medical personnel to control the size of each balloon independently. Also, as described, the urethra catheter 1 - 10 has a urine or bodily fluid extraction opening 1 - 4 that communicates with a tube 1 - 15 that is used to remove fluids in the bladder that are taken out by an extraction opening connection 1 - 5 of the balloon inflator 1 - 30 and the associated tube 1 - 15 . The extraction opening 1 - 4 contains an inner seal 1 - 18 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the bladder. The rectum catheter 1 - 11 has the female or a male connection 1 - 8 of the balloon inflator 1 - 20 , that can be used to insert any form of a sensor for dose measurement and while removing human waste by an extraction opening 1 - 12 in the rectum catheter 1 - 11 . The extraction opening 1 - 12 contains an inner seal 1 - 17 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the rectum. The human waste removed travels through a tube 1 - 3 associated with the male or female connection 1 - 8 .
[0036] FIG. 4 shows an exemplary medical device, similar to that shown in FIG. 3 , that includes a rectum catheter 1 - 11 attached to a urethra catheter 1 - 10 . The rectum catheter 1 - 11 includes a first position rectum balloon 1 - 2 and a second position rectum balloon 4 - 1 , as well as a balloon inflator 1 - 20 , as a multi-balloon inflator, having connections 1 - 7 , 1 - 8 and 4 - 2 ; and the urethra catheter 1 - 10 includes a first position urethra catheter balloon 1 - 1 , as well as a balloon inflator 1 - 30 having connections 1 - 5 and 1 - 6 . The rectum catheter 1 - 11 may be attached by a locking mechanism 1 - 9 to the urethra catheter 1 - 10 , as described. The rectum catheter 1 - 11 contains two balloons. The second position rectum balloon 4 - 1 contains radioactive isotopes, provided via the connection 4 - 2 , while the first position rectum balloon 1 - 2 can contain air or liquid, such as a liquid saline solution, to fill the balloon via the connection 1 - 7 . The rectum catheter 1 - 11 contains a measuring device 5 - 1 for dose measurement, as can be inserted through the connection 1 - 8 of a balloon inflator 1 - 20 , similar to that previously described, that allows for measuring the dose that is applied to the patient. Next, a measuring device 5 - 2 for dose measurement, similar to that previously described, can also be inserted through an extraction opening connection 1 - 5 of a balloon inflator 1 - 30 and into an associated tube 1 - 15 of the urethra catheter 1 - 10 , and along with the measuring device 5 - 1 , as can be inserted through an extraction opening connection 1 - 8 of the balloon inflator 1 - 20 in the rectum catheter 1 - 11 , can allow medical personnel to measure the dose from two different locations at the same time. Also, as described, the urethra catheter 1 - 10 has a urine or bodily fluid extraction opening 1 - 4 that is used to remove fluids in the bladder that are taken out by the extraction opening connection 1 - 5 of the balloon inflator 1 - 30 and into the associated tube 1 - 15 of the extraction opening connection 1 - 5 . The extraction opening 1 - 4 contains an inner seal 1 - 18 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the bladder. The rectum catheter 1 - 11 has the female or a male connection 1 - 8 of the balloon inflator 1 - 20 , that can be used to insert any form of a sensor for dose measurement and simultaneously remove human waste by an extraction opening 1 - 12 in the rectum catheter 1 - 11 . The extraction opening 1 - 12 contains an inner seal 1 - 17 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the rectum. The human waste removed travels through a tube 1 - 3 associated with the male or female connection 1 - 8 .
[0037] FIG. 5A shows an exemplary medical device, similar to those previously described, that includes a rectum catheter 1 - 11 attached to a urethra catheter 1 - 10 . The urethra catheter 1 - 10 includes a first position urethra catheter balloon 1 - 1 , as well as a balloon inflator 1 - 30 having connections 1 - 5 and 1 - 6 . The rectum catheter 1 - 11 includes a first position rectum balloon 1 - 2 , a second position radiation balloon 4 - 1 , a third position rectum balloon 7 - 1 and is attached to the urethra catheter 1 - 10 , as well as including a balloon inflator 1 - 20 , as a multi-balloon inflator 1 - 20 , having connections 1 - 7 , 1 - 8 , 7 - 3 and 4 - 2 . The rectum catheter 1 - 11 may be attached by a locking mechanism 1 - 9 to the urethra catheter 1 - 10 , as described. The rectum catheter 1 - 11 has three balloons 1 - 2 , 4 - 1 and 7 - 1 ; however, there can be any number of balloons, as can be spaced from each other on the catheter 1 - 11 , depending upon the length of the catheter 1 - 11 . The rectum catheter 1 - 11 has the second position radiation balloon 4 - 1 that contains radioactive isotopes, inserted via the connection 4 - 2 , while the first position rectum balloon 1 - 2 and the third position rectum balloon 7 - 1 may contain no dose delivery mechanism. The first position rectum balloon 1 - 2 can be inflated via the male/female connection 1 - 7 , and the second position rectum balloon 4 - 1 can be inflated via the male/female connection 4 - 2 . The third position rectum balloon 7 - 1 can be inflated via the male/female connection 7 - 3 . Referring to FIG. 5B , an A-A view 7 - 2 of the rectum catheter 1 - 11 provides a further illustration of when there are a plurality of balloons on a single catheter, such as the rectum catheter 1 - 11 . The A-A view 7 - 2 shows a cross-sectional view of the rectum catheter 1 - 11 and the respective tubes, or connections, 4 - 2 , 7 - 3 , 1 - 7 for inflating or deflating the respective balloons, as well as the connection 1 - 8 that communicates with an opening 1 - 12 . By having multiple balloons on a single catheter, the shape of each balloon can be changed relative to the location of the catheter, such as the rectum catheter 1 - 11 , in the human body to allow for a proper fixture. Also, as described, the urethra catheter 1 - 10 has a urine or bodily fluid extraction opening 1 - 4 associated with a tube 1 - 15 that is used to remove fluids in the bladder that are taken out by an extraction opening connection 1 - 5 of the balloon inflator 1 - 30 and the associated tube 1 - 15 . The extraction opening 1 - 4 contains an inner seal 1 - 18 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the bladder. The rectum catheter 1 - 11 has the female or a male connection 1 - 8 of a balloon inflator 1 - 20 , that can be used to insert any form of a sensor for dose measurement and simultaneously remove human waste by the opening 1 - 12 in the rectum catheter 1 - 11 . The extraction opening 1 - 12 contains an inner seal 1 - 17 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the rectum. The human waste removed travels through a tube 1 - 3 associated with the male or female connection 1 - 8 .
[0038] FIG. 6A shows an exemplary medical device, similar to that shown in FIG. 5A , that includes a rectum catheter 1 - 11 attached to a urethra catheter 1 - 10 , as well as a balloon inflator 1 - 20 , as a multi-balloon inflator, having connections 1 - 7 , 1 - 8 , 7 - 3 and 4 - 2 . The urethra catheter 1 - 10 includes a first position urethra catheter balloon 1 - 1 , as well as a balloon inflator 1 - 30 having connections 1 - 5 and 1 - 6 . The rectum catheter 1 - 11 may be attached by a locking mechanism 1 - 9 to the urethra catheter 1 - 10 , as described. The rectum catheter 1 - 11 includes a collapsed first position rectum balloon 1 - 2 as a collapsed balloon 8 - 1 as can be inflated via the connection 1 - 7 , a second position radiation balloon 4 - 1 as can be inflated or filled with a radioactive material, e.g. radioactive isotopes, via the connection 4 - 2 of the balloon inflator 1 - 20 , and a third position rectum balloon 7 - 1 as can be inflated via the connection 7 - 3 ; and the balloons 1 - 2 (the collapsed balloon 8 - 1 ), 4 - 1 and 7 - 1 can be spaced from each other along the length of the catheter 1 - 11 , such as illustrated in FIG. 6A . The collapsed balloon 8 - 1 allows for minimum expansion of the balloon, such as by inflation thereof via the connection 1 - 7 , to keep the human tissue from being moved into any direction. Furthermore, a measuring device 8 - 2 , similar to those previously described, can be inserted into an open section (tube) 1 - 3 associated with the connection 1 - 8 in the rectum catheter 1 - 11 of the balloon inflator 1 - 20 . The benefit for having multiple balloons allows the control of how much dose can be given. Next, a measuring device 8 - 3 , similar to those previously described, can also be inserted into the urethra catheter 1 - 10 through an extraction opening connection 1 - 5 of the balloon inflator 1 - 30 and into an associated tube 1 - 15 of the extraction opening connection 1 - 5 , along with a measuring device 8 - 2 , in the rectum catheter 1 - 11 to allow medical personnel to measure the dose from two different locations at the same time. Referring to FIG. 6B , an A-A view 7 - 2 of the rectum catheter 1 - 11 provides a further illustration of when a plurality of balloons are on a single catheter, such as the rectum catheter 1 - 11 . The A-A view 7 - 2 shows a cross-sectional view of the rectum catheter 1 - 11 and the respective tubes, or connections, 4 - 2 , 7 - 3 , 1 - 7 for inflating or deflating the respective balloons, as well as the connection 1 - 8 that communicates with an extraction opening 1 - 12 . By having multiple balloons on a single catheter, the shape of each balloon can be changed relative to the location of the catheter, such as the rectum catheter 1 - 11 , in the human body to allow for a proper fixture. The advantage for having multiple balloons allows medical personnel to have more control. Also, as described, the urethra catheter 1 - 10 has a urine or bodily fluid extraction opening 1 - 4 that is used to remove fluids in the bladder that are taken out by the extraction opening connection 1 - 5 of the balloon inflator 1 - 30 and by the associated tube 1 - 15 . The extraction opening 1 - 4 contains an inner seal 1 - 18 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the bladder. The rectum catheter 1 - 11 has the female or a male connection 1 - 8 of the balloon inflator 1 - 20 , that can be used to insert any form of a sensor for dose measurement and simultaneously remove human waste by the extraction opening 1 - 12 in the rectum catheter 1 - 11 . The extraction opening 1 - 12 contains an inner seal 1 - 17 that only allows for a single direction flow for removal of bodily fluids and does not allow for fluids to be inserted into a body cavity, such as the rectum. The human waste removed travels through a tube 1 - 3 associated with the male or female connection 1 - 8 .
[0039] FIG. 7 is an illustration of how both a urethra catheter 10 - 1 and a rectum catheter 10 - 6 are inserted into the human body. The urethra catheter 10 - 1 is inserted into the penis via the urethra. Thereafter, the medical personnel inflates a balloon 10 - 2 on the urethra catheter 10 - 1 . This will allow the surrounding tissue to expand and move out of the way to create space near the prostate 10 - 5 . Furthermore, the rectum catheter 10 - 6 can be inserted into the rectum of the patient. The rectum catheter 10 - 6 has a first position rectum balloon 10 - 3 and a second position rectum balloon 10 - 4 . Looking specifically at this illustration of FIG. 7 , but not limiting it to just the second position rectum balloon 10 - 4 , the second position rectum balloon 10 - 4 contains radioactive isotopes. This can be used to dose the prostate 10 - 5 , and the first position rectum balloon 10 - 3 can be used as a locking or fixing mechanism to the hold the rectum catheter 10 - 6 in place. Furthermore, a measuring device for dose measurement, similar to those previously described, can be inserted into both the urethra catheter 10 - 1 and the rectum catheter 10 - 6 .
[0040] FIG. 8 is another illustration of how both the urethra catheter 10 - 1 and the rectum catheter 10 - 6 are inserted into the human body. The urethra catheter 10 - 1 is inserted all the way into the male bladder and inflated with a balloon 11 - 1 . The inflation of the balloon 11 - 1 will not allow for the urethra catheter 10 - 1 to slip out of the bladder. Furthermore, the rectum catheter 10 - 6 has a first position rectum balloon 10 - 3 and a second position rectum balloon 10 - 4 . Looking specifically at this illustration of FIG. 8 , but not limiting it to just the second position rectum balloon 10 - 4 , the second position rectum balloon 10 - 4 contains radioactive isotopes. This second position rectum balloon 10 - 4 can be used to dose the prostate 10 - 5 , and the first position rectum balloon 10 - 3 can be used as a locking or fixing mechanism to hold the rectum catheter 10 - 6 in place. Furthermore, a measuring device for dose measurement, similar to those previously described, can be inserted into both the urethra catheter 10 - 1 and the rectum catheter 10 - 6 .
[0041] 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 fo 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.
[0042] Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims.
[0043] With this description, those skilled in the art may recognize other equivalents to the specific embodiments described herein. Such equivalents are intended to be encompassed by the claims attached hereto. | According to one general aspect, there is a multi-balloon catheter for medical applications that includes a multi-balloon inflator that inflates multiple balloons on a single catheter, an extraction point used to remove human fluids from the human body, and a connecting point that allows a syringe or a machine to insert air or any other liquid, such as a liquid saline solution, for inflation of a corresponding balloon of the multiple balloons or insert radioactive isotopes into the multi-balloon inflator. | 0 |
The present invention relates to a method for triggering a cleaning, ventilating, disinfecting or deodorizing process, as well as to an apparatus carrying out the method and to applications of the method.
BACKGROUND OF THE INVENTION
A self-cleaning toilet is known from the firm CWS International AG, Baar, having a toilet seat which rotates after actuation of water flushing system. In one version, the rotation is triggered by an electrical contact (microswitch; infrared sensor) connected to the actuating lever of the flushing tern. In the second version, the inflowing flushing water, or water mains system, drives a turbine which sets in motion, a generator, the drive motors for the cleaning and infection of the toilet seat.
Generally, the known arrangements have proved successful in practice. However, it has been found that problems relating to as of responsibility and competence in respect of tallation and maintenance arise, since the installation cannot be dealt with by the ordinary sanitary fitter. In addition, the fact that the control and drive unit of the apparatus is connected to the flushing cistern brings further advantages owing to the highly specific nature of the arrangement, such as unintentionally initiated operations, as well as a system-related susceptibility to faults.
Generic methods and devices are published in WO85/01560, in which there is arranged in close proximity to a water outlet, e.g. a shower, an acoustic sensor which, initiated by an acoustic signal, activates a solenoid valve and thus controls the water flow in a contactless manner. The resultant signal voltage is adjusted in an amplifier circuit and at a rectifier bridge using a so-called differentiating network and allows only a rudimentary adaptation to the local circumstances. This device is thus restricted to individual applications, as a plurality of water outlets equipped in the same way and located one beside the other would undergo mutual initiation and activation. Also, the reliability of the signal detection is inadequate and not sufficiently reproducible for numerous applications.
It is therefore the object of the invention to trigger a physical/technical procedure only when this is intended by the user or operator of the installation. Instances of triggering due to incomplete flushing and/or inflow procedures are also to be eliminated; the procedure to be triggered must take place in an operationally reliable manner. A plurality of adjacent inflow and/or flushing procedures must also be possible without these influencing one another.
Furthermore, the need for intervention in the rest of the apparatus region is to be obviated; the responsibility of the installation and maintenance staff must be able to be clearly laid down, without tasks which are foreign to their trade being assigned to them.
The subject of the invention is to allow further damp-room-related applications over and above the direct toilet use.
BRIEF DESCRIPTION OF THE INVENTION
This object is achieved by the method of the present invention wherein an acoustic sensor is arranged in close proximity to a flushing or inflow of a liquid. The output of the sensor activates a desired device. The location of the acoustic sensor in close proximity to the inflow of a liquid causes a first, spatial and selective differentiation in the event of a plurality of identical or similar sound sources being present. The method results in an improved differentiation of the triggering sound source from interfering sources which may be present.
The dimensioning of the filter and thus the method can be optimized by a spectral analysis.
The method of the invention may include a calibration step utilizing sequential signal values to derive an average for reference.
After the calibration, the activation of the physical/technical device can be reproducibly realized. In particular, this allows incomplete flushing and/or inflow procedures to be detected. Other inflow procedures which occur during use are also reliably detected as such, that is to say the device cannot be unintentionally activated.
A band filtering in accordance with the apparatus is particularly suitable for monitoring the flushing inflow into a toilet bowl. An active band filter in the range of 8+/-1 kHz can be realized outstandingly well and economically.
The use of an electret microphone is also particularly advantageous owing to its selective reception characteristic and its robust design.
The invention may be employed in connection with cleaning and disinfection of a toilet seat, and prevents triggering of a cleaning procedure on the toilet seat at the wrong time. In addition, there results the great practical advantage of the cleaning and disinfection being completely independent of the rest of the sanitary installation and thus of a clear separation of fields, between sanitary fitter and equipment supplier or equipment technician, in respect of the fitting and also maintenance of the devices being ensured.
The control of an extractor in a toilet and/or in the toilet room allows ventilation which is favourable in terms of energy, and prevents unpleasant draughts.
Deodorant procedures can also be triggered when these are necessary, i.e. instances of inappropriate and material-consuming regular triggering associated with ordinary door actuations can be eliminated.
Applications can be used to reduce the water consumption; moreover, they allow the inclusion of further cleaning procedures associated with the use, for example, of a public toilet.
Devices which are additionally present can also be disabled. and/or activated in order to allow, for example, their use only in conjunction with a controlled toilet use.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the subject of the invention are described in more detail below with reference to drawings, in which:
FIG. 1 shows a block diagram of an electronic circuit for carrying out the method;
FIG. 2 shows the flow diagram relating to a program which allows calibration and adaptation of the acoustic sensor and the evaluation circuit to the characteristic of the sound source;
FIG. 3 shows the signal detection sequence for triggering a proper toilet seat cleaning cycle; and
FIG. 4 shows a simplified representation of a toilet with cleaning and disinfecting apparatus and a targeted extraction of unpleasant odours at the place where they arise.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method for triggering a cleaning, ventilating, disinfecting or deodorizing process as well as to an apparatus for carrying out the method and to applications of the method.
BACKGROUND OF THE INVENTION
A self-cleaning toilet is known from the firm CWS International AG, Baar, having a toilet seat which rotates after actuation of the water flushing system. In one version, the rotation is triggered by an electrical contact (microswitch; infrared sensor) connected to the actuating lever of the flushing cistern. In the second version, the inflowing flushing water, or the water mains system, drives a turbine which sets in motion, via a generator, the drive motors for the cleaning and disinfection of the toilet seat.
Generally, the known arrangements have proved successful in practice. However, it has been found that problems relating to areas of responsibility and competence in respect of installation and maintenance arise, since the installation cannot be dealt with by the ordinary sanitary fitter. In addition, the fact that the control and drive unit of the apparatus is connected to the flushing cistern brings further disadvantages owing to the highly specific nature of the arrangement, such as unintentionally initiated operations, as well as a system-related susceptibility to faults.
Generic methods and devices are published in WO85/01560, in which there is arranged in close proximity to a water outlet, e.g. a shower, an acoustic sensor which, initiated by an acoustic signal, activates a solenoid valve and thus controls the water flow in a contactless manner. The resultant signal voltage is adjusted in an amplifier circuit and at a rectifier bridge using a so-called differentiating network and allows only a rudimentary adaptation to the local circumstances. This device is thus restricted to individual applications, as a plurality of water outlets equipped in the same way and located one beside the other would undergo mutual initiation and activation. Also, the reliability of the signal detection is inadequate and not sufficiently reproducible for numerous applications.
It is therefore the object of the invention to trigger a physical/technical procedure only when this is intended by the user or operator of the installation. Instances of triggering due to incomplete flushing and/or inflow procedures are also to be eliminated; the procedure to be triggered must take place in an operationally reliable manner. A plurality of adjacent inflow and/or flushing procedures must also be possible without these influencing one another.
Furthermore, the need for intervention in the rest of the apparatus region is to be obviated; the responsibility of the installation and maintenance staff must be able to be clearly laid down, without tasks which are foreign to their trade being assigned to them.
The subject of the invention is to allow further damp-room-related applications over and above the direct toilet use.
BRIEF DESCRIPTION OF THE INVENTION
This object is achieved by the method of the present invention wherein an acoustic sensor is arranged in close proximity to a flushing or inflow of a liquid. The output of the sensor activated a design device. The location of the acoustic sensor in close proximity to the inflow of a liquid causes a first, spatial and selective differentiation in the event of a plurality of identical or similar sound sources being present. The method results in an improved differentiation of the triggering sound source from interfering sources which may be present.
The dimensioning of the filter and thus the method can be optimized by a spectral analysis.
The method of the invention may included a calibration step utilizing sequential signal values to derive an average for reference. After the calibration, the activation of the physical/technical device can be reproducibly realized.
The control of an extractor in a toilet and/or in the toilet room allows ventilation which is favourable in terms of energy, and prevents unpleasant draughts.
Deodorant procedures can also be triggered when these are necessary, i.e. instances of inappropriate and material-consuming regular triggering associated with ordinary door actuations can be eliminated.
Applications can be used to reduce the water consumption; moreover, they allow the inclusion of further cleaning procedures associated with the use, for example, of a public toilet.
Devices which are additionally present can also be disabled and/or activated in order to allow, for example, their use only in conjunction with a controlled toilet use.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the subject of the invention are described in more detail below with reference to drawings, in which:
FIG. 1 shows a block digram of an electronic circuit for carrying out the method;
In particular, this allows incomplete flushing and/or inflow procedures to be detected. Other inflow procedures which occur during use are also reliably detected as such, that is to say the device cannot be unintentionally activated.
A band filtering in accordance with the apparatus is particularly suitable for monitoring the flushing inflow into a toilet bowl. An active band filter can be realized outstandingly well and economically.
The use of an electret microphone is also particularly advantageous owing to its selective reception characteristic and its robust design.
The invention may be employed in connection with cleaning and disinfection of a toilet seat, and prevents triggering of a cleaning procedure on a toilet seat at the wrong time. In addition, there results the great practical advantage of the cleaning and disinfection being completely independent of the rest of the sanitary installation and thus of a clear separation of fields, between sanitary fitter and equipment supplier or equipment technician, in respect of the fitting and also maintenance of the devices being ensured.
FIG. 2 shows the flow diagram relating to a program which allows calibration and adaptation of the acoustic sensor and the evaluation circuit to the characteristic of the sound source;
FIG. 3 shows the signal detection sequence for triggering a proper toilet seat cleaning cycle; and
FIG. 4 shows a simplified representation of a toilet with cleaning and disinfecting apparatus and a targeted extraction of unpleasant odours at the place where they arise.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a commercially available quad amplifier is denoted by A100. This amplifier comprises series-connected operational amplifiers A1 to A4 which are operated or fed back in the customary fashion according to their function.
The series of amplifiers thus comprises a single four-stage wide-band operational amplifier A100; one of the type LM 837N (National Semiconductors, USA) has proved successful.
This operational amplifier A100 is fed an input signal e, the frequency-selective output signal from an acoustic sensor; the amplified and demodulated control signal is denoted by S. The characteristic earthing of the amplifier A100 is necessary for electrical and safety reasons. | This invention concerns a process for actuating a physical/technical process, particularly in toilette facilities, which employs a sound sensor (M) with signal analysis which is located in close proximity to a liquid inlet (8). In a device for automatic cleaning of toilette seats (4), the sensor (M) is built in next to the flushing water inlet. The flushing noises are selected using a signal analysis circuit and cleaning of the seat (4) and evacuation of odors (G) via a ventilator (15) is only triggered if the flushing process has been clearly detected. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. provisional patent application Ser. No. 60/620,149, filed on Oct. 18, 2004, which is hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to audio signal processing, and in particular, relates to a system that includes a Class D amplifier for audio signal amplification and other audio signal processing.
BACKGROUND INFORMATION
[0003] Class-D audio amplifiers are often used for audio amplification because of their power efficiency. Typically, the Class D audio amplifier is operated in the switch mode with minimized internal power consumption. It produces a rectangular wave at the output stage that is filtered before delivered to a load. The filtered signal wave is an amplified version of the input signal wave. Class D audio amplifiers are usually used for high power applications. For low power applications, Class A/B amplifiers are still popular.
[0004] When the input audio signal exceeds the audio amplifier's linear range, the output of the amplifier saturates. Oscillations at the audible band are often observed when the amplifier enters the saturation condition and exits the saturation condition, as indicated in FIG. 6 . This may result in the “clipping” of audible noises. This problem is more severe in the class D audio amplifier because the switching power supply can skip switching cycles due to the minimum on and off time constraints. If the power supply skips sufficient cycles, the effective operation frequency may enter the audible frequency range and induce unexpected audible noises.
[0005] There are several known methods to resolve the problem. The first method is to limit the amplitude of the input signal with a clamping circuit. However, without information on the audio source's output impedance, this may not be practical and can degrade the audio signal quality. The second method is to add an automatic gain control (AGC) pre-amplifier before the input of the class-D audio amplifier. This AGC pre-amplifier limits the input signal amplitude to prevent the output saturation, but the implementation is rather complex and adds a significant cost. The limitation may get more severe for low frequency audio signals. The third method is to add a high-pass filter to limit the minimum audio frequency passing into the class-D amplifier, but may not solve the problem completely.
[0006] Accordingly, more improvements are needed to reduce audio noise near saturation in the class D audio amplifier.
SUMMARY
[0007] The following embodiments and aspects are illustrated in conjunction with systems, circuits, and methods that are meant to be exemplary and illustrative. In various embodiments, the above problem has been reduced or eliminated, while other embodiments are directed to other improvements.
[0008] A method introduces a noise reduction feedback network. The noise reduction feedback network is coupled to an output stage and a control stage of an audio amplifier. It includes a detect circuit and a modulation circuit. The detect circuit is coupled to the output stage to monitor output voltages, detect output voltages near saturation states, and produce a control signal or multiple control signals to the modulation circuit. Once output voltages are near saturation state, the modulation circuit produces adjustable currents to the control stage to modulate output signal(s) and remove audible oscillations near saturation.
[0009] In a non-limiting embodiment, the detect circuit may include two back-to-back transistors or two back-to-back “Zener” diodes being coupled to the output stage. The two transistors are activated once the output voltages are in the near saturation states. Adjustable signals are produced by the modulation circuit according to the output voltages when two transistors are activated. These adjustable signals feed back to the control stage. The sinusoidal output waveforms become more “curved” rather than being clipped in near saturation region.
[0010] In another non-limiting embodiment, the detect circuit may include a transistor coupled between a supply voltage, Vcc, and the output stage, and a second transistor coupled between the ground and the output stage. Both transistors are activated as long as the output voltage is not in a near saturation state. The first transistor becomes deactivated once the output voltage is near the Vcc region and the second transistor becomes deactivated once the output voltage is near the ground voltage region. The first transistor is also coupled to a third transistor in the current circuit. These two transistors are such coupled that the third transistor is only activated once the first transistor is deactivated and becomes deactivated once the first transistor is activated. The second transistor is also coupled to a fourth transistor in the current circuit. These two transistors are such coupled that the fourth transistor is only activated once the second transistor is deactivated and becomes deactivated once the second transistor is activated. If the output voltage is near saturation state, either the third transistor or the fourth transistor in the current circuit produces an adjustable current to the control stage to modulate the output signals.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The following figures illustrate embodiments of the invention. These figures and embodiments provide examples of the invention and they are non-limiting and non-exhaustive.
[0012] FIG. 1 is a circuit schematic showing embodiments of a system having a Class D amplifier and other components that are useable for audio signal amplification and other audio signal processing.
[0013] FIG. 2 is an example of the invention in a bridge tied load (BTL) Class D amplifier.
[0014] FIG. 3 shows output waveforms with and without the invention in the BTL Class D amplifier.
[0015] FIG. 4 is a circuit block diagram showing embodiments of a system having an audio amplifier and other components that are useable for audio signal amplification and other audio signal processing.
[0016] FIG. 5 is another example of a noise reduction feedback network.
[0017] FIG. 6 shows a waveform with “clipping” audible noise in an amplifier without the present invention.
DETAILED DESCRIPTION
[0018] Embodiments of a system and method that uses an audio amplifier and accompanying circuitry to achieve low noise audio signal amplification and other audio signal processes are described in detail herein. In the following description, some specific details, such as example circuits and example values for these circuit components, are included to provide a thorough understanding of embodiments of the invention. One skilled in relevant art will recognize, however, that the invention can be practiced without one or more specific details, or with other methods, components, materials, etc.
[0019] The present invention relates to circuits and methods of producing low noise amplified audio signals. Proposed circuits in an audio amplifier can monitor output signals, detect output signals near saturation state, and produce an adjustable current to a control stage of the amplifier to modulate output signals and remove oscillation near saturation.
[0020] FIG. 1 is an embodiment of a system according to the invention. The system comprises a control stage, A, an output stage, O, and a noise reduction feedback network, Y.
[0021] An input signal, Vin, is coupled to an input node, X 1 , through a capacitor, Cin 1 , and a resistor, Rin 1 . Another input node, X 2 , is coupled to ground through a resistor, Rin 2 , and a capacitor, Cin 2 . The nodes, X 1 and X 2 , are coupled together by a capacitor, C 2 . The signals at the node, X 1 , comprise three components: AC portions of Vin, a feedback signal from the node, S 1 , and a feedback signal from the upper portion of a noise reduction feedback network, Y. The signals at the node, X 2 , comprise three components: a portion of signal from X 1 coupled through C 2 , a feedback signal from the node, S 2 , and a feedback signal from the lower portion of the noise reduction feedback network, Y.
[0022] The control stage A includes 4 transistors, M 1 , M 2 , M 3 , and M 4 , that serve as power output switching devices. M 1 and M 2 drive output switching node, S 1 ; while M 3 and M 4 drive output switching node, S 2 . In the upper half of the control stage A, M 2 's source terminal is coupled to ground and M 1 's drain terminal is coupled to a power supply, Vcc. M 2 's drain terminal and M 1 's source terminal are both coupled to the switching node S 1 . The node S 1 is coupled to the input node, X 1 , through a resistor, Rfb 1 . In the lower half of the control stage A, M 4 's source terminal is coupled to ground and M 3 's drain terminal is coupled to the power supply, Vcc. M 4 's drain terminal and M 3 's source terminal are both coupled to the switching node S 2 . The node S 2 is coupled to the input node, X 2 , through a resistor, Rfb 2 .
[0023] The noise reduction feedback network comprises adjustable current sources (I 1 and I 2 ), and a control circuit triggered by the output signal difference between V+ and V−, Vd. The control circuit is in an “OFF” state unless Vd exceeds a preset voltage level. The adjustable current sources are controlled by the control circuit. When current sources are turned on by the control circuit, extra current flows to the input nodes, X 1 , and X 2 . This extra current sets the minimum switching frequencies of two comparators, CMP 1 and CMP 2 , in the control stage A. The input node, X 1 , is a negative summing node for the comparator, CMP 1 , and it is a positive summing node for the comparator, CMP 2 . The input node, X 2 , is a positive summing node for the comparator, CMP 1 , and it is a negative summing node for the comparator, CMP 2 . The output signal of CMP 1 provides an input signal of a logic gate driver, LDR 1 . An output of LDR 1 , LDR 11 , drives the gate of the transistor, M 1 . Another output of LDR 1 , LDR 12 , drives the gate of the transistor, M 2 . The output signal of CMP 2 provides an input signal of a logic gate driver, LDR 2 . An output of LDR 2 , LDR 21 , drives the gate of the transistor, M 3 . Another output of LDR 2 , LDR 22 , drives the gate of the transistor, M 4 .
[0024] In output stage, O, a rectangular waveform at the node S 1 is filtered by an inductor, LL 1 , and a capacitor, Cout 1 , which is coupled to ground, and then delivered to an output node, V+. A rectangular waveform at the node S 2 is filtered by an inductor, LL 2 , and a capacitor, Cout 2 , which is coupled to ground, and then delivered to an output node, V−. The output stage O is used to drive a load, such as a loudspeaker, SP. A capacitor, C 3 , is connected in parallel with SP and coupled between V+ and V−.
[0025] An example of one embodiment of the present invention used in a bridge tied load (BTL) Class D amplifier is shown FIG. 2 . The system comprises a class D amplifier circuit AA, an output stage, OO, and a noise reduction feedback network, YY.
[0026] An input signal is coupled to a node XX 1 through a capacitor, C 6 , and a resistor R 3 . Ground is coupled to a node XX 2 through a capacitor, C 28 , and a resistor R 6 . The capacitor, C 6 , is introduced to block DC components of input signal. XX 1 and XX 2 , are coupled by a capacitor, C 12 . The signal at a node SW 1 is fed back to XX 1 through a resistor, R 10 , a grounded capacitor, C 17 , and a resistor, R 11 . The signal at a node SW 2 is fed back to XX 2 through a resistor, R 18 , connected to a grounded capacitor, C 16 , and through a resistor, R 19 .
[0027] The rectangular waveform at SW 1 is filtered by an inductor, L 1 , and a capacitor, C 7 , and then delivered to an output node OUT 1 +. The rectangular waveform at SW 2 is filtered by an inductor, L 2 , and a capacitor, C 22 , and then delivered to an output node OUT 1 −. The stage OO further includes a loudspeaker, SP 1 :A, and a capacitor, C 9 , connected in parallel with SP 1 :A and coupled between OUT 1 + and OUT 1 −. C 9 filters high frequency noise between nodes OUT 1 + and OUT 1 −.
[0028] The noise reduction feedback network YY connects the output node, OUT 1 + and OUT 1 −, and the input nodes, XX 1 and XX 2 . A node, T 1 , is connected with OUT 1 + through a resistor, R 30 . A node, T 2 , is connected with OUT 1 − through a resistor, R 31 . The node T 1 is connected with the node T 2 through a resistor R 29 . The combination of R 29 , R 30 , and R 31 helps to define adjustable currents of the circuit YY in the discussion below.
[0029] The node T 1 is also connected to the node T 2 through a resistor, R 12 , two back-to-back transistors Q 11 and Q 12 , and a resistor, R 15 . In the upper half of the circuit YY, the emitters and collectors of transistors Q 11 and Q 12 are all connected. The base of the transistor Q 11 is connected to the bases of a transistor Q 7 , and a transistor Q 8 . The emitters of the transistor Q 7 and the transistor Q 8 are connected and further connected to the node T 1 through a resistor R 36 . The collector of the transistor Q 7 is connected to the node X 1 through a diode, D 22 , and a resistor R 22 ; and the collector of the transistor Q 8 is connected to the node X 1 through a diode, D 21 , and the resistor R 22 . In the lower half of the circuit YY, the base of the transistor Q 12 is connected to the bases of a transistor Q 9 , and a transistor Q 10 . The emitters of the transistor Q 7 and the transistor Q 8 are connected and further connected to the node T 2 through a resistor R 37 . The collector of the transistor Q 9 is connected to the node XX 2 through a diode, D 23 , and a resistor R 24 ; and the collector of the transistor Q 10 is connected to the node X 2 through a diode, D 24 , and the resistor R 24 .
[0030] The back-to-back transistors, Q 11 and Q 12 , have a minimum turn-on voltage, V 1 . The transistors, Q 7 , Q 8 , Q 9 , and Q 10 , typically have a turn-on voltage V 2 . In the conditions, the voltage difference, Vd, between the node OUT 1 + and the node OUT 1 − exceeds V 1 . The transistors, Q 11 and Q 12 are turned on. Once |Vd| exceeds V 1 +2V 2 , either Q 7 or Q 8 is turned on in the upper half of circuit YY. The current feeds back to the node XX 1 through either D 22 or D 21 and the resistor, R 22 . The extra current increases the voltage switching frequency at the node XX 1 and defines a minimum switching frequency for the top comparator in the upper half of YY. The increased minimum frequency produces a more “curved” sinusoidal waveform in the near “clipping” range. This helps to eliminate the audio noises when output sinusoidal waves enter and exit the voltage “clipping” range. A similar analysis applies to the lower half of circuit YY. Once |Vd| exceeds V 1 +2V 2 , either Q 9 or Q 10 is turned on in the lower half of circuit YY. The current feeds back to the node XX 2 through either D 23 or D 24 and the resistor, R 24 . The extra current increases the voltage switching frequency at the node XX 2 and defines the minimum switching frequency for the lower comparator in the lower half of YY.
[0031] FIG. 3 illustrates output waveforms in the BTL Class D amplifier with and without the present invention. The BTL circuit without the noise reduction feedback network produces low frequency oscillation that may be in the audible frequency range; however; the circuit with the network produces clean output voltages without any low frequency oscillations.
[0032] The noise reduction feedback network is not limited to the example given above. It can be applied to any class D audio amplifier and other audio amplifiers. FIG. 4 provides schematic showing a system that comprises an audio input, a control stage, an output stage, and a noise reduction network that receives the feedback signals from the output stage. The noise reduction network modulates the control stage to eliminate the audible oscillation at the output stage when the output is near saturation.
[0033] Another example of embodiments of the invention is illustrated in FIG. 5 . Vout+ and Vout− are two input nodes of a noise reduction feedback network while FB 1 and FB 2 are two output nodes of the noise reduction network in FIG. 5 ( a ). FIGS. 5 ( b ) and 5 ( c ) are detailed schematics showing embodiments of the circuit. In FIG. 5 ( b ), Vout+ is connected to the base of a transistor, Q 3 , through a resistor, R 13 , and the base of a transistor, Q 4 , through a resistor, R 14 . The emitter of the transistor, Q 3 , is coupled to a power source, Vcc, and the emitter of the transistor, Q 4 , is coupled to the ground. The base of a transistor, Q 1 , is connected to the collector of the transistor, Q 3 , and they are coupled to the ground through a resistor, R 5 . The emitter of the transistor, Q 1 , is coupled to the power source, Vcc, through a resistor, R 1 ; while the collector of Q 1 is connected to a node FB 1 through a resistor, R 2 . The base of a transistor, Q 2 , is connected to the collector of the transistor, Q 4 , and they are coupled to the power source, Vcc, through a resistor, R 6 . The emitter of the transistor, Q 2 , is coupled to the ground through a resistor, R 4 ; while the collector of Q 2 is connected to the node FB 1 through a resistor, R 3 . In FIG. 5 ( c ), Vout− is connected to the base of a transistor, Q 7 , through a resistor, R 15 , and the base of a transistor, Q 8 , through a resistor, R 16 . The emitter of the transistor, Q 7 , is coupled to the power source, Vcc, and the emitter of the transistor, Q 8 , is coupled to the ground. The base of a transistor, Q 5 , is connected to the collector of the transistor, Q 7 , and they are coupled to the ground through a resistor, R 11 . The emitter of the transistor, Q 5 , is coupled to the power source, Vcc, through a transistor, R 7 ; while the collector of Q 5 is connected to a node FB 2 through a resistor, R 8 . The base of a transistor, Q 6 , is connected to the collector of the transistor, Q 8 , and they are coupled to the power source, Vcc, through a resistor, R 12 . The emitter of the transistor, Q 6 , is coupled to the ground through a resistor, R 10 ; while the collector of Q 6 is connected to the node FB 2 through a resistor, R 9 .
[0034] When the output voltage at Vout+, VOUT+, is in the range between Vbe(Q 4 ) and (Vcc−Vbe(Q 3 )), transistors, Q 3 and Q 4 , are activated; while transistors, Q 1 and Q 2 , are deactivated. The noise reduction network does not provide feedback signals to the node FB 1 . When VOUT+ is less than Vbe(Q 4 ), the transistor, Q 4 , becomes deactivated; while the transistor, Q 2 , becomes activated. The network provides an adjustable feedback current through Q 2 to the node FB 1 . When VOUT+ is larger than (Vcc−Vbe(Q 3 )), the transistor, Q 3 , becomes, deactivated; while the transistor, Q 1 , becomes activated. The network provides an adjustable feedback current through Q 1 to the node FB 1 . The same analysis applies to the node Vout− and the node FB 2 in circuit of FIG. 5 ( c ). When the output voltage at Vout−, VOUT−, is in the range between Vbe(Q 8 ) and (Vcc−Vbe(Q 7 )), transistors, Q 7 and Q 8 , are activated; while transistors, Q 5 and Q 6 , are deactivated. The noise reduction network does not provide feedback signal to the node FB 2 . When VOUT− is less than Vbe(Q 8 ), the transistor, Q 8 , becomes deactivated; while the transistor, Q 6 , becomes activated. The network provides an adjustable feedback current through Q 6 to the node FB 2 . When VOUT− is larger than (Vcc−Vbe(Q 7 )), the transistor, Q 7 , becomes deactivated; while the transistor, Q 5 , becomes activated. The network provides an adjustable feedback current through Q 5 to the node FB 2 .
[0035] Assume Vbe(Q 3 )=Vbe(Q 4 )=Vbe(Q 7 )=Vbe(Q 8 )=Vbe, the noise reduction network in FIGS. 5 ( b ) and 5 ( c ) produces an adjustable feedback current through the node FB 1 when VOUT+ in the range [0, Vbe] and [Vcc−Vbe, Vcc]; and an adjustable feedback current through the node FB 2 when VOUT− in the range [0, Vbe] and [Vcc−Vbe, Vcc]. These feedback currents define a minimum switching frequency of the amplifier control stage in FIG. 4 . The increased minimum frequency produces a more “curved” sinusoidal waveform in the near “clipping” range of output signals, which is schematically shown in FIG. 5 ( d ).
[0036] In present invention, a noise reduction feedback network is introduced between an amplifier control stage and an output stage. The noise reduction feedback network couples with the input terminals of the amplifier control stage with output terminals of the output stage. It monitors the output voltages of the output stage, and remains “inactivated” as long as output voltages are not near saturation. The waveforms of output voltage are the amplified curves of input voltages with substantially the same shape. Once output voltages are near saturation, the noise reduction feedback network starts to be activated. In one embodiment, it sends an adjustable current to the input terminals of amplifier control stage. The adjustable current increases and defines the minimum switching frequency of the amplifier control stage. As a result, the waveforms of output voltage near saturation become more “curved” sinusoidal waveforms comparing with those of input signal. In another embodiment, the noise reduction feedback network reduces the close-loop gain of the amplifier control stage. It has the similar effect on the output voltage near saturation and the waveforms of output voltage near saturation become more “curved” sinusoidal waveforms comparing with those of input signal. The present invention has many advantages over approaches in references. The circuit is very simple and has high efficiency and fast loop response. The output signals in non-saturation region, together with its quality, are not affected by the “inactivated” noise reduction feedback network. The output signals near saturation and inside saturation regions are amplified by less close-loop gains than those in non-saturation regions. Their waveforms become more “curved”, which, in turn, greatly reduce or eliminate audio noises near or in the saturation regions.
[0037] The description of the invention and its applications as set forth herein is illustrative and is not intended to limit the scope of the invention. Variations and modifications of the embodiments disclosed herein are possible, and practical alternatives to and equivalents of the various elements of the embodiments are known to those of ordinary skill in the art. Other variations and modifications of the embodiments disclosed herein may be made without departing from the scope and spirit of the invention. | An amplifier circuit performs audio signal processing and other signal processing by using a noise reduction feedback network. The noise reduction feedback network turns on automatically when output signals are in or near voltage saturation state. The network provides feedback signals to the input terminals of the amplifier's control stage and modulates the control signals. It prevents audio frequency noise associated with “clipping”. | 7 |
BACKGROUND OF THE INVENTION
This invention is concerned with a dart stretcher.
More particularly, the invention is concerned with the removal of fullness at the end of a dart when sewing of a pocket welting onto a garment having a dart and is to be used in conjunction with pocket welting machines.
DESCRIPTION OF THE PRIOR ART
So far as applicant is aware, there is no presently available automatic dart stretcher to remove the fullness of a material located at the end of a dart, and the particular function heretofore was usually and conventionally carried out by an operator by hand.
As is well known, in the manufacture of clothing, such as trousers, coats, dresses, etc., in addition to the loss of a great deal of production time by the operator, inaccurate sewing of the pocket welting to the dart may result in a poorly made garment.
More specifically, when an operator of a pocket welting machine must manually remove the fullness of material located at the end of a dart, this is a slow, tedious and time-consuming operation. In the usual situation, the operator must stretch or tug at the garment before actually commencing the sewing to remove the fullness. If the fullness is not removed, the garment area near the fullness will bunch up during the sewing process and will cause or result in a fold to be sewn into the garment or an unsewn portion. Of course, such garments must then be set aside to be manually repaired or scrapped altogether.
It is believed that there is no commercially available device which will remove the fullness at the end of a dart without some additional hand-handling or manual operation by the operator or increased cycle time.
Machines for holding material so that further operations can be performed are known, and an example is U.S. Pat. No. 4,341,169 to Mainot et al., which is concerned with the manufacture of a welted opening in a piece of material. In machines of this type, different pieces of material are held together so that the pocket opening can be made and then the several pieces of material are moved to another manufacturing station. However, the aforesaid patent does not contemplate the sewing of a pocket welting to a dart.
There are also machines provided with vertically movable left and right clamping feet, but these are not intended for use in stretching operations in directions orthogonal to each other.
SUMMARY OF THE INVENTION
The automatic dart stretcher is intended for use in connection with pocket welting machines.
It is an object of the invention to provide automatic machinery for use in connection with the removal of the fullness of material located at the end of a dart.
A further purpose of the invention is the provision of an automatic dart stretcher for use in connection with pocket welting machines.
A feature of the invention is the provision of a dart stretching apparatus having a pair of upper and a pair of lower clamping feet so that the upper and lower feet can move laterally and longitudinally relative to each other to provide for stretching in both lateral and longitudinal directions. The upper and lower feet move both individually and as a unit. Specifically, the upper feet and lower feet move longitudinally relative to each other, and the upper left and lower left feet move transversely as a unit with respect to the upper right and lower right feet and vice-versa.
For the sake of simplicity, the preferred form of the invention contemplates that the lower feet be movable in both longitudinal and transverse directions, while the upper feet are only movable in the transverse direction.
The automatic dart stretcher, according to the invention, operates during the normal loading cycle. The garment is loaded onto the base plate of a pocket welting machine, and the automatic dart stretcher uses partial pressure to clamp different areas of the material encompassing the dart and stretching takes place in orthogonal directions relative to the dart.
To these ends, the invention consists in the provision of an automatic dart stretcher comprising a pair of spaced connecting arms; a first pair of clamping feet, one of the clamping feet being operatively associated with each of the connecting arms; a second pair of clamping feet operatively associated with the first pair of spaced connecting arms and the first pair of clamping feet; and each of the first and second pair of clamping feet are coupled for movement together in a first direction towards and away from each other and the first and second pair of clamping feet are associated with each other so that each pair moves as a unit in a second direction orthogonal to the first direction.
The invention is also concerned with a method for automatically eliminating fullness in a garment material located at the end of a dart, which comprises feeding the garment material to a pocket or pocket welting sewing machine in which a dart stretcher according to the invention is associated with a sewing machine for sewing a pocket, gripping the material at four spaced points about the edges of the dart formed by a previous cut into the material and then sewn to reduce the fullness of the material to form the dart and moving the gripped material by means of the clamping feet in orthogonally related directions by the four spaced gripping points or areas under the gripping feet to remove the fullness in the material about the dart.
The pocket or pocket welting is then sewn in a substantially orthogonal direction to the material at an end of the dart remote from the top edge of the garment, such as trousers.
The method includes gripping the material at four orthogonal points or areas quadrilaterally arranged about the dart, imparting a separation movement in a first direction between one set of two gripping points or areas and a second set of the remaining two gripping points or areas, and then imparting another separation movement in an orthogonal direction to the first direction between another grouping of the four points or areas to effect a stretch of the material in a first direction and then in a second direction normal to the first direction. Gripping all four points or areas can take place simultaneously so that stretching, in effect, takes place by stretching the material from a center point defined by the intersection of lines orthogonal to lines forming each two adjacent clamping points or areas.
It is also contemplated that both directions of stretching take place simultaneously with the feet moving in both longitudinal and transverse directions after the feet are brought into contact with the material.
BRIEF DESCRIPTION OF THE DRAWING
In order that the invention will be clearly understood and readily carried into effect, reference will now be had to the accompanying drawings in which:
FIG. 1 is a plan view of an automatic dart stretcher in accordance with the invention placed onto a material, shown in phantom, and showing a dart seam already sewn therein, the automatic dart stretcher being shown in its initial condition just as it contacts the material; the left side portion of the clamping feet are broken away to show the dart seam and the area to which the pocket welting is to be sewn and in a relative position with respect to the seam after the material has had part of its fullness removed but prior to the sewing of the pocket welting.
FIG. 2 is a front elevational view looking in the direction of arrow 2 on FIG. 1 and from the bottom thereof, with the material omitted; the feet of the dart stretcher are shown in their actual initial position, partially separated in this position for positioning on opposite sides of the pocket welting and just prior to or upon initial engagement with the material.
FIG. 3 is a side view looking in the direction of arrow 3 on FIG. 1 and looking at the left side of the dart stretcher as seen in FIG. 1, but with the material shown in an unstretched condition; the dart stretcher is shown in its normal or actual retracted condition and above the material just prior to initial engagement of the dart stretcher with the material and just prior to commencement of stretching.
FIG. 4a shows the dart stretcher in a first or its initial condition with the left and right feet spaced from each other prior to activation thereof. FIG. 4a is a partial front view looking in the direction along line 4--4 of FIG. 1, and showing the first position with all the feet in a raised position above the material. The material is shown raised above the table level in a somewhat exaggerated condition to emphasize that the material is not flat on the table.
FIG. 4b is also a partial front view looking in the direction along line 4--4 of FIG. 1 and shows the dart stretcher in a second or one of its intermediate positions after it has commenced its movement for lowering onto the material to be stretched and in contact with the material; FIG. 4b also is useful to indicate either the initial engagement of the feet of the dart stretcher with the material or an intermediate position of stretching of the material after engagement with the material but before final stretching; FIG. 4b is also a partial front view looking in the direction of line 4--4 of FIG. 1.
FIG. 4c is also a partial front view looking in the direction of line 4--4 of FIG. 1 showing the front feet in a condition moved from the FIGS. 4a and 4b position, and showing the feet in their final position; the feet are shown in relation to the material after being placed onto and engaged with the material and the material is fully stretched to remove any fullness thereof.
FIG. 5a is a right side view looking in the direction of arrow 3 in FIG. 1 at the left side of the dart stretcher as depicted in FIG. 1 with the material in a partially stretched and in an unstretched condition; the material is shown after engagement by the dart stretcher with the material on each side of the dart in an intermediate stretched condition; the dart stretcher is shown in a position of operation after the FIG. 3 position, in an exaggerated manner in its position after the engagement position with the material and after some stretching has taken place; and FIG. 5b shows the dart stretcher in its final stretched condition, with the fullness of the material on opposite sides of the dart removed.
FIGS. 6a to 6c are schematic showings of three different views of the dart stretcher schematically showing the feet in different positions and in the positions shown in FIGS. 4a, 4b and 4c, respectively, as well as FIGS. 3, 5a and 5b, respectively; the feet being moved in a first direction and then in a second direction perpendicular to the first direction; the material has been omitted for the sake of clarity; FIG. 6a shows the feet in their initial or rest position just prior to engagement with the material; FIG. 6b shows the feet after being engaged with the material or at the instant of engagement between the feet and the material and the commencement of stretching; and FIG. 6c shows the feet of the dart stretcher moved to its final position to stretch the material in both the longitudinal and lateral directions, the lower feet of the dart stretcher being moved from the upper feet longitudinally to stretch the material in its longitudinal direction and the left pair of feet being moved from the right pair of feet to stretch the material in both the lateral or transverse direction;
FIGS. 7a and 7b are each sections of the upper clamping feet taken along line 7--7 of FIG. 1 showing the clamping feet in their initial and final positions; FIG. 7a shows the rear feet in their actual initial condition with the material thereunder in the unstretched condition shown somewhat exaggerated, and FIG. 7b shows the feet in their lateral separated condition to stretch the material thereunder in contact with the feet. The seam was omitted to show that the material around the seam is stretched.
FIGS. 8a and 8b are partially sectional enlarged side views taken on line 8--8 of FIG. 1 showing one pair of the lower and upper feet in their initial position together and separate positions, respectively; and
FIGS. 9a and 9b are partial sectional views of the lower feet looking in the direction of arrow 2 in FIG. 1 with the upper feet omitted; FIG. 9a shows the lower feet in their initial condition prior to activation in the same position as in FIG. 4a, and FIG. 9b shows the lower feet in their final expanded condition, as in FIG. 4c.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, and in particular to FIG. 1, dart stretcher 10 according to the invention is positioned onto a piece of material M schematically shown having an area at which a pocket P is to be formed shown in broken outline proximate to and adjacent with a previously sewn seam S forming a dart. The top of the material edge of the garment is designated T and generally is useful to indicate for purposes of explanation that the dart starts at the top to narrow the article of clothing above the position for the pocket P. That is, as one moves down from the top T, to move towards the pocket, the material extent widens. In order for the material M at the pocket P proximate to the seam S in the unsewn condition of the pocket to have any fullness of material around the dart seam S in the material M removed, dart stretcher 10 in accordance with the teachings of this invention is used.
Suffixes L and R are used specifically to indicate the same member used with the left clamping and right clamping foot, respectively. The same reference numerals and letters are used throughout all of the Figures.
Dart stretcher 10, as indicated heretofore, is shown in FIG. 1 with some portions removed or omitted merely for purposes of explanation. When dart stretcher 10 is initially applied to material M in the preferred embodiment, seam S for the dart is not visible.
Dart stretcher 10 includes a pair of upper right and left clamping feet 12R and 12L and a pair of lower right and left clamping feet 14R and 14L relatively movable towards and away from each other as shown by double-headed arrows 16 parallel to dart seam S on material M. Upper and lower feet 12 and 14 move as a unit in the direction of double-headed arrows 16R and 16L towards and away from each other, and right and left lower feet 14R and 14L also move as a unit in a direction towards and in a direction in opposition to right and left upper feet 12R and 14L in the direction of double-headed arrows 18R and 18L which are orthogonal to arrows 16 and seam S. Double headed arrows are shown to indicate that each upper clamping foot 12R and 12L is movable separately or together to the right or to the left. Lower clamping feet 14R and 14L are movable towards and away from upper clamping feet 12R and 12L. When the dart stretcher is initially applied to material M, lower clamping feet 14L and 14R are juxtaposed or next to upper clamping feet 12L and 12R, respectively, and cover up dart seam S. The upper clamping foot 12 and the lower clamping foot 14R have been partially cut away to show seam S. The left and right clamping feet are spaced from each other, somewhat as shown in FIG. 1, and as shown in some of the other Figures to provide space for the pocket P. In any event, the left and right clamping feet are spaced from each other so that they are on opposite sides of the pocket P.
Dart stretcher 10 includes right and left connecting arms 20R and 20L for carrying and supporting right and left upper and lower feet 12R, 12L and 14R, 14L as noted for movement towards and away from each other in accordance with the direction shown by vertically oriented arrows 16 and horizonally oriented arrows 18. Each connecting arm 20R, 20L includes a support member 22R, 22L which is fixed to right and left connecting arms 20R, 20L respectively, see FIGS. 7a and 7b. Each support member 22R, 22L carries a piston rod guide block or housing 23R, 23L, piston-cylinder combination 24R, 24L, and adjustable angle plates 25R, 25L, respectively.
Referring now more particularly to FIGS. 1, 7a and 7b, upper clamping feet 12 each includes a pad 26R, 26L, and is coupled to the piston-cylinder combination 24R, 24L and is pneumatically controlled through fluid inlets 34 and fluid outlets 36 to move upper clamping feet 12 from their initial material engagement position as shown in FIG. 7a to their final material stretched position shown in FIG. 7b.
The relative initial and final positions of upper clamping feet 12 are adjustable and pre-positionable, and for this purpose, support member 22 includes a base portion 38 through which passes retaining screw 40 to hold piston rod guide block 23 in position. Each upper clamping foot 12 is provided with an extension limiting member in the form of angle plates 25 which is adjustable in the same direction that upper clamping feet 12 move, i.e., the limiting members are movable and adjustable in both directions of arrows 16 as indicated by the double head on the arrows. For this purpose, each of the limiting members is L-shaped with a horizontal arm 42 and a vertical arm 44; each arm 42 has an elongated opening 46 for receiving a locking and adjusting screw 48 which cooperates with washer 50 to lock the arm 42 of limiting member 25 to piston rod guide block 23. For this purpose, piston rod guide block 25 is suitably tapped to receive locking and adjusting screw 48. Movement of extension limiting member 44 in the direction of arrows 16 changes the amount of movement of upper clamping feet in the direction of arrows 16. Adjustment of adjusting or set screws 48 will limit travel of angle plates 25 and cooperates with set screw 48 to determine the size of gap 49 at the end of travel of the clamp foot assemblies.
Locking nut 52 is provided to connect and disconnect upper clamping foot 12 to and from threaded end portion of piston rod 32 which rides within cylinder 30 in housing 23. Of course, other suitable connect and disconnect means may be used.
Referring now more particularly to FIGS. 1 to 3, lower clamping feet 14L and 14R are each provided with a pad 54 similar to or equivalent to pad 26. As best seen in FIGS. 1, 3 and 5, piston-cylinder combination 56 couples an upper 12 and a lower clamping foot 14 to each other for movement along double-headed arrow 18 to remove fullness in the material M in their extended condition. Piston-cylinder combination 56 in a manner similar to piston-cylinder combination 28 includes a piston 58 which is movable in response to pneumatic control and includes inlet pneumatic means shown as tube 62 in order to move piston 58 towards the right from its initial position as shown in FIG. 3 to one of its intermediate positions shown in FIG. 5a to its final position shown in FIG. 5b for moving lower clamping foot 14 away from upper clamping foot 12 and remove the fullness from material M in the direction of arrows 18 and to flatten the area around dart seam S as much as possible, particularly in the area of the seam S to which the pocket welting will be adjacently placed.
To control the relative spacing between the upper and lower clamping feet, adjusting screw 64 (see FIG. 1) has one end fixed to upper clamping foot 12 and lower clamping foot 14 is provided with a passageway through which the other end 65 of adjusting screw 64 passes for connection with collar 66 to provide for relative limited and controlled movement of lower clamping foot 14 relative to upper clamping foot 12 and a controlled change in the relative spacing between the upper and lower clamping feet in response to separation therebetween imparted by piston 58.
Lower clamping feet 14 also have a pivot block assembly 68 connected with piston 58 and lower clamping foot 14 is held for movement in the direction of arrow 16 together with upper clamping foot 12 as a unit by means of alignment shaft 70 and adjusting screw 64. Movement in one of the directions of arrow 18 of lower clamping foot 14 relative to upper clamping foot 12 is controlled by piston-cylinder combination 56 and limited by a separation distance controlled by the combination of piston 58, adjusting screw 64 and collar 56.
FIGS. 9a and 9b show lower clamping foot 14 with pads 54 which may be the same as or equivalent to pads 26.
The clamping feet generally define the points or corners of a four-sided closed polygonal projection and quadriangular enclosed area.
DESCRIPTION OF OPERATION
Referring now more particularly to FIGS. 6a, 6b and 6c to explain the operation and relative movement of the clamping feet.
The dart stretcher according to the invention is placed onto material M having a dart seam S and a pocket P with left clamping feet 12L and 14L on one side of the opening for pocket P and right clamping feet 12R and 14R on the other side of the unsewn portion for pocket P, located substantially in the spacing 78 between left and right clamping feet after initial engagement and after final stretching the clamping feet 12R and 14R are separated from each other so that dart seam S is visible.
Right clamping feet 12R, 14R and left clamping feet 12L, 14L are movable as a unit towards and away from each other in the direction of arrows 16. Feet 12R, 14R form a first group and feet 12L, 14L form a second group to remove the fullness in a direction normal to dart seam S and aligned with the area of pocket P juxtaposed to dart seam S, and feet 12R, 12L form a third group and feet 14R, 14L form a fourth group for movement relatively to each other in a direction normal to the movement of groups one and two and to the dart seam S. Movement in the four opposed directions is sufficient to remove the fullness of the material around dart seam S.
Referring now more particularly to FIGS. 6a, 6b and 6c, FIG. 6a shows all four clamping feet in their initial position just prior to engagement with the material M and the position taken when all four clamping feet are first engaged with the material quadrilaterally arranged about the dart seam S. In FIG. 6a, feet, 12L and 14L are next to each other in abutment with each other and feet 12R and 14R are also in abutment with each other. However, it is preferred that the feet 12L, 14L as a unit be spaced from feet 12R, 14L as a unit to be spaced from the periphery of pocket P. FIG. 6b, shows the upper and lower left clamping feet moved apart as a unit in the tranerverse direction and, in the longitudinal direction, the upper feet are now spaced from the lower feet and spaced further from the upper and lower right clamping feet than that shown in FIG. 6a to increase spacing 78. It should be noted that feet 12L and 14L are moved as a unit and feet 12R and 14R are moved together as a unit. Movement together takes place in both directions laterally, as shown by arrows 16. Also, feet 12L, 12R are moved or spaced from feet 14L, 14R to leave a space 80.
For certain purposes if desired, one set of clamping feet may be held stationary, and the other set may be moved towards or away from the one set in the lateral direction. Activation of piston-cylinder combination ation 24 results in imparting movement to each set of clamping feet. In FIG. 6c, there is shown a further separation of the lower clamping feet 14L, 14R from the upper clamping feet 12L, 12R, respectively. One movement is made of 12L, 14L as unit and/or 12R, 14R as unit, then lower clamping feet 14L, 14R are moved as a unit by piston-cylinder combination 56L, 56R, respectively.
The lower clamping feet as shown are movable longitudinally in either direction as shown by the double headed arrows 18. It is also within the scope of the invention to have each lower clamping foot moved individually or together. The upper clamping feet can be movable in the longitudinal direction.
While there is shown what is considered to be the preferred embodiments of the invention, various changes and modifications may be made therein without departing from the scope of the invention. | An automatic dart stretcher for removal of the fullness of material from a portion of a garment around a dart seam to faciliate the sewing of a pocket welting onto the garment proximate thereto; two pairs clamping feet are provided to hold the material in an orthogonal and a parallel direction relative to the seam; the two pairs of clamping feet being orthogonally movable relative to each other, one clamping foot of each pair of clamping being movable together in a first direction and one clamping foot of each pair of feet being movable in a second direction orthogonal to the first direction. | 3 |
TECHNICAL FIELD
This invention relates to a marble board game, particularly one having a playing surface indented by marble rest positions wherein answers to questions are coverable by marbles in the rest positions.
BACKGROUND OF THE INVENTION
Many marble games are known in which a playing field is defined --if only by drawing a ring on the ground as in the traditional game wherein a player obtains each marble he can remove from the field by launching a marble onto it from outside the field. Some games have a board with a circumscribed playing field having a multiplicity of marble rest positions thereon, as in so-called Chinese checkers.
Locations on the board of a marble board game may have like values, or may have unlike values determined by their respective row and column intersection (or otherwise), or may have no value at all. Regardless, a marble game may be diverting but otherwise have little educational value. In my view, a game could as well provide both diversion and education simultaneously, and would be more worthwhile for so doing.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide players of it with both entertainment and education.
Another object of this invention is to teach players of this game something they would be less likely to learn--or to enjoy learning--in the absence of the game itself.
A further object of the invention is to educate the players in a subject not normally presented in the guise of a marble game.
Other objects of the present invention, together with means and methods for attaining the various objects, will be apparent from the following description and accompanying diagrams of preferred embodiments, which are presented by way of example rather than limitation.
SUMMARY OF THE DRAWINGS
FIG. 1 is a partially vertically exploded perspective view of a game board and marble launchers according to the present invention;
FIG. 2 is a plan view of the game board of the preceding view;
FIG. 3 is a sectional elevation taken at III--III on FIG. 2;
FIG. 4A is a left side elevation of the preceding game board;
FIG. 4B is a right side elevation of the same game board;
Fig, 5A is a perspective view of associated items of play;
Fig, 5B is a perspective view of other associated play items;
FIG. 6 is a perspective view of an alternate marble board; and
FIG. 7 is a plan view of an assembled game board and associated items of this invention in stowed arrangement, as stored or shipped.
DESCRIPTION OF THE INVENTION
FIG. 1 shows components of a game board according to this invention vertically exploded (as disassembled) for increased clarity, including marble launchers 4 upstanding in blind vertical bores 34 in the top surface of the corners of rectangular board holder 30.
Each marble launcher comprises an upstanding cylindrical body 9 with neck 8 of reduced diameter extending further upward a lesser distance thereabove. Inclined channel member 6 is intercepted by the neck and is thereby divided into upper storage track portion 5 and lower launching track portion 7.
From top to bottom, the game board components include barrier rack 11, marble board 21, board holder 30, and board underliner 49. The rack is square, with rounded corners plus diagonal corner braces 12 defining (with the corners) respective triangular wells 16. It will become apparent that the rack horizontally bounds the field of play and so functions as a barrier to retain therewithin marbles launched onto the field, which is constituted by the marble board.
Marble board 21 is square, with three rounded corners and its fourth corner 22 chamfered in alignment with a diagonal brace of the rack. The board has a multiplicity of marble-receiving indentations 27, as marble rest positions, arranged in rows and columns and joined by higher intervening surface 25 having a multiplicity of saddle-like portions 23, one between each pair of adjacent indentations. Each such indentation resembles an open-top cone and tapers to a diameter (open or closed) smaller than a given marble diameter.
Board holder 30 is rectangular and somewhat resembles an ornate picture frame, with stepped edge 39 bordering opening 31, in which marble board 21 fits. The opening is substantially square, but with one oblique corner 32 aligned with chamfered edge 22 of board 21. Square pathway 37 of successive individual segments 37' (marked with play messages) borders opening 31, including its oblique corner. A couple of marble launchers 4 are shown upstanding in corner bores 34. The left edge of the board (outside the bordering segmented pathway) has three rectangular recesses 33, 33' and 33" laterally spaced from one another and erupting to the exterior edge, each adapted to hold a small deck of cards. The opposite edge of the board has like rectangular recesses 36, 36' and 36" laterally spaced from one another and erupting to the edge, each adapted to hold a stack of paper money, and has also rather similar recess 38 with a lip inclined from the outer edge, being adapted thereby to hold coins.
Board underliner 49 is like marble board 21 in outline, having chamfered edge 42. The underliner bears a multiplicity of answer markings 47 aligned with respective marble indentations 27 (here openings) in the board. As such answers are preferably numerical in nature, little space is needed in which to represent them.
FIG. 2 shows assembled game board 10 of this invention, made up of the parts shown disassembled in the preceding view. Centermost is marble board 21, overlain along its perimeter by barrier rack 11, and both surrounded on all sides (in the plane of the view) by board holder 30. Crossing FIG. 2 in a generally diagonal direction from the lower left to the upper right is sight line III--III along which the next view is taken in the direction of the end arrows.
FIG. 3, taken on FIG. 2 as just noted, shows assembled game board 10 in sectional elevation, featuring board holder 30 supporting on its stepped edge 39 both underliner 49 and overlying marble board 21. The top surface of the board holder supports barrier rack 11 surrounding the marble board.
FIGS. 4A and 4B show assembled game board in elevation from the left and right sides, respectively. In both views, board holder 30 and overlying barrier rack 11 hide the marble board from view. In FIG. 4A, card recesses 33, 33,, and 33" are visible from left to right in the near edge of the board holder. In FIG. 4B, the near edge of the board holder shows--as the bank--from right to left: bill-holding recesses 36, 36', and 36", also coin-holding recess 38.
FIGS. 5A and 5B show, in perspective and on an enlarged scale, associated items useful in the playing of games based upon game board 10. FIG. 5A shows question cards 53, misfortune cards 53', and good fortune cards 53"--which are located in respective recesses 33, 33', and 33" during play. FIG. 5B shows die 50, marbles 60, player pieces 54, simulated bills 56 ($100), 56' ($10), and 56" ($1) --placed in respective recesses 36, 36', 36" during play--and coins 58 (e.g., dimes) similarly placed in recess 38 during play.
FIG. 6 shows, in perspective, alternative marble board 61, with open-top conical marble indentations 67 in top surface 65, which has saddle-like portions 63 between each pair of adjacent indentations. Unlike previous marble board 21, marble board 61 has underliner 69 integrally formed or attached by suitable fasteners. Answers may be on the underliner or within the base of closed conical indentations.
FIG. 7 shows in plan game board 10, including barrier rack 11, marble board 21, and board holder 30--upon which are stowed all the associated items: cards 53, 53', 53" in recesses 33, 33', 33", and money 56, 56', 56", 58 in recesses 36, 36', 36", 38; marble launchers 4, lying just outside rack 11; and--within the rack--die 50, player pieces 54, and marbles 60 arranged in the triangular wells. Not shown is a set of instructions for one or more games, which may be in a pamphlet or on the inside cover of a box for the game, or even printed on the board support itself.
Use of the game board and associated items of this invention to play an arithmetic game will be readily understood from the foregoing description, with reference to the various Figures, as follows.
In setting up to play the game, each player selects a marble launcher and sets it upright with its base in the corner recess on the player's right. Each player selects a colored player piece and takes the prescribed number of marbles of that color (e.g., 5 or 6) and places them on the upper or storage portion of the launcher's track. The player on the "bank" side of the game board places the simulated bills and coins in the appropriate recesses and also gives each player a given initial amount of simulated money. The player on the opposite side of the board places the respective card decks in their appropriate recesses.
One of the pathway segments is marked START HERE. The players each roll the die once, and the highest scored goes first. In the event of a tie, the tying players roll further to break the tie(s). The starting player rolls the die and moves his or her player piece the corresponding one to six segments clockwise (to the player's left) from the starting segment. Upon reaching any segment a player reads the instructional message on that segment and does whatever it requires--which may necessitate one or more other players doing something in addition or instead of the first player.
A frequent instruction on the pathway is for a player to roll one or more marbles and to answer the question(s) posed on the 22 marble field adjacent to the particular marble indentation(s) in which the marble(s) come to rest--or optionally keyed, as by indentation row and column number to a separate printed question list.
The players have the same number of marbles apiece, about enough to fill the upper tracks of their respective launchers. If instructed to launch one or more marbles, a player manually turns the launcher to aim in the desired azimuthal direction, transfers the marble(s) to the lower or launching track (individually or together), and releases the same to roll onto the playing field. Each marble will come to rest in an indentation, whereupon the player may be obligated to read and answer one or more questions.
After answering, the player lifts each marble and reads the answer covered thereby. The player gets a reward (usually money, perhaps another turn, etc.) if the answer is correct, or suffers a penalty if the answer is incorrect, as stated in the previous instruction or otherwise according to the rules. The marbles are then replaced into the upper or storage track of the player's launcher.
An alternative instruction is to draw a card, which may be a question card with a stated reward for the right answer and penalty for the wrong answer, or may be a misfortune card (lose money, turn, etc.) or a good fortune card (win money, another turn, etc.). Diverse rules and/or instructions may accompany otherwise identical physical board components for similar use, except as modified by the reward or penalty messages or the rules or instructions themselves.
The end of the game may be determined by time, total number of turns, players losing (or winning) the initially allocated money, etc. In any event the player with the most money at the end of the game wins. Of course, everyone answering questions is likely to improve at arithmetic (or other subject matter) in striving to win.
This invention does not require any unusual materials or method of fabrication. The game board components can be pressed or molded metal, plastic, wood fiber, or the like. The segmental path messages and the playing field questions and underlying answers can be molded therein or printed directly thereon or on labels adhesively applied thereto. The marble launchers can be made of like material The cards, die, marbles, money, and players' pieces are conventional constituents of many games. Everything can be packaged in a box of the type commonly used for board games.
This game is especially suited to arithmetical or other mathematical questions because the answers are short, usually expressed as a relatively short number or other set of numerals, so a marble of modest size can cover such an answer satisfactorily. Of course, other types of questions may be substituted for arithmetical ones, such as algebraic, geometric, or trigonometric. It will be apparent that locating answers on a separate underlying layer enables more than one overlying question layer to be used with the same answers, as 4 may be the answer to 2+2, 2×2, 20÷5, etc. Other relatively quantitative subjects also are suitable because of their usually short and often numerical answers, such as aeronautical, astronomical, chemical, geographic, meteorological, oceanographic, etc.
Only the playing surface and underliner need be changed to convert to a different subject or at least a different set of questions and answers. Where the answer underliner is integral with or fastened to the playing surface--or where the answers are printed in closed conical or similar indentations--board interchangeability or game convertibility is further simplified to preclude getting wrong combinations of questions and answers.
Preferred embodiments and variants have been suggested for this invention. Other modifications may be made, as by adding, combining, deleting, or subdividing compositions, parts, or steps, while retaining all or some of the advantages and benefits of the present invention--which itself is defined in the following claims. | Educational marble board game for facilitating the teaching of arithmetic or other mathematical or related mainly numerical games. Marble launchers fitting upright near corners of a game board, outside a bounded generally horizontal playing surface, store marbles for use by the players. The players move player pieces along a pathway and receive instructions printed on the pathway segments. Released marbles are launched individually or together onto the playing surface, where they come to rest in respective indentations. Underneath each rest position is an answer to a question posed to the player, as by being keyed to the row and column in which the rest position indentation is located or alternatively printed directly on the playing surface alongside the marble rest position. Players are rewarded for correct answers, penalized for incorrect ones, or both, and optionally also by chance, with simulated money. | 0 |
FIELD OF THE INVENTION
This invention relates to a combination electrical cord support for supporting an electrical cord of an electrical appliance and a holder for holding an article. The invention is particularly useful, but not limited, to an attachment for an ironing board for supporting the electrical cord of an electric iron above an ironing surface and for holding an article, such as a spray starch can or a beverage container.
BACKGROUND OF THE INVENTION
It is known to have cord support devices for supporting the electrical cord of an electric iron so that the cord will not interfere with the clothes being ironed. It is further known to incorporate on cord support devices an outlet for receiving the plug at the end of the electrical cord which is supported by the cord support device. U.S. Pat. Nos. 2,478,498 and 2,715,002 disclose such apparatus.
Frequently, an ironer wishes to have things like spray starch or other clothing treatments at hand while ironing. This means that it is frequently necessary to place such articles on the ironing board, which interferes with ironing, or to place them on a nearby surface, which is not convenient. In the case of a beverage container or other open container, the container could tip or fall spilling the contents on the ironing board or floor.
It is desired to have an apparatus for supporting the electrical cord and also for storing an article, such as spray starch can or beverage container.
It is further desired that a portion of the apparatus, such as an article holder, be removable from the ironing board when not in use in order to facilitate storage.
SUMMARY OF THE INVENTION
This invention relates to an apparatus mounted on an ironing board for guiding a cord of an iron and providing a holder for an article. The article has a clamp section for releasably securing the apparatus to the ironing board. A flexible cord support is pivotably attached to the clamp for supporting the electrical cord of the electrical appliance above the ironing board. An article holder is mounted to the clamp for holding an article. An electrical receptacle is carried by the clamp for receiving a plug of the electrical cord of the iron.
In a preferred embodiment, the clamp is "C" shaped and has a pair of leg portions extending from an end portion. One leg portion is adapted for engaging the ironing surface of the ironing board. The other leg portion is located below the underside of the ironing surface, an adjusting screw is threadedly journaled in a threaded bolt in the other leg portion. A movable jaw at an end of the adjusting screw located between the leg portions engages the underside of the ironing board for securing the apparatus to the ironing board. The flexible cord support has a first rod, a second rod and a resilient spring section. The first rod has a cord receiving end for receiving the cord. The resilient spring section is secured to a lower end of the first rod. The second rod has an upper end for detachably receiving the resilient spring section. A lower end of the second rod has a foot pivotably received by an opening defined by a brace and the upper leg portion of the clamp for permitting movement of the cord support between a raised position and a retracted position. A locking tab on the foot of the rod is releasably retained by a detent on the brace. The locking tab is engaged with and disengaged from the detent by sliding the foot relative to the brace. Engaging the locking tab with the detent retains the cord support in the raised position. The article holder has a pair of tangs detachably received by openings in a mounting brace mounted to the clamp.
Further objects, features and advantages of the present invention will become more apparent to those skilled in the art as the nature of the invention is better understood from the accompanying drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a perspective view of the invention, with the cord support in an installed raised position, and with the ironing board shown in phantom.
FIG. 2 is an enlarged view of the invention partially disassembled for storage, with the lower portion of the cord support shown in its retracted position in phantom.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like numerals indicate like elements, there is illustrated an apparatus in accordance with the present invention. The apparatus 10 comprises a releasable clamp 12 for releasably securing the apparatus to a work surface, a flexible cord support 44 and a detachable article holder 66 which can be selectably attached to and detached from the apparatus.
In a preferred embodiment, the releasable clamp is a "C" shaped clamp 12 having an end portion 14 from which extend an upper leg portion 16 and lower leg portion 18. It is recognized that the releasable clamp means could also be a squeeze or friction clamp or other securing device. The end portion 14 and upper leg portion 16 and lower leg portion 18 of the clamp 12 define a bight or opening between them. The clamp 12 receives an ironing board 22, shown in phantom, in the bight between the leg portions 16 and 18. The upper leg portion 16 engages an ironing surface 23 of the ironing board 22. The lower leg portion 18 has a threaded hole, not shown, which receives an adjustment screw such as a threaded eye bolt 26. The eye bolt 26 has an eye portion 28 at one end to facilitate the rotation of bolt 26 by the thumb and fingers. A movable clamp jaw in the form of a plastic cap 30 is located on the other end of the threaded bolt 26 between leg portions 16 and 18 and has a flat surface 32 for engaging tile underside of the ironing board 22. The apparatus 10 is thus clamped to the ironing board 22 by sandwiching the ironing board between the upper leg portion 16 and the plastic cap 30.
The clamp 12 includes a retainer for retaining the flexible cord support 44 on clamp 12. The support may be integral with the clamp 12 or may comprise a separate brace 34 mounted to the upper leg portion 16 of the clamp 12, as shown. The brace 34 has a "U" shaped bend 36 and is secured to the upper leg portion 16 of the clamp 12, such as by rivets on either side of the "U" shaped bend 36. The upper leg portion 16 and the "U" shaped bend 36 of the brace 34 define an opening 38 which receives the cord support 44. The brace 34 has a detent such as a "L" shaped tab 40 projecting upward from the upper leg 16.
The cord support 44 is in the form of a flexible mast and has a foot portion 60 at one end, a cord receiving portion 52 at the other end to receive the electrical cord, and a flexible portion 50 for at least a part of its length between the ends. In a preferred embodiment, the cord support 44 has a first rod 46, a second rod 48, and a coiled spring resilient section 50 joining the first and second rods 46 and 48. The first, and upper, rod 46 has at an upper end a helical bent portion 52. The helical bent portion 52 is formed to provide spaces in the helical bent portion 52 allow the electrical cord from the iron, not shown, to be placed in the spaces so that the cord is supported above the ironing surface 23 of the ironing board 22. The lower end of the first rod 46 is attached to the coiled spring resilient section 50. The second, and lower, rod 48 of the cord support 44 has an upper end 58 which detachably receives the coiled spring resilient section 50, as best seen in FIG. 2. The second rod 48 also has a "L" shaped bend defining the foot 60 at the lower end. The foot 60 is pivotably and slideably received by the opening 38 defined by the "U" shaped bend 36 of the brace 34. At the end of the foot 60, extending at an angle of approximately 90° from the foot 60, is a tab 62. The tab 62 is retained by the "L" shaped tab 40 of the brace 34, which acts as a detent, to hold the cord support 44 in a raised position, as shown in FIG. 1.
In a preferred embodiment, the detachable article holder 66 has a lower circular hoop 68 and a pair of support bars 70. The support bars 70 are secured to the lower circular hoop 68 and form chords of the circle defined by hoop 68, thereby defining a base for retaining an article such as a can of starch, a spray bottle, a beverage container, or a remote control. The article holder 66 also has an upper hoop 72. The upper hoop 72 has a circular portion for approximately 345° and each end of the circular portion of the upper hoop 72 has a tang 74 depending downward therefrom. The article holder 66 has four vertical supports 76 extending between the lower hoop 68 and upper hoop 72 for spacing the hoops 68 and 72 and defining the article holder 66. The vertical supports 76 can be located inside or outside the hoops 68 and 72, and cooperate with upper hoop 72 to provide lateral support for an article. The article holder 66 has a vertical support bar 84 extending between the tangs 74 of the upper hoop 72. A single tang could be integral with one of the vertical supports instead of the tangs integral with the upper hoop 72. The detachable article holder 66 could also be made of other materials such as molded plastic.
The clamp 12 has a second support for detachably mounting the article holder 66. In a preferred embodiment, the clamp 12 has a second brace 78. The second brace 78 has a pair of "U" shaped bends 80. The second brace 78 is spot welded to the base 14 of the clamp 12 such that the "U" shaped bends 80 each define an opening 82, as best seen in FIG. 2, for detachably receiving the tangs 74 of the upper hoop 72.
The apparatus 10 has an extension portion, such as an "L" shaped bracket 88, for mounting an female electrical outlet 96. The "L" shaped bracket 88 has a first leg 90 and a second leg 92. The first leg 90 is welded to the lower leg portion 18 of the clamp 12. The second leg 92 depends downward in the plane with the end portion 14 of the clamp 12. The second leg 92 has a threaded hole, not shown, which receives a screw 94. The apparatus 10 has an female electrical outlet 96 with an electrical cord 98 extending to a plug (not shown). The female electrical outlet 96 is secured to the second leg 92 by the screw 94 and can receive the plug from the iron. The electrical outlet 96 is shown below the article holder 66 in the Figures so that article placed in the article holder 66 will not interfere with the outlet 96. However, the outlet 96 could be place in other locations such to the side of the article holder 66, using the extension portion or directly to the underside of the lower leg 18 of the clamp 12.
Referring to FIG. 2, the apparatus 10 is shown removed from the ironing board 22. The coiled spring resilient section 50, which is attached to the first drive 46 of the cord support 44, is removed from the upper end 58 of the second rod 48. The second rod 48 is shown in phantom in a retracted position where the foot 60 has been slideably moved in the opening 38 defined by the "U" shaped bend 36 of the brace 34 such that the tab 62 is disengaged from the "L" shaped tab 40, and the foot 60 has been pivoted relative to the opening 38. The second rod 48 in the retracted position will lie against the ironing board 22 (not shown in FIG. 2), so that the ironing board 22 can be stored with the apparatus 10 still attached. The article holder 66 is removed from the second brace 78 by raising the article holder 66 vertically, thereby removing the tangs 74 from the openings 82.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | An apparatus mounts on an ironing board for guiding a cord of an iron and providing a holder for an article. The article has a clamp section for releasably securing the apparatus to the ironing board. A cord support is pivotably attached to the clamp for supporting the electrical cord of the electrical appliance above the ironing board. An article holder is mounted to the clamp for holding an article. An electrical receptacle is carried by the clamp for receiving a plug of the electrical cord of the iron. | 3 |
FIELD OF THE INVENTION
[0001] The invention relates to a photochromic dyes, and in particular to a photochromic dyes characterized in that it can change into a different color upon being excited by ultraviolet light.
BACKGROUND OF THE INVENTION
[0002] Photochromic dyes belong to a kind of organic photochromic dyes. Photochromic functional colorant refers to a pigment with special functional properties. In contrast to the conventional pigment that emphasizes only on the function of pigmentation, the pigment property of a photochromic functional dye will has its color phase changed with its outer environment, such as, for example, light, heat, electricity, solvents, pressure and pH. For the industry at present, only a small amount of photochromic dye will bring about instantly the desired color changing effect, and hence is a product of high added value and high applicability. Accordingly, most of chemists today are developing novel organic photochromic dyes in order to take advantage of more intensive applications of organic photochromic dyes.
[0003] The principle of seeing depends on the reflection or absorption of visible light by a material, that is, when the material is irradiated by light, it will absorb a portion of the incident light and reflect or refract the remaindering light into eyes such that different colors of the material can be seen. As a result, if, for example, light transmits completely through a material, the material will neither absorb nor reflect light and hence is seen to be colorless, i.e., its can not be seen by eyes. On the other hand, if the incident light is completely reflected by the material and hence presents as white, while it is black by absorbing light completely. In general, the material can have a variety of color when it absorbs or reflects only part of visible light. Therefore, the color of a material depends on not only the property and structure of the molecule itself, but also the property of light irradiated on the material.
[0004] The visible light has a wavelength in a range of from 400 nm to 800 nm, and has a relationship of its wavelength with respect to color as shown in FIG. 1 . Therefore, the color thus seen is the color exhibited from the remaindering wavelength after a material absorbing a certain part of the visible light, i.e., the basic color of a material is the complementary color of its maximum absorption wavelength. By way of example, if a material has its maximum absorption wavelength λmax=588 nm, its means that this material absorbs yellow light and hence exhibits a blue color.
[0005] Among an organic photochromic dye, the one that is most well known and has more extensive application is the photochromic dye, or known as photochromic functional colorants. The photochromic phenomenon is described earliest in the scientific literature in 1876 by E. ter Meer who found that the color of the potassium salt of dinitromethane changed under sunlight irradiation. Subsequently, W. Marckwald observed in 1899 that the color of the crystal of 1,4-dihydro-2,3,4,4-tetrachloronaphthalen-1-one changed from colorless to purple upon sunlight irradiation, while restored to its original color when the crystal was placed in dark. This light-induced color change was referred then by W. Marckwald as “photropy”. Until 1950, Y. Hirshberg suggested this light-induced color change a term as “photochromism” with a definition as “the visible light absorption spectrum of a substance will be changed considerably and reversibly as it is exposed under activating radiation, while can be restored to its original state through an opposite color change mechanism by heating, placing in dark or being irradiated by light having different wavelength”.
[0006] Since photochromic substance had been discovered in 1876, it has been developed more than hundred years. Little study had been done before 1920. More researches appeared since 1940, but were restricted to the investigation on strange chemical phenomena. Until 1956, Y. Hirshberg proposed first the application of photochromic compounds on an optical memory. Since then, many international research organizations devoted successively in this field and as a result, hundreds types of photochromic functional colorants, and particularly, even more types of organic photochromic compounds, had been developed up to date. Among these substances, 5 series are known as follow:
[0007] 1. Azobenzene Series
[0008] As shown in FIG. 2 , pigments of azobenzene series demonstrate their photochromism through cis-tans summarization. Photochromism of azobenzene series photochromic pigment takes place when trans azobenzene series pigments is irradiated under ultraviolet light, whereby their structure will transform from the more stable trans form into the liable cis form. Because the cis form has higher energy and is more liable, it can restore easily to the original trans form under visible light or heating conditions and consequently, heat extinction is occurred. Recently, Z. F. Liu et al. had studied the possibility of transforming cis-azobenzene into more stable trans-azobenzene in order to apply on optical memory.
[0009] 2. Salicylidene Aniline Series
[0010] Salicylidene aniline series photochromic pigments, as shown in FIG. 3 , were discovered by M. D. Cohen in 1962. As salicylidene aniline series photochromic pigment is irradiated by ultraviolet light, the hydrogen ion of —OH on the enol-form will be excited and transferred on a nitrogen atom to form a keto-form having a colored state. M. D. Cohen had shown that the requisite for the photochromism exhibited by this type of pigment is the presence of a —OH group on the ortho position of the Schiff's Base. If, on the other hand, the —OH group is present on para position, absence of being substituted with other group (for example, a methoxy group), the photochromism exhibited by this type of pigment will disappear. On the other hand, K. S. Sharma had study the photochromic principle of salicylidene anilines and found that the photochromism is resulted from hydrogen transfer due to cis-trans summarization during the rotation of C═N bond. This type of photochromic pigment has good photolytic property but lack of heat stability.
[0011] 3. Fulgide Series
[0012] Fulgide series, as shown in FIG. 4 , was found by H. Stobbe in 1904, and was developed further by H. G. Heller for its application for the storage and reading on optical memory. Its photochromism relies on the cyclisation of the structure of the fulgide photochromic pigment occurred upon irradiation with light of a specific wavelength and thereby producing color. Although the heat resistance and light fatigue resistance of this type of photochromic pigment are better than those of spiropyran, there are many problems to be solved, such as, for example, optical sensitivity and the like.
[0013] 4. Spiropyran Series
[0014] Spiropyran series, as shown in FIG. 5 , had been studied with respect to its photochromism first by E. Fischer in 1952. Since the applicability of spiropyrans on optical memory being proposed by Y. Hirshberg in 1956, studies on the spiropyrans photochromic material has constituted the majority of studies on photochromic materials. Results from these studies revealed that there must be a nitro-substituent present on the benzopyran ring for a compound of the spiropyran series to produce photochromism effectively. Reasons therefore comprise: 1. The nitro group can introduce a triplet-pathway to increase the quantum-yield of photocoloration; 2. The nitro group can stabilize the amphoteric ion merocyanine at its photocolorated state such that the reverse reactivity of heat extinction can be lowered. The incorporation of the nitro group, however, is not favorable for the photochemical stability of spiropyran, that is, its light fastness will be lowered.
[0015] 5. Spirooxazine Series
[0016] Spirooxazine series photochromic pigment, as shown in FIG. 6 , was discovered first by R. E. Fox in 1961. The structure of spirooxazine series photochromic pigment is similar with that of spiropyran series photochromic pigment, except that the C═C bond on the pyran ring of spiropyran is replaced with a C═N bond to form spirooxazines. The photochromism exhibited by spirooxazine series photochromic pigment is also very analogous to that by spiropyran series photochromic pigment, namely, under irradiation with ultraviolet light, the bond between the spiro carbon and the adjacent oxygen atom will take place non-uniform cleavage and form a conjugated state to become a colored merocyanine. Later studies by Nori Y. C. Chu, Susumu Kawauchi confirmed that, among existing photochromic pigments at present, spirooxazine series exhibit the best light fatigue resistance.
[0017] Each of the five series of photochromic materials described above has respective advantages and disadvantages. Nevertheless, following conditions must be satisfied with respect to their application for storage on information medium:
1. High heat stability: After irradiating the photochromic pigment with light of specific wavelength, the chemical state thus formed must exhibit good heat stability in a dark place, and the information should be stored over a long period without damage. 2. Good light fatigue resistance: The writing and erase of information can be repeated up to thousands times. 3. High sensitivity: The storage and erase of information should be done rapidly under irradiation with light of specific wavelength. 4. Extremely small damage rate: During the reading and resolving of the information recorded by the photochromic pigment, the degree of damage of the pigment should be extremely low.
[0022] Although the possibility of photochromic pigments for applying on optical memory was proposed as early as in 1956 by Y. Hirshberg, this applicability of photochromic material in the storage on an optical memory has never been practiced heretofore for following reasons:
1. Most of the photochromic pigments had poor heat stability. 2. They might be degraded or denatured after use or storage for a long period.
[0025] Spirooxazine series pigment is well known as the one exhibiting the best light fatigue resistance amount photochromic pigments. This type of pigment has the best light fatigue resistance among the well-known photochromic pigments.
[0026] In order to overcome the problem of degradation due to repeated use or long-term storage occurred in the early application of photochromic pigment on optical memory, the inventor had devoted to improve and innovate, and, after carrying out intensive study for many years, had accomplished successfully the photochromic functional colorants according to the invention that has lower cost, is simpler to synthesis and more suitable to apply on optical memory.
SUMMARY OF THE INVENTION
[0027] The primary object of the invention is to provide a photochromic functional colorants characterized in that it exhibits high heat stability, good light fatigue resistance and high sensitivity.
[0028] The secondary object of the invention is to provide a photochromic functional colorant characterized in that it can be prepared by simple synthetic and purification steps with cheap materials and greatly lowered cost.
[0029] Another object of the invention is to provide a photochromic functional colorant characterized in that it has higher absorption coefficient to ultraviolet light, greater solubility in organic solvent and easy to application.
[0030] The photochromic functional colorant that can realize objects described above is the photochromic functional colorant with a chemical formula shown in FIG. 7 .
[0031] In the formula shown in FIG. 7 , R 1 and R 2 is independently selected from the group consisting of a linear or branched alkyl containing 1 to 20 carbon atoms, a linear or branched alkenyl containing 2 to 20 carbon atoms, a linear or branched alkynyl containing 2 to 20 carbon atoms, a linear or branched alkoxy containing 1 to 20 carbon atoms, a haloalkyl, haloalkenyl, a halogen atom- or hydrogen atom-containing functional groups; R 3 may be a secondary amino group with a linear, cyclic or branched functional group containing 1 to 10 carbon atoms attached on its secondary nitrogen atom. The photochromic functional colorant according to the invention can be formulated with a suitable organic solvent and can change its color upon excited by ultraviolet light.
BRIEF DESCRIPTION OF THE DRAWING
[0032] The present invention may best be understood through the following description with reference to the accompanying drawings, in which:
[0033] FIG. 1 is a graph showing the relationship of the absorption wavelength and the color.
[0034] FIG. 2 shows the general structure of the azobenzene series pigment.
[0035] FIG. 3 shows the general structure of the salicylidene aniline series pigment.
[0036] FIG. 4 shows the general structure of the fulgide series pigment.
[0037] FIG. 5 shows the general structure of the spiropyran series pigment.
[0038] FIG. 6 shows the general structure of the spirooxazine series pigment.
[0039] FIG. 7 shows the chemical structure of the spirooxazine dye according to the invention.
[0040] FIG. 8 illustrates the synthesis of Fisher base (c)°
[0041] FIG. 9 illustrates the synthesis of spirooxarines dye (e).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The technical disclosure of the invention will be now illustrated in conjunction with the accompanied drawings as follow. As stated above, the invention provides a dye that can be used in the recording layer of a high-density recordable optical disk. This dye has a chemical structure as shown in FIG. 7 .
[0043] In the formula shown in FIG. 7 , R 1 and R 2 is independently a linear or branched alkyl containing 1 to 20 carbon atom, such as, for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, neobutyl, pentyl, isopentyl, neopentyl, hexyl, isohexyl, neohexyl, cyclohexyl, heptyl, octyl, nonyl, decyl, 2-methylbutyl, 3-methylbutyl, 2-methylpentyl, 3-methylpentyl, 4-methylpentyl, 2,3-dimethylbutyl, 2-ethylhexyl, 3-methylhexyl, 4-methylhexyl, 5-methylhexyl, 2,4-dimethylpentyl, 2-methyl-5-butylhexyl, 2,5-dimethylhexyl, 6-methylheptyl, 2-methylheptyl, 2,2-dimethylheptyl, 4-methylheptyl, 5-methylheptyl, 3,5-dimethylheptyl, 2,5-dimethylheptyl, 2,4-dimethylheptyl; a linear or branched alkenyl containing 2 to 20 carbon atom, such as, for example, ethenyl, propenyl, butenyl, isobutenyl, pentenyl, isopentenyl, hexenyl, isohexenyl, cyclohexenyl, heptenyl, octenyl, nonenyl, decenyl, 2-methylbutenyl, 3-methylbutenyl, 2-methylpentenyl, 3-methylpentenyl, 4-methylpentenyl, 2,3-dimethylbutenyl, 2-ethylhexenyl, 3-methylhexenyl, 4-methylhexenyl, 5-methylhexenyl, 2,4-dimethylhexenyl, 2-methyl-5-butylhexenyl, 2,5-dimethylhexenyl, 6-methylheptenyl, 2-methylheptenyl, 2,2-dimethylheptenyl, 4-methylheptenyl, 5-methylheptenyl, 3,5-dimethylheptenyl, 2,5-dimethylheptenyl, 2,4dimethylheptenyl, 2,5-dimethyl-5-hexenyl, 2,5-dimethyl-1-hexenyl; a linear or branched alkynyl containing 2 to 20 carbon atom, such as, for example, ethynyl, propynyl, butynyl, pentynyl, hexynyl, isohexynyl, cyclohexynyl, heptynyl, octynyl, nonynyl, decynyl, 3-methylbutynyl, 3-methylpentynyl, 4-methylpentynyl; or a linear or branched alkoxy containing 1 to 20 carbon atom, such as, for example, methyl ethyl ether, methyl propyl ether, methyl isopropyl ether, methyl butyl ether, methyl isobutyl ether, methyl pentyl ether, methyl isopentyl ether, ethyl ethyl ether, ethyl propyl ether, ethyl isopropyl ether, ethyl butyl ether, ethyl isobutyl ether, ethyl pentyl ether, ethyl isopentyl ether, propyl ethyl ether, propyl propyl ether, propyl isopropyl ether, propyl butyl ether, propyl isobutyl ether, propyl pentyl ether, propyl isopentyl ether; haloalkyl, such as, for example, chloromethyl, dichloromethyl, trichloromethyl, 1-chloroethyl, 1,2-dichloroethyl, 1,1,2,2-tetrachloroethyl, 1-chloropropyl, 2-chloropropyl, 1,2-dichloropropyl, 1,1,2,2-tetrachloropropyl, 1-chlorobutyl, 2-chlorobutyl, 1,2-dichlorobutyl, 1,1,2,2-tetrachlorobutyl, 1-chloropentyl, 2-chloropentyl, 1,2-dichloropentyl, 1,1,2,2-tetrachloropentyl, 1-chlorohexyl, 2-chlorohexyl, 1,2-dichlorohexyl, 1,1,2,2-tetrachlorohexyl, 1-chlorocyclohexyl, 2-chlorocyclohexyl, 1,2-dichlorocyclohexyl, 1,1,2,2-tetrachlorocyclohexyl, 1-chlorocyclohexyl, 2-chlorocyclohexyl, 1,2-dichlorocyclohexyl, 1,1,2,2-tetrachlorocyclohexyl, bromomethyl, dibromomethyl, tribromomethyl, 1-bromoethyl, 1,2-dibromoethyl, 1,1,2,2-tetrabromoethyl, 1-bromopropyl, 2-bromopropyl, 1,2-dibromopropyl, 1,1,2,2-tetrabromopropyl, 1-bromobutyl, 2-bromobutyl, 1,2-dibromobutyl, 1,1,2,2-tetrabromobutyl, 1-bromopentyl, 2-bromopentyl, 1,2-dibromopentyl, 1,1,2,2-tetrabromopentyl, 1-bromohexyl, 2-bromohexyl, 1,2-dibromohexyl, 1,1,2,2-tetrabromohexyl, 1-bromocyclohexyl, 2-bromocyclopentyl, 1,2-dibromocyclopentenyl, 1,1,2,2-tetrabromocyclopentenyl, 1-bromocyclohexyl, 2-bromocyclohexyl, 1,2-dibromocyclohexyl, 1,1,2,2-tetrabromocyclohexyl, iodomethyl, diiodomethyl, triiodomethyl, 1-iodoethyl, 1,2-diiodoethyl, 1,1,2,2-tetraopdpethyl, 1-iodopropyl, 2-iodopropyl, 1,2-diiodopropyl, 1,1,2,2-tetraiodopropyl, 1-iodobutyl, 2-iodobutyl, 1,2-diiodobutyl, 1,1,2,2-tetraiodobutyl, 1-iodopentyl, 2-iodopentyl, 1,2-diiodopentyl, 1,1,2,2-tetraiodopentyl, 1-iodohexyl, 2-iodohexyl, 1,2-diiodohexyl, 1,1,2,2-tetraiodohexyl, 1-iodocyclopentyl, 2-iodocyclopentyl, 1,2-diiodocyclopentyl, 1,1,2,2-tetraiodocyclopentyl, 1-iodocyclohexyl, 2-iodocyclohexyl, 1,2-diiosocyclohexyl, 1,1,2,2-tetraiodocyclohexyl, fluoromethyl, difluoromethyl, trifluoromethyl, 1-fluoroethyl, 1,2-difluoroethyl, 1-fluoropropyl, 2-fluoropropyl, 1,2-difluoropropyl, 1-fluorobutyl, 2-fluorobutyl, 1,2-difluorobutyl, 1-fluoropentyl, 2-fluoropentyl, 1,2-difluoropentyl, 1-fluorohexyl, 2-fluorohexyl, 1,2-difluorohexyl, 1-fluorocyclopentyl, 2-fluorocyclopentyl, 1,2-difluorocyclopentyl, 1-fluorocyclohexyl, 2-fluorocyclohexyl, 1,2-difluorocyclohexyl; haloakenyl, such as, for example, 1-chloroethenyl, 1,2-dichloroethenyl, 1,1,2,2-tetrachloroethenyl, 1-chloropropenyl, 2-chloropropenyl, 1,2-dichloropropenyl, 1,1,2,2-tetrachloropropenyl, 1-chlorobutenyl, 2-chlorobutenyl, 1,2-dichlorobutenyl, 1,1,2,2-tetrachlorobutenyl, 1-chloropentenyl, 2-chloropentenyl, 1,2-dichloropentenyl, 1,1,2,2-tetrachloropentenyl, 1-chlorohexenyl, 2-chlorohexenyl, 1,2-dichlorohexenyl, 1,1,2,2-tetrachlorohexenyl, 1-bromoethenyl, 1,2-dibromoethenyl, 1,1,2,2-tetrabromoethenyl, 1-bromopropenyl, 2-bromopropenyl, 1,2-dibromopropenyl, 1,1,2,2-tetrabromopropenyl, 1-bromobutenyl, 2-bromobutenyl, 1,2-dibromobutenyl, 1,1,2,2-tetrabromobutenyl, 1-bromopentenyl, 2-bromopentenyl, 1,2-dibromopentenyl, 1,1,2,2-tetrabromopentenyl, 1-bromohexenyl, 2-bromohexenyl, 1,2-dibromohexenyl, 1,1,2,2-tetrabromohexenyl, 1-iodoethenyl, 1,2-diiodoethenyl, 1,1,2,2-tetraiodoethenyl, 1-iodopropenyl, 2-iodopropenyl, 1,2-diiodopropenyl, 1,1,2,2-tetraiodopropenyl, 1-iodobutenyl, 2-iodobutenyl, 1,2-diiodobutenyl, 1,1,2,2-tetraiodobutenyl, 1-iodopentenyl, 2-iodopentenyl, 1,2-diiodopentenyl, 1,1,2,2-tetraiodopentenyl, 1-iodohexenyl, 2-iodohexenyl, 1,2-diiodohexenyl, 1,1,2,2-tetraiodohexenyl; halogen, such as, for example, fluoro, chloro, bromo, or iodo; or hydrogen; wherein R 3 may be a secondary amino group substituted on its nitrogen atom with a linear, cyclic or branched alkyl containing 1 to 20 carbon atom, such as, for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, neobutyl, pentyl, isopentyl, neopentyl, hexyl, isohexyl, neohexyl, cyclohexyl, heptyl, octyl, nonyl, decyl, 2-methylbutyl, 3-methylbutyl, 2-methylpentyl, 3-methylpentyl, 4-methylpentyl, 2,3-dimethylbutyl, 2-ethylhexyl, 3-methylhexyl, 4-methylhexyl, 5-methylhexyl, 2,4-dimethylpentyl, 2-methyl-5-butylhexyl, 2,5-dimethylhexyl, 6-methylheptyl, 2-methylheptyl, 2,2-dimethylheptyl, 4-methylheptyl, 5-methylheptyl, 3,5-dimethylheptyl, 2,5-dimethylheptyl, 2,4-dimethylheptyl.
[0044] This spirooxazines dye is dissolved in an organic solvent such as, for example, toluene, xylene, methanol or ethanol, and irradiated with ultraviolet light at 365 nm, the solution can absorb light with a wavelength between 540 and 600 nm.
[0045] For better understanding the above-mentioned and other objects, features and advantages of the invention, the following examples are provided and used to illustrate the invention more detained in conjunction with the accompanied drawings.
[0046] The photochromic functional colorant, spirooxarines, of a structure shown in FIG. 7 , according to the invention can be synthesized by the following steps:
[0047] 1. The Synthesis of Fisher Base (c):
[0048] As illustrated in the synthetic scheme shown in FIG. 8 , 20.9 g (0.100 mol) of 2,3,3-trimethyl-4,5-benzo-3H-indole, 17.0 g (0.120 mol) of methyl iodide and 200 ml of ethyl acetate were charged in a 500-ml rounded bottom flask and the resulting reaction mixture was heated at 50° C. with stirring for 4 hours. At the end of the reaction, the reaction flask was cooled to 0° C., filtered off organic salts through a filtering funnel (step (b)), and the solid on the funnel was washed with a small amount of ethyl acetate. The thus obtained solid organic salts was basified directly with 3 N sodium hydroxide solution and then extracted several times with ethyl acetate. The combined extracts were concentrated under reduced pressure to remove ethyl acetate to obtain 18.9 g (yield: 84.8%) of Fischer base (c) product.
[0049] 2. Synthesis of Spirooxarines (e) Dye
[0050] According to the reaction scheme illustrated in FIG. 9 , Fischer base (3.0 g, 13.43 mmol) was weighed in a reaction flask. Then, piperidine (2.06 g, 24.17 mmol) and 15 ml ethyl acetate were added and the resulting mixture was heated at 66° C. with stirring for 30 minutes. Thereafter, 1-nitroso-2-naphthol (3.02 g, 17.46 mmol) was added thereto and the reaction was continued for 6 hours. At the end of the reaction, the reaction mixture was cooled to room temperature, and extracted with 3 N HCl aqueous solution. The organic layer was washed with saturated aqueous sodium bicarbonate solution, and saturated brine. The extraction procedure was repeated twice, and then the organic phase was dried over anhydrous sodium carbonate, filtered and concentrated under reduced pressure. The residue was purified with silica gel column chromatography (CH 2 Cl 2 /n-Hexane) to obtain 3.12 g (yield: 50.3%) of the desired spirooxarines (e) product. NMR:
[0051] The change of the thus synthesized spirooxazines in a solvent upon UV irradiation was investigated as follow. The compound was formulated at a concentration of 20 ppm in ethanol and the UV/VIS spectrum of this solution was recorded with reference to ethanol as the standard before UV irradiation. Its maximum absorption was observed at 357 nm. After irradiating under a UV lamp (6 W, 365 nm) for 30 seconds, the UV/VIS absorption spectrum of the same solution was recorded with reference to the original non-irradiated solution, and observed a maximum absorption band at 578 nm.
[0052] While the invention has been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. | The invention provides a photochromic dye of a structure containing a common structure of spirooxazine series compounds and three substituents. The photochromic dye according to the invention exhibits characteristics of a high heat stability, good light fatigue resistance, high sensitivity, extremely degradation rate and the like. This photochromic dye can be formulated with suitable organic solvents and used as photochromic functional colorants under UV light excitation. Further, this photochromic dye can be synthesized and purified in simple steps with cheap raw materials and hence at a greatly lowered production cost. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to a downhole filtration tool for use in oil, gas, and water wells, and more particularly to a downhole filtration tool having a carbon steel mandrel surrounded by a non-metallic element giving the filter improved permeability, resistance to chemical breakdown, and physical strength.
[0003] 2. Description of the Related Art
[0004] Oil and gas wells and water wells include a wellbore extending into a well to some depth below the surface. Typically, the wellbore is lined with casing to strengthen the walls of the borehole. To further strengthen the walls of the borehole, the annular area formed between the casing and the borehole is typically filled with cement to permanently set the casing in the wellbore. The casing is then perforated to allow production fluids to enter the wellbore and be retrieved at the surface of the well.
[0005] Various types of downhole equipment, such as pumps and similar devices, are used to move production fluids from within the wellbore to the surface. A typical downhole arrangement would include a string composed of a series of tubes or tubing suspended from the surface. One type of well-known pump is a downhole electrical submersible pump (ESP). The ESP either includes or is connected to a downhole motor which is sealed so that the whole assembly is submerged in the fluid to be pumped. The motor is connected to a power source at the surface and operates beneath the level of the fluid downhole in order to pump the fluid to the surface. A component is connected to the motor which prevents well fluid from entering the motor and equalizes internal motor pressure with the well annulus pressure.
[0006] A number of factors may be detrimental to the production of the ESP, such as the presence of foreign solid particles, such as sand, sediment, and scale. The amount and size of sand and other solid particles in the fluid may vary widely depending on the well and the conditions encountered. In enhanced recovery operations, for example, fluids may be pumped down the well to stimulate production causing additional movement of sands and solids. The sand and other solid particles act as abrasives and, over time, are damaging to the operation of the pump.
[0007] Yet another problem typically encountered in wells is an excess amount of gas or gas bubbles entering the intake of the pump causing the pump to decrease in efficiency. ESPs have dramatically lower efficiencies with significant fractions of gas, and at some point, the pump may become “gas locked” and damage to the pump and/or motor may result.
[0008] Many types of filters have been designed for use with ESPs. Such filters typically include a filter element designed to screen solid particles from the pump intake; however, the filtered particulates often become entrapped in the filter element. The amount of particulate material collected on the filter element is directly proportional to the to the pressure drop that occurs across the filter element. Since an excessive pressure drop across the filter element can significantly reduce fluid flow, the filter element must be periodically changed or cleaned. Often, this is done by removing the ESP from the fluid and removing the filter element. This can be a timely and inconvenient process. Pumps with intricate backwashing systems have been designed, but these are often expensive and cannot be used to retrofit existing systems. As a result, many pumps are generally operated without any filter and therefore experience early pump failure and extensive and costly down time.
[0009] A problem associated with conventional downhole filtration tools arises in high temperature and/or high pressure applications. High downhole temperatures are generally above 200° F. and up to 450° F., while high downhole pressures are generally above 7,500 psi and up to 15,000 psi. Another problem with downhole filtration tools occurs in both high pH (e.g., more than 8.0) and low pH (e.g., less than 6.0) environments. In these extreme downhole conditions, conventional filters become ineffective and suffer from degradation.
[0010] It is therefore desirable to provide an improved downhole filtration tool for use in oil, gas, and water wells.
[0011] It is further desirable to provide a downhole filtration tool that is connected to and suspended from downhole equipment, such as but not limited to, an ESP and operates as an intake to the pump.
[0012] It is still further desirable to provide a downhole fluid filtration tool capable of separating sand and other solid particles from production fluid while also preventing an undue amount of gas from entering the pump.
[0013] It is yet further desirable to provide a downhole filtration tool having a carbon steel mandrel surrounded by a non-metallic filter element giving the downhole filtration tool improved permeability, resistance to chemical breakdown, and physical strength.
SUMMARY OF THE INVENTION
[0014] In general, the invention relates to a downhole filtration tool having a metallic mandrel juxtaposed between opposing end fittings. The mandrel has a plurality of diametrical perforations and an interior chamber aligned along an axial flow passage through the downhole filtration tool. The end fittings have opposing generally planar axial or open ends axially aligned and coaxially spaced along the flow passage. The downhole filtration tool also has at least one open weave fiberglass filter element circumferentially surrounding the mandrel. The filter element includes a plurality of angularly biased passages extending upwardly at an angle, such as about 10 degrees, and approximately tangentially in relation to the annulus. The filter element includes vortex flow disrupter sections on opposing terminating ends. Each of the flow disrupter sections may be constructed from a rigid resin forming an internal annular shoulder. In addition, the downhole filtration tool includes a separating annulus between the filter element and the mandrel, with the end fittings closing terminal ends of the annulus.
[0015] The mandrel can also include a first terminating end with external threads and a second terminating end with external threads. The first terminating end and/or the second terminating end of the mandrel can include a mandrel threadlock, with each of the mandrel threadlocks being respectively axially aligned with a threadlock channel in the end fitting. The mandrel may be fabricated from investment cast precipitation-hardening corrosion-resistant steel, such as carbon steel, with the end fittings also being fabricated from steel.
[0016] Each of the end fittings can also include a reduced diameter neck with internal threads connected to the external threads of the first terminating end and the second terminating end of the mandrel. Further, each of the end fittings can include a sealing element supported within a circular seal groove for establishing sealing engagement with an external cylindrical sealing surface of the end fitting and an internal cylindrical sealing surface on the vortex flow disrupter section. Additionally, each of the end fittings can include circular sealing elements or seal assemblies located intermediate of an external, circular stop shoulder of the end fitting and the flow disrupter section. The seal assemblies can be carried within a circular seal groove.
[0017] The filter element of the downhole filtration tool may be fabricated from polyurethane, a phenolic, an epoxy resin or a blended epoxy resin, such as a low viscosity, liquid epoxy resin manufactured from bisphenol A or F and epichlorohydrin. The filter element can also be fabricated from a polymeric composite reinforced by fibers, such as glass, carbon and/or aramid, stacked in layers angled at about 30 degrees to about 70 degrees relative to an axis of the filter element.
[0018] Moreover, the downhole filtration tool can have a tight meshed screen or other filter media positioned within the separating annulus. The screen may be fabricated from stainless steel, a meta-aramid fiber, or a meta-aramid fiber blended with a para-aramid, antistatic or other synthetic fibers. The screen is supported by a mesh standoff along the perforations of the mandrel, and the filter element, the screen and the mesh standoff concentrically surround the mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a sectional, partial cutaway view of downhole equipment incorporating the downhole filtration tool disclosed herein connected in a production string;
[0020] FIG. 2 is a diametric cross-sectional view of an example of a downhole filtration tool in accordance with an illustrative embodiment of the invention disclosed herein;
[0021] FIG. 3 is a cross-sectional view of a lower end fitting of the downhole filtration tool shown in FIG. 2 ;
[0022] FIG. 4 is a top plan view of the mounting connector shown in FIG. 3 ;
[0023] FIG. 5 is a cross-sectional view of an upper end fitting of the downhole filter tool shown in FIG. 2 ;
[0024] FIG. 6 is a bottom plan view of the coupler shown in FIG. 5 ;
[0025] FIG. 7 is a cross-sectional view of the mandrel of the downhole filtration tool shown in FIG. 2 ;
[0026] FIG. 8 is a cross-sectional view of the vortex flow disrupter section and the filter element of the downhole filtration tool shown in FIG. 2 ;
[0027] FIG. 9 is a cross-sectional view along line 9 - 9 of the downhole filtration tool shown in FIG. 2 ;
[0028] FIG. 10 is an exploded view of area 10 of the filter element as shown in FIG. 8 ;
[0029] FIG. 11 is a diametric cross-sectional view of another example of a downhole filtration tool in accordance with an illustrative embodiment of the invention disclosed herein;
[0030] FIG. 12 is a cross-sectional view of the mandrel and the filter screen element of the downhole filtration tool shown in FIG. 11 ;
[0031] FIG. 13 is an exploded view of area 13 of the mandrel and the filter screen element as shown in FIG. 12 ; and
[0032] FIG. 14 is a cross-sectional view along line 14 - 14 of the downhole filtration tool shown in FIG. 11 .
[0033] Other advantages and features will be apparent from the following description and from the claims.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The embodiments discussed herein are merely illustrative of specific manners in which to make and use this invention and are not to be interpreted as limiting in scope.
[0035] While the invention has been described with a certain degree of particularity, it is to be noted that many modifications may be made in the construction and the arrangement of its components without departing from the scope of the invention. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification.
[0036] The description of the invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as “front,” “rear,” “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly” etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of description and do not require that the machine be constructed or the method to be operated in a particular orientation. Terms, such as “connected,” “connecting,” “attached,” “attaching,” “join” and “joining” are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece.
[0037] Referring to the figures of the drawings, wherein like numerals of reference designate like elements throughout the several views, and initially to FIG. 1 depicting a sectional view of a downhole filtration tool 10 and downhole equipment used to raise production fluids to the surface. A subterranean well 12 includes a casing 14 which extends from the surface downhole. The casing 14 includes perforations 16 that allow production fluids to pass through the casing 14 . An electrical submersible pump 18 is lowered into the well 12 beneath the level of fluid. The pump 18 is suspended from a string 20 which may be composed of a series of tubes or tubing suspended from the surface, such as from a rig or derrick (not shown). The pump 18 includes a motor (not shown) that is sealed from the fluids. The motor is powered by electrical energy supplied by an energy source at the surface, such as a generator (not shown). The pump 18 is connected to the downhole filtration tool 10 by way of a seating nipple 22 and/or a tubing sub 24 . The pump 18 , the motor, the seating nipple 22 , the tubing sub 24 and other downhole equipment each has an external diameter less than an interior diameter of the casing 14 . Downhole fluid enters the filtration tool 10 and is forced by the motor upward through an axial flow passage 26 of the downhole filtration tool 10 to the pump 18 , which draws the fluid through the string 20 to the surface where it is collected in a tank (not shown) or otherwise delivered by a pipeline or other known means.
[0038] FIGS. 2 through 10 illustrate the downhole filtration tool 10 having a first end terminating in an upper end fitting 28 , which connects with an intake end of the pump 18 or may be connected to other downhole equipment, such as the tubing sub 24 . As illustrated, the end fitting 28 has a reduced diameter neck 30 with internal threads 32 that are connected to a first terminating end of a mandrel 34 with external threads 36 . A sealing element 38 may be supported within a circular seal groove 40 of the neck 30 , which establish sealing engagement with an external cylindrical sealing surface 42 of the end fitting 28 and an internal cylindrical sealing surface 44 on a first terminating end of a vortex flow disrupter section 46 of the downhole filtration tool 10 . The end fitting 28 is also provided with circular sealing elements or seal assemblies 48 located intermediate of an external, circular stop shoulder 50 of the end fitting 28 and the flow disrupter section 46 . The seal assemblies 48 may be carried within a circular seal groove 52 . The sealing element 38 and/or the sealing assemblies 48 can be constructed from elastomer and polymer materials capable of accomplishing effective sealing at normal to high operating temperatures and at all pressure ranges. The end fitting 28 also includes an internally threaded section 54 that receives an externally threaded section 56 of the tubing sub 24 and other downhole equipment. Additionally, the end fitting 28 may include a threadlock channel 58 having internal threads 60 .
[0039] The downhole filtration tool 10 has a second end terminating in a lower end fitting 62 , which connects with the motor or other downhole equipment. The lower end fitting 62 has a first terminating end with a reduced diameter neck 64 having external threads 68 that are connected to the motor or other downhole equipment. The lower end fitting 62 also includes a second terminating end with a reduced diameter neck 70 having internal threads 72 that are connected to a second terminating end of the mandrel 34 with external threads 74 . Similarly to the upper end fitting 28 , the lower end fitting 62 may include a sealing element 76 supported within a circular seal groove 78 of the neck 70 , which establish sealing engagement with an external cylindrical sealing surface 80 of the end fitting 62 and an internal cylindrical sealing surface 82 on a second terminating end of the vortex flow disrupter section 46 of the downhole filtration tool 10 . The end fitting 62 is also provided with circular sealing elements or seal assemblies 84 located intermediate of an external, circular stop shoulder 86 of the end fitting 62 and the flow disrupter section 46 . The seal assemblies 84 may be carried within a circular seal groove 66 . The sealing element 76 and/or the sealing assemblies 84 can be constructed from elastomer and polymer materials capable of accomplishing effective sealing at normal to high operating temperatures and at all pressure ranges. Additionally, the end fitting 62 may include a threadlock channel 88 having internal threads 90 .
[0040] The mandrel 34 is connected intermediate of and juxtaposed between the upper end fitting 28 and the lower end fitting 62 . An interior chamber 98 within the mandrel 34 is axially aligned along the flow passage 26 through the downhole filtration tool 10 . In addition, a central bore 97 in the upper end fitting 28 and a central bore 99 in the lower end fitting 62 have opposing generally planar axial or open ends that are axially aligned and coaxially spaced along the flow passage 26 . The mandrel 34 includes the first terminating end with external threads 36 and the second terminating end with external threads 74 . In addition, the first terminating end and/or the second terminating end of the mandrel 34 include a mandrel threadlock 92 and 94 , which is axially aligned with the threadlock channel 58 in the upper end fitting 28 and the threadlock channel 88 in the lower end fitting 62 , respectively. The mandrel 34 includes a plurality of diametrical perforations 96 along its length to permit fluids to pass from the well 12 into the interior chamber 98 within the mandrel 34 . The perforations 96 may be round as illustrated or may be slotted or a combination of holes and slots that are punched or drilled through the mandrel 34 . The mandrel 34 may be fabricated from investment cast precipitation-hardening corrosion-resistant steel, such carbon steel accompanied with steel upper and lower end fittings 28 and 62 .
[0041] A removable filter element 100 concentrically surrounds the mandrel 34 . A separating annulus 102 is formed between the filter element 100 and the mandrel 34 , and the upper end fitting 28 and the lower end fitting 62 close a first terminating end and a second terminating end of the annulus 102 . The filter element 100 includes a plurality of angularly biased passages 104 extending upwardly at an angle 106 of approximately 10 degrees and approximately tangentially 108 in relation to the annulus 102 . If the filter element 100 becomes clogged or damaged, the filter element 100 may be removed and replaced as necessary. In addition, the filter element 100 may be constructed as single standalone elements or as stackable elements. A first end and a second end of the filter element 100 each respectively terminate with the vortex flow disrupter section 46 . The flow disrupter section 46 is constructed of a rigid resin that forms a terminal end collar. The inner periphery of the disrupter section 46 may include an annular shoulder 118 that contacts the neck 30 of the end fitting 28 .
[0042] The filter element 100 is an open weave fiberglass filter constructed to withstand very high or low pH environments as well as elevated temperatures and high pressure differentials. The filter element is constructed of a polymeric composite that is reinforced by a continuous fiber such as glass, carbon, or aramid, for example, having a porosity of between about 33% to about 43% per linear foot. The individual fibers are typically layered parallel to each other, and wound layer upon layer. However, each individual layer is wound at an angle of about 45 degrees to provide additional strength and stiffness to the composite material in high temperature and pressure downhole conditions. The polymeric composite may be polyurethane, a phenolic, an epoxy resin, such as a low viscosity, liquid epoxy resin manufactured from bisphenol A or F and epichlorohydrin (e.g., EPON™ Resin 862, Momentive Specialty Chemicals, Inc.) or a blended epoxy resin. Prepreg strands and rovings (e.g., Advantax®, Owens Corning Composite Materials, LLC; 346 Type 30® Roving, Owens Corning Composite Materials, LLC) can also be used to form a matrix or the fibers can be wet wound. A post cure process may be performed to achieve greater strength of the material, and heat can be added during the curing process to provide the appropriate reaction energy to drive the cross-linking of the matrix to completion. The composite may also be exposed to ultraviolet light or a high-intensity electron beam to provide the reaction energy to cure the polymeric composite. The foregoing materials are merely examples that may be utilized in constructing the downhole filtration tool 10 and other materials may be employed to suit the particular usage of the downhole filtration tool 10 .
[0043] Referring now to FIGS. 11 through 13 illustrating an embodiment of the downhole filtration tool 10 having an additional tight meshed screen or other filter media 110 positioned within the separating annulus 102 . The screen 110 may be constructed from stainless steel, a meta-aramid fiber (e.g., NOMEX®, Du Pont) or a meta-aramid fiber blended with a para-aramid, antistatic or other synthetic fibers. The screen 110 may be supported by a mesh standoff 112 along the perforations 96 of the mandrel 34 . In addition, the terminating ends of the screen 110 may include a double fold 114 . Terminating ends of the screen 110 and the mesh standoff 112 may be respectively secured to the mandrel 34 above the uppermost and below the lowermost perforations 96 by a suitable easily removable tape, band, strap or the like 116 . As illustrated, the filter element 100 , the screen 110 and the mesh standoff 112 concentrically surround the mandrel 34 .
[0044] During operation, fluid from the well 12 will sequentially flow through the perforations 16 in the casing 14 , through the filter element 100 , through the screen 110 , if present, and/or the mesh standoff 112 , through the perforations 96 in the mandrel 36 , through the interior chamber 98 of the mandrel 36 and through the upper end fitting 28 to an intake nut (not shown) and the pump 18 . The casing perforations 16 will filter out larger solids and the filter element 100 will filter out smaller sand and other solid particles. The screen 110 and the standoff 112 , if present, prevent loss of filter media through the perforations ( 16 ).
[0045] Whereas, the embodiments have been described in relation to the drawings, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the scope of this invention. | A downhole filtration tool to remove sand and other solid particles from production fluid in a subterranean well. The downhole filtration tool includes a perforated mandrel surrounded by at least one filter element made of an open weave polymeric fiberglass material. In addition, the downhole filtration tool may include an additional screen or mesh installed in a separating annulus intermediate of the mandrel and the filter element to provide a filter having improved permeability and resistance to chemical and physical forces. | 4 |
CROSS-REFERENCES TO RELATED APPLICATION
[0001] This patent application claims the benefit of priority under 35 U.S.C. §119 of Korean Patent Application No. 10-2008-0084563 filed on Aug. 28, 2008, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to novel phenylacetate derivatives or pharmaceutically acceptable salts thereof, a preparation method thereof, and a composition for prevention or treatment of diseases induced by activation of a T-type calcium ion channel containing the same as an active ingredient.
[0004] 2. Description of the Related Art
[0005] These calcium ion channels are divided into a high-voltage activated calcium channel and a low-voltage activated calcium channel, among which a T-type calcium ion channel is a representative low-voltage activated calcium channel.
[0006] Calcium ion channels play an important role in the intracellular signal transduction by increasing intracellular calcium concentration through nerve cell stimulation. These calcium channels are divided into a high-voltage activated calcium channel and a low-voltage activated calcium channel, and a T-type calcium ion channel is a representative example of the low-voltage activated calcium channels. The T-type calcium ion channel is found in central muscles, endocrine glands in the adrenal, sinoatrial node, and heart. A T-type calcium ion channel antagonist is known to have therapeutic effect on brain diseases, such as epilepsy and hypertension cardiac diseases, such as encephalopathy and angina pectoris [Hosravani, Houman et al., “Effects of Cav3.2 channel mutations linked to idiopathic generalized epilepsy”, Annals of Neurology (2005), 57(5), 745-749; Vitko, Iuliia et al., “Functional characterization and neuronal modeling of the effects of childhood absence epilepsy variants of CACNA1H, a T-type calcium channel”, Journal of Neuroscience (2005), 25(19), 4844-4855]. A recent study reported that a T-type calcium ion channel antagonist has an activity in treatment of chronic pain [ Drugs of the Future (2005), 40, 573-580]. For example, Mibefradil and Ethosuximide, as T-type calcium ion channel antagonists, showed dosage-dependent reversed mechanic and thermal induction in a spinal nerve ligation animal model, thus ascertaining that the T-type calcium ion channel antagonists have a therapeutic effect on neurogenic pains [Barton, Matthew E. et al., “The antihyperalgesic effects of the T-type calcium channel blockers ethosuximide, trimethadione, and mibefradil”, European Journal of Pharmacology (2005), 521(1-3), 79-85].
[0007] Calcium plays an important role as an intracellular messenger and regulates a variety of cellular processes. Calcium is known to be involved in cell growth among the cellular processes, and it is expected that a T-type calcium ion channel antagonist may have an anticancer activity [Nat. Rev. Mol. Cell Biol. 2003, 4, 517-529].
[0008] Calcium channel blockers can be classified into three classes: dihydropyridines (e.g., nifedipine), benzothiazepines (e.g., diltiazem), and phenylalkylamines (e.g., verapamil).
[0009] When the current is measured, a T-type calcium ion channel is activated at potential near the resting membrane potential, and the current is quickly activated and referred to as “transient” due to its fast inactivation. As the single channel conductance in the calcium ion channel has tiny characteristics compared to different calcium ion channels, the calcium ion channel is referred to as “T-type calcium ion channel” after the first alphabet representing these characteristics. Compared to other calcium ion channels, the T-type calcium ion channel has the activation of such a low threshold that it serves as a pacemaker, which produces simultaneous action potentials in the sinoatrial node and nerve cells, leading to the atrium contraction and is known to be involved in smooth muscle contraction, secretion of cortisol and aldosterone in adrenal cortex, excitability of Nerve, and development of tissues. In the T-type, 3 classes of the subtype cDNA are cloned and expressed. Each of them is expressed as a 1G (Cav3.1), a 1H (Cav3.2), and a 1I (Cav3.3), and then the measured currents exhibit characteristics such as activation and inactivation reaction rates, slow activation reduction, and tiny single channel conductance as known in the art. However, the a 1I shows very slow activation and inactivation reaction rates compared to the a 1G and a 1H .
[0010] Much has not yet been known about the T-type due to the lack of the specific blockers, and more researches should be carried out. Recent studies show that in addition to functions by the calcium ion channels, such as muscular contraction, synaptic transmission, hormone secretion, control of enzyme activity, and control of gene expression, knockout of genes encoding calcium ion channels and a variety of hereditary diseases related to nerve, muscle, and visual sense are induced by mutation in the calcium ion channel. Thus, the importance of studies on calcium ion channels is being emphasized. Most of the calcium ion channel antagonists used in the studies as drugs have shown a physiological activity predominantly in the L-type calcium ion channels. However, these drugs show side effects such as excessive contraction of muscles, increased secretion from neurohormones, and coronary occlusion. Therefore, to reduce these side effects and enhance the efficacy of the drugs, screening efforts to find blockers which exhibit a selective activity to the T-type are underway.
[0011] Among the conventional calcium ion channel blockers, flunarizine, U-92032, nicardipine, and mibefradil are exemplary materials which show a selective inhibitory activity. These usually have diphenylmethylpiperazine or dihydropyridine structures as a basic framework.
[0012] Mibefradil is the first commercially available as a T-type calcium ion channel antagonist. The mibefradil showed more inhibitory activity to the T-type than to the L-type by 10 to 30 times, but was banned from the market due to drug interactions with antihistamines such as especially, astemizole to be metabolized in cytochrome P-450 3A4 and 2D6. Therefore, there remains a demand on urgent development of T-type calcium ion channels.
[0013] There have been many efforts to develop T-type calcium ion channel antagonists, but there are few selective T-type calcium ion channel antagonists. Compounds with quinazoline as a basic framework are disclosed in Korean Pat. Nos. 784,195, 754,325, and 749,743. Compounds with isoxazole as a framework are disclosed in Korean Pat. No. 616,099, and compounds with 1,3-dioxoisoindole as a framework are disclosed in Korean Pat. No. 743,255.
[0014] However, there still remains a demand on T-type calcium ion channel antagonists with good selectivity to T-type calcium ion channels, good pharmacokinetics profile, good ADME (adsorption, distribution, metabolism, excretion) and having a therapeutic effect on related diseases such as hypertension, cancer, epilepsy, and neurogenic pains. Thus, there is a need to develop materials which have a different structure from conventional T-type calcium ion channel antagonists and a higher selectivity.
[0015] The present inventors attempted to develop novel T-type calcium ion channel antagonists which may effectively inhibit the activity of T-type calcium ion channels, synthesized novel phenylacetate derivatives, and confirmed that the phenylacetate derivatives show the inhibitory activity of T-type calcium ion channels, thereby leading to completion of the present invention.
SUMMARY OF THE INVENTION
[0016] The object of the present invention is to provide phenylacetate derivatives which may effectively inhibit T-type calcium ion channels, or pharmaceutically acceptable salts thereof.
[0017] Another object of the present invention is to provide intermediates when the phenylacetate derivatives are prepared.
[0018] Further object of the present invention is to provide a composition for prevention and treatment of diseases cause by the activity of T-type calcium ion channels, containing phenylacetate derivatives or pharmaceutically acceptable salts thereof as an effective ingredient.
[0019] To achieve the objects, the present invention provides new phenylacetate derivatives or pharmaceutically acceptable salts thereof.
[0020] The present invention also provides a preparation method of the phenylacetate derivatives.
[0021] Furthermore, the present invention provides intermediates when the phenylacetate derivatives are prepared.
[0022] The present invention also provides a composition for prevention and treatment of diseases cause by the activity of T-type calcium ion channels, containing phenylacetate derivatives or pharmaceutically acceptable salts thereof as an effective ingredient.
[0023] The composition containing the phenylacetate derivatives according to the present invention effectively inhibits the activity of T-type calcium ion channels and may be useful for prevention or treatment of diseases such as hypertension, cancer, epilepsy, and neurogenic pains induced by the activity of T-type calcium ion channels.
[0024] The present invention provides phenylacetate derivatives represented by the following Chemical Formula 1, or pharmaceutically acceptable salts thereof.
[0000]
[0025] Where,
[0026] X is independently or selectively one or more substituents selected from the group consisting of H, halogen, and a C 1-4 alkoxy,
[0027] R 1 is a C 1-4 linear or branched alkyl,
[0028] R 2 is
[0000]
[0029] where R 3 and R 4 are independently or selectively H, a C 1-4 linear or branched alkyl, or a C 1-4 alkoxy, and
[0030] Y is C or N.
[0031] R 5 is a C 1-4 linear or branched alkyl substituted by one or more C 5-6 aryl; unsubstituted, or one or more halogens, a C 1-4 linear or branched alkyl, a C 1-4 linear or branched alkyl substituted by one or more halogens, or phenyl substituted by a C 1-4 alkoxy; unsubstituted, or one or more halogens, a C 1-4 linear or branched alkyl, a C 1-4 linear or branched alkyl substituted by one or more halogens, or benzyl substituted by a C 1-4 alkoxy; or unsubstituted, or one or more halogens, a C 1-4 linear or branched alkyl, a C 1-4 linear or branched alkyl substituted by one or more halogens, or benzylidene substituted by a C 1-4 alkoxy.
[0032] Preferably,
[0033] X is independently or selectively one or more substituents selected from the group consisting of H, fluoride, chloride, bromide, methoxy and ethoxy,
[0034] R 1 is methyl, ethyl, propyl, and isopropyl,
[0035] R 2 is
[0000]
[0036] where R 3 and R 4 are independently or selectively H, methyl, ethyl, methoxy or ethoxy, and
[0037] Y is C or N.
[0038] R 5 is benzhydryl; unsubstituted, or one or more fluoride, chloride, bromide, methyl, ethyl, methyl substituted by one or more fluorides, and phenyl substituted by methoxy or ethoxy; unsubstituted, or one or more fluoride, chloride, bromide, methyl, ethyl, methyl substituted by one or more fluorides, and benzyl substituted by methoxy or exthoxy; or unsubstituted, or benzylidene substituted by one or more fluoride, chloride, bromide, methyl, ethyl, methoxy or ethoxy.
[0039] More preferably,
[0040] X is one or more substituents selected from the group consisting of H, fluoride, bromide and ethoxy,
[0041] R 1 is methyl or ethyl,
[0042] R 2 is
[0000]
[0043] where R 3 and R 4 are independently or selectively H, methyl or methoxy,
[0044] Y is C or N, and
[0045] R 5 is benzhydryl, phenyl, fluorophenyl, chlorophenyl, methoxyphenyl, fluorobenzyl, trifluoromethylbenzyl, chlorobenzyl, dichlorobenzyl, 2-chloro-6-fluorobenzyl, methylbenzyl, t-butylbenzyl, methoxybenzyl, trimethoxybenzyl, fluorobenzylidene, chlorobenzylidene, methylbenzylidene or methoxybenzylidene.
[0046] The piperidine derivatives represented by the Chemical Formula 1 are more specifically described as followings:
[0047] (1) 5-{[3-(1H-benzimidazole-2-yl)propyl]methylamino}-2-(4-bromophenyl)-2-isopropylpentanoic acid methyl ester;
[0048] (2) 2-(4-bromophenyl)-2-isopropyl-5-(4-phenylpiperazine-1-yl)pentanoic acid methyl ester;
[0049] (3) 2-(4-bromophenyl)-2-isopropyl-5-[4-(4-methoxybenzylidene)piperidine-1-yl]pentanoic acid methyl ester;
[0050] (4) methyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropyl-2-(4-methoxyphenyl)pentanoate;
[0051] (5) methyl 2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(4-methoxyphenyl)pentanoate;
[0052] (6) methyl 5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropyl-2-(4-methoxyphenyl)pentanoate;
[0053] (7) methyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(3,4-dimethoxyphenyl)-2-isopropylpentanoate;
[0054] (8) methyl 2-(3,4-dimethoxyphenyl)-2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)pentanoate;
[0055] (9) methyl 2-(3,4-dimethoxyphenyl)-5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropylpentanoate;
[0056] (10) ethyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropyl-2-phenylpentanoate;
[0057] (11) ethyl 5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropyl-2-phenylpentanoate;
[0058] (12) methyl 2-(4-bromophenyl)-5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropylpentanoate;
[0059] (13) methyl 2-(4-bromophenyl)-2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)pentanoate;
[0060] (14) methyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(3-bromophenyl)-2-isopropylpentanoate;
[0061] (15) methyl 2-(3-bromophenyl)-2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)pentanoate;
[0062] (16) methyl 2-(3-bromophenyl)-5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropylpentanoate;
[0063] (17) methyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0064] (18) methyl 2-(4-fluorophenyl)-2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)pentanoate;
[0065] (19) methyl 5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0066] (20) ethyl 2-isopropyl-5-(4-(2-methoxyphenyl)piperazine-1-yl)-2-phenylpentanoate;
[0067] (21) ethyl 2-isopropyl-5-(4-(3-methoxyphenyl)piperazine-1-yl)-2-phenylpentanoate;
[0068] (22) ethyl 2-isopropyl-5-(4-(4-methoxyphenyl)piperazine-1-yl)-2-phenylpentanoate;
[0069] (23) ethyl 2-isopropyl-5-(4-(4-methoxybenzyl)piperazine-1-yl)-2-phenylpentanoate;
[0070] (24) ethyl 5-(4-(2-fluorophenyl)piperazine-1-yl)-2-isopropyl-2-phenylpentanoate;
[0071] (25) ethyl 5-(4-(4-fluorophenyl)piperazine-1-yl)-2-isopropyl-2-phenylpentanoate;
[0072] (26) ethyl 5-(4-(4-fluorobenzyl)piperazine-1-yl)-2-isopropyl-2-phenylpentanoate;
[0073] (27) methyl 5-(4-benzhydrylpiperazine-1-yl)-2-(4-bromophenyl)-2-isopropylpentanoate;
[0074] (28) methyl 2-(4-bromophenyl)-5-(4-(2-fluorophenyl)piperazine-1-yl)-2-isopropylpentanoate;
[0075] (29) methyl 2-(4-bromophenyl)-5-(4-(4-fluorophenyl)piperazine-1-yl)-2-isopropylpentanoate;
[0076] (30) methyl 2-(4-bromophenyl)-5-(4-(2-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0077] (31) methyl 2-(4-bromophenyl)-5-(4-(3-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0078] (32) methyl 2-(4-bromophenyl)-5-(4-(4-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0079] (33) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate;
[0080] (34) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate;
[0081] (35) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(2-methoxyphenyl)piperazine-1-yl)pentanoate;
[0082] (36) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methoxyphenyl)piperazine-1-yl)pentanoate;
[0083] (37) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methoxyphenyl)piperazine-1-yl)pentanoate;
[0084] (38) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methoxybenzyl)piperazine-1-yl)pentanoate;
[0085] (39) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(2,3,4-trimethoxybenzyl)piperazine-1-yl)pentanoate;
[0086] (40) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methylbenzyl)piperazine-1-yl)pentanoate;
[0087] (41) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methylbenzyl)piperazine-1-yl)pentanoate;
[0088] (42) methyl 2-(4-bromophenyl)-5-(4-(4-t-butylbenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0089] (43) methyl 2-(4-bromophenyl)-5-(4-(3-chlorophenyl)piperazine-1-yl)-2-isopropylpentanoate;
[0090] (44) methyl 2-(4-bromophenyl)-5-(4-(3-chlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0091] (45) methyl 2-(4-bromophenyl)-5-(4-(4-chlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0092] (46) methyl 2-(4-bromophenyl)-5-(4-(3,4-dichlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0093] (47) methyl 2-(4-bromophenyl)-5-(4-(2-chloro-6-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0094] (48) methyl 2-(3-bromophenyl)-5-(4-(2-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0095] (49) methyl 2-(3-bromophenyl)-5-(4-(3-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0096] (50) methyl 2-(3-bromophenyl)-5-(4-(4-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0097] (51) methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(3-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate;
[0098] (52) methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(4-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate;
[0099] (53) methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(4-methoxybenzyl)piperazine-1-yl)pentanoate;
[0100] (54) methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(3,4,5-trimethoxybenzyl)piperazine-1-yl)pentanoate;
[0101] (55) methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(3-methylbenzyl)piperazine-1-yl)pentanoate;
[0102] (56) methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(4-methylbenzyl)piperazine-1-yl)pentanoate;
[0103] (57) methyl 2-(3-bromophenyl)-5-(4-(4-t-butylbenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0104] (58) methyl 2-(3-bromophenyl)-5-(4-(3-chlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0105] (59) methyl 2-(3-bromophenyl)-5-(4-(4-chlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0106] (60) methyl 2-(3-bromophenyl)-5-(4-(3,4-dichlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate;
[0107] (61) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-phenylpiperazine-1-yl)pentanoate;
[0108] (62) methyl 5-(4-benzhydrylpiperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0109] (63) methyl 2-(4-fluorophenyl)-5-(4-(2-fluorophenyl)piperazine-1-yl)-2-isopropylpentanoate;
[0110] (64) methyl 2-(4-fluorophenyl)-5-(4-(4-fluorophenyl)piperazine-1-yl)-2-isopropylpentanoate;
[0111] (65) methyl 5-(4-(2-fluorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0112] (66) methyl 5-(4-(3-fluorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0113] (67) methyl 5-(4-(4-fluorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0114] (68) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(3-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate;
[0115] (69) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(4-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate;
[0116] (70) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(2-methoxyphenyl)piperazine-1-yl)pentanoate;
[0117] (71) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(3-methoxyphenyl)piperazine-1-yl)pentanoate;
[0118] (72) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(4-methoxyphenyl)piperazine-1-yl)pentanoate;
[0119] (73) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(4-methoxybenzyl)piperazine-1-yl)pentanoate;
[0120] (74) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(2,3,4-trimethoxybenzyl)piperazine-1-yl)pentanoate;
[0121] (75) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(3-methylbenzyl)piperazine-1-yl)pentanoate;
[0122] (76) methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(4-methylbenzyl)piperazine-1-yl)pentanoate;
[0123] (77) methyl 5-(4-(4-t-butylbenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0124] (78) methyl 5-(4-(3-chlorophenyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0125] (79) methyl 5-(4-(3-chlorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0126] (80) methyl 5-(4-(4-chlorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0127] (81) methyl 5-(4-(3,4-dichlorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate;
[0128] (82) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methoxybenzyl)piperidine-1-yl)pentanoate;
[0129] (83) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methoxybenzylidene)piperidine-1-yl)pentanoate;
[0130] (84) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methoxybenzyl)piperidine-1-yl)pentanoate;
[0131] (85) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methylbenzylidene)piperidine-1-yl)pentanoate;
[0132] (86) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methylbenzyl)piperidine-1-yl)pentanoate;
[0133] (87) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methylbenzylidene)piperidine-1-yl)pentanoate;
[0134] (88) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methylbenzyl)piperidine-1-yl)pentanoate;
[0135] (89) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(2-methylbenzylidene)piperidine-1-yl)pentanoate;
[0136] (90) methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(2-methylbenzyl)piperidine-1-yl)pentanoate;
[0137] (91) methyl 2-(4-bromophenyl)-5-(4-(4-chlorobenzylidene)piperidine-1-yl)-2-isopropylpentanoate;
[0138] (92) methyl 2-(4-bromophenyl)-5-(4-(4-chlorobenzyl)piperidine-1-yl)-2-isopropylpentanoate;
[0139] (93) methyl 2-(4-bromophenyl)-5-(4-(3-chlorobenzylidene)piperidine-1-yl)-2-isopropylpentanoate;
[0140] (94) methyl 2-(4-bromophenyl)-5-(4-(3-chlorobenzyl)piperidine-1-yl)-2-isopropylpentanoate;
[0141] (95) methyl 2-(4-bromophenyl)-5-(4-(4-fluorobenzylidene)piperidine-1-yl)-2-isopropylpentanoate;
[0142] (96) methyl 2-(4-bromophenyl)-5-(4-(4-fluorobenzyl)piperidine-1-yl)-2-isopropylpentanoate;
[0143] (97) methyl 2-isopropyl-5-(4-(4-methoxybenzylidene)piperidine-1-yl)-2-(4-methoxyphenyl)pentanoate;
[0144] (98) methyl 2-isopropyl-5-(4-(4-methoxybenzyl)piperidine-1-yl)-2-(4-methoxyphenyl)pentanoate;
[0145] (99) methyl 2-isopropyl-5-(4-(3-methoxybenzylidene)piperidine-1-yl)-2-(4-methoxyphenyl)pentanoate;
[0146] (100) methyl 2-isopropyl-5-(4-(3-methoxybenzyl)piperidine-1-yl)-2-(4-methoxyphenyl)pentanoate;
[0147] (101) methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(4-methylbenzylidene)piperidine-1-yl)pentanoate;
[0148] (102) methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(4-methylbenzyl)piperidine-1-yl)pentanoate;
[0149] (103) methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(3-methylbenzylidene)piperidine-1-yl)pentanoate;
[0150] (104) methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(3-methylbenzyl)piperidine-1-yl)pentanoate;
[0151] (105) methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(2-methylbenzylidene)piperidine-1-yl)pentanoate;
[0152] (106) methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(2-methylbenzyl)piperidine-1-yl)pentanoate;
[0153] (107) methyl 5-(4-(4-chlorobenzylidene)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate;
[0154] (108) methyl 5-(4-(4-chlorobenzyl)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate;
[0155] (109) methyl 5-(4-(3-chlorobenzylidene)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate;
[0156] (110) methyl 5-(4-(3-chlorobenzyl)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate;
[0157] (111) methyl 5-(4-(4-fluorobenzylidene)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate; and
[0158] (112) methyl 5-(4-(4-fluorobenzyl)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate.
[0159] The phenylacetate derivatives of the present invention, represented by the Chemical Formula 1 may be used in the form of a pharmaceutically acceptable salt, and acid addition salts formed by pharmaceutically acceptable free acids are useful as salts. The acid addition salts may be obtained from inorganic acids, such as hydrochloric acid, nitric acid, phosphoric acid, sulfuric acid, hydrobromic acid, hydriodic acid, nitrous acid or phosphorous acid and non-toxic organic acids, such as aliphatic mono- and dicarboxylates, phenyl-substituted alkanoate, hydroxyl alkanoate and alkanedioate, aromatic acids, and non-toxic organic acids, such as aliphatic and aromatic sufonic acids. These pharmaceutically non-toxic salts include sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, nitrate, phosphate, monohydrogen phosphate, dihydrogen phosphate, metaphosphate, pyrophosphate chloride, bromide, iodide, fluoride, acetate, propionate, decanoate, caprylate, acrylate, formate, isobutyrate, caprate, heptanoate, propiolate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, butyne-1,4-dioate, hexane-1,6-dioate, benzoate, chlorobenzoate, methylbenzoate, dinitro benzoate, hydroxybenzoate, methoxybenzoate, phthalate, terephthalate, benzenesulfonate, toluenesulfonate, chlorobenzensulfonate, xylenesulfonate, phenylacetate, phenylpropionate, phenylbutyrate, citrate, lactate, β-hydroxybutyrate, glycolate, maleate, tartrate, methanesulfonate, propanesulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate or mandelate.
[0160] The acid addition salts according to the present invention may be prepared by conventional methods, for example by dissolving derivatives of the Chemical Formula 1 in excess of an acid addition salt and precipitating the resulting salts in an water-miscible organic solvent, for example, methanol, ethanol, acetone or acetonitrile.
[0161] After the solvent from the mixture or acid in excess is evaporated, the salts may be prepared by drying the precipitated salts or filtration under vacuum.
[0162] Pharmaceutically acceptable salts may also be prepared using bases. Alkali metals or alkali earth metals may be obtained, for example by dissolving the compound in excess of an alkali metal hydroxide or an alkali earth metal hydroxide solution, filtrating the non-soluble compound salts, evaporating the filtrate, and drying it. Then, suitable pharmaceutically acceptable salts include sodium, potassium or calcium salts. In addition, the corresponding salts are obtained by reacting alkali metals or alkali earth metals with a suitable silver salt (ex., silver nitrate).
[0163] The phenylacetate derivatives represented by the Chemical Formula 1 include pharmaceutically acceptable salts, all the salts prepared by conventional methods, hydrates and solvates.
[0164] The acid addition salts may be synthesized by conventional methods, for example by dissolving the compound of the Chemical Formula 1 in a water-miscible solvent, for example, acetone, methanol, ethanol, or acetonitrile, adding an organic acid in excess or an acid-water solution of inorganic acids, and then precipitating or crystallizing it. After the solvent from the mixture or acid in excess is evaporated, the acid addition salts may be obtained or the precipitated salts may be prepared from the filtrate evaporated under vacuum.
[0165] As described in the following Reaction Formula 1, the present invention provides a preparation method of phenylacetate derivatives, including:
[0166] Preparing an ester compound of Chemical Formula 3 by esterification reaction of a carboxyl acid compound of Chemical Formula 2 as a starting material under an acid catalyst (Step 1);
[0167] Preparing a compound of Chemical Formula 4 by reacting the compound of Chemical Formula 3 obtained from step 1 with t-butoxide and isopropyl bromide (Step 2);
[0168] Preparing a compound of Chemical Formula 5 by reacting the compound of Chemical Formula 4 obtained from step 2 with 1,3-dibromopropane (Step 3); and
[0169] Preparing the compound of Chemical Formula 1 by reacting the compound of Chemical Formula 5 obtained from step 3 with a compound of Chemical Formula 6 or Chemical Formula 7 (Step 4).
[0000]
[0170] (Where, R 1 , R 2 , R 3 , R 4 , R 5 , X, and Y are as defined in the Chemical Formula 1).
[0171] Hereinafter, the preparation method according to the present invention will be described step-by-step.
[0172] Step 1
[0173] The Step 1 according to the present invention is a step of preparing an ester compound of Chemical Formula 3 by esterification reaction of a carboxyl acid compound of Chemical Formula 2 as a starting material under an acid catalyst.
[0174] The compound of Chemical Formula 2 as a starting material is commercially available or obtained by a synthesis method known in the art.
[0175] The reaction in the Step 1 is commonly known in the organic chemistry art, and the reaction conditions such as reaction solvents, reaction temperature, and reaction times may be suitably selected, considering reactants and products. For example, methanol was used as a reaction solvent, and the compound of the Chemical Formula 3 was obtained by heating or refluxing the mixture at 85˜95° C. under an acid catalyst, especially in the presence of sulfuric acid for 2˜4 hours.
[0176] Step 2
[0177] The Step 2 according to the present invention is a step of preparing a compound of Chemical Formula 4 by reacting the compound of Chemical Formula 3 in the step 1 with t-butoxide and isopropyl bromide.
[0178] Specifically, a compound of Chemical Formula 4 may be obtained by dissolving the compound of Chemical Formula 3 and t-butoxide in anhydrous dimethylformamide as a reaction solvent, adding isopropyl bromide into the mixture, and stirring the mixture at room temperature for 2˜4 hours.
[0179] Step 3
[0180] The Step 3 according to the present invention is a step of preparing a compound of Chemical Formula 5 by reacting the compound of Chemical Formula 4 in the step 2 with 1,3-dibromopropane.
[0181] Anhydrous tetrahydrofuran may be used as a reaction solvent.
[0182] Specifically, amines such as diisopropylamine, and a solution of n-butyllithium in hexane are added into the reaction solvent at low temperatures of −75˜−80° C. A compound of Chemical Formula 5 may be obtained by adding and stirring the compound of Chemical Formula 4, dropping 1,3-dibromopropane into the solution, and stirring it at room temperature overnight.
[0183] Step 4
[0184] The Step 4 according to the present invention is a step of preparing the compound of Chemical Formula 1 by reacting the compound of Chemical Formula 5 in the step 3 with the compound of Chemical Formula 6 or Chemical Formula 7.
[0185] When the compound of Chemical Formula 5 is reacted with benzimidazole derivatives, the compound of Chemical Formula 1 may be obtained by dissolving the compound of Chemical Formula 5 into methanol, adding variously substituted benzimidazole derivatives and potassium carbonate, and heating or refluxing the mixture at 85˜95° C. for 2˜4 hours.
[0186] When the compound of Chemical Formula 5 is reacted with piperazine or piperidine derivatives, the compound of Chemical Formula 1 may be obtained by dissolving the compound of Chemical Formula 5 in acetonitrile, adding variously substituted piperazine or piperidine derivatives, triethylamine, and sodium iodate, and heating or refluxing the mixture at 85˜95° C. for 2˜4 hours.
[0187] Furthermore, the present invention provides compounds represented by the following Chemical Formula 3, Chemical Formula 4, or Chemical Formula 5 produced as intermediates when the phenylacetate derivatives are prepared.
[0000]
[0188] In the chemical formulas 3˜5, X and R 1 are as defined in the Chemical Formula 1.
[0189] After the phenylacetate derivatives or intermediates are prepared above by the present invention, their molecular structures may be identified by IR, NMR, mass spectroscopy, liquid chromatography, X-ray crystallography, and comparison of the actual element analysis values with the calculated values.
[0190] Furthermore, the present invention provides a composition for prevention or treatment of diseases induced by the activation of T-type calcium ion channels, containing the phenylacetate derivatives or pharmaceutically acceptable salts thereof as an active ingredient.
[0191] The T-type calcium ion channel is found in central muscles, endocrine glands in the adrenal, sinoatrial node, and heart. A T-type calcium ion channel antagonist is known to have therapeutic effect on brain diseases, such as epilepsy and hypertension cardiac diseases, such as encephalopathy and angina pectoris [Hosravani, Houman et al., “Effects of Cav3.2 channel mutations linked to idiopathic generalized epilepsy”, Annals of Neurology (2005), 57(5), 745-749; Vitko, Iuliia et al., “Functional characterization and neuronal modeling of the effects of childhood absence epilepsy variants of CACNA1H, a T-type calcium channel”, Journal of Neuroscience (2005), 25(19), 4844-4855]. A recent study reported that a T-type calcium ion channel antagonist has an activity in treatment of chronic pain [ Drugs of the Future (2005), 40, 573-580]. For example, Mibefradil and Ethosuximide, as T-type calcium ion channel antagonists, showed dosage-dependent reversed mechanic and thermal induction in a spinal nerve ligation animal model, thus ascertaining that the T-type calcium ion channel antagonists have a therapeutic effect on neurogenic pains [Barton, Matthew E. et al., “The antihyperalgesic effects of the T-type calcium channel blockers ethosuximide, trimethadione, and mibefradil”, European Journal of Pharmacology (2005), 521(1-3), 79-85].
[0192] Calcium plays an important role as an intracellular messenger and regulates a variety of cellular processes. Calcium is known to be involved in cell growth among the cellular processes, and it is expected that a T-type calcium ion channel antagonist may have an anticancer activity [Nat. Rev. Mol. Cell Biol. 2003, 4, 517-529].
[0193] It is shown that the phenylacetate derivatives and pharmaceutically acceptable salts thereof as an active ingredient in the composition according to the present invention significantly inhibit the streams of calcium ions in the T-type calcium ion channels of HEK293 cells (See Experimental Example 1 and Table 2). Thus, the composition according to the present invention effectively inhibits the activation of T-type calcium ion channels and may be useful in the prevention or treatment of diseases, such as hypertension, cancer, epilepsy, and neurogenic pains induced by the activation of T-type calcium ion channels.
[0194] In addition, the present invention provides the use of the phenylacetate derivatives of Chemical Formula 1 used in the manufacture of drugs for prevention and treatment of diseases, such as hypertension, cancer, epilepsy, and neurogenic pains induced by the activation of T-type calcium ion channels, or pharmaceutically acceptable salts thereof.
[0195] Furthermore, the present invention provides a method for treatment of diseases, such as hypertension, cancer, epilepsy, and neurogenic pains induced by the activation of T-type calcium ion channels, including administering a pharmaceutically effective amount of the phenylacetate derivatives of Chemical Formula 1 or pharmaceutically acceptable salts thereof to mammals or patients in need. The mammals include humans.
[0196] When the composition of the present invention is used as a medicine, a pharmaceutical composition containing the phenylacetate derivatives represented by Chemical Formula 1, or pharmaceutically acceptable salts thereof as an active ingredient may be prepared in the forms of, but not limited to, various oral or parenteral administrations and administered.
[0197] Formulations for oral administration include, for example, tablets, pills, soft/hard capsules, solutions, suspensions, emulsions, syrups, granules, and elixirs. These formulations contain a diluent (ex., lactose, dextrose, sucrose, mannitol, sorbitol, cellulose and/or glycine) and a lubricant (ex., silica, talc, stearic acid and magnesium or calcium salts thereof, and/or polyethylene glycol) as well as an active ingredient. The tablets may also contain a binding agent, such as magnesium aluminum silicate, starch paste, gelatin, methylcellulose, sodium carboxymethylcellulose, and/or polyvinylpyrrolidine. In some cases, they may contain a disintegrating agent such as starch, agar, alginic acid, or sodium salt thereof, or boiling mixture and/or an absorbent, a colorant, a flavoring agent, and a sweetening agent.
[0198] A pharmaceutical composition of the derivatives represented by Chemical Formula 1 as an active ingredient may be parenterally administered. The parenteral administration includes injection methods such as subcutaneous, intravenous or intramuscular injection, or intrapleural injection.
[0199] To prepare a formulation for parenteral administration, the phenylacetate derivatives of Chemical Formula 1 or pharmaceutically acceptable salts thereof may be mixed with a stabilizer or a buffer in water, and prepared in an ampoule or a vial unit dosage form. The composition may be sterilized and/or contain expedients such as preservatives, stabilizers, wetting agents, or emulsifiers, salts for osmotic pressure and/or buffers, and other therapeutically useful materials. It may be prepared by conventional methods, such as mixing, granulation, or coating method.
[0200] The dosage of the compound of the present invention may depend on the age, body weight, and sex of a patient, the dosage form, and the severity of the disease. For a 70 kg adult patient, the dosage is generally 0.1˜1,000 mg/day, preferably 1˜500 mg/day, and may be administered once a day to several times a day at a constant time interval at the discretion of the doctor or pharmacist.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0201] Hereinafter, the present invention will be described by Embodiments and Experimental Examples. However, the following embodiments are given to illustrate the present invention, are not to be construed as being limiting.
<Embodiment 1> Preparation of 5-{[3-(1H-benzimidazole-2-yl)propyl]methylamino}-2-(4-bromophenyl)-2-isopropylpentanoic acid methyl ester
Step 1: Preparation of (4-bromophenyl)acetic acid methyl ester
[0202] (4-bromophenyl)acetic acid (10 g, 1 eq) was dissolved in methanol. 10 ml conc. H 2 SO 4 was added into the solution and the mixture was heated and refluxed for 3 hours. When the reaction was completed, the mixture was vacuum distilled and extracted with ethyl acetate and water. After the organic layer was washed with saturated NaHCO 3 , the target compound (4-bromophenyl)acetic acid methyl ester was obtained by drying the layer with anhydrous magnesium sulfate and removing the solvent at low pressures (9.87 g, 93%).
[0203] 1 H NMR (400 MHz, CDCl 3 ) δ 7.45 (d, J=8.4 Hz, 2H) , 7.16 (d, J=8.4 Hz, 2H) 3.70 (s, 3H), 3.59 (s, 2H)
Step 2: Preparation of 2-(4-bromophenyl)-3-methylbutyric acid methyl ester
[0204] The (4-bromophenyl)acetic acid methyl ester in the Step 1 and potassium t-butoxide (4.8 g, 1 eq) were dissolved in 200 ml DMF at 0° C. Isopropyl bromide (4 ml. 1 eq) was added into the mixture and stirred at room temperature for 3 hours. When the reaction was completed, the mixture was extracted 3 times with ethyl acetate and water, and washed with saline solution. After the organic layer was dried with anhydrous and the solvent was removed at low pressures, the target compound 2-(4-bromophenyl)3-methylbutyric acid methyl ester was obtained by separation and purification of the mixture using a column chromatography (ethyl acetate:n-hexane=1:10) (6.60 g, 57%).
[0205] 1H NMR (400 MHz, CDCl3) δ 7.42 (d, J=8.3 Hz, 2H), 7.20 (d, J=8.4 Hz, 2H), 3.64 (s, 3H), 3.11 (d, J=10.5 Hz, 1H), 2.31-2.25 (m, 1H), 1.01 (d, J=6.5 Hz, 3H), 0.69 (d, J=6.7 Hz, 3H)
Step 3: Preparation of 5-bromo-2-(4-bromophenyl)-2-isopropylpentanoic acid methyl ester
[0206] Diisopropylamine (5.04 ml, 1.5 eq) in anhydrous THF at −78° C. and n-butyllithium in hexane were mixed and dissolved into 2.5 M of solution (10.55 ml, 1.1 eq). The 2-(4-bromophenyl)-methylbutyric acid methyl ester (6.5 g, 1 eq) in the Step 2 was added into the solution and stirred. After 30 minutes, 1,3-dibromopropane (7.31 ml, 3 eq) was dissolved in anhydrous THF. The mixture was dropped into the solution and stirred at room temperature overnight. When the reaction was completed, the compound was extracted with diethylether and water, washed with 1N HCl and saturated NaHCO 3 . The organic layer was dried with anhydrous magnesium sulfate and the solvent was removed at low pressures. Subsequently, the target compound 5-bromo-2-(4-bromophenyl)-2-isopropylpentanoic methyl ester was obtained by separation and purification of the mixture using a column chromatography (ethyl acetate:n-hexane=1:100) (5.98 g, 44%).
[0207] 1H NMR (400 MHz, CDCl3) δ 7.46 (d, J=8.7 Hz, 2H), 7.08 (d, J=8.7 Hz, 2H), 3.74 (s, 3H), 3.38-3.30 (m, 2H), 2.43-2.38 (m, 1H), 2.22-2.15 (m, 1H), 2.10-2.03 (m, 1H), 1.73-1.69 (m, 1H), 1.60-1.53 (m, 1H), 0.89 (d, J=6.7 Hz, 3H), 0.80 (d, J=6.8 Hz, 3H)
Step 4: Preparation of 5-{[3-(1H-benzimidazole-2-yl)propyl]methylamino}-2-(4-bromophenyl)-2-isopropylpentanoic acid methyl ester
[0208] After the 5-bromo-2-(4-bromophenyl)-2-isopropylpentanoic acid methyl ester (1 g, 1 eq) was dissolved in ethanol, [3-(1H-benzimidazole-2-yl)propyl]methylamine (0.66 g, 1 eq) as a benzimidazole derivative, and potassium carbonate (0.58 g, 1.2 eq) were added into the solution and heated and refluxed for 3 hours. When the reaction was completed, the precipitate was filtrated and the solvent was removed at low pressures. The target compound 5-{[3-(1H-benzimidazole-2-yl)propyl]methylamino}-2-(4-bromophenyl)-2-isopropyl pentanoic acid methyl ester was obtained by separation and purification of the mixture using a column chromatography (ethyl acetate:methanol=10:1) (635 mg, 36%).
[0209] 1H NMR (400 MHz, CDCl3) δ 7.45 (bs, 2H), 7.39 (d, J=8.6 Hz, 2H), 7.18 (dd, J=6.0, 3.1 Hz, 2H), 7.10 (d, J=8.6 Hz, 2H), 3.69 (s, 3H), 3.04 (t, J=6.4 Hz, 2H), 2.48 (t, J=5.8 Hz, 2H), 2.40-2.35 (m, 3H), 2.21 (s, 3H), 2.10-2.04 (m, 1H), 1.98-1.89 (m, 3H), 1.43-1.23 (m, 2H), 0.85 (d, J=6.8 Hz, 3H), 0.74 (d, J=6.8 Hz, 3H)
<Embodiment 2> Preparation of 2-(4-bromophenyl)-2-isopropyl-5-(4-phenylpiperazine-1-yl)pentanoic acid methyl ester
Step 1˜3: Preparation of 5-bromo-2-(4-bromophenyl)-2-isopropylpentanoic acid methyl ester
[0210] The target compound was obtained by repeating the same process as in the Steps 1˜3 of Embodiment 1.
Step 4: Preparation of 2-(bromophenyl)-2-isopropyl-5-(4-phenylpiperazine-1-yl)pentanoic acid methyl ester
[0211] After the 5-bromo-2-(4-bromophenyl)-2-isopropylpentanoic acid methyl ester (200 mg, 1 eq) was dissolved in acetonitrile, 4-phenylpiperazine (70 mg, 1 eq) as a piperazine derivative, Et 3 N (0.06 ml, 1.2 eq), and sodium iodate were added into the solution and heated and refluxed for 3 hours. When the reaction was completed, the precipitate was filtrated and the mixture was vacuum distilled and extracted with ethyl acetate and water. After the organic layer was washed with 1N HCl and saturated NaHCO 3 , the target compound 2-(4-bromophenyl)-2-isopropyl-5-(4-phenylpiperazine-1-yl)pentanoic acid methyl ester was obtained by drying the mixture with anhydrous sodium sulfate and removing the solvent at low pressures (69 mg, 42%).
[0212] 1H NMR (400 MHz, CDCl3) δ 12.92 (s, 1H), 7.45-7.40 (m, 5H), 7.27-7.25 (m, 1H), 7.07-7.00 (m, 2H). 4.28 (s,2H), 3.76 (s, 3H), 3.59-3.56 (m, 4H), 3.48-3.45 (m, 1H), 3.02 (s, 2H), 2.41-2.25 (m, 2H), 1.91-1.76 (m, 2H), 1.46-1.24 (m, 2H), 0.91 (d, J=6.5 Hz, 3H), 0.80 (d, J=6.6 Hz, 3H)
<Embodiment 3> Preparation of 2-(4-bromophenyl)-2-isopropyl-5-[4-(4-methoxybenzylidene)piperidine-1-yl]pentanoic acid methyl ester
[0213] Except that 4-(4-methoxybenzylidene)piperidine (122 mg, 1 eq) as a piperidine derivative instead of a piperazine derivative in the Step 4 was used, the target compound 2-(4-bromophenyl)-2-isopropyl-5-[4-(4-methoxybenzylidene)piperidine-1-yl]pentanoic acid methyl ester was obtained by carrying out the same processes as in the Embodiment 2 (212 mg, 81%).
[0214] 1H NMR (400 MHz, CDCl3) δ 7.42 (d, J=8.5 Hz, 2H), 7.11 (d, J=8.7 Hz, 2H), 7.06 (d, J=8.6 Hz, 2H), 6.84 (d, J=8.7 Hz, 2H), 6.20 (s, 1H), 3.80 (s, 3H), 3.72 (s, 3H), 2.43-2.36 (m, 5H), 2.35-2.27 (m, 5H), 2.02-1.96 (m, 3H), 1.27 (m, 1H), 0.85 (d, J=6.7 Hz, 3H), 0.75 (d, J=6.8 Hz, 3H)
<Embodiment 4> Preparation of methyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropyl-2-(4-methoxyphenyl)pentanoate
[0215] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (146 mg, 37%).
<Embodiment 5> Preparation of methyl 2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(4-methoxyphenyl)pentanoate
[0216] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (118 mg, 43%).
<Embodiment 6> Preparation of methyl 5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropyl-2-(4-methoxyphenyl)pentanoate
[0217] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (158 mg, 38%).
<Embodiment 7> Preparation of methyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(3,4-dimethoxyphenyl)-2-isopropylpentanoate
[0218] Except that (3,4-dimethoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (508 mg, 37%).
<Embodiment 8> Preparation of methyl 2-(3,4-dimethoxyphenyl)-2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)pentanoate
[0219] Except that (3,4-dimethoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (179 mg, 43%).
<Embodiment 9> Preparation of methyl 2-(3,4-dimethoxyphenyl)-5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropylpentanoate
[0220] Except that (3,4-dimethoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (63 mg, 46%).
<Embodiment 10> Preparation of ethyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropyl-2-phenylpentanoate
[0221] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (35 mg, 20%).
<Embodiment 11> Preparation of ethyl 5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropyl-2-phenylpentanoate
[0222] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (208 mg, 49%).
<Embodiment 12> Preparation of methyl 2-(4-bromophenyl)-5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropylpentanoate
[0223] Except that (3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (112 mg, 22%).
<Embodiment 13> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)pentanoate
[0224] Except that (3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (127 mg, 23%).
<Embodiment 14> Preparation of methyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(3-bromophenyl)-2-isopropylpentanoate
[0225] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (70 mg, 54%).
<Embodiment 15> Preparation of methyl 2-(3-bromophenyl)-2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)pentanoate
[0226] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (115 mg, 83%).
<Embodiment 16> Preparation of methyl 2-(3-bromophenyl)-5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-isopropylpentanoate
[0227] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (65 mg, 47%).
<Embodiment 17> Preparation of methyl 5-((3-(1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0228] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (76 mg, 27%).
<Embodiment 18> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-((3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)pentanoate
[0229] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5-methoxy-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (133 mg, 46%).
<Embodiment 19> Preparation of methyl 5-((3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)(methyl))amino)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0230] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(5,6-dimethyl-1H-benzo[d]imidazole-2-yl)propyl)methylamine was used as a benzimidazole derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 1 (118 mg, 42%).
<Embodiment 20> Preparation of ethyl 2-isopropyl-5-(4-(2-methoxyphenyl)piperazine-1-yl)-2-phenylpentanoate
[0231] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (78 mg, 57%).
<Embodiment 21> Preparation of ethyl 2-isopropyl-5-(4-(3-methoxyphenyl)piperazine-1-yl)-2-phenylpentanoate
[0232] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (84 mg, 61%).
<Embodiment 22> Preparation of ethyl 2-isopropyl-5-(4-(4-methoxyphenyl)piperazine-1-yl)-2-phenylpentanoate
[0233] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (75 mg, 56%).
<Embodiment 23> Preparation of ethyl 2-isopropyl-5-(4-(4-methoxybenzyl)piperazine-1-yl)-2-phenylpentanoate
[0234] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methoxybenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (38 mg, 53%).
<Embodiment 24> Preparation of ethyl 5-(4-(2-fluorophenyl)piperazine-1-yl)-2-isopropyl-2-phenylpentanoate
[0235] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2-fluorophenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (75 mg, 57%).
<Embodiment 25> Preparation of ethyl 5-(4-(4-fluorophenyl)piperazine-1-yl)-2-isopropyl-2-phenylpentanoate
[0236] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-fluorophenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (71 mg, 54%).
<Embodiment 26> Preparation of ethyl 5-(4-(4-fluorobenzyl)piperazine-1-yl)-2-isopropyl-2-phenylpentanoate
[0237] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (54 mg, 40%).
<Embodiment 27> Preparation of methyl 5-(4-benzhydrylpiperazine-1-yl)-2-(4-bromophenyl)-2-isopropylpentanoate
[0238] Except that benzhydrylpiperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (114 mg, 58%).
<Embodiment 28> Preparation of methyl 2-(4-bromophenyl)-5-(4-(2-fluorophenyl)piperazine-1-yl)-2-isopropylpentanoate
[0239] Except that (2-fluorophenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (45 mg, 26%).
<Embodiment 29> Preparation of methyl 2-(4-bromophenyl)-5-(4-(4-fluorophenyl)piperazine-1-yl)-2-isopropylpentanoate
[0240] Except that (4-fluorophenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (27 mg, 6%).
<Embodiment 30> Preparation of methyl 2-(4-bromophenyl)-5-(4-(2-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0241] Except that (2-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (103 mg, 58%).
<Embodiment 31> Preparation of methyl 2-(4-bromophenyl)-5-(4-(3-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0242] Except that (3-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (103 mg, 59%).
<Embodiment 32> Preparation of methyl 2-(4-bromophenyl)-5-(4-(4-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0243] Except that (4-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (101 mg, 57%).
<Embodiment 33> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate
[0244] Except that (3-(trifluoromethyl)benzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (124 mg, 65%).
<Embodiment 34> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate
[0245] Except that (4-(trifluoromethyl)benzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (97 mg, 51%).
<Embodiment 35> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(2-methoxyphenyl)piperazine-1-yl)pentanoate
[0246] Except that (2-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (83 mg, 47%).
<Embodiment 36> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methoxyphenyl)piperazine-1-yl)pentanoate
[0247] Except that (3-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (55 mg, 31%).
<Embodiment 37> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methoxyphenyl)piperazine-1-yl)pentanoate
[0248] Except that (4-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (55 mg, 31%).
<Embodiment 38> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methoxybenzyl)piperazine-1-yl)pentanoate
[0249] Except that (4-methoxybenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (93 mg, 52%).
<Embodiment 39> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(2,3,4-trimethoxybenzyl)piperazine-1-yl)pentanoate
[0250] Except that (2,3,4-trimethoxybenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (121 mg, 60%).
<Embodiment 40> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methylbenzyl)piperazine-1-yl)pentanoate
[0251] Except that (3-methylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (112 mg, 64%).
<Embodiment 41> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methylbenzyl)piperazine-1-yl)pentanoate
[0252] Except that (4-methylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (107 mg, 61%).
<Embodiment 42> Preparation of methyl 2-(4-bromophenyl)-5-(4-(4-t-butylbenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0253] Except that (4-t-butylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (80 mg, 42%).
<Embodiment 43> Preparation of methyl 2-(4-bromophenyl)-5-(4-(3-chlorophenyl)piperazine-1-yl)-2-isopropylpentanoate
[0254] Except that (3-chlorophenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (60 mg, 34%).
<Embodiment 44> Preparation of methyl 2-(4-bromophenyl)-5-(4-(3-chlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0255] Except that (3-chlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (112 mg, 69%).
<Embodiment 45> Preparation of methyl 2-(4-bromophenyl)-5-(4-(4-chlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0256] Except that (4-chlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (111 mg, 63%).
<Embodiment 46> Preparation of methyl 2-(4-bromophenyl)-5-(4-(3,4-dichlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0257] Except that (3,4-dichlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (100 mg, 52%).
<Embodiment 47> Preparation of methyl 2-(4-bromophenyl)-5-(4-(2-chloro-6-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0258] Except that (2-chloro-6-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (125 mg, 66%).
<Embodiment 48> Preparation of methyl 2-(3-bromophenyl)-5-(4-(2-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0259] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (95 mg, 68%).
<Embodiment 49> Preparation of methyl 2-(3-bromophenyl)-5-(4-(3-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0260] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (98 mg, 71%).
<Embodiment 50> Preparation of methyl 2-(3-bromophenyl)-5-(4-(4-fluorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0261] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (94 mg, 68%).
<Embodiment 51> Preparation of methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(3-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate
[0262] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(trifluoromethyl)benzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (77 mg, 51%).
<Embodiment 52> Preparation of methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(4-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate
[0263] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-(trifluoromethyl)benzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (77 mg, 51%).
<Embodiment 53> Preparation of methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(4-methoxybenzyl)piperazine-1-yl)pentanoate
[0264] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methoxybenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (75 mg, 53%).
<Embodiment 54> Preparation of methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(3,4,5-trimethoxybenzyl)piperazine-1-yl)pentanoate
[0265] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3,4,5-trimethoxybenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (104 mg, 66%).
<Embodiment 55> Preparation of methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(3-methylbenzyl)piperazine-1-yl)pentanoate
[0266] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-methylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (96 mg, 70%).
<Embodiment 56> Preparation of methyl 2-(3-bromophenyl)-2-isopropyl-5-(4-(4-methylbenzyl)piperazine-1-yl)pentanoate
[0267] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (75 mg, 54%).
<Embodiment 57> Preparation of methyl 2-(3-bromophenyl)-5-(4-(4-t-butylbenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0268] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-t-butylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (89 mg, 60%).
<Embodiment 58> Preparation of methyl 2-(3-bromophenyl)-5-(4-(3-chlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0269] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-chlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (96 mg, 67%).
<Embodiment 59> Preparation of methyl 2-(3-bromophenyl)-5-(4-(4-chlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0270] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-chlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (114 mg, 80%).
<Embodiment 60> Preparation of methyl 2-(3-bromophenyl)-5-(4-(3,4-dichlorobenzyl)piperazine-1-yl)-2-isopropylpentanoate
[0271] Except that (3-bromophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3,4-dichlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (79 mg, 55%).
<Embodiment 61> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-phenylpiperazine-1-yl)pentanoate
[0272] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and phenylpiperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (145 mg, 59%).
<Embodiment 62> Preparation of methyl 5-(4-benzhydrylpiperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0273] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and benzhydrylpiperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (45 mg, 30%).
<Embodiment 63> Preparation of methyl 2-(4-fluorophenyl)-5-(4-(2-fluorophenyl)piperazine-1-yl)-2-isopropylpentanoate
[0274] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2-fluorophenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (69 mg, 53%).
<Embodiment 64> Preparation of methyl 2-(4-fluorophenyl)-5-(4-(4-fluorophenyl)piperazine-1-yl)-2-isopropylpentanoate
[0275] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-fluorophenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (88 mg, 68%).
<Embodiment 65> Preparation of methyl 5-(4-(2-fluorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0276] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (80 mg, 60%).
<Embodiment 66> Preparation of methyl 5-(4-(3-fluorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0277] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (120 mg, 90%).
<Embodiment 67> Preparation of methyl 5-(4-(4-fluorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0278] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-fluorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (106 mg, 79%).
<Embodiment 68> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(3-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate
[0279] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-(trifluoromethyl)benzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (154 mg, 52%).
<Embodiment 69> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(4-(trifluoromethyl)benzyl)piperazine-1-yl)pentanoate
[0280] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-(trifluoromethyl)benzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (110 mg, 37%).
<Embodiment 70> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(2-methoxyphenyl)piperazine-1-yl)pentanoate
[0281] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (110 mg, 41%).
<Embodiment 71> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(3-methoxyphenyl)piperazine-1-yl)pentanoate
[0282] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (155 mg, 58%).
<Embodiment 72> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(4-methoxyphenyl)piperazine-1-yl)pentanoate
[0283] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methoxyphenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (172 mg, 65%).
<Embodiment 73> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(4-methoxybenzyl)piperazine-1-yl)pentanoate
[0284] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methoxybenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (186 mg, 68%).
<Embodiment 74> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(2,3,4-trimethoxybenzyl)piperazine-1-yl)pentanoate
[0285] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2,3,4-trimethoxybenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (187 mg, 60%).
<Embodiment 75> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(3-methylbenzyl)piperazine-1-yl)pentanoate
[0286] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-methylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (222 mg, 84%).
<Embodiment 76> Preparation of methyl 2-(4-fluorophenyl)-2-isopropyl-5-(4-(4-methylbenzyl)piperazine-1-yl)pentanoate
[0287] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (201 mg, 76%).
<Embodiment 77> Preparation of methyl 5-(4-(4-t-butylbenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0288] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-t-butylbenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (150 mg, 55%).
<Embodiment 78> Preparation of methyl 5-(4-(3-chlorophenyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0289] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-chlorophenyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (207 mg, 77%).
<Embodiment 79> Preparation of methyl 5-(4-(3-chlorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0290] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-chlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (238 mg, 86%).
<Embodiment 80> Preparation of methyl 5-(4-(4-chlorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0291] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-chlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (194 mg, 70%).
<Embodiment 81> Preparation of methyl 5-(4-(3,4-dichlorobenzyl)piperazine-1-yl)-2-(4-fluorophenyl)-2-isopropylpentanoate
[0292] Except that (4-fluorophenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3,4-dichlorobenzyl)piperazine was used as a piperazine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 2 (239 mg, 80%).
<Embodiment 82> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methoxybenzyl)piperidine-1-yl)pentanoate
[0293] Except that (4-methoxybenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (232 mg, 80%).
<Embodiment 83> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methoxybenzylidene)piperidine-1-yl)pentanoate
[0294] Except that (3-methoxybenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (219 mg, 86%).
<Embodiment 84> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methoxybenzyl)piperidine-1-yl)pentanoate
[0295] Except that (3-methoxybenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (207 mg, 81%).
<Embodiment 85> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methylbenzylidene)piperidine-1-yl)pentanoate
[0296] Except that (4-methylbenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (236 mg, 92%).
<Embodiment 86> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(4-methylbenzyl)piperidine-1-yl)pentanoate
[0297] Except that (4-methylbenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (226 mg, 85%).
<Embodiment 87> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methylbenzylidene)piperidine-1-yl)pentanoate
[0298] Except that (3-methylbenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (224 mg, 85%).
<Embodiment 88> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(3-methylbenzyl)piperidine-1-yl)pentanoate
[0299] Except that (3-methylbenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (225 mg, 88%).
<Embodiment 89> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(2-methylbenzylidene)piperidine-1-yl)pentanoate
[0300] Except that (2-methylbenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (93 mg, 71%).
<Embodiment 90> Preparation of methyl 2-(4-bromophenyl)-2-isopropyl-5-(4-(2-methylbenzyl)piperidine-1-yl)pentanoate
[0301] Except that (2-methylbenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (98 mg, 74%).
<Embodiment 91> Preparation of methyl 2-(4-bromophenyl)-5-(4-(4-chlorobenzylidene)piperidine-1-yl)-2-isopropylpentanoate
[0302] Except that (4-chlorobenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (114 mg, 88%).
<Embodiment 92> Preparation of methyl 2-(4-bromophenyl)-5-(4-(4-chlorobenzyl)piperidine-1-yl)-2-isopropylpentanoate
[0303] Except that (4-chlorobenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (113 mg, 87%).
<Embodiment 93> Preparation of methyl 2-(4-bromophenyl)-5-(4-(3-chlorobenzylidene)piperidine-1-yl)-2-isopropylpentanoate
[0304] Except that (3-chlorobenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (81 mg, 80%).
<Embodiment 94> Preparation of methyl 2-(4-bromophenyl)-5-(4-(3-chlorobenzyl)piperidine-1-yl)-2-isopropylpentanoate
[0305] Except that (3-chlorobenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (118 mg, 87%).
<Embodiment 95>Preparation of methyl 2-(4-bromophenyl)-5-(4-(4-fluorobenzylidene)piperidine-1-yl)-2-isopropylpentanoate
[0306] Except that (4-fluorobenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (105 mg, 77%).
<Embodiment 96> Preparation of methyl 2-(4-bromophenyl)-5-(4-(4-fluorobenzyl)piperidine-1-yl)-2-isopropylpentanoate
[0307] Except that (4-fluorobenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (129 mg, 98%).
<Embodiment 97> Preparation of methyl 2-isopropyl-5-(4-(4-methoxybenzylidene)piperidine-1-yl)-2-(4-methoxyphenyl)pentanoate
[0308] Except that phenylacetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methoxybenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (231 mg, 88%).
<Embodiment 98> Preparation of methyl 2-isopropyl-5-(4-(4-methoxybenzyl)piperidine-1-yl)-2-(4-methoxyphenyl)pentanoate
[0309] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methoxybenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (196 mg, 75%).
<Embodiment 99> Preparation of methyl 2-isopropyl-5-(4-(3-methoxybenzylidene)piperidine-1-yl)-2-(4-methoxyphenyl)pentanoate
[0310] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-methoxybenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (214 mg, 84%).
<Embodiment 100> Preparation of methyl 2-isopropyl-5-(4-(3-methoxybenzyl)piperidine-1-yl)-2-(4-methoxyphenyl)pentanoate
[0311] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-methoxybenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (222 mg, 87%).
<Embodiment 101> Preparation of methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(4-methylbenzylidene)piperidine-1-yl)pentanoate
[0312] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methylbenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (222 mg, 87%).
<Embodiment 102> Preparation of methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(4-methylbenzyl)piperidine-1-yl)pentanoate
[0313] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-methylbenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (217 mg, 82%).
<Embodiment 103> Preparation of methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(3-methylbenzylidene)piperidine-1-yl)pentanoate
[0314] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-methylbenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (228 mg, 86%).
<Embodiment 104> Preparation of methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(3-methylbenzyl)piperidine-1-yl)pentanoate
[0315] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-methylbenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (222 mg, 86%).
<Embodiment 105> Preparation of methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(2-methylbenzylidene)piperidine-1-yl)pentanoate
[0316] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2-methylbenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (107 mg, 79%).
<Embodiment 106> Preparation of methyl 2-isopropyl-2-(4-methoxyphenyl)-5-(4-(2-methylbenzyl)piperidine-1-yl)pentanoate
[0317] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (2-methylbenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (111 mg, 82%).
<Embodiment 107> Preparation of methyl 5-(4-(4-chlorobenzylidene)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate
[0318] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-chlorobenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (109 mg, 83%).
<Embodiment 108> Preparation of methyl 5-(4-(4-chlorobenzyl)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate
[0319] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-chlorobenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (106 mg, 81%).
<Embodiment 109> Preparation of methyl 5-(4-(3-chlorobenzylidene)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate
[0320] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-chlorobenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (81 mg, 62%).
<Embodiment 110> Preparation of methyl 5-(4-(3-chlorobenzyl)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate
[0321] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (3-chlorobenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (122 mg, 89%).
<Embodiment 111> Preparation of methyl 5-(4-(4-fluorobenzylidene)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate
[0322] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-fluorobenzylidene)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (118 mg, 86%).
<Embodiment 112> Preparation of methyl 5-(4-(4-fluorobenzyl)piperidine-1-yl)-2-isopropyl-2-(4-methoxyphenyl)pentanoate
[0323] Except that (4-methoxyphenyl)acetic acid instead of (4-bromophenyl)acetic acid was used in the Step 1 and (4-fluorobenzyl)piperidine was used as a piperidine derivative in the Step 4, the target compound was obtained by carrying out the same processes as in the Embodiment 3 (97 mg, 73%).
[0324] The structure and 1 H NMR data of the phenylacetate derivatives in the Embodiment 4-112 obtained by the preparation method of the present invention are described in the following Table 1.
[0000]
TABLE 1
Embodi
ment
Structure
NMR
4
7.45 (bs, 2 H), 7.17 (dd. J = 6.0, 3.2 Hz, 2 H), 7.04 (d, J = 8.8 Hz, 2 H), 6.80 (d, J = 8.9 Hz, 2 H), 3.77 (s, 3 H), 3.69 (s, 3 H), 3.05 (t, J = 6.3 Hz, 2 H), 2.49 (t, J = 5.9 Hz, 2 H), 2.42-2.36 (m, 3 H), 2.23 (s, 3 H), 2.17-2.10 (m, 1 H), 1.96-1.87 (m, 4 H), 1.49-1.25 (m, 2 H), 0.87 (d, J = 6.7 Hz, 3 H), 0.77 (d, J = 6.8 Hz, 3 H)
5
7.34-7.32 (m, 1 H), 7.03 (d, J = 8.8 Hz, 2 H), 6.97 (bs, 1 H), 6.81-6.75 (m, 3 H), 3.81 (s, 3 H), 3.76 (s, 3 H), 3.68 (s, 3 H), 2.98 (t, J = 6.3 Hz, 2 H), 2.45 (d, J = 5.8 Hz, 2 H), 2.40-2.34 (m, 3 H), 2.19 (s, 3 H), 2.09-2.06 (m, 1 H), 1.93-1.87 (m, 3 H), 1.44-1.26 (m, 2 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
6
7.25 (bs, 2 H), 7.04 (d, J = 8.8 Hz, 2 H), 6.79 (d, J = 8.8 Hz, 2 H), 3.76 (s, 3 H), 3.69 (s, 3 H), 3.00-2.97 (m, 2 H), 2.44 (t, J = 5.9 Hz, 2 H), 2.40-2.33 (m, 3 H), 2.33 (s, 6 H), 2.16 (s, 3 H), 2.20-2.06 (m, 1 H), 1.96-2.88 (m, 3 H), 1.45-1.26 (m, 2 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
7
7.52-7.50 (m, 2 H), 7.17-7.15 (m, 2 H), 6.74 (d, J = 8.3 Hz, 1 H), 6.68-6.64 (m, 2 H), 3.84 (s, 3 H), 3.79 (s, 3 H), 3.69 (s, 3 H), 3.03 (t, J = 6.3 Hz, 2 H), 2.49 (t J = 5.6 Hz, 2 H), 2.42-2.37 (m, 3 H), 2.22 (s, 3 H), 2.14-2.11 (m, 2 H), 1.95-1.89 (m, 3 H), 1.48-1.25 (m, 2 H), 0.87 (d, J = 6.7 Hz, 3 H), 0.77 (d, J = 6.7 Hz, 3 H)
8
7.41-7.31 (m, 1 H), 6.99 (m, 1 H), 6.81 (dd, J = 8.7, 2.4 Hz, 1 H), 6.74 (d, J = 8.4 Hz, 1 H), 6.69-6.64 (m, 2 H), 3.85 (s, 3 H), 3.82 (s, 3 H), 3.80 (s, 3 H), 3.70 (s, 3 H), 3.02-2.99 (m, 3 H), 2.47 (t, J = 5.1 Hz, 2 H), 2.41-2.40 (m, 4 H), 2.23 (s, 3 H), 2.12-2.08 (m, 2 H), 1.94-1.91 (m, 3 H), 1.49-1.25 (m, 2 H), 0.87 (d, J = 6.7 Hz, 3 H), 0.79 (d, J = 6.8 Hz, 3 H)
9
7.25 (s, 1 H), 6.74 (d, J = 8.3 Hz, 1 H), 6.96-6.61 (m, 2 H), 3.83 (s, 3 H), 3.79 (s, 3 H), 3.70 (s, 3 H), 2.99-2.96 (m, 2 H), 2.51-2.36 (m, 5 H), 2.32 (s, 6 H), 2.18 (s, 3 H), 2.11-2.08 (m, 2 H), 1.96-1.90 (m, 3 H), 1.45-1.27 (m, 2 H), 0.87 (d, J = 6.7 Hz, 3 H), 0.78 (d, J = 6.8 Hz, 3 H)
10
7.53-7.43 (m, 2 H), 7.29-7.27 (m, 1 H), 7.23-7.21 (m, 1 H), 7.18-7.10 (m, 5 H), 4.24-4.18 (m, 2 H), 3.07 (t, J = 6.3 Hz, 2 H), 2.51 (t, J = 5.7 Hz, 2 H), 2.45-2.39 (m, 3 H), 2.31 (s, 3 H), 2.19 (m, 1 H), 1.96-1.95 (m, 4 H), 1.54-1.49 (m, 2 H), 1.23 (t, J = 7.1 Hz, 3 H), 0.88 (d, J = 6.8 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
11
7.29-7.27 (m, 2 H), 7.25-7.18 (m, 3 H), 7.15-7.13 (m, 2 H), 4.24-4.22 (m, 2 H), 3.01-2.98 (m, 2 H), 2.46-2.38 (m, 5 H), 2.33 (m, 6 H), 2.18 (m, 3 H), 1.92-1.89 (m, 3 H), 1.50-1.46 (m, 2 H), 1.24 (t, J = 7.1 Hz, 3 H), 0.88 (d, J = 6.7 Hz, 3 H), 0.79 (d, J = 6.8 Hz, 3 H)
12
7.39 (d, J = 8.5 Hz, 2 H), 6.99 (d, J = 8.6 Hz, 2 H), 3.68 (s, 3 H), 2.97 (t, J = 6.7 Hz, 2 H), 2.43 (t, J = 6.3 Hz, 2 H), 2.39-2.34 (m, 3 H), 2.32 (s, 6 H), 2.16 (s, 3 H), 2.10-2.03 (m, 1 H), 1.96-1.87 (m, 3 H), 1.41-1.20 (m, 2 H), 0.83 (d, J = 6.7 Hz, 3 H), 0.72 (d, J = 6.8 Hz, 3 H)
13
7.39 (dd, J = 6.8. 1.9 Hz, 2 H), 7.33 (d, J = 7.7 Hz, 1 H), 7.02-6.99 (m, 3 H), 6.82 (dd, J = 8.7, 2.4 Hz, 1 H), 3.82 (s, 3 H), 3.68 (s, 3 H), 3.00 (t, J = 6.3 Hz, 2 H), 2.46 (t, J = 5.9 Hz, 2 H), 2.38-2.34 (m, 3 H), 2.20 (s, 3 H), 2.09-2.06 (m, 1 H), 1.96-1.90 (m, 3 H), 1.44-1.23 (m, 2 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.73 (d, J = 6.8 Hz, 3 H)
14
10.95 (s, 1 H), 7.44 (dd, J = 6.0, 3.2 Hz, 1 H), 7.39-7.36 (m, 1 H), 7.31-7.30 (m, 1 H), 7.20-7.15 (m, 3 H), 7.12 (d, J = 7.9 Hz, 1 H), 7.06-7.04 (m, 1 H), 3.75 (s, 1 H), 3.70 (s, 3 H), 3.16 (t, J = 6.2 Hz, 2 H), 2.82-2.79 (m, 1 H), 2.69-2.64 (m, 1 H), 2.42 (s, 3 H), 2.35-2.30 (m, 1 H), 2.14-2.02 (m, 3 H), 1.86-1.82 (m, 1 H), 1.31-1.25 (m, 2 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.77 (d, J = 6.8 Hz, 3 H)
15
7.48-7.22 (m, 3 H), 7.16-7.00 (m, 3 H), 6.84-6.80 (m, 1 H), 3.80 (s, 3 H), 3.76 (s, 3 H), 3.72 (s, 3 H), 3.29-3.23 (m, 5 H), 3.10-3.07 (m, 2 H), 2.95-2.90 (m, 2 H), 2.65 (s, 2 H), 2.33-2.29 (m, 2 H), 2.20-2.16 (m, 3 H), 1.89-1.79 (m, 2 H), 1.68-1.65 (m, 1 H), 1.38-1.32 (m, 1 H), 0.85 (d, J = 6.6 Hz, 3 H), 0.77 (d, J = 6.9 Hz, 3 H)
16
7.38-7.27 (m, 2 H), 7.24-7.22 (m, 1 H), 7.19-7.10 (m, 2 H), 7.07-7.01 (m, 1 H), 3.74 (s, 3 H), 3.70 (s, 1 H), 3.67 (s, 1 H), 3.21-3.18 (m, 2 H), 3.05-3.03 (m, 2 H), 2.73-2.68 (m, 1 H), 2.34 (s, 2 H), 2.30 (s, 6 H), 2.02 (m, 2 H), 1.85-1.75 (m, 2 H), 1.24 (s, 2 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
17
12.05 (bs, 1 H), 7.44 (s, 2 H), 7.17 (dd, J = 8.3, 5.7 Hz, 2 H), 7.12-7.08 (m, 4 H), 3.64 (s, 3 H), 2.79 (t, J = 7.4 Hz, 2 H), 2.38-2.33 (m, 5 H), 2.20 (s, 3 H), 1.92-1.87 (m, 3 H), 1.23-1.19 (m, 1 H), 1.051.03 (m, 1 H), 0.76 (d, J = 6.6 Hz, 3 H), 0.66 (d, J = 6.7 Hz, 3 H)
18
13.83 (bs, 1 H), 7.32 (d, J = 8.7 Hz, 1 H), 7.19-7.08 (m, 4 H), 6.96 (s, 1 H), 6.73 (dd, J = 8.7, 2.3 Hz, 1 H), 3.75 (s, 3 H), 3.69 (s, 3 H), 2.76 (t, J = 7.3 Hz, 28), 2.38-2.23 (m, 5 H), 2.16 (s, 3 H), 2.04-1.97 (m, 1 H), 1.92-1.87 (m, 3 H), 1.23-1.16 (m, 28), 1.14-1.06 (m, 1 H), 0.76 (d, J = 6.6 Hz, 3 H), 0.66 (d, J = 6.7 Hz, 3 H)
19
11.83 (bs, 1 H), 7.20 (s, 1 H), 7.18-7.14 (m, 2 H), 7.12-7.08 (m, 2 H), 3.64 (s, 3 H), 2.74 (t, J = 7.4 Hz, 2 H), 2.37-2.30 (m, 3 H), 2.27 (s, 8 H), 1.98-1.96 (m, 1 H), 1.92-1.82 (m, 4 H), 1.23-1.20 (m, 1 H), 1.04-1.01 (m, 1 H), 0.76 (d, J = 6.7 Hz, 3 H), 0.66 (d, J = 6.8 Hz, 3 H)
20
7.32-7.27 (m, 2 H), 7.22-7.13 (m, 3 H), 6.93-6.86 (m, 2 H), 6.83 (dd, J = 4.6, 1.7 Hz, 2 H), 4.19 (q, J = 7.0 Hz, 2 H), 3.73 (s, 3 H), 3.37 (t, J = 7.0 Hz, 3 H), 2.89 (bs, 3 H), 2.41-2.36 (m, 5 H), 2.23 (t, J = 7.0 Hz, 2 H), 2.05-1.90 (m, 2 H), 1.29-1.22 (m, 1 H), 1.07 (t, J = 7.0 Hz, 6 H), 0.79 (d, J = 6.7 Hz, 3 H), 0.72 (d, J = 6.7 Hz, 3 H)
21
7.30 (dd, J = 7.8, 7.2 Hz, 2 H), 7.21 (m, 1 H), 7.15 (d, J = 7.8 Hz, 2 H), 7.06 (dd, J = 8.2, 8.0 Hz, 1 H), 6.47 (d, J = 8.2 Hz, 1 H), 6.39 (d, J = 1.9 Hz, 1 H), 6.32 (d, J = 8.0 Hz, 1 H), 4.14 (q, J = 7.1 Hz, 2 H), 3.68 (s, 3 H), 3.04 (s, 4 H), 2.42-2.34 (m, 4 H), 2.22 (t, J = 6.8 Hz, 2 H), 2.04-2.01 (m, 1 H), 1.92-1.87 (m, 1 H), 1.29-1.19 (m, 1 H), 1.17 (t, J = 7.1 Hz, 3 H), 1.08-1.04 (m, 1 H), 0.79 (d, J = 6.6 Hz, 3 H), 0.71 (d, J = 6.7 Hz, 3 H)
22
7.31-7.28 (m, 2 H), 7.22-7.13 (m, 3 H), 6.48 (dd, J = 9.6, 2.8 Hz, 2 H), 6.78 (dd, J = 9.6, 2.8 Hz, 2 H, 4.13 (q, J = 7.0 Hz, 2 H), 3.65 (s, 3 H), 2.93 (t, J = 4.7 Hz, 3 H), 2.35 (t, J = 4.7 Hz, 5 H), 2.22 (t, J = 7.0 Hz, 2 H), 2.21-1.86 (m, 2 H), 1.28-1.03 (m, 2 H), 0.79 (d, J = 6.7 Hz, 3 H), 0.71 (d, J = 6.8 Hz, 3 H)
23
7.29-7.27 (m, 2 H), 7.20-7.13 (m, 5 H), 6.83 (d, J = 8.4 Hz, 2 H), 4.20 (q, J = 7.1 Hz, 2 H), 3.79 (s, 3 H), 3.42 (s, 2 H), 2.46-2.39 (m, 8 H), 2.33-2.25 (m, 3 H), 2.07-1.92 (m, 2 H), 1.24 (t, J = 7.1 Hz, 3 H), 0.88 (d, J = 6.7 Hz, 3 H), 0.78 (d, J = 6.9 Hz, 3 H)
24
7.36-7.29 (m, 3 H), 7.22-7.20 (m, 2 H), 7.16 (d, J = 8.0 Hz, 2 H), 7.12-6.99 (m, 2 H), 4.20 (q, J = 7.1 Hz, 2 H), 3.58 (s, 2 H), 2.48-2.39 (m, 8 H), 2.31-2.25 (m, 3 H), 2.07-1.91 (m, 2 H), 1.39-1.30 (m, 1 H), 1.25 (t, J = 7.1 Hz, 3 H), 0.87 (d, J = 6.7 Hz, 3 H), 0.78 (d, J = 6.9 Hz, 3 H)
25
7.31-7.17 (m, 5 H), 6.96-6.83 (m, 4 H), 4.23-4.21 (m, 2 H), 3.08 (t, J = 4.9 Hz, 4 H), 2.52-2.43 (m, 4 H), 2.33 (t J = 6.6 Hz, 2 H), 2.12-1.96 (m, 2 H), 1.42-1.41 (m, 1 H), 1.27 (t, J = 7.1 Hz, 3 H), 0.88 (d, J = 6.8 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
26
7.29-7.20 (m, 4 H), 7.16 (d, J = 7.6 Hz, 3 H), 7.00-6.95 (m, 2 H), 4.20 (q, J = 7.0 Hz, 2 H), 3.44 (s, 2 H), 2.58-2.28 (m, 1 H), 2.14-1.88 (m, 2 H), 1.39-1.38 (m, 1 H), 1.25 (t, J = 7.1 Hz, 3 H), 0.86 (d, J = 6.6 Hz, 3 H), 0.78 (d, J = 6.7 Hz, 3 H)
27
13.75 (s, 1 H), 13.04 (s, 1 H), 7.86 (d, J = 6.9 Hz, 4 H), 7.48-7.34 (m, 8 H), 7.01 (d, J = 8.6 Hz, 2 H), 4.94 (s, 1 H), 4.21 (bs, 2 H), 3.95-3.92 (m, 2 H), 3.73 (s, 3 H), 3.49-3.42 (m, 1 H), 3.25 (d, J = 7.0 Hz, 1 H), 3.20 (s, 1 H), 3.01 (m, 2 H), 2.37-2.26 (m, 2 H), 1.84-1.70 (m, 4 H), 1.33-1.24 (m, 2 H), 4.24 (s, 4 H), 0.92 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
28
12.70 (s, 1 H), 7.47 (d, J = 8.5 Hz, 2 H), 7.08 (d, J = 8.6 Hz, 3 H), 7.05-6.95 (m, 3 H), 3.79 (s, 3 H), 3.69-3.62 (m, 2 H), 3.52 (d, J = 12.0 Hz, 1 H), 3.42-3.37 (m, 3 H), 2.98-2.88 (m, 4 H), 2.41-2.38 (m, 1 H), 2.20-1.91 (m, 2 H), 1.79 (m, 1 H), 1.58-1.51 (m, 2 H), 0.93 (d, J = 6.7 Hz, 3 H_, 0.83 (d, J = 6.8 Hz, 3 H)
29
13.10 (s, 1 H), 7.73 (m, 2 H), 7.45 (dd, J = 9.5, 2.7 Hz, 2 H), 7.20-7.10 (m, 2 H), 7.07 (dd, J = 6.7, 2.0 Hz, 2 H), 4.60-4.57 (m, 2 H), 3.88-3.83 (m, 2 H), 3.78 (s, 3 H), 3.68 (d, J = 12.0 Hz, 1 H), 3.55 (t, J = 14.5 Hz, 2 H), 3.45 (d, J = 12.2 Hz, 1 H), 3.04-3.00 (m, 2 H), 2.40-2.33 (m, 2 H), 1.88-1.79 (m, 2 H), 1.41 (m, 1 H), 0.96 (d, J = 6.7 Hz, 3 H), 0.83 (d, J = 6.8 Hz, 3 H)
30
13.65 (bs, 1 H), 13.25 (s, 1 H), 7.87-7.83 (m, 1 H), 7.50-7.47 (m, 1 H), 7.44 (dd, J = 6.8, 1.8 Hz, 2 H), 7.31-7.28 (m, 1 H), 7.19-7.14 (m, 1 H), 7.04 (dd, J = 6.8, 1.8 Hz, 2 H), 4.31 (s, 2 H), 4.05-4.02 (m, 2 H), 3.90 (m, 2 H), 3.76 (s, 3 H), 3.58 (d, J = 7.6 Hz, 1 H), 3.48 (t, J = 13.0 Hz, 2 H), 3.46 (d, J = 8.8 Hz, 1 H), 3.20 (s, 3 H), 3.03-2.99 (m, 2 H), 2.36-2.24 (m, 3 H), 1.83-1.71 (m, 2 H), 1.37-1.34 (m, 1 H), 1.18 (s, 5 H), 0.92 (d, J = 6.7 Hz, 3 H), 0.81 (d, J = 6.8 Hz, 3 H)
31
13.64 (s, 1 H), 13.14 (s, 1 H), 7.49-7.38 (m, 5 H), 7.18-7.11 (m, 1 H), 7.05-7.02 (m, 2 H), 4.29 (s, 2 H), 4.08-4.05 (m, 2 H), 4.02-4.00 (m, 2 H), 3.75 (s, 3 H), 3.59 (d, J = 12.5 Hz, 1 H), 3.57-3.38 (m, 3 H), 3.03-3.01 (m, 2 H), 2.36-2.25 (m, 2 H), 1.85-1.72 (m, 1 H), 1.37-1.36 (m, 1 H), 0.92 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
32
13.64 (s, 1 H), 13.19 (s, 1 H), 7.67 (dd, J = 8.4, 5.1 Hz, 2 H), 7.44 (d, J = 8.5 Hz, 2 H), 7.13 (t, J = 8.5 Hz, 2 H), 7.03 (d, J = 8.6 Hz, 2 H), 4.23 (s, 2 H), 4.08-4.02 (m, 2 H), 3.99-3.88 (m, 2 H), 3.75 (s, 3 H), 3.58 (d, J = 12.3 Hz, 1 H), 3.41 (t, J = 12.1 Hz, 3 H), 3.01-2.98 (m, 2 H), 1.82-1.71 (m, 2 H), 1.36-1.35 (m, 1 H), 0.92 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
33
13.76 (bs, 1 H), 13.09 (s, 1 H), 8.03 (d, J = 7.7 Hz, 1 H), 7.94 (s, 1 H), 7.73 (d, J = 7.7 Hz, 1 H), 7.62 (t, J = 7.8 Hz, 1 H), 7.43 (d, J = 8.6 Hz, 2 H), 7.03 (d, J = 8.6 Hz, 2 H), 4.40 (s, 2 H), 4.10-4.04 (m, 2 H), 3.94-3.90 (m, 2 H), 3.75 (s, 3 H), 3.60 (d, J = 12.4 Hz, 1 H), 3.49-3.40 (m, 3 H), 3.01 (m, 2 H), 2.37-2.25 (m, 2 H), 1.82-1.72 (m, 2 H), 1.38-1.36 (m, 1 H), 0.91 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.7 Jz, 3 H)
34
13.99 (s, 1 H), 13.23 (s, 1 H), 7.87 (d, J = 7.8 Hz, 2 H), 7.74 (d, J = 7.8 Hz, 2 H), 7.45 (d, J = 8.4 Hz, 2 H), 7.02 (d, J = 8.6 Hz, 2 H), 4.30 (s, 2 H), 4.12-4.09 (m, 2 H), 3.91-3.81 (m, 2 H), 3.76 (s, 3 H), 3.4 H (d, J = 4.3 Hz, 1 H), 3.39 (dd, J = 25.3, 11.9 Hz, 3 H), 3.01-2.92 (m, 2 H), 2.38-2.30 (m, 2 H), 1.83-1.70 (m, 6 H), 1.34 (m, 1 H), 1.25 (s, 1 H), 0.94 (d, J = 6.7 Hz, 3 H), 0.82 (d, J = 6.7 Hz, 3 H)
35
13.39 (s, 1 H), 7.46 (d, J = 8.6 Hz, 2 H), 7.40 (t, J = 7.6 Hz, 1 H), 7.06 (dd, J = 12.5, 8.5 Hz, 4 H), 4.84 (bs, 1 H), 4.25-4.08 (m, 1 H), 4.03 (s, 3 H), 3.79 (s, 3 H), 3.56-3.49 (m, 3 H), 3.40 (d, J = 12.6 Hz, 1 H), 3.03 (m, 2 H), 2.40-2.24 (m, 2 H), 1.94-1.78 (m, 2 H), 1.49-1.78 (m, 2 H), 0.94 (d, J = 6.7 Hz, 3 H), 0.83 (d, J = 6.7 Hz, 3 H)
36
13.20 (s, 1 H), 7.46 (d, J = 8.6 Hz, 2 H), 7.38 (t, J = 8.2 Hz, 1 H), 7.31 (bs, 1 H), 7.07 (d, J = 8.6 Hz, 2 H), 6.92 (dd, J = 8.3 Hz, 1.7 Hz, 1 H), 4.61-4.58 (m, 2 H), 4.01-3.89 (m, 2 H), 3.83 (s, 3 H), 3.78 (s, 3 H), 3.63 (dd, J = 28.3, 13.4 Hz, 3 H), 3.43 (d, J = 12.2 Hz, 1 H), 3.04 (bs, 2 H), 2.41-2.32 (m, 2 H), 1.91-1.79 (m, 2 H), 1.42-1.40 (m, 1 H), 0.96 (d, J = 6.7 Hz, 3 H), 0.84 (d, J = 6.7 Hz, 3 H)
37
13.10 (s, 1 H), 7.79 (d, J = 8.8 Hz, 2 H), 7.46 (d, J = 8.4 Hz, 2 H), 7.06 (d, J = 8.4 Hz, 2 H), 6.97 (d, J = 8.9 Hz, 2 H), 4.74-4.68 (m, 2 H), 4.14 (bs, 2 H), 3.82 (s, 3 H), 3.78 (s, 3 H), 3.65 (d, J = 12.7 Hz, 1 H), 3.57 (t, J = 14.0 Hz, 2 H), 3.44 (d, J = 12.0 Hz, 1 H), 3.07 (bs, 2 H), 2.40-2.34 (m, 2 H), 2.03-1.78 (m, 2 H), 1.60-1.41 (m, 1 H), 1.29-1.24 (m, 1 H), 0.96 (d, J = 6.7 Hz, 3 H), 0.83 (d, J = 6.7 Hz, 3 H)
38
13.41 (s, 1 H), 13.18 (s, 1 H), 7.55 (d, J = 8.6 Hz, 2 H), 7.45 (d, J = 8.6 Hz, 2 H), 7.04 (d, J = 8.6 Hz, 2 H), 6.95 (d, J = 8.6 Hz, 2 H), 4.16 (s, 2 H), 3.81 (s, 3 H), 3.76 (s, 3 H), 3.56 (d, J = 10.0 Hz, 1 H), 3.43-3.32 (m, 3 H), 3.01 (bs, 2 H), 2.37-2.27 (m, 2 H), 1.84-1.73 (m, 5 H), 1.42-1.25 (m, 2 H), 0.93 (d, J = 6.7 Hz, 3 H), 0.81 (d, J = 6.7 Hz, 3 H)
39
13.29 (s, 1 H), 13.13 (s, 1 H), 7.43 (dd, J = 11.8, 8.6 Hz, 3 H), 7.03 (d, J = 8.6 Hz, 2 H), 6.72 (d, J = 8.6 Hz, 1 H), 4.19 (m, 2 H), 3.97 (s, 3 H), 3.96 (s, 3 H), 3.84 (s, 3 H), 3.76 (s, 3 H), 3.48 (d, J = 9.9 Hz, 1 H), 3.44-3.38 (m, 2 H), 3.32 (d, J = 10.3 Hz, 1 H), 2.97 (bs, 2 H), 2.36-2.22 (m, 2 H), 1.86-1.72 (m, 4 H), 1.38-1.24 (m, 2 H), 0.92 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
40
13.44 (s, 1 H), 13.13 (s, 1 H), 7.44 (d, J = 8.4 Hz, 4 H), 7.33 (t, J = 7.5 Hz, 1 H), 7.22 (bs, 1 H), 7.03 (d, J = 8.5 Hz, 2 H), 4.18 (s, 2 H), 3.95-3.91 (m, 4 H), 3.75 (s, 3 H), 3.56 (d, J = 10.3 Hz, 1 H), 3.47-3.33 (m, 3 H), 3.01-2.99 (m, 2 H), 2.37 (s, 3 H), 2.34-2.25 (m, 2 H), 2.11 (bs, 1 H), 1.85-1.69 (m, 2 H), 1.36-1.33 (m, 1 H), 0.92 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.7 Hz, 3 H)
41
13.39 (s, 1 H), 13.11 (s, 1 H), 7.50 (d, J = 7.9 Hz, 2 H), 7.44 (d, J = 8.6 Hz, 2 H), 7.24 (d, J = 7.8 Hz, 2 H), 7.03 (d, J = Hz, 2 H), 4.19 (s, 2 H), 3.95-3.90 (m, 4 H), 3.11 (s, 3 H), 3.56 (d, J = 10.8 Hz, 1 H), 3.44-3.34 (m, 3 H), 3.01-2.99 (m, 2 H), 2.36 (m, 3 H), 1.84-1.71 (m, 2 H), 1.37-1.35 (m, 1 H), 0.92 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
42
13.50 (s, 1 H), 13.24 (s, 1 H), 7.55 (d J = 8.3 Hz, 2 H), 7.47-7.43 (m, 4 H), 7.04 (d, J = 8.6 Hz, 2 H), 4.18 (s, 2 H), 3.96-3.95 (m, 4 H), 3.57 (d, J = 8.3 Hz, 1 H), 3.42 (t, J = 12.0 Hz, 2 H), 3.30 (d, J = 10.0 Hz, 1 H), 2.98 (bs, 2 H), 2.39-2.31 (m, 2 H), 1.86-1.78 (m, 1 H), 1.71 (s, 5 H), 1.31 (s, 9 H), 0.94 (d, J = 6.7 Hz, 3 H), 0.82 (d, J = 6.8 Hz, 3 H)
43
13.01 (s, 1 H), 7.46 (d, J = 8.5 Hz, 2 H), 7.29 t, J = 8.1 Hz, 1 H), 7.23 (s, 1 H), 7.12-7.10 (m, 2 H), 7.05 (d, J = 7.5 Hz, 2 H), 4.07 (t, J = 12.0 Hz, 2 H), 3.79 (s, 3 H), 3.61-3.55 (m, 3 H), 3.46 (d, J = 16.8 Hz, 1 H), 3.31-3.28 (m, 2 H), 2.97 (bs, 2 H), 2.42-2.24 (m, 2 H), 1.94-1.78 (m, 2 H), 1.49-1.47 (m, 1 H), 0.94 (d, J = 6.7 Hz, 3 H), 0.83 (d, J = 6.7 Hz, 3 H)
44
13.78 (bs, 1 H), 13.18 (s, 1 H), 7.66-7.64 (m, 2 H), 7.46-7.36 (m, 4 H), 7.04 (d, J = 8.6 Hz, 2 H), 4.24 (s, 2 H), 4.06-3.91 (m, 4 H), 3.76 (s, 3 H), 3.59 (d, J = 11.2 Hz, 1 H), 3.48-3.35 (m, 3 H), 3.00 (m, 2 H), 2.38-2.28 (m, 2 H), 1.85-1.78 (m, 4 H), 1.36-1.33 (m, 1 H), 0.93 (d, J = 6.7 Hz, 3 H), 0.82 (d, J = 6.8 Hz, 3 H)
45
13.24 (bs, 1 H), 12.58 (s, 1 H), 7.63 (d, J = 8.0 Hz, 2 H), 7.45-7.41 (m, 4 H), 7.04 (d, J = 8.3 Hz, 2 H), 4.21 (s, 2 H), 3.98-3.80 (m, 2 H), 3.75 (s, 3 H), 3.62 (d, J = 10.6 Hz, 1 H), 3.48-3.44 (m, 6 H), 3.03 (m, 2 H), 2.38-2.25 (m, 2 H), 1.84-1.71 (m, 2 H), 1.43-1.37 (m, 1 H), 0.92 (d, J = 6.6 Hz, 3 H), 0.80 (d, J = 6.7 Hz, 3 H)
46
11.60 (s, 1 H), 7.96 (s, 1 H), 7.01 (d, J = 8.1 Hz, 1 H), 7.62-7.60 (m, 1 H), 7.49 (d, J = 8.5 Hz, 2 H), 7.15 (d, J = 8.5 Hz, 2 H), 4.30 (s, 2 H), 3.67 (s, 3 H), 3.63-3.43 (m, 6 H), 3.07 (m, 2 H), 2.35-1.89 (m, 2 H), 1.51-1.33 (m, 2 H), 0.77 (d, J = 6.6 Hz, 3 H), 0.67 (d, J = 6.5 Hz, 3 H)
47
12.90 (s, 1 H), 7.47-7.40 (m, 3 H), 7.34 (d, J = 8.1 Hz, 1 H), 7.15-7.13 (m, 1 H), 7.05 (d, J = 8.6 Hz, 2 H), 4.24 (s, 2 H), 3.99-3.81 (m, 4 H), 3.76 (s, 3 H), 3.58-3.52 (m, 3 H), 3.48 (d, J = 2.0 Hz, 1 H), 3.04-2.99 (m, 2 H), 2.37-2.33 (m, 1 H), 2.26-2.20 (m, 1 H), 1.88-1.82 (m, 1 H), 1.74-1.71 (m, 1 H), 1.40-1.39 (m, 1 H), 0.90 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
48
7.46-7.36 (m, 4 H), 7.22-7.17 (m, 2 H), 7.14 (d, J = 8.2 Hz, 2 H), 4.29 (s, 2 H), 3.67 (d, J = 27.7 Hz, 8 H), 3.06-2.96 (m, 2 H), 2.40-2.33 (m, 1 H), 2.07-1.77 (m, 2 H), 1.42-1.23 (m, 2 H), 0.79 (d, J = 6.7 Hz, 3 H), 0.68 (d, J = 6.7 Hz, 3 H)
49
7.41-7.36 (m, 3 H), 7.22-7.12 (m, 5 H), 4.19 (s, 2 H), 3.68 (s, 3 H), 3.33 (bs, 8 H), 3.07-2.94 (m, 2 H), 2.41-2.34 (m, 1 H), 2.06-1.78 (m, 2 H), 1.40-1.12 (m, 2 H), 0.68 (d, J = 6.7 Hz, 3 H), 0.63 (d, J = 6.5 Hz, 3 H)
50
7.41 (dd, J = 8.7, 5.3 Hz, 2 H), 7.23-7.11 (m, 4 H), 7.05-6.98 (m, 2 H), 4.31 (s, 2 H), 3.68 (s, 3 H), 3.54-3.41 (m, 8 H), 3.08-3.01 (m, 2 H), 2.41-2.36 (m, 1 H), 2.05-2.00 (m, 1 H), 1.87-1.83 (m, 1 H), 1.43-1.26 (m, 2 H), 0.78 (d, J = 6.8 Hz, 3 H), 0.67 (d, J = 6.7 Hz, 3 H)
51
7.41-7.36 (m, 3 H), 7.21 (dd, J = 7.7, 2.6 Hz, 1 H), 7.17-7.08 (m, 4 H), 4.19 (s, 2 H), 3.67 (s, 3 H), 3.32 (bs, 8 H), 3.08-2.99 (m, 2 H), 2.38-2.35 (m, 1 H), 2.05-1.78 (m, 2 H), 1.40-1.12 (m, 2 H), 0.78 (d, J = 6.5 Hz, 3 H), 0.68 (d, J = 6.6 Hz, 3 H)
52
9.43 (s, 2 H), 7.87-7.80 (m, 4 H), 7.45 (d, J = 7.8 1 H), 7.36-7.35 (m, 1 H), 7.29 (t, J = 7.9 Hz, 2 H), 7.19 (d, J = 8.0 Hz, 1 H), 4.43 (s, 2 H), 3.69 (s, 3 H), 3.64-3.41 (m, 8 H), 3.09 (m, 3 H), 2.39-2.35 (m, 1 H), 2.07-1.89 (m, 2 H), 1.52-1.26 (m, 2 H), 0.79 (d J = 6.6 Hz, 3 H), 0.70 (d, J = 6.7 Hz, 3 H)
53
7.40 (dd, J = 7.8, 1.0 Hz, 1 H), 7.38 (t, J = 1.6 Hz, 1 H), 7.30 (d, J = 8.7 Hz, 2 H), 7.24-7.13 (m, 2 H), 6.95 (d, J = 8.7 Hz, 2 H), 4.17 (s, 2 H), 3.73 (s, 3 H), 3.67 (s, 3 H), 3.33 (bs, 8 H), 3.02-2.92 (m, 2 H), 2.38-2.33 (m, 1 H), 2.05-1.77 (m, 2 H), 1.38-1.21 (m, 2 H), 0.78 (d, J = 6.7 Hz, 3 H), 0.67 (d, J = 6.7 Hz, 3 H)
54
7.41-7.38 (m, 2 H), 7.19 (t, J = 7.7 Hz, 1 H), 7.14 (d, J = 7.5 Hz, 1 H), 7.05 (d, J = 8.7 Hz, 1 H), 6.80 (d, J = 8.7 Hz, 1 H), 4.09 (s, 2 H), 3.80 (s, 3 H), 3.77 (s, 3 H), 3.75 (s, 3 H), 3.67 (s, 3 H), 3.22 (bs, 6 H), 2.94-2.86 (m, 2 H), 2.39-2.33 (m, 1 H), 2.01-1.78 (m, 2 H), 1.38-1.22 (m, 2 H), 0.78 (d, J = 6.7 Hz, 3 H), 0.67 (d, J = 6.7 Hz , 3 H)
55
7.41-7.38 (m, 2 H), 7.30-7.26 (m, 2 H), 7.22-7.15 (m, 4 H), 7.17 (dd, J = 11.0, 4.0 Hz, 4 H), 4.67 (s, 2 H), 4.22 (s, 3 H), 3.67 (bs, 8 H), 3.01-2.81 (m, 2 H), 2.24 (s, 3 H), 2.05-2.00 (m, 1 H), 1.84-1.78 (m, 1 H), 1.38-1.24 (m, 2 H), 0.79 (d, J = 6.5 Hz, 3 H), 0.68 (d, J = 6.6 Hz, 3 H)
56
7.40 (d, J = 7.8 Hz, 1 H), 7.38 (m, 1 H), 7.26-7.21 (m, 4 H), 7.19 (d, J = 7.8 Hz, 1 H), 7.14 (d, J = 8.0 Hz, 1 H), 4.20 (s, 2 H), 3.67 (s, 3 H), 3.36 (bs, 8 H), 3.04-2.96 (m, 2 H), 2.40-2.34 (m, 1 H), 2.24 (s, 3 H), 2.06-1.77 (m, 2 H), 1.41-1.25 (m, 2 H), 0.79 (d, J = 6.7 Hz, 3 H), 0.68 (d, J = 6.7 Hz, 3 H)
57
7.48 (d, J = 8.2 Hz, 2 H), 7.41-7.38 (m, 2 H), 7.31 (d, J = 8.2 Hz, 2 H), 7.16 (dd, J = 19.3, 7.8 Hz, 2 H), 4.24 (s, 2 H), 3.67 (s, 3 H), 3.39 (bs, 8 H), 3.06-2.97 (m, 2 H), 2.39-2.34 (m, 1 H), 2.05-1.77 (m, 2 H), 1.41-1.24 (m, 2 H), 1.19 (s, 9 H), 0.79 (d, J = 6.7 Hz, 3 H), 0.68 (d, J = 6.7 Hz, 3 H)
58
7.41-7.37 (m, 4 H), 7.21-7.12 (m, 2 H), 4.21 (s, 2 H), 3.67 (s, 3 H), 3.45 (s, 2 H), 3.36 (bs, 8 H), 3.04-2.86 (m, 2 H), 2.38-2.35 (m, 1 H), 2.05-1.77 (m, 2 H), 1.39-1.22 (m, 2 H), 0.73 (d, J = 6.5 Hz, 3 H), 0.68 (d, J = 6.5 Hz, 3 H)
59
11.64 (s, 1 H), 7.68-7.63 (m, 2 H), 7.53-7.49 (m, 2 H), 7.45 (d, J = 7.9 Hz, 1 H), 7.35 (s, 1 H), 7.28 (t, J = 7.9 Hz, 1 H), 7.19 (d, J = 7.9 Hz, 1 H), 4.36-4.24 (m, 2 H), 3.68 (s, 3 H), 3.64-3.44 (m, 8 H), 3.06 (s, 2 H), 2.39-2.33 (m, 1 H), 2.08-1.90 (m, 2 H), 1.52-1.21 (m, 2 H), 0.78 (d, J = 6.6 Hz, 3 H), 0.68 (d, J = 6.8 Hz, 3 H)
60
7.54-7.51 (m, 2 H), 7.41-7.38 (m, 2 H), 7.27 (dd, J = 8.2, 2.0 Hz, 1 H), 7.19 (t, J = 7.8 Hz, 1 H), 7.14 (d, J = 8.0 Hz, 1 H), 4.22 (s, 2 H), 3.67 (s, 3 H), 3.37 (bs, 8 H), 3.05-2.97 (m, 2 H), 2.38-2.33 (m, 1 H), 2.05-1.77 (m, 2 H), 1.42-1.23 (m, 2 H), 0.79 (d, J = 6.7 Hz, 3 H), 0.68 (d, J = 6.7 Hz, 3 H)
61
12.70 (s, 3 H), 7.32-7.29 (m, 2 H), 7.19-7.14 (m, 2 H), 7.09-7.01 (m, 2 H), 6.97-6.93 (m, 1 H), 6.89-6.87 (m, 2 H), 3.79 (s, 3 H), 3.66-3.50 (m, 5 H), 3.42 (d, J = 11.7 Hz, 1 H), 2.92-2.82 (m, 4 H), 2.40-2.37 (m, 1 H), 2.20-2.16 (m, 1 H), 1.96-1.90 (m, 1 H), 1.78-1.77 (m, 1 H), 1.66 (s, 1 H), 1.57-1.55 (m, 1 H), 0.92 (d, J = 6.8 Hz, 3 H), 0.82 (d, J = 6.8 Hz, 3 H)
62
13.64 (s, 1 H), 12.95 (s, 1 H), 7.86 (d, J = 6.3 Hz, 4 H), 7.46-7.35 (m, 6 H), 7.12-7.08 (m, 2 H), 7.02-6.97 (m, 2 H), 4.93 (s, 1 H), 4.25-4.23 (m, 2 H), 3.98-3.93 (m, 2 H), 3.75 (s, 3 H), 3.32 (d, J = 12.3 Hz, 1 H), 3.00-2.96 (m, 2 H), 2.37-2.26 (m, 2 H), 1.82-1.73 (m, 5 H), 1.34-1.25 (m, 1 H), 0.92 (d, J = 6.8 Hz, 3 H), 0.81 (d, J = 6.8 Hz, 3 H)
63
7.19 (dd, J = 8.6, 3.3 Hz, 2 H), 7.08-7.01 (m, 6 H), 3.68 (s, 3 H), 3.49-3.43 (s, 4 H), 3.07-2.95 (m, 6 H), 2.42-2.36 (m, 1 H), 2.08-1.82 (m, 2 H), 1.44-1.28 (m, 2 H), 0.79 (d, J = 6.6 Hz, 3 H), 0.68 (d, J = 6.6 Hz, 3 H)
64
11.11 (s, 1 H), 7.23 (dd, J = 8.8, 3.4 Hz, 2 H), 7.18-7.02 (m, 4 H), 6.98 (dd, J = 9.1, 4.5 Hz, 2 H), 3.68 (s, 3 H), 3.64 (d, J = 12.5 Hz, 2 H), 3.40 (d, J = 11.0 Hz, 2 H), 3.14-3.00 (m, 6 H), 2.40-2.37 (m, 1 H), 2.05-1.89 (m, 2 H), 1.59-1.35 (m, 2 H), 0.79 (d, J = 6.6 Hz, 3 H), 0.69 (d, J = 6.7 Hz, 3 H)
65
7.40 (dd, J = 14.8, 7.2 Hz, 1 H), 7.20-7.14 (m, 5 H), 7.01 (t, J = 8.8 Hz, 2 H), 4.30 (s, 2 H), 3.66 (s, 3 H), 3.46-3.40 (m, 8 H), 3.09-3.00 (m, 2 H), 2.39-2.33 (m, 1 H), 2.05-1.98 (m, 2 H), 1.41-1.25 (m, 2 H), 0.77 (d, J = 6.7 Hz, 3 H), 0.66 (d, J = 6.7 Hz, 3 H)
66
13.69 (bs, 1 H), 13.26 (s, 1 H), 7.84 (t, J = 7.3 Hz, 1 H), 7.47 (dd, J = 14.0, 6.7 Hz, 1 H), 7.29 (d, J = 7.6 Hz, 1 H), 7.17 (d, J = 8.9 Hz, 1 H), 7.19-7.13 (m, 2 H), 7.00 (t, J = 8.5 Hz, 2 H), 4.30 (s, 2 H), 4.06-4.01 (m, 2 H), 3.90 (m, 2 H), 3.76 (s, 3 H), 3.58 (d, J = 12.2 Hz, 1 H), 3.51-3.40 (m, 3 H), 3.03-2.95 (m, 2 H), 2.37-2.24 (m, 2 H), 1.37-1.34 (m, 1 H), 0.91 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.7 Hz, 3 H)
67
7.43-7.41 (m, 4 H), 7.22-7.15 (m, 4 H), 4.30 (s, 2 H), 3.70 (s, 3 H), 3.52-3.44 (m, 8 H), 3.09-3.07 (m, 2 H), 2.39 (m, 1 H), 2.06-2.04 (m, 1 H), 1.84-1.81 (m, 1 H), 1.45-1.28 (m, 2 H), 0.80 (d, J = 5.3 Hz, 3 H), 0.69 (d, J = 5.4 Hz, 3 H)
68
7.77-7.73 (m, 2 H), 7.62 (dd, J = 11.6, 7.7 Hz, 2 H), 7.19-7.15 (m, 2 H), 7.05-7.00 (m, 2 H), 4.41 (s, 2 H), 3.67 (s, 3 H), 3.09-3.00 (m, 2 H), 2.40-2.34 (m, 1 H), 2.06-1.80 (m, 2 H), 1.43-1.26 (m, 2 H), 0.78 (d, J = 6.6 Hz, 3 H), 0.67 (d, J = 6.7 Hz, 3 H)
69
13.70 (s, 1 H), 12.99 (s, 1 H), 7.90 (d, J = 8.1 Hz, 2 H), 7.72 (d, J = 8.1 Hz, 2 H), 7.12 (dd, J = 8.9, 5.2 Hz, 2 H), 7.04-6.99 (m, 2 H), 4.40 (s, 2 H), 4.15-4.05 (m, 2 H), 3.93 (s, 2 H), 3.75 (s, 3 H), 3.64 (d, J = 12.5 Hz, 1 H), 3.53-3.45 (m, 3 H), 3.07-3.01 (m, 2 H), 2.38-2.26 (m, 2 H), 1.82-1.73 (m, 1 H), 1.40-1.38 (m, 1 H), 0.91 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
70
13.73 (s, 1 H), 7.43 (s, 1 H), 7.24-7.20 (m, 1 H), 7.16 (dd, J = 8.8, 5.3 Hz, 2 H), 7.05-6.94 (m, 4 H), 4.12-4.06 (m, 1 H), 3.97 (s, 3 H), 3.79 (s, 3 H), 3.52-3.42 (m, 6 H), 2.99-2.88 (m, 2 H), 2.40-2.26 (m, 1 H), 2.23-2.20 (m, 1 H), 1.96-1.88 (m, 1 H), 1.80-1.78 (m, 1 H), 1.55-1.51 (m, 1 H), 0.92 (d, J = 6.7 Hz, 3 H), 0.82 (d, J = 6.8 Hz, 3 H)
71
12.82 (s, 1 H), 7.31-7.26 (m, 1 H), 7.16 (dd, J = 8.7, 5.3 Hz, 2 H), 7.05-7.01 (m, 2 H), 6.92 (s, 2 H), 6.74 (d, J = 7.7 Hz, 1 H), 4.27-4.09 (m, 2 H), 3.80 (s, 3 H), 3.79 (s, 3 H), 3.73-3.68 (m, 3 H), 3.47 (s, 2 H), 3.01 (m, 2 H), 2.40-2.35 (m, 1 H), 2.32-2.24 (m, 1 H), 1.94-1.78 (m, 2 H), 1.49-1.48 (m, 1 H), 0.93 (d, J = 6.8 Hz, 3 H), 0.82 (d, J = 6.7 Hz, 3 H)
72
12.73 (s, 1 H), 7.55 (s, 2 H), 7.16 (dd, J = 8.9, 5.3 Hz, 2 H), 7.05-7.01 (m, 2 H), 6.93 (d, J = 8.0 Hz, 2 H), 4.43 (s, 2 H), 3.81 (s, 3 H), 3.79 (s, 3 H), 3.70 (d, J = 9.5 Hz, 3 H), 3.57-3.52 (m, 3 H), 3.08-3.04 (m, 2 H), 2.40-2.29 (m, 2 H), 1.92-1.77 (m, 2 H), 1.46-1.44 (m, 1 H), 0.94 (d, J = 6.7 Hz, 3 H), 0.83 (d, J = 6.8 Hz, 3 H)
73
12.85 (s, 1 H), 7.57 (d, J = 8.6 Hz, 2 H), 7.13 (dd, J = 8.7, 5.3 Hz, 2 H), 7.06-7.01 (m, 2 H), 6.94 (d, J = 8.7 Hz, 2 H), 4.24 (s, 2 H), 3.99-3.89 (m, 4 H), 3.81 (s, 3 H), 3.76 (s, 3 H), 3.61 (d, J = 9.9 Hz, 1 H), 3.50-3.45 (m, 3 H), 3.08-3.01 (m, 2 H), 2.36-2.24 (m, 2 H), 1.83-1.73 (m, 2 H), 1.42-1.38 (m, 1 H), 0.91 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
74
12.73 (s, 1 H), 12.61 (s, 1 H), 7.42 (d, J = 8.7 Hz, 1 H), 7.13 (dd, J = 8.8. 5.2 Hz, 2 H), 7.03-6.99 (m, 2 H), 6.73 (d, J = 8.7 Hz, 1 H), 4.23 (s, 2 H), 3.98 (s, 6 H), 3.87 (s, 3 H), 3.85 (s, 3 H), 3.77 (s, 3 H), 3.58 (d, J = 9.7 Hz, 2 H), 3.52-3.44 (m, 3 H), 3.05-3.03 (m, 2 H), 2.37-2.34 (m, 1 H), 2.25-2.21 (m, 1 H), 1.85-1.73 (m, 2 H), 1.42 (m, 1 H), 0.91 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
75
12.63 (s, 1 H), 7.47-7.46 (m, 1 H), 7.34-7.29 (m, 1 H), 7.23 (d, J = 8.8 Hz, 1 H), 7.13 (dd, J = 8.9, 5.2 Hz, 2 H), 7.03-6.99 (m, 2 H), 4.27 (s, 2 H), 4.02-3.94 (m, 4 H), 3.76 (s, 3 H), 3.63 (d, J = 9.5 Hz, 1 H), 3.53-3.50 (m, 3 H), 3.11-3.03 (m, 2 H), 2.37 (s, 3 H), 2.33-2.23 (m, 1 H), 1.83-1.73 (m, 2 H), 1.40-1.37 (m, 1 H), 0.91 (d, J = 6.8 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
76
12.74 (bs, 1 H), 7.54 (d, J = 7.6 Hz, 2 H), 7.23 (d, J = 7.8 Hz, 2 H), 7.13 (dd, J = 8.7, 5.3 Hz, 2 H), 7.03-6.99 (m, 2 H), 4.31 (s, 2 H), 3.99-3.94 (m, 6 H), 3.75 (s, 3 H), 3.71-3.51 (m, 5 H), 3.11-3.08 (m, 2 H), 2.35 (s, 4 H), 2.28-2.22 (m, 1 H), 1.88-1.81 (m, 2 H), 1.42 (m, 1 H), 0.90 (d, J = 6.8 Hz, 3 H), 0.79 (d, J = 6.7 Hz, 3 H)
77
7.57 (d, J = 8.2 Hz, 2 H), 7.45 (d, J = 8.2 Hz, 2 H), 7.13 (dd, J = 8.8, 5.3 Hz, 2 H), 7.03-6.99 (m, 2 H), 4.27 (s, 2 H), 3.95-3.90 (m, 4 H), 3.76 (s, 3 H), 3.60-3.48 (m, 4 H), 3.10-3.03 (m, 2 H), 2.37-2.22 (m, 2 H), 1.86-1.72 (m, 2 H), 1.30 (s, 9 H), 0.91 (d, J = 6.7 Hz, 3 H), 0.80 (d, J = 6.8 Hz, 3 H)
78
11.06 (s, 1 H), 7.25-7.21 (m, 3 H), 7.16-7.12 (m, 2 H), 7.01-7.00 (m, 1 H), 6.90 (dd, J = 8.4, 1.9 Hz, 1 H), 6.84 (dd, J = 7.9, 1.4 Hz, 1 H), 3.92 (s, 3 H), 3.82 (d, J = 13.2 Hz, 2 H), 3.69 (s, 3 H), 3.39 (d, J = 11.4 Hz, 2 H), 3.17 (t, J = 12.3 Hz, 2 H), 3.08-3.03 (m, 4 H), 2.49-2.48 (m, 1 H), 2.05-1.92 (m, 2 H), 1.57-1.56 (m, 1 H), 1.38-1.20 (m, 2 H), 0.79 (d, J = 6.7 Hz, 3 H), 0.70 (d, J = 6.6 Hz, 3 H)
79
7.46-7.44 (m, 2 H), 7.39-7.31 (m, 2 H), 7.17 (dd, J = 8.4, 5.4 Hz, 2 H), 7.05-7.00 (m, 2 H), 4.33 (s, 2 H), 3.67 (s, 3 H), 3.50 (m, 8 H), 3.10-3.02 (m, 2 H), 2.40-2.34 (m, 1 H), 2.07-1.99 (m, 1 H), 1.87-1.81 (m, 1 H), 1.43-1.26 (m, 2 H), 0.78 (d, J = 6.6 Hz, 3 H), 0.67 (d, J = 6.6 Hz, 3 H)
80
7.37 (dd, J = 26.4, 8.4 Hz, 4 H), 7.17 (dd, J = 8.8, 5.4 Hz, 2 H), 7.04-7.01 (m, 2 H), 4.27 (s, 2 H), 3.67 (s, 3 H), 3.48-3.43 (m, 8 H), 3.09-3.01 (m, 2 H), 2.40-2.33 (m, 1 H), 2.05-1.79 (m, 2 H), 1.43-1.25 (m, 2 H), 0.78 (d, J = 6.8 Hz, 3 H), 0.67 (d, J = 6.7 Hz, 3 H)
81
7.58-7.57 (m, 1 H), 7.54 (d, J = 8.2 Hz, 1 H), 7.30 (dd, J = 8.3, 1.9 Hz, 1 H), 7.16 (dd, J = 8.7. 5.4 Hz, 2 H), 7.04-7.00 (m, 2 H), 4.34 (s, 2 H), 3.67 (s, 3 H), 3.51 (m, 7 H), 3.13-3.04 (m, 2 H), 2.40-2.33 (m, 1 H), 2.06-1.79 (m, 2 H), 1.43-1.26 (m, 2 H), 0.78 (d, J = 6.6 Hz, 3 H), 0.66 (d, J = 6.7 Hz, 3 H)
82
7.40 (d, J = 8.6 Hz, 2 H), 7.04 (dd, J = 4.0, 8.7 Hz, 4 H), 6.80 (d, J = 8.6 Hz, 2 H), 3.78 (s, 3 H), 3.70 (s, 3 H), 2.78 (d, J = 10.7 Hz, 2 H), 2.44 (d, J = 7.1 Hz, 2 H), 2.42-2.38 (m, 1 H), 2.24-2.04 (m, 2 H), 1.98-1.92 (m, 2 H), 1.77-1.76 (m, 2 H), 1.58 (d, J = 11.9 Hz, 2 H), 1.46-1.41 (m, 1 H), 1.22-1.10 (m, 2 H), 0.84 (d, J = 6.8 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
83
7.43 (d, J = 8.6 Hz, 2 H), 7.21 (t, J = 7.8 Hz, 1 H), 7.06 (d, J = 8.6 Hz, 2 H), 6.81-6.73 (m, 3 H), 6.23 (s, 1 H), 3.79 (s, 3 H), 3.72 (s, 3 H), 2.51-2.48 (m, 2 H), 2.45-2.41 (m, 3 H), 2.40-2.28 (m, 6 H), 2.04-1.99 (m, 2 H), 1.60 (m, 1 H), 1.36-1.30 (m, 1 H), 1.22-1.19 (m, 1 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
84
7.41 (d, J = 8.6 Hz, 2 H), 7.18 (t, J = 7.8 Hz, 1 H) 7.04 (d, J = 8.7 Hz, 2 H), 6.76-6.67 (m, 3 H), 3.79 (s, 3 H), 3.70 (s, 3 H), 2.80 (m, 2 H), 2.49 (d, J = 7.1 Hz, 2 H), 2.40-2.38 (m, 1 H), 2.24 (m, 2 H), 1.98-1.92 (m, 2 H), 1.88-1.78 (m, 2 H), 1.61 (d, J = 11.8 Hz, 2 H), 1.50-1.47 (m, 1 H), 1.30-1.23 (m, 2 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
85
7.42 (d, J = 6.6 Hz, 2 H), 7.12-7.08 (m, 4 H), 7.06 (d, J = 6.7 Hz, 2 H), 6.22 (s, 1 H), 3.71 (s, 3 H), 2.48-2.47 (m, 2 H), 2.45-2.42 (m, 3 H), 2.40-2.35 (m, 3 H), 2.32 (s, 3 H), 2.31-2.28 (m, 2 H), 2.03-1.92 (m, 3 H), 1.36-1.30 (m, 1 H), 1.25-1.19 (m, 1 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
86
7.40 (d, J = 8.7 Hz, 2 H), 7.08-7.05 (m, 3 H), 7.03-6.96 (m, 3 H), 2.78 (d, J = 11.4 Hz, 2 H), 2.45 (d, J = 7.1 Hz, 2 H), 2.42-2.37 (m, 1 H), 2.30 (s, 3 H), 2.25-2.20 (m, 2 H), 2.01-1.92 (m, 3 H), 1.80-1.73 (m, 2 H), 1.58 (d, J = 11.9 Hz, 2 H), 1.451.44 (m, 1 H), 1.30-1.26 (m, 2 H), 1.25-1.18 (m, 2 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
87
7.42 (d, J = 8.7 Hz, 2 H), 7.22-7.15 (m, 1 H), 7.06 (d, J = 8.6 Hz, 2 H), 7.01-6.98 (m, 3 H), 6.23 (s, 1 H), 2.49-2.47 (m, 2 H), 2.45-2.34 (m, 3 H), 2.33 (s, 3 H), 2.30-2.26 (m, 3 H), 2.05-1.93 (m, 3 H), 1.37-1.30 (m, 1 H), 1.27-1.19 (m, 1 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
88
7.41 (d, J = 8.7 Hz, 2 H), 7.17-7.12 (m, 1 H), 7.04 (d, J = 8.7 Hz, 2 H), 6.98 (d, J = 7.5 Hz, 1 H), 6.94-6.89 (m, 2 H), 2.79 (d, J = 11.4 Hz, 2 H), 2.46 (d, J = 7.0 Hz, 2 H), 2.42-2.38 (m, 1 H), 2.31 (s, 3 H), 2.25-2.21 (m, 2 H), 2.04-1.92 (m, 3 H), 1.78-1.76 (m, 2 H), 1.60 (d, J = 11.8 Hz, 2 H), 1.47 (m, 1 H), 1.30-1.27 (m, 1 H), 1.26-1.23 (m, 2 H), 1.21-1.18 (m, 1 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
89
7.42 (d, J = 8.7 Hz, 2 H), 7.17-7.10 (m, 4 H), 7.06 (d, J = 8.7 Hz, 2 H), 6.19 (s, 1 H), 2.45-2.43 (m, 2 H), 2.41-2.36 (m, 3 H), 2.30 (s, 6 H), 2.23 (s, 3 H), 2.07-1.96 (m, 3 H), 1.37-1.32 (m, 1 H), 1.27-1.19 (m, 1 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
90
7.41 (d, J = 8.7 Hz, 2 H), 7.12-7.06 (m, 4 H), 7.05 (d, J = 8.7 Hz, 2 H), 2.79 (d, J = 11.5 Hz, 2 H), 2.51 (d, J = 7.0 Hz, 2 H), 2.42-2.39 (m, 1 H), 2.28 (s, 3 H), 2.24-2.21 (m, 2 H), 2.04-1.92 (m, 3 H), 1.78-1.73 (m, 2 H), 1.60 (d, J = 11.8 Hz, 2 H), 1.47-1.45 (m, 1 H), 1.35-1.31 (m, 3 H), 1.29-1.20 (m, 1 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
91
7.41 (d, J = 8.6 Hz, 2 H), 7.27-7.23 (m, 2 H), 7.11-7.07 (m, 2 H), 7.06 (d, J = 8.7 Hz, 2 H), 6.19 (s, 1 H), 3.72 (s, 3 H), 2.46-2.41 (m, 4 H), 2.36-2.27 (m, 5 H), 2.05-1.92 (m, 3 H), 1.36-1.31 (m, 1 H), 1.27-1.20 (m, 1 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
92
7.41 (d, J = 8.7 Hz, 2 H), 7.28-7.20 (m, 2 H), 7.19-7.13 (m, 2 H), 7.04 (d, J = 8.7 Hz, 2 H), 3.70 (s, 3 H), 2.78 (d, J = 11.3 Hz, 2 H), 2.51 (d, J = 7.0 Hz, 1 H), 2.47 (d, J = 7.1 Hz, 1 H), 2.42-2.38 (m, 3 H), 2.25-2.21 (m, 2 H), 2.04-1.92 (m, 3 H), 1.80-1.74 (m, 2 H), 1.60-1.55 (m, 2 H), 1.48-1.44 (m, 1 H), 1.31-1.25 (m, 2 H), 1.24-1.18 (m, 3 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
93
7.41 (d, J = 8.6 Hz, 2 H), 7.24-7.20 (m, 1 H), 7.16-7.14 (m, 2 H), 7.06 (d, J = 8.7 Hz, 2 H), 7.04-7.02 (m, 1 H), 2.47-2.42 (m, 4 H), 2.36-2.32 (m, 4 H), 2.31-2.27 (m, 2 H), 2.04-1.93 (m, 3 H), 1.37-1.30 (m, 1 H), 1.27-1.19 (m, 2 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
94
7.41 (d, J = 8.7 Hz, 2 H), 7.08-7.03 (m, 4 H), 6.96-6.91 (m, 2 H), 3.70 (s, 3 H), 2.79 (d, J = 11.5 Hz, 2 H), 2.48 (d, J = 7.1 Hz, 2 H), 2.42-2.38 (m, 1 H), 2.25-2.21 (m, 2 H), 2.04-1.92 (m, 3 H), 1.79-1.74 (m, 2 H), 1.57 (d, J = 11.8 Hz, 2 H), 1.44 (m, 1 H), 1.29-1.27 (m, 2 H), 1.25-1.22 (m, 2 H), 1.19 (m, 1 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
95
7.42 (d, J = 8.7 Hz, 2 H), 7.15-7.11 (m, 2 H), 7.06 (d, J = 8.7 Hz, 2 H), 7.00-6.96 (m, 2 H), 6.20 (s, 1 H), 3.72 (s, 3 H), 2.44-2.38 (m, 4 H), 2.34-2.27 (m, 6 H), 2.05-1.93 (m, 3 H), 1.36-1.29 (m, 1 H), 1.27-1.19 (m, 1 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
96
7.40 (d, J = 8.6 Hz, 2 H), 7.08-7.04 (m, 4 H), 6.94 (d, J = 8.7 Hz, 2 H), 3.70 (s, 3 H), 2.78 (d, J = 11.4 Hz, 2 H), 2.47 (d, J = 7.1 Hz, 2 H), 2.42-2.39 (m, 1 H), 2.25-2.21 (m, 2 H), 2.03-1.97 (m, 3 H), 1.96-1.93 (m, 2 H), 1.57 (d, J = 8.0 Hz, 2 H), 1.46-1.41 (m, 1 H), 1.34-1.31 (m, 2 H), 1.29-1.16 (m, 3 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
97
7.12-7.06 (m, 4 H), 6.84 (dd, J = 3.4, 8.8 Hz, 4 H), 6.19 (s, 1 H), 3.79 (s, 6 H), 3.71 (s, 3 H), 2.49-2.46 (m, 2 H), 2.43-2.42 (m, 3 H), 2.33-2.31 (m, 5 H), 2.29-2.27 (m, 2 H), 2.04-1.93 (m, 3 H), 1.82-1.80 (m, 1 H), 1.39-1.33 (m, 1 H), 1-.30-1.22 (m, 2 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.76 (d, J = 6.8 Hz, 3 H)
98
7.07 (d, J = 8.8 Hz, 2 H), 7.04 (d, J = 8.6 Hz, 2 H), 6.81 (dd, J = 6.9, 8.8 Hz, 4 H), 3.79 (s, 3 H), 3.77 (s, 3 H), 3.69 (s, 3 H), 2.80 (d, J = 11.4 Hz, 2 H), 2.44 (d, J = 7.0 Hz, 2 H), 2.41-2.38 (m, 1 H), 2.24 (t, J = 7.4 Hz, 2 H), 2.00-1.93 (m, 3 H), 1.77-1.75 (m, 2 H), 1.57 (d, J = 12.7 Hz, 2 H), 1.29-1.26 (m, 2 H), 1.25-1.20 (m, 5 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
99
7.21 (t, J = 7.8 Hz, 1 H), 7.09 (d, J = 8.8 Hz, 2 H), 6.88 (dd, J = 2.1, 8.8 Hz, 1 H), 6.83 (d, J = 8.8 Hz, 2 H), 6.79-6.73 (m, 2 H), 6.23 (s, 1 H), 3.79 (s, 6 H), 3.71 (s, 3 H), 2.50-2.39 (m, 5 H), 2.36-2.29 (m, 5 H), 2.07-1.95 (m, 3 H), 1.27-1.24 (m, 3 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
100
7.17 (t, J = 7.8 Hz, 1 H) 7.07 (d, J = 8.8 Hz, 2 H), 6.90-6.87 (m, 1 H), 6.82 (d, J = 8.8 Hz, 2 H), 6.72-6.67 (m, 2 H), 3.79 (s, 3 H), 3.78 (s, 3 H), 3.69 (s, 3 H), 2.81 (d, J = 11.0 Hz, 2 H), 2.48 (d, J = 7.0 Hz, 2 H), 2.41-2.24 (m, 2 H), 2.02-1.92 (m, 3 H), 1.80 (m, 2 H), 1.59 (d, J = 13.0 Hz, 2 H), 1.49-1.44 (m, 1 H), 1.34-1.29 (m, 2 H), 1.25-1.23 (m, 3 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
101
7.12-7.06 (m, 6 H), 6.83 (d, J = 8.9 Hz, 2 H), 6.21 (s, 1 H), 3.79 (s, 3 H), 3.71 (s, 3 H), 2.50-2.47 (m, 2 H), 2.45-2.43 (m, 2 H), 2.35-2.27 (m, 9 H), 2.07-1.95 (m, 3 H), 1.40-1.33 (m, 1 H), 1.31-1.22 (m, 1 H), 0.84 (d, J = 6.6 Hz, 3 H), 0.76 (d, J = 6.6 Hz, 3 H)
102
7.08-7.00 (m, 6 H), 6.82 (d, J = 8.0 Hz, 2 H), 3.79 (s, 3 H), 3.64 (s, 3 H), 2.80 (d, J = 10.4 Hz, 2 H), 2.46 (d, J = 6.6 Hz, 2 H), 2.41-2.38 (m, 1 H), 2.30 (s, 3 H), 2.25-2.22 (m, 2 H), 2.04-1.92 (m, 3 H), 1.77 (m, 2 H), 1.58 (d, J = 12.2 Hz, 2 H), 1.45 (m, 1 H), 1.33-1.23 (m, 4 H), 0.82 (d, J = 6.3 Hz, 3 H), 0.75 (d, J = 6.4 Hz, 3 H)
103
7.21-7.17 (m, 1 H), 7.09 (d, J = 8.9 Hz, 2 H), 7.01-6.97 (m, 3 H), 6.83 (d, J = 8.8 Hz, 2 H), 6.23 (s, 1 H), 3.79 (s, 3 H), 3.71 (s, 3 H), 2.56-2.51 (m, 2 H), 2.50-2.43 (m, 3 H), 2.41-2.37 (m, 5 H), 2.33 (s, 3 H), 2.05-1.95 (m, 3 H), 1.38 (m, 1 H), 1.27-1.25 (m, 2 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
104
7.16-7.13 (m, 1 H), 7.07 (d, J = 8.9 Hz, 2 H), 6.99-6.87 (m, 3 H), 6.82 (d, J = 8.9 Hz, 2 H), 3.79 (s, 3 H), 3.70 (s, 3 H), 2.86 (d, J = 12.8 Hz, 2 H), 2.47 (d, J = 6.9 Hz, 2 H), 2.41-2.38 (m, 1 H), 2.31 (s, 3 H), 2.01-1.91 (m, 3 H), 1.89-1.85 (m, 2 H), 1.61 (d, J = 13.5 Hz, 2 H), 1.50-1.45 (m, 1 H), 1.37-1.30 (m, 3 H), 1.28-1.25 (m, 2 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.7 Hz, 3 H)
105
7.17 (m, 2 H), 7.12 (dd, J = 3.5, 5.7 Hz, 2 H), 7.09 (d, J = 8.8 Hz, 2 H), 6.83 (d, J = 8.8 Hz, 2 H), 6.19 (s, 1 H), 3.79 (s, 3 H), 3.71 (s, 3 H), 2.48-2.47 (m, 2 H), 2.44-2.37 (m, 3 H), 2.31-2.30 (m, 6 H), 2.23 (s, 3 H), 2.05-1.96 (m, 3 H), 1.37-1.39 (m, 1 H), 1.28-1.25 (m, 2 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
106
7.13-7.04 (m, 6 H), 6.82 (d, J = 8.8 Hz, 2 H), 3.79 (s, 3 H), 3.70 (s, 3 H), 2.83 (d, J = 11.0 Hz, 2 H), 2.51 (d, J = 6.9 Hz, 2 H), 2.42-2.38 (m, 1 H), 2.28 (s, 3 H), 2.02-1.92 (m, 3 H), 1.80-1.79 (m, 2 H), 1.61 (d, J = 12.6 Hz, 2 H), 1.48 (m, 1 H), 1.38-1.32 (m, 3 H), 1.25-1.24 (m, 2 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
107
7.25 (d, J = 8.9 Hz, 2 H), 7.09 (dd, J = 3.0, 8.9 Hz, 4 H), 6.83 (d, J = 8.9 Hz, 2 H), 6.19 (s, 1 H), 3.79 (s, 3 H), 3.71 (s, 3 H), 2.46-2.44 (m, 3 H), 2.39-2.30 (m, 5 H), 2.05-1.95 (m, 3 H), 1.38 (m, 1 H), 1.27-1.24 (m, 1 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.76 (d, J = 6.8 Hz, 3 H)
108
7.24-7.11 (m, 4 H), 7.07 (d, J = 8.8 Hz, 2 H), 6.82 (d, J = 8.8 Hz, 2 H), 3.79 (s, 3 H), 3.69 (s, 3 H), 2.82 (d, J = 9.6 Hz, 2 H), 2.51 (d, J = 7.1 Hz, 1 H), 2.47 (d, J = 7.0 Hz, 1 H), 2.41-2.38 (m, 1 H), 2.26 (m, 2 H), 1.60 (d, J = 12.8 Hz, 2 H), 1.55-1.49 (m, 1 H), 1.33-1.24 (m, 4 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
109
7.22-7.20 (m, 1 H), 7.16-7.14 (m, 2 H), 7.09 (d, J = 8.8 Hz, 2 H), 7.06-7.04 (m, 1 H), 6.83 (d, J = 8.8 Hz, 2 H), 6.18 (s, 1 H), 3.79 (s, 3 H), 3.71 (s, 3 H), 2.47-2.44 (m, 4 H), 2.43-2.36 (m, 4 H), 2.32-2.28 (m, 2 H), 2.05-1.95 (m, 3 H), 1.27-1.24 (m, 2 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.76 (d, J = 6.8 Hz, 3 H)
110
7.27-7.24 (m, 1 H), 7.18-7.13 (m, 3 H), 7.07 (d, J = 8.9 Hz, 2 H), 6.82 (d, J = 8.9 Hz, 2 H), 3.79 (s, 3 H), 3.69 (s, 3 H), 2.80 (d, J = 11.4 Hz, 2 H), 2.51 (d, J = 7.1 Hz, 2 H), 2.51-2.41 (m, 1 H), 2.24 (t, J = 7.2 Hz, 2 H), 2.01-1.92 (m, 3 H), 1.78-1.76 (m, 2 H), 1.58 (d, J = 12.6 Hz, 2 H), 1.48 (m, 1 H), 1.32-1.21 (m, 3 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.74 (d, J = 6.8 Hz, 3 H)
111
7.12-7.11 (m, 2 H), 7.09 (d, J = 8.9 Hz, 2 H), 7.00-6.95 (m, 2 H), 6.83 (d, J = 8.9 Hz, 2 H), 6.20 (s, 1 H), 3.79 (s, 3 H), 3.71 (s, 3 H), 2.46-2.43 (m, 4 H), 2.41-2.35 (m, 4 H), 2.32-2.28 (m, 2 H), 2.05-1.95 (m, 3 H), 1.37-1.25 (m, 2 H), 0.85 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
112
7.14-7.04 (m, 4 H), 6.98-6.91 (m, 2 H), 6.82 (d, J = 8.9 Hz, 2 H), 3.79 (s, 3 H), 3.69 (s, 3 H), 2.81 (d, J = 11.4 Hz, 2 H), 2.47 (d, J = 7.0 Hz, 2 H), 2.41-2.38 (m, 1 H), 2.25 (t, J = 7.1 Hz, 2 H), 2.02-1.92 (m, 3 H), 1.81-1.77 (m, 2 H), 1.57 (d, J = 13.0 Hz, 2 H), 1.44 (m, 1 H), 1.30-1.22 (m, 4 H), 0.84 (d, J = 6.7 Hz, 3 H), 0.75 (d, J = 6.8 Hz, 3 H)
EXPERIMENTAL EXAMPLE 1
Measurement of Ion Current Inhibition on T-Type Calcium Ion Channels Using a Patch Clamp
[0325] (1) Cell Culture and Preparation
[0326] HEK293 cell strains (a 1G cell strain: KCTC 10519BP), in which a 1G T-type calcium ion channels and Kir2.1 channels were stably expressed, were obtained from the GenBank of Korea Research Institute of Bioscience & Biotechnology (KRIBB). In a cell culture device provided with 95% oxygen and 5% carbon dioxide, T-type calcium ion channel expressed cells were cultured in Dulbecco's modified Eagle's medium (DMEM) supplemented with 10% fetal bovine serum (FBS), and hERG channels were cultured in MEM supplemented with 10% FBS. 20 hours prior to the use of the medium for expression of hERG channels, the Tet-expression system was activated by treating the medium with 1 μg/ml doxycycline.
[0327] The cells in the experiment was passaged once in three days, and collected when the cells were grown to 50˜80% confluency in the Petri dish. Prior to the experiment, the cells were separated from the dish using trypsin-EDTA (0.25×) and a single cell was prepared using a pippet. Trypsin was removed using a centrifuge, an extracellular solution was added, and cells floating automatically by a Patchliner were used at room temperature.
[0328] (2) Experimental Solution
[0329] As a solution composition for measurement of activation of T-type calcium ion channels, 140 mM NaCl, 2 mM CaCl 2 , 4 mM KCl, 1 mM MgCl 2 , 5 mM D-glucose, and 10 mM HEPES (pH 7.4) were used for an extracellular solution, and 50 mM KCl, 10 mM NaCl, 60 mM KF, 2 mM MgCl2, 10 mM HEPES, and 20 mM EGTA (pH 7.2) were used for an intracellular solution. To maintain the pre-cellular state, a seal reinforced solution was added. When T-type calcium ion channel expression cells were used, an extracellular solution supplemented with 10 mM Ba 2+ was added and records about the result were made. A 100 mM stock solution was prepared by dissolving each experimental compound in dimethylsulfoxide (DMSO), and IC 50 was measured after the solution was diluted with an extracellular solution supplemented with Ba 2+ at 10 nM to 100 μM.
[0330] (3) Electro-Physiological Technique and Data Processing
[0331] The current was measured through an EPC10 amplifier (HEKA, Germany) by a precellular patch clamp technique using NPC©-16 Patchliner (Nanion Technologies, Germany). Cell suspensions and various experimental solutions were automatically aliquotted into chips (NPC-16 Chip, Nanion Technologies, Germany) by experimental devices. A cell membrane potential was fixed at −100 mV for measurement of activation of T-type calcium ion channels. When a low polarization was performed at −20 mV for 300 ms, the inward current was measured at ten-second intervals.
[0332] Cells were treated in the compounds in Embodiments 1, 4, 5, 10˜13, 23, 26, 30˜32, 34, 35, and 38˜40 at each concentration for about 20 seconds, and mibefradil, useful as a T-type calcium ion channel inhibitor, was used as a control group. The IC50 graphs and values were obtained from the automatic calculation of inhibition rates of the peak current using an experimental data analysis program IGOR Pro (WaveMetrics, USA). The results were indicated in the following Table 2.
[0000]
TABLE 2
Division
% inhibition rate (10 μM)
IC50 (μM)
Embodiment 1
96.9 ± 0.59
8.17 ± 0.48
(nM)
Embodiment 4
93.5 ± 3.2
0.19 ± 0.001
Embodiment 5
91.7 ± 1.9
0.88 ± 0.07
Embodiment 10
98.3 ± 0.9
0.25 ± 0.005
Embodiment 11
91.4 ± 0.4
0.10 ± 0.01
Embodiment 12
94.2 ± 0.4
53.02 ± 4.87
(nM)
Embodiment 13
94.5 ± 1.2
0.25 ± 0.01
Embodiment 23
96.3 ± 1.7
0.34 ± 0.02
Embodiment 26
94.0 ± 2.5
0.26 ± 0.03
Embodiment 30
90.4 ± 3.2
0.74 ± 0.02
Embodiment 31
89.3 ± 1.6
0.98 ± 0.11
Embodiment 32
96.5 ± 1.7
1.11 ± 0.05
Embodiment 34
93.0 ± 1.5
0.28 ± 0.02
Embodiment 35
94.1 ± 1.5
95.04 ± 14.78
(nM)
Embodiment 38
96.0 ± 1.7
0.48 ± 0.08
Embodiment 39
95.1 ± 1.9
0.32 ± 0.01
Embodiment 40
94.9 ± 1.5
0.39 ± 0.03
Control group
95.9 ± 1.7
1.34 ± 0.49
(mibefradil)
[0333] As indicated in Table 2, the calcium ion channel inhibitory activation (IC 50 ) of the phenylacetate derivatives according to the present invention is 53.02±4.87 nM˜0.98±0.11 82 M. It can be known that they show better calcium ion channel inhibitory activation, compared to mibefradil (1.34±0.49 μM) as a T-type calcium ion channel inhibitor in the art.
[0334] Thus, the composition according to the present invention effectively inhibits the T-type calcium ion channel activation and may be useful for prevention or treatment of diseases such as hypertension, cancer, epilepsy, and neurogenic pains related with T-type calcium channels.
[0335] The phenylacetate derivatives represented by the Chemical Formula 1 may be formulated in various forms according to the intended purpose: The following examples illustrate several preparation methods including the compound represented in the Chemical Formula 1, but the present invention should not be limited to this.
PREPARATION EXAMPLE #1
Tablets (Direct Compression)
[0336] 5.0 mg of an active ingredient was sieved, followed by preparation of tablets by mixing and compressing 14.1 mg of lactose, 0.8 mg of CrossPovidone USNF, and 0.1 mg of magnesium stearate.
PREPARATION EXAMPLE #2
Tablets (Wet Granulation)
[0337] 5.0 mg of an active ingredient was sieved, followed by mixing 16.0 mg of lactose and 4.0 mg of starch. 0.3 mg of Polysolvate 80 was dissolved in purified water, and by microgranulation, by adding the appropriate amount of the solution. The microgranules were dried and sieved, followed by mixing 2.7 mg of colloidal silicon dioxide and 2.0 mg of magnesium stearate. Tablets were prepared by compressing the compounds.
PREPARATION EXAMPLE #3
Powders and Capsules
[0338] 5.0 mg of an active ingredient was sieved, followed by mixing 14.8 mg of lactose, 10.0 mg of polyvinyl pyrrolidone, and 0.2 mg of magnesium stearate with it. The compound was filled into a hard No. 5 gelatin capsule using an appropriate apparatus.
PREPARATION #4
Injections
[0339] Injection was prepared by containing 100 mg of an active ingredient, as well as 180 mg of mannitol, 26 mg of Na 2 HPO 4 .12H 2 O, and 2947 mg of distilled water. | Disclosed herein are a new phenylacetate derivative represented by Chemical Formula 1 or pharmaceutically acceptable salt thereof, a preparation method thereof, and a composition for prevention or treatment of diseases induced by the activation of T-type calcium ion channels containing the same. The composition containing the phenylacetate derivative according to the present invention effectively inhibits the activation of T-type calcium ion channels and may be useful in the prevention or treatment of diseases such as hypertension, cancer, epilepsy, and neurogenic pains induced by the activation of T-type calcium ion channels.
wherein, X, R 1 , and R 3 are as defined herein. | 2 |
This application is a National Stage Application of PCT/US2012/033317, filed 12 Apr. 2012, and which application is incorporated herein by reference. To the extent appropriate, a claim of priority is made to the above disclosed application.
BACKGROUND
Offshore oil drilling and production operations are conducted through a pipe, called a riser, running from a subsea wellhead to a surface platform or floating vessel. In order to support the weight of these risers and to control the stresses induced by ocean currents and vessel motions, the upper end of the riser is connected to a tensioning device. This riser tensioner maintains a predetermined range of tension throughout a range of vertical and lateral motions of the drilling or production rig.
The conventional approach to tensioning risers is to use a combination of a hydraulic or pneumatic mechanical cylinder, pressurized using a compressed gas, to apply the tensioning forces to the riser. Each riser tensioner is located on a deck of the floating platform or floating vessel and is structurally connected through its cylinders to the riser. The cylinders may be connected to the risers with wire rope or chain or directly connected through cylinder rods. The pressurized gas volume is typically contained in a separate pressure vessel referred to as an “accumulator”, positioned alongside the cylinder, which supplies sufficient gas volume to act as a gas spring. This combination of cylinder and accumulator acts to compress or expand the gas in response to vessel or riser movements, thereby maintaining a relatively uniform tension level in the riser.
For example, FIG. 1 illustrates a conventional wire riser tensioner system 100 including a double-acting hydraulic cylinder 110 , a high-pressure accumulator 130 , and a low-pressure accumulator 140 . A piston 120 is disposed within an interior of the hydraulic cylinder 110 and configured to slide along an axial direction therein. The piston 120 includes a piston seat 122 and a piston extension 124 . The piston seat 122 divides the interior of the cylinder 110 into a first variable-volume section 112 and a second variable-volume section 114 . The volumes of the sections 112 , 114 vary based on the position of the piston seat 122 within the cylinder 110 . The piston extension 124 extends upwardly through the second section 114 of the cylinder 110 . In certain implementations, the piston extension 124 may be hollow to reduce the weight of the piston 120 .
A first sealing arrangement 127 is disposed at the piston seat 122 of the piston 120 to provide a seal between the first and section sections 112 , 114 of the cylinder 110 . A second sealing arrangement 129 is disposed between the piston extension 124 and an exterior of the cylinder 110 to seal the interior of the cylinder 110 as the piston 120 is slid therein. The second sealing arrangement 129 is located at an opposite end of the piston 120 from the first sealing arrangement 127 .
The high-pressure accumulator 130 defines an interior 132 in which a first high pressure fluid (e.g., oil) may be stored. The high-pressure accumulator 130 is coupled to the cylinder 110 via a first flow path 150 . The first flow path 150 provides a fluid pathway between the high-pressure accumulator 130 and the first variable volume section 112 of the cylinder 110 . In certain implementations, the first flow path 150 extends between a bottom of the high-pressure accumulator 130 and a bottom of the cylinder 110 . In certain implementations, a valve (e.g., an anti-recoil valve, a flow shut-off valve, etc.) 155 is disposed in the first flow path 150 .
The high-pressure accumulator 130 also is configured to hold a second high-pressure fluid (e.g., compressed air, compressed nitrogen, or other gas). One or more air pressure vessels (APV's) 170 may be coupled to the high-pressure accumulator 130 via piping 175 . Each APV 170 provides additional volume in which to store the second high-pressure fluid. In certain implementations, the APVs 170 are coupled to the high-pressure accumulator 130 using a ball-valve 172 or other valve arrangement. Providing additional volume in which the second high-pressure fluid may be contained aids in stabilizing the pressure of the second high-pressure fluid across the system 100 .
The low-pressure accumulator 140 defines an interior 142 in which a low-pressure fluid (e.g., a lubricant) may be stored. The low-pressure accumulator 140 is coupled to the cylinder 110 via a second flow path 160 . The second flow path 160 provides a fluid pathway between the low-pressure accumulator 140 and the second variable volume section 114 of the cylinder 110 . For example, the second flow path 160 provides a fluid pathway between the low-pressure accumulator 140 and an annulus area around the piston extension 124 . In certain implementations, the second flow path 160 extends between a top of the low-pressure accumulator 140 and a top of the cylinder 110 . The low-pressure accumulator 140 is isolated from the high-pressure accumulator 130 .
Accordingly, as the piston 120 is moved within the cylinder 110 , the first high-pressure fluid is moved between the high-pressure accumulator 130 and the first variable-volume section 112 of the cylinder 110 through the first flow path 150 . In addition, the low-pressure fluid is moved between the low-pressure accumulator 140 and the second variable volume section 114 of the cylinder 110 through the second flow path 160 as the piston 120 moves in the cylinder 110 .
SUMMARY
Aspects of the present disclosure relate to a riser tensioner arrangement including a high-pressure accumulator; a cylinder; a piston slidingly disposed within an interior volume of the cylinder; a first flow path coupling an interior volume of the high-pressure accumulator with a first volume of the cylinder to enable a first high-pressure fluid to flow therebetween; and a second flow path coupling the interior volume of the high-pressure accumulator with a second volume of the cylinder to enable a second high-pressure fluid to flow therebetween. The piston includes a seat and an extension. The piston seat separates the interior volume of the cylinder into the first volume and the second volume. The extension extends upwardly from the seat through the second volume. The extension defines a hollow interior that is coupled to the second volume of the cylinder via at least one aperture.
Other aspects of the present disclosure related to a method of manufacturing a riser tensioner including a high-pressure accumulator and a pusher-type cylinder. The method includes hollowing an interior of a piston-rod to provide an interior volume; defining at least one aperture through a sidewall of the piston-rod to provide access to the interior volume of the piston-rod; and positioning the piston-rod within a cylinder to separate an interior volume of the cylinder into first and second variable-volume sections. The second variable-volume section includes the hollow interior of the piston-rod and a volume of an annulus area around the piston-rod. In certain implementations, the method also may include coupling a first end of the high-pressure accumulator to the first variable-volume section of the cylinder via a first flow path; and coupling a second end of the high-pressure accumulator to the second variable-volume section of the cylinder via a second flow path.
A variety of additional aspects will be set forth in the description that follows. These aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which the embodiments disclosed herein are based.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:
FIG. 1 is a schematic diagram of a conventional riser tensioner system;
FIG. 2 is a schematic diagram of an example riser tensioner system including a hydraulic cylinder having a piston defining a hollow space accessible through apertures defined in a sidewall of the piston;
FIG. 3 is a schematic diagram of the example riser tensioner system of FIG. 2 showing the piston moved to a second position; and
FIG. 4 is a diagram of another example riser tensioner system having features that are examples of inventive aspects of the present disclosure.
DETAILED DESCRIPTION
Reference will now be made in detail to the exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like structure.
FIG. 2 illustrates an example riser tensioner system 200 including a hydraulic cylinder 210 and a high-pressure accumulator 230 . The riser tensioner system 200 does not include a low-pressure accumulator. A piston 220 is disposed within an interior of the hydraulic cylinder 210 and is configured to slide along an axial direction A therein. The piston 220 includes a piston seat 222 and a piston extension 224 . The piston seat 222 divides the interior of the cylinder 210 into a first variable-volume section 212 and a second variable-volume section 214 . The volumes of the sections 212 , 214 vary based on the position of the piston seat 222 within the cylinder 210 .
The piston extension 224 includes a sidewall 226 that extends upwardly from the piston seat 222 through the cylinder 210 to define an annular region 223 around the sidewall 226 . As the piston 220 slides within the cylinder 210 , the annular region 223 around the piston extension 224 grows and shrinks (e.g., compare FIGS. 2 and 3 ). The piston sidewall 226 defines a hollow interior 225 that is accessible from the annular region 223 through one or more apertures 228 defined in the sidewall 226 . Accordingly, the second variable-volume section 214 of the cylinder 210 is defined by the annular region 223 around the piston extension 224 and the hollow interior 225 of the piston extension 224 .
The one or more apertures 228 are disposed in the sidewall 226 above the piston seat 222 . In certain implementations, multiple apertures 228 are circumferentially spaced in a ring around the piston extension 224 . In certain implementations, the apertures 228 are disposed in a ring disposed directly above the piston seat 222 . In certain implementations, the apertures 228 include a single row of circumferentially spaced apertures 228 . In other implementations, additional rings of apertures 228 may be provided.
A first sealing arrangement 227 is disposed at the piston seat 222 of the piston 220 to provide a seal between the first and second variable-volume sections 212 , 214 of the cylinder 210 . The first sealing arrangement 227 is configured to slide with the piston seat 222 along an inner wall of the cylinder 210 . A second sealing arrangement 229 is disposed between the sidewall 226 of the piston extension 224 and an exterior of the cylinder 210 to seal the interior of the cylinder 210 as the piston 220 is slid therethrough. The second sealing arrangement 229 is located at an opposite end of the piston 220 from the first sealing arrangement 227 . Each sealing arrangement 227 , 229 may include one or more O-rings or other sealing structures.
To aid in lubricating the first sealing arrangement 227 of the piston 220 when the piston 220 slides within the cylinder 210 , a lubricant bath 290 may be supplied in the second variable-volume section 214 of the cylinder 210 . The lubricant bath 290 includes a volume of lubricant disposed on the piston seat 222 to provide lubrication to the first sealing arrangement 227 as the piston 220 slides within the cylinder 210 . In certain implementations, the lubricant bath 290 only partially fills the cylinder 210 . In certain implementations, the lubricant bath 290 has a volume that is substantially smaller than the second variable-volume section 214 of the cylinder 210 . In the example shown, the lubricant bath 290 has a height H 2 that is less than a height H 1 of the apertures 228 extending through the sidewall 226 of the piston 220 (see FIG. 2 ).
In some implementations, a lubrication tank 295 is coupled to the cylinder 210 to provide lubricant to the second sealing arrangement 229 of the piston 220 . In certain implementations, the lubrication tank 295 is isolated from the second variable-volume section 214 of the cylinder 210 . The lubrication tank 295 is substantially smaller than the low pressure accumulator 140 of FIG. 1 . In certain implementations, the lubrication tank 295 is substantially smaller than the second variable-volume section 214 of the cylinder 210 . In the example shown, the lubrication tank 295 is substantially smaller than annular region 223 extending between the sidewalls 226 of the piston 220 and the inner surface of the cylinder 210 .
A first high pressure fluid (e.g., a non-compressible fluid such as oil or other liquid) may flow between the first variable-volume section 212 of the cylinder 210 and an interior 232 of the high-pressure accumulator 230 . In certain implementations, the high-pressure accumulator 230 is coupled to the cylinder 210 via a first flow path 250 . The first flow path 250 provides a fluid pathway between the interior 232 of the high-pressure accumulator 230 and the first variable-volume section 212 of the cylinder 210 . In certain implementations, the first flow path 250 extends between a bottom of the high-pressure accumulator 230 and a bottom of the cylinder 210 . In certain implementations, a valve (e.g., an anti-recoil valve) 255 is disposed in the first flow path 250 to control fluid flow between the cylinder 210 and the accumulator 230 .
The high-pressure accumulator 230 also is configured to hold a second high-pressure fluid (e.g., a compressible fluid such as compressed air, compressed nitrogen, or other gas). The second high-pressure fluid acts as a spring (e.g., via compression and decompression) against the first high-pressure fluid. A second flow path 280 extends between the high-pressure accumulator 230 and the cylinder 210 for passage of the second high-pressure fluid therebetween. In particular, the second flow path 280 provides a fluid pathway between the high-pressure accumulator 230 and the second variable volume section 214 of the cylinder 210 . In certain implementations, the second flow path 280 extends between a location towards a top of the high-pressure accumulator 230 and a location towards a top of the cylinder 210 .
One or more air pressure vessels (APV's) 270 may be coupled to the high-pressure accumulator 230 via piping 275 . Each APV 270 provides additional volume in which to store the second high-pressure fluid. In certain implementations, the APVs 270 are coupled to the high-pressure accumulator 230 using a ball-valve 272 or other valve arrangement. The extra volume gained from the piston extension interior 225 and annulus space around the piston extension 224 of the cylinder 210 increases the total gas capacity of the system without enlarging the volume of the high-pressure accumulator 230 or adding additional APV's 270 . In certain implementations, the number of APV's 270 utilized in a system may be reduced, thereby reducing cost and the spatial footprint of the system. In the example shown in FIG. 2 , the riser tensioner system 200 includes fewer APV's 270 than the conventional riser tensioner system 100 of FIG. 1 .
FIG. 3 illustrates example fluid flow of the first high-pressure fluid along the first flow path 250 between the accumulator 230 and the cylinder 210 . FIG. 3 also illustrates example fluid flow of the second high-pressure fluid along the second flow path 280 between the accumulator 230 and the cylinder 210 . As the piston 220 slides upwardly along the axis A, the first high-pressure fluid stored in the accumulator 230 flows into the first variable-volume section 212 of the cylinder 210 through the first flow path 250 . The annular region 223 in the second variable-volume section 214 of the cylinder 210 shrinks. Accordingly, the second high-pressure fluid compresses. The pressure of the second fluid stabilizes across the system including the hollow interior 225 of the piston extension 224 , the annular region 223 of the cylinder 210 , the interior 232 of the accumulator 230 , and any connected APVs.
As the piston 220 slides downwardly along the axis A, the piston seat 222 pushes the first high-pressure fluid back into the accumulator 230 through the first flow path 250 . The piston seat 222 may draw the second fluid into the second variable-volume section 214 from the accumulator 230 through the second flow path 280 . The pressure of the second fluid stabilizes across the system including the hollow interior 225 of the piston extension 224 , the annular region 223 of the cylinder 210 , the interior 232 of the accumulator 230 , and any connected APVs.
FIG. 4 illustrates another example implementation of a riser tensioner system 300 including a hydraulic cylinder 310 and a high-pressure accumulator 330 . The riser tensioner system 300 does not include a low-pressure accumulator. A piston 320 is disposed within an interior of the hydraulic cylinder 310 and is configured to slide along an axial direction therethrough. The piston 320 includes a piston seat 322 and a piston extension 324 . The piston seat 322 divides the interior of the cylinder 310 into a first variable-volume section 312 and a second variable-volume section 314 . The volumes of the sections 312 , 314 vary based on the position of the piston seat 322 within the cylinder 310 .
The piston extension 324 includes a sidewall 326 that extends upwardly from the piston seat 322 through the cylinder 310 to define an annular region 323 around the sidewall 326 . As the piston 320 slides within the cylinder 310 , the annular region 323 around the piston extension 324 grows and shrinks. In the example shown, the annular region 323 has substantially less volume than the hollow interior 325 of the piston extension 324 . In other implementations, however, piston extension 324 may be sized so that the annular region 323 has a greater or lesser volume. The piston sidewall 326 defines a hollow interior 325 that is accessible from the annular region 323 through one or more apertures 328 defined in the sidewall 326 . Accordingly, the second variable-volume section 314 of the cylinder 310 is defined by the annular region 323 around the piston extension 324 and the hollow interior 325 of the piston extension 324 . In the example shown, four apertures 328 are visible extending through the piston sidewall 326 in a ring. In other implementations, a greater or lesser number of apertures 328 may be provided in the piston 320 .
A first sealing arrangement 327 is disposed at the piston seat 322 of the piston 320 to provide a seal between the first and second variable-volume sections 312 , 314 of the cylinder 310 . The example piston seat 322 shown in FIG. 4 is taller than the piston seat 222 shown in FIGS. 2 and 3 . A second sealing arrangement 329 is disposed between the piston extension 324 and an exterior of the cylinder 310 to seal the interior of the cylinder 310 as the piston 320 is slid therethrough. The second sealing arrangement 329 is located at an opposite end of the piston 320 from the first sealing arrangement 327 . A conduit 397 for connection to a lubrication tank port is provided at the second sealing arrangement 329 .
A valve conduit 372 also is provided at the top of the high-pressure accumulator 330 for receiving piping to connect one or more APVs. First and second fluid conduits 350 , 380 also are shown extending between the cylinder 310 and the high-pressure accumulator 330 . In the example shown, the first flow path 350 has a larger cross-dimension (e.g., diameter) than the second flow path 380 . In other implementations, each of the flow paths 350 , 380 may have a greater or lesser cross-dimension. In certain implementations, the first flow path 350 passes through a valve 355 and the second flow path 380 is open.
Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are appended hereto. | Certain types of riser tensioner arrangements include a high-pressure accumulator; a pusher-type hydraulic cylinder; a first flow path coupling the high-pressure accumulator with a first volume of the cylinder to enable a first high-pressure fluid to flow therebetween; and a second flow path coupling the high-pressure accumulator with a second volume of the cylinder to enable a second high-pressure fluid to flow therebetween. The piston includes a seat and a hollow extension that defines part of the second volume of the cylinder. | 5 |
FIELD OF INVENTION
[0001] This invention relates generally to system and method for securing a load to a flat bed truck. More particularly, the system and method include a removable railing system for ensuring that a load remains on a flat bed truck during transit, but which can be removed when necessary to assist in unloading of the truck.
BACKGROUND OF THE INVENTION
[0002] A quite common type of truck trailer is the so-called “stake bed truck” that provides a flat cargo area with no roof or permanently affixed sidewalls. These types of vehicles are typically used to carry very heavy loads, generally of the character that the load needs to be placed on the truck with the use of a crane or fork lift truck. The stakes are typically removable from a series of spaced apart pockets provided around the periphery of the truck bed in a rub rail that borders the bed. Straps or chains are typically secured to the stakes or to the rub rail adjacent to the pockets and placed over the load to secure it to the truck bed. For the transportation of rolled steel products, the pockets are often spaced apart at intervals of about 21 inches along the periphery of the truck.
[0003] Presently, compact, heavy objects that have rounded surfaces can be difficult to transport on such conventional flat bed trucks. For example, the transport of cylindrical coils of rolled sheet steel has proven particularly problematic to transfer safely and efficiently with a flat bed truck. Such rolls of sheet steel typically vary in their dimensions from a diameter of 24 inches to 36 inches and a width from 12 inches to 36 inches. Rolls of sheet steel are difficult to transport because even relatively narrow rolls (less than 21 inches) often weigh more than 700 pounds. Even when strapped down to the conventional steel stake systems typically utilized with flat bed trucks, steel rolls can, due to their weight, compact size and curved outer surface, work free of the strapping and roll off of the bed of the truck. Such an occurrence can create a very dangerous situation for the truck driver and the other vehicles traveling the roads. Also, since the heavy loads that flat bed trucks carry usually necessitate being loaded from their sides by one or more forklifts, it is important that any system for securing such loads allow for easy access to the sides of the truck. Thus, there is a need for a more secure way to transport heavy dense, but highly mobile cargo, such as rolls of sheet steel, on flat bed trucks, which also allows for efficient access to the sides of the truck in order to unload the cargo with a forklift.
[0004] One prior attempt to provide flat bed trucks and trailers with a load securing structure was to equip them with longitudinally spaced-apart, insertable gates, which can be removed during loading and then reinstalled after loading to secure the load in place on the bed of the truck. Typically, the prior art gates were constructed from at least two elongated vertically extending stakes that are telescopically receivable within longitudinally spaced-apart pockets provided along the sides of the truck bed. The vertical stakes were sometimes connected together by vertically spaced-apart wooden or metal slats that are typically about 4 to 6 feet long. U.S. Pat. No. 6,325,438 B1 discloses a side gate assembly that is hinged to the flat bed in a manner that allows them to be folded onto the truck to allow the loaded from the side by a forklift truck. However, the system of the '438 patent is bulky, complex and costly and thus inadequate for many situations. Furthermore, the light weight construction of the hinged, foldable gates and the wide spacing of their stake members do not provide a sufficiently robust structure to prevent a seven hundred pound roll of sheet steel from breaking through the gates and falling off of the flat bed.
[0005] For the transportation of logs, special flat beds logging trucks or trailers have been designed with movable stakes that constrain the logs on the truck or trailer. These stakes are placed inside a bunk pocket. The bunk pockets are secured to a bunk which is a member that passes under the truck or trailer bed and supports the bunk pocket into which the stakes are placed. Once the logs are placed on the trailer inside the stakes, a safety wrapper chain or strap is added to further secure the logs to the truck or trailer bed in compliance with transportation regulations. U.S. Pat. No. 6,722,828 B2 discloses a logging truck with a system configured to constraining logs to be hauled on a truck or trailer without the use of safety wrapper chains or straps to secure the load. This is accomplished by utilizing stakes, bunks, bunk pockets, a head board and a tail board to constrain logs on the bed of the truck or trailer. The stakes disclosed in the '828 patent constrain the logs movement from side to side on the truck or trailer. However, the stakes of the '828 patent are permanently mounted, which make it difficult to allow side fork lift access to the truck. Moreover, the spacing of the stakes in the '828 system would not be appropriate for loads that are more compact than logs, such as sheet steel rolls.
[0006] There are also a number of removable cover systems for flatbed trailers, which include stake-supported panels extending longitudinally along sides of the trailer and bow-supported tarp cover secured over the trailer and the upper portions of the panels. These systems are typically referred to as tarp-and-rack systems or side kits, and versions of these systems have been commercially available for a number of years. U.S. Pat. No. 7,350,842 B2 includes a relatively detailed discussion of various iterations of such systems. However, those systems involve more expense and labor to construct than is desirable and further are believed to lack the strength required to secure the relatively heavy, highly movable loads for which the current system has been designed. Further, where unloading or loading cargo requires ready forklift access to the sides of the truck, tarp and racks systems are too time-consuming and labor intensive to disassemble to be feasible for most jobs. Further, as such systems are primarily designed to sheltering cargo on the truck bed rather than securing heavy loads. Thus, they are not believed to be sufficiently robust for use with heavy, compact highly mobile cargo, like rolls of sheet steel.
OBJECTS OF THE INVENTION
[0007] One object of the invention is to provide a cost effective system and method to assist in constraining heavy, dense highly mobile cargo, from falling off a flat bed truck during transit.
[0008] Another object of the invention is to provide such a robust rail system and method which further allows for quick and efficient forklift access from the sides of the flat bed truck for loading and unloading cargo therefrom.
[0009] A further objective is to provide a removable, adjustable rail system to assist in constraining a heavy, highly mobile load on a flat bed truck.
[0010] A still further object of the invention is to provide a method for providing side loading access to a flat bed truck through a rail system for assisting in securing a load to a flat bed truck.
BRIEF SUMMARY OF THE INVENTION
[0011] One embodiment of the invention provides a detachable railing system for assisting in securing a load to a flat bed truck. The railing system including a plurality of detachable stakes have one end dimensioned for telescopic mating with a pocket formed along the periphery of the flat bed truck. Each of the plurality of stakes has a saddle portion extending outwardly therefrom and which is dimensioned for receipt of one end of an arm. A plurality of arms is dimensioned to be inserted into at least one of the saddles of the plurality of stakes and is further dimensioned to span the length between adjacent stakes when the stakes are mounted a predetermined distance apart near the periphery of the flat bed truck. The plurality of arms is further adapted to detachably mounted into at least one of the saddle portions of at least one of the plurality of stakes. Preferably, the arms are pivotally mounted to the saddles by means of a hinging bolt on a first end and a lock pin on a second end. In order for the pivotally mounted arm to clear the saddle portion during pivoting, its ends are preferably cut on angle to allow for rotation of the portion of the arm opposite the pivot bolt to swing past the saddle. Further, the plurality of stakes are each preferably provided with a stop block along at least one of their outer surfaces to ensure that they are at a uniform height when inserted into the plurality of pockets formed on the flat bed truck. Moreover, the stakes are also preferably provided with an arm retaining tang which is dimensioned for a tight friction fit with the arm when the arm is pivoted into a substantially upright position. Also, the tang is provided with a removable pin for temporarily securing the arm in an upright position during loading and unloading cargo.
[0012] In another embodiment of the invention, an alternate detachable railing system for assisting in securing a load to a flat bed truck is provided. The alternate railing system includes a plurality of detachable stakes have one end dimensioned for telescopic mating with a pocket formed along the periphery of the flat bed truck bed. Each of the plurality of stakes has a boot portion adjustably attached thereto. Each of the boots portions has at least one saddle portion extending outwardly therefrom, which is dimensioned for receipt of one end of an arm. Each of the boots, in turn, are dimensioned to telescopically mate with a stake such that the boots can slide along the vertical length of the stakes to allow the railing system of this embodiment of the invention to be adjusted to a plurality of different rail heights. A plurality of arms are dimensioned to be received into at least one of the saddles of the plurality of stakes, and the arms are further dimensioned to span the length between adjacent stakes when mounted a predetermined distance apart near the periphery of the flat bed truck. In one embodiment of the invention, including the adjustable boots, the arm portion may also be pivotally mounted to the saddles of the boot.
[0013] In a still further embodiment of the invention, a method and system is provided for converting conventional flat bed stakes into a railing system. The method includes providing a plurality of boots being adapted to be attached to conventional flat bed stakes. The plurality of boots are attached to each of the plurality of conventional stakes by attaching bolts or the like through the boot into holes drilled into the conventional stakes. Each of the boots portions has at least one saddle portion extending outwardly from each of the conventional stakes. The conversion kit further includes a plurality of arms that are dimensioned to be received into at least one of the saddles attached to each of the plurality of stakes and is further dimensioned to span the length between adjacent stakes when mounted a predetermined distance apart near the periphery of the flat bed truck. A first end of each of the plurality of arms is inserted into a saddle portion mounted to a first of the plurality of stakes. Then, a second end of each of the plurality of arms is inserted into an adjacent saddle attached to an adjacent conventional stake. In some cases, the conventional stakes may have holes already drilled in them at an acceptable height for mounting the boots. However, if this is not the case, the kit may include instructions for drilling appropriate holes for receipt of bolts for attaching the boots to the conventional stakes.
[0014] Still further, the present invention includes a method of loading or unloading a load from a flat bed truck including the steps of removing a mounting pin from a pivotally mounted arm forming at least a portion of a railing around the periphery of a flat bed truck. Next, the arm is pivoted upwardly into a substantially upright position to allow a forklift to access a load located on the flatbed truck between adjacent stakes of the railing system mounted along the periphery of the flat bed truck. If the load or the distance between the forks of the forklift to be removed is larger than the spacing between the stakes of the railing system, one or more of the stakes may be removed by first removing the locking pin on one end of the arm, pivoting the arm into its upright position, and pulling the stake from the pocket on the flat bed truck. In one preferred method the invention, the stakes are provided with a friction fit tang member that temporarily retains the vertical, pivoted arm while the load is being accessed by the forklift. In one preferred method of the invention, the pivoted arm is temporarily secured in the vertical position by the insertion of a pin through the arm and into a hole in the tang.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a plan view of a pair of stakes and an arm connecting same in accordance with one embodiment of the railing system of the invention;
[0016] FIG. 2 is a plan view of a pair of stakes with the arm raised and pinned into a tang in accordance with the railing system depicted in FIG. 1 ;
[0017] FIG. 3 is a plan view of a pair of stakes with the arm partially lowered in accordance with the railing system shown in FIG. 1 ;
[0018] FIG. 4 is an enlarged perspective view of a stake with arm attached thereto in a raised position with the arm secured in the tang by a pin in accordance with the railing system shown in FIG. 1 ;
[0019] FIG. 5 is an enlarged plan view of a partially disassembled stake with an arm detached there from in accordance with the railing system shown in FIG. 1 ;
[0020] FIG. 6 is a rub-rail on a flat bed truck for receipt of the stakes of railing system of the applicant's invention;
[0021] FIG. 7 is an enlarged perspective view of an alternate embodiment of a stake in accordance with an alternate embodiment of the railing system of the invention.
[0022] FIG. 8 is a plan view of a boot portion of the rail system of FIG. 7 .
[0023] FIG. 9 is a side view of a boot portion of the rail system of FIG. 7 .
[0024] FIG. 10 is a side view of an arm portion of the rail system of FIG. 7 .
[0025] FIG. 11 is a perspective view of another alternate embodiment of the railing system of the invention showing the system assembled in a double arm configuration.
[0026] FIG. 12 is a perspective view of the railing system of FIG. 11 showing the arms in a partially upwardly pivoted position.
[0027] FIG. 13 is a perspective view of disassembled components of the railing system of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] As shown in FIG. 2 , one embodiment of the railing system of the invention includes at a plurality of stakes 20 , which are dimensioned to be received into pockets 22 located in the rub-rail 24 of a flat bed truck 26 . Each pair of stakes, e.g., 20 a and 20 b , include a connecting arm 28 which is dimensioned to span the distance between each pair of stakes. The connecting arm 28 is further dimensioned for receipt in saddles 30 a, 30 b on each of the stakes 20 a, 20 b. The arm 28 and stakes 20 a, 20 b combining to form one segment of the railing system in accordance with the embodiment of FIG. 1 . The railing system of this embodiment of applicant's invention may include multiple railing segments arranged adjacent to one another, or alternately may have one or more gaps formed there between where the cargo being hauled lends its self to being securely retained by an intermittent rail arrangement. Railing systems in accordance with the embodiment of FIG. 1 have been field tested to withstand the force of a rolling 500/600 lbs. 2 inch thick solid wall steel being dropped from a height of about two feet causing a rolling velocity of about 5 mph onto a flat bed truck contacting the railing without damaging either the railing system of coiled steel roll.
[0029] Turning now in more detail to the stakes 20 a, 20 b, as shown in FIG. 1 , when the arm 28 is fully assembled, it is held in place by bolt 32 on one end and a pin 34 on a second end. The pin 34 is preferably a temporary locking style pin, such as cotter type pin, so that the arm 28 can be securely affixed to the stake, but also easily removed therefrom in order to partially disassemble the railing system in order to allow side access to the flat by a forklift between the adjacent stakes. In this vein, FIG. 2 shows stakes 20 a, 20 b with arm 28 pivoted upwardly such that the arm 28 is held in that upright position by tang 36 and tang pin 38 . Tang 36 is dimensioned for a friction fit with arm 28 when arm 28 is pivoted into its upright or partially disassembled configuration for purposes of unloading the cargo from the side with a fork lift. Tang pin 38 is also preferably a cotter style pin which allows the tang pin to be quickly and securely installed as well as removed to facilitate assembly and disassembly of the railing system. As can be further seen in FIG. 2 , arm 28 includes a bias cut end 40 to prevent the end of the arm 28 from impinging on saddle 30 a when being swung to its upright position. Stake 20 b is provided with pin aperture 42 , which is dimensioned to receive pin 34 during assembly of the rail system. Stakes 20 a and 20 b further include stops 44 a, 44 b, which are dimensioned to prevent over insertion of the stakes 20 a and 20 b into the pockets 22 a, 22 b of rub-rail 24 . This keep the railing system at a uniform pre-determined height relative the bed. Where one or more cargo items are wider than the gap between the stakes, it will sometimes be necessary to remove one or more stake to access such wide cargo items with the fork lift from the side of the truck.
[0030] In FIG. 3 , stakes 20 a and 20 b are shown with arm 28 partially pivoted toward sleeve 30 b. Tang pin aperture 46 can be best seen in FIG. 3 , and it is dimensioned for receipt of tang pin 38 . Arm 28 further includes arm tang aperture 48 , which is positioned and dimensioned to align with tang pin aperture 46 on stake 20 a when arm 28 is fully pivoted into its upright position. Arm 28 is further provided with arm sleeve aperture 43 which is positioned and dimensioned to align with sleeve aperture 42 when arm 28 is fully downwardly pivoted into sleeve 30 b.
[0031] With regard to FIG. 4 , arm 28 is shown in its fully upright position with a pin 38 securing it in that position. Pin 38 is shown with cotter element 50 inserted into pin and aperture formed on the end of pin 38 to prevent inadvertent swinging of arm 28 should, for example, a forklift or cargo bump into the arm during unloading of the flat bed 26 of the truck. Stake 20 a may optionally include sleeve aperture 42 a so that sleeve 30 a may receive the second end of an additional arm piece (not shown) so that stakes may be joined sleeve to arm to sleeve to arm to create multiple segments to the rail system of the embodiment of FIGS. 1-5 .
[0032] Concerning FIG. 5 , stake 20 a is shown without arm 28 connected thereto. In this view, arm aperture 52 a is best seen. Arm pin aperture 52 a is dimensioned for receipt of arm bolt 32 . Arm bolt 32 may be secured with nut (not shown) to allow disassembly of arm and stake 20 a. Optionally, bolt aperture 52 a can be threaded on side of the sleeve so that bolt 32 can be tightened directly on the sleeve. Further, sleeve 30 b may also be provided with a bolt aperture 52 b dimensioned to receive a bolt (not shown) to secure a second arm to sleeve 30 b in order to create a multiple segment railing system. The stakes 20 a, 20 b of the embodiment of FIGS. 1-5 are preferably manufactured from ⅛ thick, hollow tubing steel stock of ASTM A-500 Grade B. The sleeves 30 a and 30 b are preferably fabricated from 11 gauge steel tubing, steel stock and then welded to sleeves 20 a and 20 b, respectively. Tang 46 is welded to stake 20 a. Stops 44 a and 44 b are fabricated from ½ inch A-36 HR Steel roll, steel stock and are then welded to stakes 20 a and 20 b. Each of the apertures 42 a, 42 b, 46 , 48 , 52 a, 52 b, are machined into the applicable part utilizing a CNC drilling tool. The arms 28 may also be made from ⅛ inch thick 6061-T6 grade aluminum tube stock.
[0033] Turning now to FIG. 7 , an alternate embodiment of the railing system of the applicant's invention is illustrated, which includes stake 120 and boot 121 . Boot 121 further includes a pair of saddles 130 a and 130 b for receipt of an end of an arm 128 (see FIG. 10 ). Each end of the arms 128 are held in similar boots (not shown) on adjacent stakes (not shown) to from a rail. Again, as with the previous embodiment of the invention, the railing system can be continuous around the periphery of the truck bed, may cover a portion of the periphery, or may be discontinuous. The boot 121 has a central aperture 123 , best seen in FIG. 8 , which is dimensioned for telescopically mating with stake 120 . Boot 121 includes boot holes 125 a, 125 b, 125 c, 125 d which are dimensioned to receive mounting bolts 127 a, 127 b, 127 c, 127 d, respectively so that the boot 121 can be detachably mounted to the stake 120 through any two sets of aligning stake holes 129 ab , 129 cd , 129 ef , 129 gh , 129 ij , 129 kl located on side walls 133 a,b of boot 121 via insertion of boot bolts 132 a and 132 b. The saddles 130 a and 130 b may further include aligned apertures 135 a, 135 b and 137 a, 137 b which are dimension to receive cotter pins 141 a , 141 b to hold arms 128 to boot 120 . The arms 128 have an aperture on each end 139 a , 139 b, which are dimensioned and positioned to receive the cotter pins 141 a and 141 b for securing the arm 128 to boots 121 located on adjacent stakes 120 .
[0034] Turning to FIGS. 11-13 , another alternate embodiment of the railing system of the applicant's invention is illustrated, which includes stakes 220 and boots 221 . Each boot 221 further includes a pair of saddles 230 a and 230 b for receipt of an end of an arm 228 (see FIG. 11 ). Each end of the arms 228 are held in similar boots on adjacent stakes 221 to form a rail. As shown in FIGS. 11 and 13 , the rail may include more than one set of arms 228 between the posts. Such a double (or even triple arm) configurations may be used where steel rolls of different heights are being simultaneously transported or where the driver or operator believes that additional strength may be needed to contain an especially heavy, or especially mobile load. Again as with the previous embodiments of the invention, the railing system can be continuous around the periphery of the truck bed, may cover a portion of the periphery, may be discontinuous, or may include diverse segments which are either single, double, or triple armed. The boots 221 each have a central aperture 223 , best seen in FIG. 11 , which is dimensioned for telescopically mating with stake 220 . Boot 221 includes boot holes 225 a and 225 b which are dimensioned to receive mounting bolts 227 respectively so that the boot 221 can be detachably mounted to the stake 220 through any pair of aligned stake holes 229 ab , 229 cd , 229 ef , 229 gh , 229 ij , located on side walls 233 a,b of boots 221 via insertion of boot bolts 227 a and 227 b. The saddles 230 a and 230 b may further include aligned apertures 235 a, 235 b, which are dimension to receive cotter pins 214 a, 214 b to hold arms 228 to boots 220 . The arms 228 have an aperture on each 239 a, 239 b, which are dimensioned and positioned to receive the cotter pins 241 a and 241 b for securing each end of arm 228 to boots 221 located on adjacent stakes 220 . In the embodiment of FIGS. 11-13 , the arms 228 are shown with only a single angled end 240 . However, to allow pivoting from either end of the arms 228 , it is contemplated that commercial versions of the rail systems of FIGS. 11-13 would include an angled end 240 on both ends of each of the arms 228 . Furthermore, it is preferred that the stakes 220 also include a rub rail retention hole 260 , which is dimensional to receive a cotter type pin (not shown) that will prevent the stake from bouncing upwardly out of a rub rail pocket when a truck encounters bumpy terrain that might dislodge one or more stakes of the rail system. The retention hole 260 is spaced apart from stops 244 along the bottom of the stakes 220 a distance that is slightly larger than the height of rub rail pockets 22 (see FIG. 6 ). The stakes 220 of the rail system of FIGS. 11-13 have a stop 244 for engaging the upper portion of the rub rail pocket 22 and the cotter pin inserted into the retention hold 260 for engaging the bottom portion of the rub rail pocket. This arrangement ensures that the railing system will not become unintentionally dislodged during transit. | The invention provides a detachable railing system for assisting in securing a load to a flat bed truck. The railing systems of the invention include a plurality of detachable stakes have one end dimensioned for telescopic mating with a pocket formed along the periphery of the flat bed truck. Each of the plurality of stakes has a saddle portion extending outwardly therefrom and which is dimensioned for receipt of one end of an arm. A plurality of arms is dimensioned to be inserted into at least one of the saddles of the plurality of stakes and is further dimensioned to span the length between adjacent stakes when the stakes are mounted a predetermined distance apart near the periphery of the flat bed truck. The plurality of arms is further adapted to detachably mounted into at least one of the saddle portions of at least one of the plurality of stakes. | 1 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to data transmission. More particularly the invention comprises a system that transmits simultaneously a plurality of data signals through air and water where the sending and receiving ends will be separated from further communication at the end of the data transmission. In other words prelaunch information is sent to a launch vehicle wherein one of the mediums to be penetrated is water.
2. Description of the Prior Art
A previous method of transmitting the prelaunch weapon communications comprises using a large umbilical cable. This cable carried information from the tube door to the weapon. When the weapon is launched, the cable would disengage by breaking two shear screws and remain in the tube, while the weapon proceeded on its mission. Unfortunately, due to the fragile nature of the shear screws, problems molding the cable ends and user error, the failure rate of these cables is often above 10%. In addition, these cables are only good for one use without being returned to a refit facility. Even then, they often could not be used a second time due to corrosion.
SUMMARY OF THE INVENTION
The present invention comprises a data communication system for transmitting data from a fire control system to a weapon electronic system such as that on a torpedo where one of the mediums through which the data passes is water and following the transmission of data the weapon holding the weapon electronic system is fired. The data communication system has a multiplexer for receiving parallel data and transmitting the data in multiplexed serial form. A first acoustic transducer receives the serial electronic data and converts it to acoustic form which is transmitted across a gap of water. A second acoustic transducer receives the acoustic data and returns it to serial electronic data. A demultiplexer receives the serial electronic data and converts it to parallel data for receipt by the weapon electronic system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prelaunch weapon communication system in accordance with the present invention;
FIG. 2 is a modified version of the system of FIG. 1 showing separate transmitting and receiving transducers; and
FIG. 3 is a modified version of the system of FIG. 1 showing multiple transducers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 there is shown a fire control system 10 for transmitting information to a weapon electronic system 12. In order to allow the weapon electronic system to send information back to the fire control system the process about to be described with reference to FIG. 1 is reversed.
The fire control system 10 sends parallel data over lines 13 to a multiplexer 14. The multiplexer 14 converts the received parallel data to serial multiplexed form and transmits this serial data to an acoustic transducer 16 over line 17. The acoustic transducer 16 is mounted to the wall or door of the launch tube 18 and is made watertight by the use of watertight connectors, seal or other well known devices. The acoustic transducer 16 converts the received electrical signal to an acoustic signal and transmits this as acoustic data 20 through a water medium 22 of approximately three inches to another acoustic transducer 24 that is mounted to the shell of a weapon 26. The acoustic data 20 is reconverted to multiplexed electronic serial data and transmitted over line 28 to demultiplexer 30. The de-multiplexer 30 reconverts the serial data to parallel data and transmits it to the weapons electronic system 12 over lines 32.
Referring now to FIG. 2 there is shown a prelaunch communication system having one set of components for transmitting information from a fire control system 110 to a weapons electronics system 112 and a separate set of components for transmitting information from the weapons electronics system 112 to the fire control system 110. The information from fire control system 110 to weapon electronics 112 is transmitted similar to that recited for FIG. 1. Parallel data is forwarded to multiplexer 114 over lines 113. Serial data is forwarded to acoustic transducer 116 over line 117. Acoustic data is forwarded to acoustic transducer 124 through the water medium 122. Serial data is then forwarded to de-multiplexer 130 over line 128 and parallel data is transmitted to weapon electronics 112 over lines 132.
Information from the weapon electronics system 112 to fire control system 110 is transmitted in a similar fashion utilizing parallel line 140, multiplexer 142, line 144, acoustic transducer 146, water medium 122 for acoustic data 148, acoustic transducer 150, line 152, demultiplexer 154, parallel lines 156 and fire control system 110.
The acoustic transducers 116 and 124 carrying acoustic data 120 should be separated an adequate distance from acoustic transducers 146 and 150 carrying acoustic data 148 so that interference from cross talk does not occur. This distance can be easily determined by cut-and-try methods for each type facility.
For systems having a large amount of simultaneous data to be transmitted the arrangement shown in FIG. 3 could be used. The operation of each path is similar to that described for FIG. 1.
The fire control system 10a has three separate paths available for transmitting information to weapon electronics system 12a. Information can also be sent from weapon electronics system 12a to fire control system 10a. The components used in FIG. 3 are similar to those of FIG. 1 and use the same numerical notation with a letter added for distinguishing them. The launch tube wall 18a and weapon shell 26a would be modified for the additional transducers. Each transducer pair 16a and 24a, 16b and 24b, and 16c and 24c should be adequately spaced from each other transducer to prevent cross talk.
There has therefore been described a transmission system for sending prelaunch weapon information in which the use of an umbilical cable. This has the advantage that with the loading of a new weapon the system is immediately ready for reuse with no worry of damage to the umbilical cord. The use of an acoustic data link for transmission is a new feature in devices of this nature.
It will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. | The transmission of prelaunch weapon communication in a submarine is accoished without the use of an umbilical cord. Acoustic transducers transmit and receive acoustic data through water in place of the umbilical cord. The data transmitted through the water from the launch tube wall to the weapon is in serial format having been converted from parallel data by multiplexing. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to European Patent Application No. 15 190 395.2 filed on Oct. 19, 2015, the disclosure of which is incorporated by reference herein in its entirety.
FILED OF THE INVENTION
[0002] The present invention relates to a method for using a service of a mobile packet core network in a communication system comprising a mobile device, a node, a mobile packet core network and a wireless radio access network, whereby the mobile device accesses the mobile packet core network via the wireless radio access network, whereby the mobile device during a setup of a connection of the mobile device to the wireless radio access network determines whether the wireless radio access network is a trustworthy wireless radio access network and at least if the wireless radio access network is not trustworthy establishes a secure tunnel connection to a node of the communication system for triggering a usage of a service of the mobile packet core network by an authentication entity of the mobile packet core network.
[0003] The present invention further relates to a node of a communication system comprising a mobile device, a mobile packet core network and a wireless radio access network to which the mobile device can establish a secure tunnel connection.
[0004] Another object of the invention is a provisioning system of a communication system comprising a mobile device, a mobile packet core network and a wireless radio access network.
[0005] Furthermore, the invention relates to a system for using a service of a mobile core packet network in a communication system comprising a node of the communication system, a provisioning system of the communication system and a mobile device of the communication system.
BACKGROUND
[0006] The prior art proposes methods to provide the possibility to use mobile data over a wireless radio access network, for example a Wi-Fi technology, as an additional radio access network. A disadvantage by using mobile data, in particular services of the mobile packet core network is that it is not ensured that the mobile device requesting the access to the service of the mobile packet core network is authorized. Therefore, a need for a solution allowing a secure access to core services of the mobile packet core network and also a secure access to the internet is given.
[0007] Known from the prior art for the aforementioned case are authentication methods, such as EAP-SIM/AKA, WPA2 and so called IPsec tunnels for Wi-Fi access to a mobile packet core network, which is also referred to as MNO (MNO: Mobile Operator Network). In these approaches, the identification of the user of the mobile device may be considered, for instance by using the MSISDN (MSISDN: Mobile Subscriber Integrated Services Digital Network) and/or the IMSI (IMSI: International Mobile Subscriber Identity) representing identification, the overall security remains flawed. A drawback of the EAP-SIM/AKA authentication known from the 3GPP standard is that an access to information stored on a SIM (SIM: Subscriber Identity Module) or USIM (USIM: Universal SIM) is required so that for instance the MSISDN and/or IMSI can be used for the authentication. Therefore, devices, which are not equipped with a SIM or USIM cannot get access to services of the mobile packet core network even though the device may be capable of getting access, for instance by using a wireless radio access network to connect to the mobile packet core network. Furthermore, especially an application on a device cannot get access to the information stored on the SIM respectively USIM, for instance, the SIM credentials, even if the device is equipped with a SIM or USIM, when the device is not ePDG (ePDG: evolved Packet Data Gateway) compliant.
[0008] The prior art document WO2015/131949 A1proposes a method for the solution of some of the aforementioned drawbacks by using credentials stored within a mobile device as credentials towards an entity of the mobile packet core network to authorize the user of the mobile device. The credentials are created during an initial setup. Devices, which are not equipped with a SIM or an USIM should get a so called virtual MSISDN and/or virtual SIM, which is generated during the initial setup by the mobile network and stored within a database of the mobile packet core network, whereby the database stores the relationship between the credentials stored within the mobile device and a MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI. For using a service of a mobile packet core network the mobile device transmits the certificate to an entity of the mobile packet core network, which triggers the database to get the linked MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI, which are used to establish a connection between the mobile device and the mobile packet core network. A first drawback of the proposed solution is that the credentials can be copied to other devices so that these devices can get access to the mobile packet core network as well. This is susceptible for fraud by unauthorized users. Furthermore, each time an access is requested from the mobile device to the mobile packet core network, the entity of the mobile packet core network has to trigger the database for receiving the linked MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI to establish a secure connection. The data traffic of such a solution is quite high so that there are significant operational costs. Furthermore, these known solutions require a modification of several standard nodes and require that each device requesting access to the mobile packet core network has to get a dedicated certificate, which creates further costs.
[0009] Regarding the aforementioned prior art it is the technical object of the invention to provide a solution, which reduces the operational costs of operating for triggering a usage of a service of a mobile packet core network by a mobile device and which enhances the security of using a service of a mobile packet core network when accessing the mobile packet core network via a not trustworthy wireless radio access network from the mobile device.
SUMMARY
[0010] As a technical solution the invention proposes a method for using a service of a mobile packet core network in a communication system comprising a mobile device, a node, a mobile packet core network and a wireless radio access network, whereby the mobile device accesses the mobile packet core network via the wireless radio access network, whereby the mobile device during a setup of a connection of the mobile device to the wireless radio access network determines whether the wireless radio access network is a trustworthy wireless radio access network and at least if the wireless radio access network is not trustworthy establishes a secure tunnel connection to a node of the communication system for triggering a usage of a service of the mobile packet core network by an authentication entity of the mobile packet core network, which is characterized in that the secure tunnel connection is established by using a token respectively key stored within the mobile device and received from the mobile device by the node, whereby the token respectively key comprises at least a certificate for authentication to the authentication entity, a MSISDN respectively a virtual MSISDN (vMSISDN) and/or an IMSI respectively a virtual IMSI (vIMSI) allocated to the user of the mobile device and whereby the token respectively key is generated by the node using general security mechanisms, in particular TPM (TPM: Trusted Platform Module) and/or MD5 (MD5: Message-Digest Algorithm 5).
[0011] In the sense of the invention a token respectively key is a kind of information that comprises essential information for executing the invention in particular information for using a service of the mobile packet core network. The term token and the term key mark exactly the same and for reasons of simplicity the term token is used in the following.
[0012] The communication system according to the invention comprises a mobile device, a node, a mobile packet core network and a wireless radio access network.
[0013] The mobile device can be a mobile phone, smart phone, tablet or any other mobile communication device capable of connecting to a wireless radio access network. In the following, the mobile device may be referred to as user equipment (UE). In particular the mobile device can be capable of supporting a classic mobile radio access technology, for example Wi-Fi, and/or capable of connecting to the mobile packet core network via radio access networks which are different from the wireless radio access networks, which are for instance GRAN, GERAN, UTRAN or E-UTRAN. Thus, the present invention supports mobile devices a SIM or an USIM and also mobile devices without a SIM or an USIM, for example a device with Wi-Fi only capabilities.
[0014] The mobile packet core network is a packet switched domain network. The mobile packet core network can in particular be a network according to 2G-, 3G, and or LTE (3GPP)-standards. The mobile packet core network comprises entities such as data bases, for instance HLR (HLR: Home Location Register), HSS (HSS: Home Subscriber Server), VLR (VLR: Visitor Location Register), EIR (EIR: Equipment Identity Register) as well as service entities such as MSC (MSC: Mobile Switching Centre), SMSC (SMSC: Short Message Service Centre) and an AAA server (AAA: Authentication, Authorization and Accounting server). The AAA server will hereinafter be referred to as AAA.
[0015] The wireless radio access network is a radio access network for access to the mobile packet core network. It should be noted that this radio access network hereinafter will be referred to as wireless radio access network in order to distinguish it from other radio access networks which may be used by the mobile device to access the mobile packet core network directly. The wireless radio access network can in particular be a wireless local area network (WLAN) and most preferably a Wi-Fi (Wireless Fidelity) network. The Wi-Fi network is in particular a network governed by protocol IEEE 802.11 which defines the communication in this network.
[0016] In the communication system according to the invention, wireless radio access technology is thus combined with the communication via mobile packet core network for accessing the core network, for example for retrieving content from the internet.
[0017] The node of the communication system is an entity of the communication system, preferably a VPN (Virtual Private Network) concentrator node or an ePDG (ePDG: evolved Packed Data Gateway), or in the alternative a TTG (TTG: Tunnel Termination Gateway), which receives an authorization request of a mobile device, in particular by an enhanced ANDSF application (ANDSF: Access Network Discovery and Selection Function) for authorization of a user for the usage of a service of the mobile packet core network. In a preferred embodiment the node is part of the mobile packet core network.
[0018] A VPN concentrator is a type of aforementioned node that provides a secure creation of VPN connections and delivery of messages and/or services between VPN nodes. The VPN concentrator node is able to terminate a secure tunnel connection, for instance an IPSec tunnel and forward the traffic to a TWAN (TWAN: Trusted Wireless Access Network). This forwarding of traffic is used, when no ePDG node is available in the mobile packet core to get access to it. The TWAN can be part of the mobile packet core network, or could be part of the communication system with access to the mobile packet core network. An ePDG provides security mechanisms such as IPsec tunneling of connections with a mobile device over an untrusted non-3GPP access, such as an untrusted Wi-Fi network. A TTG terminates IPsec tunnels and maps the IPSec tunnels into GTP tunnels terminated in the GGSN (GGSN: Gateway GPRS Support Node), whereby the GGSN is typically not able to terminate IPSec tunnels. In one embodiment the aforementioned node of the communication system is only part of the communication system, and not a part of the mobile packet core network. Said node outside of the mobile packet core network has or is able to get access to the mobile packet core network. This can be realized in a preferred embodiment by a VPN concentrator node—inside or outside of the mobile packet core network—and a TWAN outside of the mobile packet core network, but with access to the mobile packet core network. Incoming traffic is terminated by the VPN concentrator node and forwarded to the TWAN so that a secure tunnel connection is established between the mobile device and the mobile packet core network.
[0019] The service of the mobile packet core network is provided by establishing a secure tunnel connection between the mobile device and the mobile packet core network. The secure tunnel connection is preferably a connection according to the GTPv2 (GTP: GPRS Tunneling Protocol; v2: for LTE-networks), so that a provisioning of services of the mobile packet core network is possible even when the mobile device requesting the service is accessing via an untrustworthy network. The services of the mobile packet core network can be divided into two parts: the first part comprises services of the trusted function of the mobile packet core network and the second part comprises services of the untrusted function of the mobile packet core network.
[0020] According to the present invention the determination of the trustworthiness of a wireless radio access network on side on the mobile device is determined by an application, preferably by the aforementioned enhanced ANDSF application, executed on the mobile device. The application determining the trustworthiness of a wireless radio access network is preferably previously downloaded to and installed on the mobile device. In a preferred embodiment, the application determining the trustworthiness of a wireless radio access network is downloaded and installed onto the mobile device via an ACS (ACS: Auto Configuration Server) of the mobile packet core network provided by the Mobile Network Operator.
[0021] In a further embodiment of the present invention the secure tunnel connection to a node of the mobile packet core network is established by an application executed by the mobile device, preferably a VPN application on part of the mobile device. According to a further embodiment of the present invention the application establishing the secure tunnel connection to a node of the mobile packet core network is started by the application determining the trustworthiness of the wireless radio access network, if the wireless radio access network is not trustworthy.
[0022] In a preferred embodiment of the invention the application (enhanced ANDSF application) is an ANDSF client, which is able to retrieve a token from an entity of the mobile packet core network, preferably a node of the mobile packet core network during an initial setup. Furthermore, the ANDSF client is able to manage the token and/or capable of starting the application establishing the secure tunnel connection on the mobile device, when the wireless radio access network is not trustworthy. The enhanced ANDSF application is for managing. VPN functions are used to terminate. The application establishing the secure tunnel connection is preferably previously downloaded to and installed on the mobile device. In a preferred embodiment, the application establishing the secure tunnel connection is downloaded and installed onto the mobile device via an ACS (ACS: Auto Configuration Server) of the mobile packet core network provided by the Mobile Network Operator.
[0023] In a further embodiment the application determining the trustworthiness of the wireless radio access network and the application establishing the secure tunnel connection to a node of the communication system are combined into a single application executed and running on the mobile device. The combination of both aforementioned applications into a single application is not necessary for the present invention, but a possible embodiment.
[0024] During a usage for the first time by requesting access to the mobile packet core network, also referred to as initial setup, preferably requested via the enhanced ANDSF application, the node of the communication system generates a token, which is used by the mobile device to establish a secure tunnel connection between the mobile device and the mobile packet core network. The token comprises at least a certificate for authentication to the authentication entity, preferably the AAA, a MSISDN respectively virtual MSISDN and an IMSI respectively virtual IMSI allocated to the user of the mobile device. The aforementioned information is needed to get access to the mobile packet core network of the mobile device via an untrusted network. The certificate can be created individually a provisioning system, for instance based on a MSISDN respectively virtual MSISDN and/or an IMSI respectively virtual IMSI. The certificate is created by a PM (PKI: Preshared key infrastructure) or a CA (CA: Certificate Authority) of the provisioning system. The relationship between a MSISDN respectively virtual MSISDN and/or an IMSI respectively virtual IMSI can be located in a database of the communication system, in particular a database of the node. The node triggers for instance a provisioning system, which retrieves the MSISDN and/or IMSI during the initial setup out of a data base of the mobile packet core network, or, when the device requesting the initial setup not equipped with a SIM or USIM, generated a virtual MSISDN and/or virtual IMSI.
[0025] According to the invention the token is generated by the node using general security mechanisms, in particular TPM or MD5. As a result, the token is encrypted so that when the token is transmitted to the mobile device after completion of the initial setup, the token is stored within the mobile device in an encrypted manner Therefore, it cannot be seen from the outside what is within the token, which enhances the security of the invention so that it is very hard for unauthorized users to get their hands on the token, because they do not know that behind the encrypted data a token is represented, which comprises a certificate, a MSISDN respectively a virtual MSISDN and an IMSI respectively virtual IMSI and which are required to get access to a mobile packet core network via a secure tunnel connection from the mobile device to the mobile packet core network. As a result, only the node, which generated the token knows the used certificate, MSISDN respectively virtual MSISDN and IMSI respectively virtual IMSI. Furthermore, only the node that generated the token knows the exact key of the used general security mechanism, which was used for the generation of token and which can be used for decrypting the data of the token.
[0026] In a further embodiment the node transmits the generated token to a provisioning system, in particular of the mobile packet core network for verifying the generated token at the first time a usage of a service of the mobile packet core network is requested by the mobile device. Advantageously, after the generation of the token during the initial setup, the token is transmitted to the provisioning system. The provisioning system is able to verify the token, for instance by checking the check sum of the used general security mechanism. In an embodiment, the provisioning system transmits the token to the mobile device or the token can be directly transmitted to the mobile device without transmitting the token beforehand to the provisioning system. But the provisioning system is required in a preferred embodiment of the invention, which enhances the security of the proposed solution even more by adding a second security instance to the proposed method.
[0027] In a preferred embodiment the token further comprises a timer and/or counter value for preventing fraud of the token by decrementing the timer and/or counter value by 1 by the provisioning system during the first time a usage of a service of the mobile packet core network is requested by the mobile device, whereby the token is transmitted from the provisioning system to the mobile device after the decrement. This is done preferably during the initial setup, for instance on request of the enhanced ANDSF application, and is done in particular automatic after the generation of the token by the node. For example the token is generated by the node and comprises a timer and/or counter, which is set to the enhanced value of 1. After the generation of the token, the token is transmitted to the provisioning system, which verifies the received token and reduces the timer and/or counter value by 1 to the value of 0. The value is always decremented by 1, if the token is received by the provisioning system during the first time a usage of a service of the mobile packet core network is requested by a mobile device, preferably by the enhanced ANDSF application of the mobile device. After the decrement, the token is transmitted to the mobile device and is stored within the mobile device and has got at that time the timer and/or counter value of 0.
[0028] If the token is copied unauthorized to another device, and the unauthorized device requests access, e. g. an authentication request, to the mobile packet core network, the token is—as described above—transmitted to the provisioning system since it is the first time this devices requests access to the mobile packet core network. The provisioning system decrements the timer and/or counter value by 1, so that the timer and/or counter value equals now −1 and is sent back to the mobile device. When the mobile device tries to establish a secure tunnel connection to the mobile packet core network, the timer and/or counter value can be checked and when it does not equal the value of 0, the used token is rejected since fraud is very likely. Of course, other implementations, which realize the same effect are possible.
[0029] Another embodiment is characterized in that the node rejects the received token if the timer and/or counter value is decremented by more than 1 to prevent fraud of the token.
[0030] In an embodiment of the invention the node verifies the received token by using general security mechanisms used to generate the token when an authentication request of the mobile device is received. It can be checked, if the token was changed in some manner which can be an indicator for fraud. If a change of the token is determined, the token is rejected so that the access of the mobile device to the mobile packet core network requesting the authorization is denied.
[0031] In another embodiment, the node extracts the certificate, the MSISDN respectively the virtual MSISDN and the IMSI respectively virtual IMSI out of the received token. Advantageously, this is done after the successful verification of the received token during an authorization request received by the node from the mobile device. The extracted information is used for establishing a secure tunnel connection between the mobile device and the mobile packet core network for using a service of the mobile packet core network.
[0032] An embodiment of the invention is characterized in that the node passes the extracted certificate to the authentication entity, in particular to an authentication entity of the mobile packet core network, which uses the certificate for triggering usage of a service of the mobile packet core network. For instance, the node does an EAP-TLS authentication via the authentication entity with the extracted certificate for authentication of the user towards the authentication entity. If the authentication is successful, the authentication entity sends an acknowledgement or suchlike back to the node so that the node knows that the user requesting to get access to a service of the mobile packet core network is authorized.
[0033] In preferred embodiment of the invention the node uses the extracted MSISDN respectively virtual MSISDN and IMSI respectively virtual IMSI to establish the secure tunnel connection to the mobile packet core network for triggering usage of a service of the mobile packet core network. The secure tunnel connection is preferably using a GTPv2 (GTP: GPRS Tunneling Protocol) for establishing the connection.
[0034] In another embodiment of the invention, the node retrieves a MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI allocated to the user of the mobile device out of a database of the communication system, in particular triggered by the provisioning system. An embodiment of the invention is characterized in that the provisioning system generates a virtual MSISDN and a virtual IMSI if the mobile device does not have a SIM respectively an USIM (also called SIM-less or USIM-less device), and reports the generated virtual MSISDN and virtual IMSI to the node of the communication system. The generated virtual MSISDN and virtual IMSI are reported to the node, so that the token can be generated accordingly. The usage of a virtual MSISDN and/or virtual IMSI advantageously allows the usage of the proposed solution even if the mobile device can access the communication system only via a wireless radio access network, preferably the mobile device is a wireless-radio-access-network-only (Wi-Fi-only) device. Advantageously, there is no limitation for e. g. Gi-LAN services using the virtual MSISDN and/or the virtual IMSI in comparison to MSISDN and/or IMSI. Thus it is possible to use the virtual MSISDN and/or the virtual IMSI in case of untrusted networks. For this a client on the mobile device might need to be modified.
[0035] A virtual MSISDN and/or a virtual IMSI according to the invention is a piece of information or an identifier with a data format or structure similar to a MSISDN for a virtual MSISDN or an IMSI for a virtual IMSI. The virtual MSISDN and/or the virtual IMSI provided are designed to use services of the mobile packet core network without having to use a SIM or USIM with a mobile device. Advantageously, the virtual MSISDN and/or the virtual IMSI works inside the mobile network environment or if the mobile device is changed to support this. For this the virtual MSISDN and/or the virtual IMSI is advantageously stored and provided within the mobile packet core network and/or the mobile device. With this a virtual MSISDN and/or a virtual IMSI according to the present invention advantageously services could be offered as with a standard MSISDN and/or IMSI. The services offered are preferably based on a profile stored in the mobile packet core network, for example in the HLR or the HSS. The services advantageously comprise charging services and/or authentication services of the mobile packet core network. Using a virtual MSISDN and/or virtual IMSI allows the usage of other wireless or wired technologies, for example Bluetooth or Ethernet, for accessing the mobile packet core network with a mobile device. A further preferred embodiment of the invention suggests the usage of a Wi-Fi- or IP-webcam as a mobile device without a SIM/USIM. The Wi-Fi- or IP-webcam gets a virtual MSISDN and/or a virtual IMSI so that an access with these devices to the mobile packet core network is possible. For instance in case of a movement in the monitored area of the Wi-Fi- or IP-webcam signaling of the movement is possible.
[0036] A preferred embodiment is characterized in that the provisioning system is part of the node and/or the node is part of the mobile packet core network. Therefore, the provisioning system and the node are combined and form an entity, which can be a node, in particular a VPN concentrator node or an ePDG respectively TTG, or included into a node, in particular into a VPN concentrator node or an ePDG respectively TTG, in particular of the mobile packet core network.
[0037] In a further embodiment the token is stored securely within the mobile device. Advantageously, there is no possibility for a user or any kind of application other than the enhanced ANDSF application and/or VPN client application to access the stored token without being approved by the mobile network operator. This feature enhances the security of the invention even more.
[0038] As a technical solution to the aforementioned problem the invention furthermore proposes a node of a communication system comprising a mobile device, a mobile packet core network to which the mobile device can establish a secure tunnel connection and a wireless radio access network, which is characterized in that the node comprises means for generating a token using general security mechanisms, in particular TPM (TPM: Trusted Platform Module) and/or MD5 (MD5: Message-Digest Algorithm 5), whereby the token comprises at least a certificate for authentication to the authentication entity, a MSISDN respectively a virtual MSISDN and/or an IMSI respectively a virtual IMSI allocated to a user of the mobile device, and means for establishing a secure tunnel connection to the mobile packet core network by using a token received by the mobile device.
[0039] Advantageously, the node furthermore comprises means for transmitting the generated token to a provisioning system, in particular of the mobile packet core network for verifying the generated token at the first time a usage of a service of the mobile packet core network is requested by the mobile device.
[0040] In a preferred embodiment, the node is characterized by means for rejecting a received token, if the timer and/or counter value of the token is decremented by more than 1 to prevent fraud of the token.
[0041] Another embodiment of the node furthermore comprises means for verifying a token received by the mobile device by using general security mechanisms used to generate the token when an authentication request of the mobile device is received.
[0042] An embodiment of the invention is characterized by means for extracting the certificate, the MSISDN respectively the virtual MSISDN and the IMSI respectively the virtual IMSI out of the received token.
[0043] In another embodiment of the invention the node is characterized by means for passing the extracted certificate to an authentication entity (AAA), in particular an authentication entity (AAA) of the mobile packet core network for triggering a usage of a service of the mobile packet core network.
[0044] In a preferred embodiment of the invention the node further comprises means for establishing a secure tunnel connection to the mobile packet core network for triggering a usage of a service of the mobile device by using the extracted MSISDN respectively virtual MSISDN and IMSI respectively virtual IMSI.
[0045] Another embodiment of the invention is characterized by means for retrieving the MSISDN respectively the virtual MSISDN and/or the IMSI respectively the virtual IMSI allocated to the user of the mobile device out of a database of the communication system, in particular triggered by a provisioning system, in particular of the mobile packet core network.
[0046] In another preferred embodiment the node is designed and/or adapted to be employed in a method according to the invention.
[0047] As a technical solution to the aforementioned problem the invention proposes a provisioning system respectively provisioning tool of the communication system, in particular of a mobile packet core network of a communication system comprising a mobile device, a mobile packet core network and a wireless radio access network, characterized in that the provisioning system comprises means for decrementing a timer and/or counter value by 1 for preventing fraud of a token during the first time a usage of a service of the mobile packet core network is requested by the mobile device, and means for transmitting a token to the mobile device after the decrement of the timer and/or counter of the token.
[0048] Advantageously, the provisioning system respectively provisioning tool comprises furthermore means for generating a virtual MSISDN and/or a virtual IMSI if the mobile device does not have a SIM.
[0049] In a preferred embodiment the provisioning system respectively provisioning tool is characterized by means for reporting the generated virtual MSISDN and/or virtual IMSI to a node of the communication system and/or means for verifying the generated token at the first time a usage of a service of the mobile packet core network is requested by the mobile device.
[0050] In another preferred embodiment the provisioning system respectively provisioning tool is part of a node, in particular a node of the mobile packet core network, preferably a node according to the present invention.
[0051] The provisioning system respectively provisioning tool is advantageously designed and/or adapted to be employed in a method according to the present invention.
[0052] As a further technical solution to the aforementioned problem the invention proposes a system for using a service of a mobile packet core network in a communication system comprising a node of the communication system, a provisioning system of the communication system, and a mobile device of the communication system, whereby the node, the provisioning system, and the mobile device are designed and/or adapted to be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] Other details, characteristics and advantages of the invention will be explained in detail in the following by means of the exemplary embodiments represented in the figures.
[0054] FIG. 1 is a schematic diagram of entities of a communication system used in a first embodiment according to the invention for using an untrusted wireless radio access network, especially Wi-Fi, as access to the trusted function of the mobile packet core network for using services of the mobile packet core network;
[0055] FIG. 2 is an information flow of the embodiment according to FIG. 1 of the invention for using wireless radio access network as access to the mobile packet core network;
[0056] FIG. 3 is a schematic diagram of entities of a communication system used in a second embodiment according to the invention for using an untrusted wireless radio access network, especially Wi-Fi, as access to the untrusted function of the mobile packet core network for using services of the mobile packet core network; and
[0057] FIG. 4 is an information flow of the embodiment according to FIG. 3 of the invention for using wireless radio access network as access to the mobile packet core network.
DETAILED DESCRIPTION
[0058] In FIG. 1 to FIG. 4 only those entities of the communication system which are being used for the method according to the present invention and which play a major role in carrying out the method according to the present invention are depicted. Further entities will be present on part of the mobile network and may be used. As the communication in such a communication system is known, these additional entities are not specifically shown or mentioned in the following. In addition, for the sake of clarity, only one mobile device (UE) is shown in FIG. 1 to FIG. 4 . It is, however, obvious that several mobile devices (UE) may be part of the communication network.
[0059] A Secure ID is a token in the sense of the invention, whereby the Secure ID comprises at least a certificate for authentication to the AAA, a MSISDN and an IMSI, or in the case the mobile device does not have a SIM respectively USIM, a virtual MSISDN and a virtual IMSI. The Secure ID is generated on part of a node of the mobile packet core network, at hand in FIG. 1 the VPN concentrator node, which is in FIG. 1 named VPN for reasons of simplicity.
[0060] A user of a mobile device (UE) is a customer respectively subscriber of services, especially core services offered by a MNO of a mobile packet core network, in particular a 2G, 3G and/or LTE network. The mobile device (UE) can access a wireless radio access network, in particular a Wi-Fi network via its Wi-Fi access points. The mobile device in the present embodiment does not offer the possibility to use, download and/or install a TTG or ePDG client.
[0061] The user has to subscribe for using such services to the MNO in advance of the method of the present invention. The subscription is done e.g. via a provisioning system or provisioning tool provided by the mobile packet core network of the MNO. The provisioning system or provisioning tool gathers the MSISDN and/or IMSI of the customer respectively of the mobile device (UE) of the customer and stores the linked information in a database of the mobile packet core network. If the customer respectively subscriber does not have or use a SIM or a USIM, the provisioning system respectively provisioning tool will generate a virtual MSISDN and/or a virtual IMSI, especially, when the customer respectively subscriber uses a Wi-Fi only device or a SIM-less respectively USIM-less device. The MSISDN respectively virtual MSISDN and/or the IMSI respectively IMSI are passed from the provisioning system respectively provisioning tool to a node of the mobile packet core network, at hand the VPN concentrator node of the mobile packet core network.
[0062] A VPN concentrator is a type of entity of the mobile packet core network that provides a secure creation of VPN connections and delivery of messages between VPN nodes. At hand, it is used for creating a token, also referred to as Secure ID, which is used for establishing a secure tunnel connection from the mobile device (UE), at hand from an enhanced ANDSF client or directly from a VPN application of the mobile device (UE) to the VPN concentrator node of the mobile packet core network.
[0063] The Secure ID as a token is generated by the VPN concentrator node of the mobile packet core network by using general security mechanisms, at hand by using TPM.
[0064] At the mobile device (UE), a VPN client respectively application and optional an enhanced ANDSF application is downloaded via ACS (ACS: Auto Configuration Server). The ACS provides the used application in the present invention to the mobile device (UE). The generated Secure ID is transferred from the VPN concentrator node of the mobile packet core network to the enhanced ANDSF application of the mobile device (UE). In the alternative, the generated Secure ID is transmitted directly to the VPN client of the mobile device, since the enhanced ANDSF application is optional. The transmission of the generated Secure ID to the mobile device (UE) is done in a secure manner, at hand by using a so called macro network. In a preferred embodiment the Secure ID is stored in a secure area of the mobile device (UE), e.g. in an encrypted area with limited access to it.
[0065] The generated Secure ID comprises furthermore a timer and/or counter in the following also referred to as counter, which will be decreased by the value of 1, when it is transmitted to the mobile device (UE). The security of the method according to the present invention is enhanced according to the aforementioned feature by the fact that if the counter has been reduced by more than the value of 1 beforehand, the Secure ID is not valid anymore and the VPN application on part of the mobile device will not work. The Secure ID is used for establishing a secure tunnel connection, at hand a secure VPN connection from an untrusted Wi-Fi network, in which the mobile device (UE) is logged on.
[0066] In a preferred embodiment, the counter value of the Secure ID is checked, when the Secure ID is transmitted from the enhanced ANDSF application or directly from the VPN application of the mobile device (UE) to the VPN concentrator node of the mobile packet core network. The VPN concentrator node of the mobile packet core network rejects the Secure ID, which the customer wants to use to establish a secure tunnel connection to the mobile packet core network of the MNO, if the counter value has been decreased by more than 1. If the received Secure ID is valid, whereby the timer of the Secure ID has a value, which was only decreased by 1 the VPN concentrator node extracts the certificate, the MSISDN respectively virtual MSISDN and the IMSI respectively virtual IMSI out of the Secure ID by using the security mechanism, which was used to generate the Secure ID and which is known by the VPN concentrator node.
[0067] The certificate is passed from the VPN concentrator node to the AAA of the mobile packet core network, or in the alternative to an equivalent PM (PKI: Pre-Shared Key Infrastructure) or CA (CA: Certificate Authority) to get secure access to the VPN concentrator node of the mobile packet core network, if the certificate approves to be valid when checked by the AAA or equivalent PKI or CA.
[0068] After the authentication of the certificate by the AAA, an acknowledgement or the like is passed back to the VPN concentrator node of the mobile packet core network, so that the MSISDN respectively virtual MSISDN and IMSI respectively virtual IMSI are used to establish a secure tunnel connection to the trusted WLAN core function of the mobile packet core network, at hand the secure tunnel connection is established to the TWAN or PGW of the mobile packet core network. As a secure tunnel connection, at hand a GTPv2 connection is used.
[0069] The secure tunnel connection is schematically drawn in FIG. 1 by using a dashed line from the mobile device to the trusted WLAN core function of the of the mobile packet core network.
[0070] The information flow of the method according to the present invention according to FIG. 2 of the embodiment according to FIG. 1 (access to trusted function of mobile packet core network) comprises the following steps:
a) User subscribe to service via provisioning system; b) Provisioning system will pass MSISDN and/or IMSI information to VPN concentrator. If subscriber does not have a SIM/USIM card, provisioning system will generate a virtual MSISDN and/or virtual IMSI; c) VPN concentrator generates a new Secure ID out of a certificate (VPN has a limited amount of certificates it could use) and the MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI. VPN is using tools like e.g. TPM to create the new Secure ID; d) User downloads the VPN client via e.g. ACS (ACS: Auto configuration server); e) VPN concentrator sends the created new Secure ID to the ANDSF or directly to the VPN client in a secure way (preferable via macro network). new Secure ID will be stored in a secure area of the device; f) Secure ID counter will be reduced by one when transmitted to VPN client. If the counter already has been reduced the new Secure ID is not valid anymore and the VPN application will not work; g) When user connects to untrusted Wi-Fi network the UE (e.g. using an enhanced ANDSF) will establish a secure VPN connection to the VPN concentrator using the new Secure ID; h) VPN concentrator verifies if this a valid new Secure ID including the verification of the new Secure ID counter. If yes the VPN concentrator extracts the new Secure ID to get the Certificate out of the pool it has and the MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI; i) VPN concentrator passes the certificate e.g. to AAA or an equivalent PM system to get secure accesses to the VPN concentrator; j) VPN concentrator will use MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI to establish a connection to TWAN and PGW; and k) Remain of the flow is standard.
[0082] FIG. 3 is a schematic diagram of entities of a communication system used in a second embodiment according to the invention. An untrusted wireless radio access network, especially Wi-Fi, is used as access to the untrusted function of the mobile packet core network for using services of the mobile packet core network. In contrast to the embodiment according to FIG. 1 , for an access to the untrusted function of the mobile packet core network the secure tunnel connection is established from a mobile device (UE) to a node of the mobile packet core network, at hand the ePDG or TTG of the mobile packet core network. The ePDG is part of an untrusted function of the mobile packet core network, if the customer wishes to establish a secure tunnel connection to this part of the mobile packet core network from its mobile device (UE). As a secure tunnel connection, at hand an IPSec tunnel connection is used between the mobile device (UE) and the ePDG. For the secure tunnel connection is schematically drawn in FIG. 3 by using a dashed line from the mobile device to the ePDG node of the mobile packet core network. Furthermore between the ePDG or TTG and the PGW/GGSN a GTPv2 connection is used, so that traffic between the mobile device to the untrusted function of the mobile packet core network can be transmitted.
[0083] The information flow of the method according to the present invention according to FIG. 4 of the embodiment according to FIG. 3 (access to untrusted function of mobile packet core network) comprises the following steps:
a) User subscribe to service via provisioning system; b) Provisioning system will pass MSISDN and/or IMSI information to ePDG. If subscriber does not have a SIM/USIM card, provisioning system will generate a virtual MSISDN and/or virtual IMSI; c) ePDG generates a new Secure ID out of a certificate (ePDG has a limited amount of certificates it could use) and the MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI. ePDG is using tools like e.g. TPM to create the new Secure ID; d) User downloads the ePDG application via e.g. ACS; e) ePDG sends the created new Secure ID to the ANDSF or directly to the ePDG application in a secure way (preferable via macro network). New Secure ID will be stored in a secure area of the device; f) New Secure ID counter will be reduced by one when transmitted to ePDG application. If the counter already has been reduced the new Secure ID is not valid anymore and the ePDG application will not work; g) When user connects to untrusted Wi-Fi network the UE (e.g. using ANDSF) will establish a secure ePDG connection to the ePDG using the new Secure ID; h) ePDG verifies if this a valid new Secure ID including the verification of the new Secure ID counter. If yes the ePDG extracts the new Secure ID to get the certificate out of the pool it has and the MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI; i) ePDG passes the certificate e.g. to AAA or an equivalent PKI system to get secure accesses to the ePDG; j) ePDG will use MSISDN respectively virtual MSISDN and/or IMSI respectively virtual IMSI to establish a connection to PGW; and k) Remain of the flow is standard.
[0095] The exemplary embodiments of the invention represented in the figures and described in connection with these only serve for explaining of the invention and are not limiting for the invention.
LIST OF REFERENCE NUMERALS
[0000]
UE/MS mobile device (mobile phone, smart phone, tablet or any other mobile communication terminal capable of connecting to a wireless radio access network)
Wi-Fi wireless radio access network
VPN Virtual Private Network
AAA Authentication, Authorization and Accounting
ANDSF Access Network Discovery and Selection Function
HLR Home Location Register
HSS Home Subscriber Server
PGW PDN (PDN: Packet Data Networks) Gateway
GGSN Gateway GPRS Support Node
ePDG evolved Packet Data Gateway
TTG Tunnel Termination Gateway
TWAN Trusted WLAN Access Network | A method is provided for using a service of a mobile packet core network in a communication system comprising a mobile device, a node, a mobile packet core network and a wireless radio access network. The mobile device accesses the mobile packet core network via the wireless radio access network. During setup of a connection of the mobile device to the wireless radio access network, the mobile device determines whether the wireless radio access network is trustworthy. If it is not trustworthy, the mobile device establishes a secure tunnel connection to the node of the communication system for triggering usage of the service of communication system by an authentication entity. The secure tunnel connection is established by using a token stored within the mobile device and received by the node. The token comprises at least a certificate for authentication to the authentication entity and is generated using general security mechanisms (e.g., TPM and/or MD5). | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2006/069766, filed Dec. 15, 2006 and claims the benefit thereof. The International Application claims the benefits of European application No. 06000337.3 filed Jan. 9, 2006, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a layer system comprising pyrochlores as claimed in the claims.
BACKGROUND OF THE INVENTION
[0003] A layer system of this type has a substrate with a metal alloy based on nickel or cobalt. Products of this type are used in particular as a component of a gas turbine, in particular as gas turbine blades or vanes or heat shields. The components are exposed to a hot-gas stream of aggressive combustion gases. Therefore, they have to be able to withstand high thermal stresses. Furthermore, it is necessary for these components to be resistant to oxidation and corrosion. Moreover, mechanical demands are imposed in particular on moving components, e.g. gas turbine blades or vanes, but also on static components. The power and efficiency of a gas turbine in which components that can be exposed to hot gas are used increase as the operating temperature rises. Therefore, constant attempts have been made to achieve a higher gas turbine performance by improving the coating system.
[0004] To achieve a high efficiency and a high power, components of the gas turbines which are particularly exposed to the high temperatures are coated with a ceramic material. This acts as a thermal barrier coating between the hot-gas stream and the metallic substrate.
[0005] The metallic base body is protected from the aggressive hot-gas stream by coatings. Modern components generally have a plurality of coatings, which each perform specific tasks. Therefore, a multilayer system is employed.
[0006] EP 0 944 746 B1 discloses the use of pyrochlores as a thermal barrier coating.
[0007] However, it is not only good thermal barrier properties which are required for a material to be used as a thermal barrier coating, but also a good bonding to the substrate.
[0008] EP 0 992 603 A1 discloses a thermal barrier coating system made up of gadolinium oxide and zirconium oxide, which is not supposed to have a pyrochlore structure.
SUMMARY OF INVENTION
[0009] Therefore, it is an object of the invention to provide a layer system which has good thermal barrier properties and also good bonding to the substrate and therefore a long service life of the entire layer system.
[0010] The object is achieved by a layer system as claimed in the claims.
[0011] The subclaims list further advantageous measures, which can be advantageously combined with one another as desired.
[0012] The invention is based on the discovery that the entire system must be considered as a single unit, rather than individual layers or individual layers in combination having to be considered and optimized in isolation from one another in order to achieve a long service life.
[0013] The layer system according to the invention has an outer ceramic layer, which includes a mixture of two pyrochlore phases, which has particularly good thermal properties (expansion coefficient matched to a substrate of a component, low coefficient of thermal conductivity) and harmonizes very well with an intermediate layer and the substrate of the component. The properties of the ceramic layer can be adapted to the substrate and the intermediate layer by way of the mixing ratio of these two pyrochlore phases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Exemplary embodiments of the invention are explained in more detail below with reference to the drawings.
[0015] In which:
[0016] FIG. 1 shows a layer system according to the invention,
[0017] FIG. 2 shows a list of superalloys,
[0018] FIG. 3 shows a gas turbine,
[0019] FIG. 4 shows a perspective view of a turbine blade or vane,
[0020] FIG. 5 shows a perspective view of a combustion chamber.
DETAILED DESCRIPTION OF INVENTION
[0021] FIG. 1 shows a layer system 1 according to the invention.
[0022] The layer system 1 comprises a metallic substrate 4 , which in particular for components used at high temperatures consists of a nickel-base or cobalt-base superalloy ( FIG. 2 ).
[0023] A metallic bonding layer 7 MCrAlX, preferably of type NiCoCrAlX is preferably present directly on the substrate 4 and preferably consists of either
[0024] (11-13) wt % cobalt, in particular 12% Co
[0025] (20-22) wt % chromium, in particular 21% Cr
[0026] (10.5-11.5) wt % aluminum, in particular 11% Al
[0027] (0.3-0.5) wt % yttrium, in particular 0.4% Y
[0028] (1.5-2.5) wt % rhenium, in particular 2.0% Re
[0029] and remainder nickel
[0030] or preferably
[0031] (24-26) wt % cobalt, in particular 25% Co
[0032] (16-18) wt % chromium, in particular 17% Cr
[0033] (9-11) wt % aluminum, in particular 10% Al
[0034] (0.3-0.5) wt % yttrium, in particular 0.4% Y
[0035] (1-2) wt % rhenium and in particular 1.5% Re
[0036] remainder nickel
[0037] or preferably
[0038] 29%-31% nickel, in particular 30% nickel,
[0039] 27%-29% chromium, in particular 28% chromium,
[0040] 7%-9% aluminum, in particular 8% aluminum,
[0041] 0.5%-0.7% yttrium, in particular 0.6% yttrium,
[0042] 0.6%-0.8% silicon, in particular 0.7% silicon and remainder cobalt,
[0043] or preferably of
[0044] 27%-29% nickel, in particular 28% nickel,
[0045] 23%-25% chromium, in particular 24% chromium,
[0046] 9%-11% aluminum, in particular 10% aluminum,
[0047] 0.5%-0.7% yttrium, in particular 0.6% yttrium and
[0048] remainder cobalt.
[0049] Preferably, the protective layer 7 consists of one of these alloys.
[0050] On this metallic bonding layer 7 , an aluminum oxide layer has formed even before the application of further ceramic layers or such an aluminum oxide layer (TGO) is formed in operation.
[0051] An inner ceramic layer 10 , preferably a fully or partially stabilized zirconium oxide layer, is preferably present on the metallic bonding layer 7 or on the aluminum oxide layer (not shown). It is preferable to use yttrium-stabilized zirconium oxide (YSZ), which preferably comprises 6 wt % to 8 wt % yttrium. It is equally possible to use calcium oxide, cerium oxide and/or hafnium oxide to stabilize zirconium oxide.
[0052] The zirconium oxide is preferably applied as a plasma-sprayed layer, but may preferably also be applied as a columnar structure by means of electron beam physical vapor deposition (EBPVD).
[0053] The layer thickness of the inner layer 10 is preferably between 10% and 50% of the total layer thickness D of inner layer 10 and outer layer 13 ( FIG. 1 ).
[0054] It is preferable for the layer thickness of the inner layer 10 to be between 10% and 40% or between 10% and 30% of the total layer thickness D.
[0055] It is likewise advantageous if the layer thickness of the inner layer 10 amounts to 10% to 20% of the total layer thickness D.
[0056] It is also preferable for the layer thickness of the inner layer 10 to be between 20% and 50% or between 20% and 40% of the total layer thickness D.
[0057] Advantageous results are likewise achieved if the inner layer 10 forms between 20% and 30% of the total layer thickness D.
[0058] It is preferable for the layer thickness of the inner layer 10 to amount to 30% to 50% of the total layer thickness D.
[0059] It is likewise advantageous if the layer thickness of the inner layer 10 makes up 30% to 40% of the total layer thickness D.
[0060] It is likewise preferable if the layer thickness of the inner layer 10 makes up between 40% and 50% of the total layer thickness D.
[0061] Although the pyrochlore phase has better thermal barrier properties than the ZrO 2 -layer, the ZrO 2 -layer may be made of equal thickness to the pyrochlore phase.
[0062] The inner ceramic layer 10 preferably has a thickness of from 40 μm to 60 μm, in particular 50 μm±10%.
[0063] The total layer thickness D of the inner layer 10 and the outer layer 13 is preferably 300 μm or preferably 400 μm. The maximum total layer thickness is advantageously 800 μm or preferably at most 600 μm.
[0064] Then, an outer ceramic layer 13 is applied to the stabilized zirconium oxide layer 10 ; according to the invention, this outer ceramic layer 13 includes two different pyrochlore phases of the general empirical formula A x B y O z where x, y≈2, z≈7, i.e. minor defects or dopants are permissible, O=oxygen.
[0065] In particular, x, y=2 and z=7.
[0066] The ceramic layer therefore includes the pyrochlores A x B y O z and C r D s O t where r, s≈2, t≈7, O=oxygen. In particular, r, s=2 and t=7.
[0067] The elements A, B, C and D may all be different from one another.
[0068] If A and C are identical, B and D are different. If B and D are identical, A and C are different.
[0069] The combination A=C and B=D is excluded.
[0070] The combinations A=D, B≠C or C=B, A≠D are in principle possible.
[0071] It is preferable to use gadolinium (Gd) for A, C.
[0072] Further examples of A, C include lanthan (La), yttrium (Y), neodymium (Nd), ytterbium (Yb), Cerium (Ce) or aluminum (Al).
[0073] Examples for B, D include hafnium (Hf), zirconium (Zr), titanium (Ti), Cerium (Ce) or tin (Sn).
[0074] It is preferable to use a hafnate or a zirconate, i.e. hafnium and/or zirconium for B, preferably Gd 2 Hf 2 O 7 (GHO) and/or Gd 2 Zr 2 O 7 (GZO).
[0075] It is preferable for the outer ceramic layer 13 to consist of two pyrochlore phases.
[0076] It is preferable to use Gd 2 Hf 2 O 7 and Gd 2 Zr 2 O 7 .
[0077] There is in this case not a solid solution of the two pyrochlore phases, i.e. for example not Gd x (Hf y Zr w )O z where x=2, y+w=2, z=7 (a solid solution also includes the pyrochlore phase but has two different elements on one lattice site (A, B); unless a solid solution is specifically referred to, a solid solution is not present).
[0078] The proportion made up of the solid solutions A x (B y D w )O z , C s (D t B q )O t or the oxides of A, B, C, D (i.e. for example Gd, Hf, Zr) amounts to at most 20 wt %, in particular at most 10 wt %.
[0079] It is preferable for the proportion formed by the two pyrochlore phases to amount to at least 80 wt %, in particular at least 90 wt %.
[0080] However, it is also possible for two solid solutions to be mixed with one another or a solid solution to be mixed with a non solid solution, i.e. for example A x (B y E w )O z and C x (D y F w )O z where E≠D and F≠B or A x B y O z and C x (D y F w )O z where F≠B.
[0081] Therefore, the outer ceramic layer 13 is produced, for example, as follows: a powder consisting of two pyrochlore phases, for example gadolinium zirconate and a powder comprising gadolinium hafnate are mixed with one another in a mixing ratio and fed to the nozzle of a plasma spray installation. Other coating processes, such as for example PVD processes, in which two ingots consisting of gadolinium zirconate and gadolinium hafnate are used, are also conceivable.
[0082] It is possible to use any desired mixing ratios of gadolinium zirconate and gadolinium hafnate. It is preferable to use a larger proportion of gadolinium zirconate.
[0083] It is also preferable to use mixing ratios of 10:90, 20:80, 30:70 or 40:60 for gadolinium hafnate to gadolinium zirconate.
[0084] It is also advantageous to use mixing ratios of 50:50, 60:40, 70:30, 80:20 or 90:10 for gadolinium hafnate to gadolinium zirconate.
[0085] It is preferable to use a mixture of Gd 2 Hf 2 O 7 and Gd 2 Zr 2 O 7 , which are preferably uniformly mixed with one another or have a gradient. Therefore, by way of example, a higher proportion of Gd 2 Zr 2 O 7 is present in the outward direction toward the hot-gas side.
[0086] The layer system 1 preferably comprises a substrate 4 , a bonding layer 7 (MCrAlY), optionally a TGO and an outer single-layer (for example GZO and/or GHO) or two-layer thermal barrier coating 13 (YSZ and GZO or GHO).
[0087] FIG. 3 shows, by way of example, a partial longitudinal section through a gas turbine 100 .
[0088] In the interior, the gas turbine 100 has a rotor 103 , with a shaft 101 , which is mounted such that it can rotate about an axis of rotation 102 and is also referred to as the turbine rotor. An intake housing 104 , a compressor 105 , a, for example, torroidal combustion chamber 110 , in particular an annular combustion chamber, with a plurality of coaxially arranged burners 107 , a turbine 108 and the exhaust-gas housing 109 follow one another along the rotor 103 .
[0089] The annular combustion chamber 110 is in communication with a, for example, annular hot-gas duct 111 , where, by way of example, four successive turbine stages 112 form the turbine 108 .
[0090] Each turbine stage 112 is formed, for example, from two blade or vane rings. As seen in the direction of flow of a working medium 113 , in the hot-gas duct 111 a row of guide vanes 115 is followed by a row 125 formed from rotor blades 120 .
[0091] The guide vanes 130 are secured to an inner housing 138 of a stator 143 , whereas the rotor blades 120 of a row 125 are fitted to the rotor 103 for example by means of a turbine disk 133 .
[0092] A generator (not shown) is coupled to the rotor 103 .
[0093] While the gas turbine 100 is operating, the compressor 105 sucks in air 135 through the intake housing 104 and compresses it. The compressed air provided at the turbine-side end of the compressor 105 is passed to the burners 107 , where it is mixed with a fuel. The mix is then burnt in the combustion chamber 110 , forming the working medium 113 . From there, the working medium 113 flows along the hot-gas duct 111 past the guide vanes 130 and the rotor blades 120 . The working medium 113 is expanded at the rotor blades 120 , transferring its momentum, so that the rotor blades 120 drive the rotor 103 and the latter in turn drives the generator coupled to it.
[0094] While the gas turbine 100 is operating, the components which are exposed to the hot working medium 113 are subject to thermal stresses. The guide vanes 130 and rotor blades 120 of the first turbine stage 112 , as seen in the direction of flow of the working medium 113 , together with the heat shield elements which line the annular combustion chamber 110 , are subject to the highest thermal stresses.
[0095] To be able to withstand the temperatures which prevail there, they can be cooled by means of a coolant.
[0096] Substrates of the components may likewise have a directional structure, i.e. they are in single-crystal form (SX structure) or have only longitudinally oriented grains (DS structure).
[0097] By way of example, iron-base, nickel-base or cobalt-base superalloys are used as material for the components, in particular for the turbine blade or vane 120 , 130 and components of the combustion chamber 110 .
[0098] Superalloys of this type are known, for example, from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949; these documents form part of the disclosure with regard to the chemical composition of the alloys.
[0099] The guide vane 130 has a guide vane root (not shown here), which faces the inner housing 138 of the turbine 108 , and a guide vane head which is at the opposite end from the guide vane root. The guide vane head faces the rotor 103 and is fixed to a securing ring 140 of the stator 143 .
[0100] FIG. 4 shows a perspective view of a rotor blade 120 or guide vane 130 of a turbo machine, which extends along a longitudinal axis 121 .
[0101] The turbo machine may be a gas turbine of an aircraft or of a power plant for generating electricity, a steam turbine or a compressor.
[0102] The blade or vane 120 , 130 has, in succession along the longitudinal axis 121 , a securing region 400 , an adjoining blade or vane platform 403 as well as a main blade or vane part 406 and a blade or vane tip 415 .
[0103] As a guide vane 130 , the vane 130 may have a further platform (not shown) at its vane tip 415 .
[0104] A blade or vane root 183 , which is used to secure the rotor blades 120 , 130 to a shaft or a disk (not shown), is formed in the securing region 400 .
[0105] The blade or vane root 183 is designed, for example, in hammerhead form. Other configurations, such as a fir-tree or dovetail root, are possible.
[0106] The blade or vane 120 , 130 has a leading edge 409 and a trailing edge 412 for a medium which flows past the main blade or vane part 406 .
[0107] In the case of conventional blades or vanes 120 , 130 , by way of example solid metallic materials, in particular superalloys, are used in all regions 400 , 403 , 406 of the blade or vane 120 , 130 .
[0108] Superalloys of this type are known, for example, from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949; these documents form part of the disclosure with regard to the chemical composition of the alloy.
[0109] The blade or vane 120 , 130 may in this case be produced by a casting process, also by means of directional solidification, by a forging process, by a milling process or combinations thereof.
[0110] Work pieces with a single-crystal structure or structures are used as components for machines which, in operation, are exposed to high mechanical, thermal and/or chemical stresses.
[0111] Single-crystal work pieces of this type are produced, for example, by directional solidification from the melt. This involves casting processes in which the liquid metallic alloy solidifies to form the single-crystal structure, i.e. the single-crystal work piece, or solidifies directionally.
[0112] In this case, dendritic crystals are oriented along the direction of heat flow and form either a columnar crystalline grain structure (i.e. grains which run over the entire length of the work piece and are referred to here, in accordance with the language customarily used, as directionally solidified) or a single-crystal structure, i.e. the entire work piece consists of one single crystal. In these processes, a transition to globular (polycrystalline) solidification needs to be avoided, since non-directional growth inevitably forms transverse and longitudinal grain boundaries, which negate the favorable properties of the directionally solidified or single-crystal component.
[0113] Where the text refers in general terms to directionally solidified microstructures, this is to be understood as meaning both single crystals, which do not have any grain boundaries or at most have small-angle grain boundaries, and columnar crystal structures, which do have grain boundaries running in the longitudinal direction but do not have any transverse grain boundaries. This second form of crystalline structures is also described as directionally solidified microstructures (directionally solidified structures).
[0114] Processes of this type are known from U.S. Pat. No. 6,024,792 and EP 0 892 090 A1; these documents form part of the disclosure with regard to the solidification process.
[0115] The blades or vanes 120 , 130 may likewise represent layer systems 1 according to the invention or have other coatings to protect them against corrosion or oxidation, e.g. (MCrAlX: M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and represents yttrium (Y) and/or silicon and/or at least one rare earth element, or hafnium (Hf)). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306454 A1, which are intended to form part of the present disclosure with regard to the chemical composition of the alloy. The density is preferably 95% of the theoretical density.
[0116] A protective aluminum oxide layer (TGO=thermal grown oxide layer) forms on the MCrAlX-layer (as an intermediate layer or as the outermost layer).
[0117] A thermal barrier coating 13 of the layer system 1 according to the invention is also present on the MCrAlX.
[0118] The thermal barrier coating 13 covers the entire MCrAlX-layer.
[0119] Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
[0120] Other coating processes are conceivable, for example atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier coating may have porous grains which include micro-cracks or macro-cracks, in order to improve the resistance to thermal shocks. The thermal barrier coating is therefore preferably more porous than the MCrAlX-layer.
[0121] The blade or vane 120 , 130 may be hollow or solid in form.
[0122] If the blade or vane 120 , 130 is to be cooled, it is hollow and may also have film-cooling holes 418 (indicated by dashed lines).
[0123] FIG. 5 shows a combustion chamber 110 of the gas turbine 100 .
[0124] The combustion chamber 110 is configured, for example, as what is known as an annular combustion chamber, in which a multiplicity of burners 107 arranged circumferentially around an axis of rotation 102 open out into a common combustion chamber space 154 , which burners generate flames 156 . For this purpose, the combustion chamber 110 overall is of annular configuration positioned around the axis of rotation 102 .
[0125] To achieve a relatively high efficiency, the combustion chamber 110 is designed for a relatively high temperature of the working medium M of approximately 1000° C. to 1600° C. To allow a relatively long service life even with these operating parameters, which are unfavorable for the materials, the combustion chamber wall 153 is provided, on its side which faces the working medium M, with an inner lining formed from heat shield elements 155 .
[0126] Moreover, on account of the high temperatures in the interior of the combustion chamber 110 , it is also possible to provide a cooling system for the heat shield elements 155 or for their holding elements. The heat shield elements 155 are then hollow, for example, and may also have cooling holes (not shown) which open out into the combustion chamber space 154 .
[0127] On the working medium side, each heat shield element 155 made from an alloy is equipped with a particularly heat-resistant protective layer (MCrAlX layer and/or ceramic coating) and therefore represents the layer system 1 according to the invention, or is made from material that is able to withstand high temperatures (solid ceramic bricks).
[0128] These protective layers may be similar to the turbine blades or vanes, i.e. for example in MCrAlX: M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and represents yttrium (Y) and/or silicon and/or at least one rare earth element, or hafnium (Hf). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition of the alloy.
[0129] It is also possible for a ceramic thermal barrier coating 13 according to the invention, to be present on the MCrAlX.
[0130] Columnar grains are produced in the thermal barrier coating by means of suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
[0131] Other coating processes are conceivable, for example atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier coating may have porous grains provided with micro-cracks or macro-cracks in order to improve its resistance to thermal shocks.
[0132] Refurbishment means that after they have been used, protective layers may have to be removed from turbine blades or vanes 120 , 130 , heat shield elements 155 (e.g. by sand-blasting). Then, the corrosion and/or oxidation layers and products are removed. If appropriate, cracks in the turbine blade or vane 120 , 130 or the heat shield element 155 are also repaired. This is followed by recoating of the turbine blades or vanes 120 , 130 , heat shield elements 155 , after which the turbine blades or vanes 120 , 130 or the heat shield elements 155 can be reused. | Heat-insulating layer systems have to be provided with along service life of the heat-insulating layer in addition to having good heat-insulating properties. The inventive layer system comprises a ceramic layer which contains a mixture of two pyrochlore phases. | 8 |
This is a division, of application Ser. No. 525,807, filed Nov. 21, 1974, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to a filter having an automatically controlled variable cut-off frequency in which the cut-off frequency is automatically varied in accordance with an input signal frequency and in which the output is maintained at a predetermined constant level, and is more particularly concerned with a device for measuring the period or frequency of an input signal by use of such a filter.
Where it is desired to determine the period of an input signal, a gate signal may be derived from the input signal so as to correspond with one period thereof, and may be used to gate reference pulses supplied to a counter. If noises are superimposed on the input signal, there will result a change in the width of the one-period gate signal which is derived therefrom, causing an error in the determination of the period. The influence of such noises can be avoided by passing the input signal through a filter which eliminates frequencies higher than the frequency of the input signal before it is supplied to a period determining apparatus. However, the frequency of the input signal is unknown generally, which explains the need to determine its period, thus precluding a proper choice of the cut-off frequency of the filter which is used to eliminate the noises. In order to permit the use of a filter having a cut-off frequency which varies with the frequency of an input signal, it has been proposed to produce a pulse having a definite width defined by zero crossover points of the input signal, which pulse is rectified to convert the input signal frequency into a voltage level so that the voltage obtained may be compared against a plurality of reference voltages in order to permit a selection of one of filters having mutually different cut-off frequencies. The proposed arrangement requires a relatively complex frequency-to-voltage converter and also requires a number of filters which must be provided. A reduction in the number of filters may result in the failure to eliminate the noises.
It is an object of the invention to provide a filter having an automatically controlled variable cut-off frequency in which the cut-off frequency is automatically varied with the frequency of an input signal by using a simple arrangement.
It is another object of the invention to provide a filter having an automatically controlled variable cut-off frequency in which the cut-off frequency is automatically varied with an input signal frequency and the output level is maintained constant to facilitate the design of following circuitry.
It is a further object of the invention to provide a filter having an automatically controlled variable cut-off frequency in which the cut-off frequency is automatically varied with an input signal frequency and the output level is maintained constant, but can be changed.
It is an additional object of the invention to provide a filter having an automatically controlled variable cut-off frequency which can be used as a variable level regulator.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a device for measuring the period or frequency of an input signal, comprising a filter circuit having a variable cut-off frequency which includes, as at least one of its components, a variable element having an electrical parameter the magnitude of which is controlled by an electrical signal. The cut-off frequency of the filter circuit is determined by the parameter value of this variable element, which may comprise a variable capacitance diode, a photoconductive element, a variable gain amplifier and the like. The output level of the filter circuit is detected by an output level detector, the output of which is supplied to the variable element as a control signal so as to maintain the output level of the filter circuit constant. The level detector may comprise a conventional detector. For example, in one embodiment in which the filter circuit is constructed as a low pass filter, an input signal having a frequency which is below the cut-off frequency of the filter will produce an output level of the filter circuit which is greater than the given level, and therefore the variable element will be controlled to decrease the cut-off frequency. Conversely, an input signal having a frequency which is higher than the cut-off frequency will produce an output level of the filter circuit which is below the given level, and in this instance the variable element will be controlled to increase the cut-off frequency. In this manner, the cut-off frequency of the filter circuit is automatically controlled in accordance with an input signal frequency, thereby enabling noises having higher frequency components to be eliminated. As a consequence, when the filter output is shaped to produce a gate signal having a duration corresponding to one period thereof, an accurate determination of the period is assured. Since the output level is maintained constant, the design of the subsequent circuit, such as a Schmidt trigger which may be used for wave shaping is facilitated. The variable element is controlled in accordance with a difference between the output level of the level detector and a reference voltage. By changing the value of the reference voltage, the output level of the filter circuit which is maintained constant can be changed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of one embodiment of the filter according to the invention;
FIG. 2 is an equivalent circuit diagram of the circuit shown in FIG. 1;
FIG. 3 graphically shows the frequency response of the filter shown in FIG. 1;
FIG. 4 is a block diagram of another embodiment of the filter according to the invention;
FIG. 5 is a block diagram of a further embodiment of the invention;
FIG. 6 is a circuit diagram of an additional embodiment of the filter according to the invention which is suitable for use with high frequency applications; and
FIG. 7 graphically shows the frequency response of the filter shown in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a filter circuit having a variable cut-off frequency, generally designated by reference numeral 1. In the embodiment shown, the filter circuit is constructed as a voltage controlled low pass CR filter. Specifically, an amplifier 2 has its noninverting input terminal connected to ground and has its inverting input terminal connected through a pair of resistors 3 and 4 with an input terminal 5. The output of the amplifier 2 is connected with the inverting input terminal through feedback resistors 6, 7. The junction between the resistors 6, 7 is connected to ground through a variable resistor which is formed by a field effect transistor 8. The resistance of the resistors 6, 7 as well as the resistance across the source and drain of the transistor 8 determine the gain of the amplifier 2, and thus these components constitute together a variable gain amplifier 11. A capacitor 9 is connected between the junction between the resistor 3, 4 and the output terminal of the amplifier 2. The resistor 4 and the capacitor 9 constitute together a low pass filter. The filter circuit 1 has an equivalent circuit as shown in FIG. 2, in which a capacitor 9' has a capacitance as expressed as (1 + A)C, wherein A represents the gain of the amplifiers 11 and C the capacitance of the capacitor 9. Representing the resistance of the resistor 4 by R, the cut-off frequency f c of the filter circuit 1 is given by the following equation: ##EQU1## Thus, the cut off frequency f c varies as the gain A of the amplifier 11 is changed. The gain A is changed by controlling the resistance across the source and drain of the field effect transistor 8. Therefore, the variable gain amplifier 11 or transistor 8 can be considered as a variable element, the electrical parameter value of which is controlled by a control signal in order to determine the cut-off frequency of the filter circuit 1.
The output of the filter circuit 1 is supplied to a level detector 10, the output of which is applied across a parallel combination 12 of a capacitor and a resistor, and is also applied to the gate of the transistor 8. Thus, the resistance across the source and drain of the transistor 8 varies in accordance with the output from the detector 10. The output of the filter circuit 1 may be supplied to a utilization unit 13, for example, a wave shaper such as a Schmidt trigger circuit.
The filter circuit 1 may have a frequency response as represented by a curve 15 shown in FIG. 3. Assuming that an input signal has a level l 1 and the trigger level of the Schmidt trigger 13 is at a level l 2 which is lower than l 1 , the overall system is arranged so that the output level of the filter circuit 1 is equal to l 2 . If an input signal applied to the terminal 5 has a frequency f s1 which is lower than the cut-off frequency f c0 of the filter circuit 1, any noise having frequencies between f s1 and f c0 will be supplied to the circuit 13, assuming that the filter circuit 1 has a constant cut-off frequency. However, in the apparatus according to the invention, the output level of the filter circuit 1 is detected by a level detector 10, whereby a higher level l 1 than the given level l 2 can be detected. The detection output causes the drain current of the transistor 8 to be increased, thereby decreasing the resistance across the source and drain thereof and also decreasing the amount of feedback through the resistors 6, 7 to result in an increase in the gain A of the amplifier 11. As a consequence, the cut-off frequency f c0 of the filter circuit 1 is lowered. This results in a shift of the curve 15 to the left on FIG. 3, with a resulting reduction in the output level of the filter circuit 1. When the level reaches l 2 , the circuit becomes stable at that point. Under this condition, the response of the filter circuit 1 is represented by a curve 16 having a cut-off frequency f c1 . Conversely, when an input signal has a frequency f s2 which is higher than the cut-off frequency f c0 of the filter circuit 1, this signal will be cut off by the filter circuit 1, whereby the output level of the filter circuit 1 will be reduced below the given value l 2 . This results in a reduction in the resistance across the source and drain of the transistor 8 to reduce the gain A of the amplifier 11, thereby increasing the cut-off frequency of the filter circuit 1 so as to shift the response to the right on FIG. 3, as represented by a curve 17 having a cut-off frequency f c2 at which an output level equal to l 2 is obtained. In this manner, the control is performed by utilizing a declining portion of the characteristic curve of the filter circuit 1 in a manner such that an input signal frequency is converted into a corresponding level, which is used to control the cut-off frequency of the filter circuit 1 so as to maintain the output signal level at the given value. By establishing a value for l 2 which satisfies the inequality l 1 > l.sub. 2, it is assured that any input frequency will lie on a point on the declining portion so that the damping characteristic of the declining portion of the characteristic curve causes a sharp attenuation of higher frequency components.
Thus, with the filter according to the invention, any noise components superimposed on an input signal and having higher frequencies can be eliminated irrespective of the frequency of the input signal. Thus, it may be utilized in the determination of the period of the input signal by a counter, by producing a gate signal which is precisely in correspondence with the period of the input signal so as to enable an accurate determination. As will be noted from the foregoing description, the detection of the output level of the filter circuit 1 may be carried out by a simple rectifier, and the control of the cut-off frequency of the filter circuit 1 can be accomplished in a simple manner as by control of the transistor 8. Since a single filter circuit 1 is used, the cut-off frequency of which is varied, the general arrangement is greatly simplified over the prior art practice where a plurality of filters are switched.
When the input signal frequency remains constant, but its level changes, the output level of the filter circuit 1 also changes, accompanying a corresponding change in the cut-off frequency f c , thereby maintaining the output level constant. As a result, the signal level supplied to the circuit 13 remains constant, assuring a reliable operation of the circuit 13 and also facilitating the design of such circuit. In order to prevent an unstable operation of the transistor 8 when an input having an excessively high amplitude is applied, an amplitude limiter or AGC circuit may be used to limit the input signal to a definite level before it is supplied to the filter circuit 1. In this manner, it is assured that the cut-off frequency of the filter circuit 1 better follows the input signal frequency even with an input of higher amplitude.
While in the above embodiment, the transistor 8 which functions as the gain controlling element is connected in shunt with the feedback path of the amplifier 11, it may be connected in series with the feedback path. Alternatively, in place of utilizing the Miller effect for the filter circuit 1, the filter circuit 1 may comprise a transistor 8 functioning as a variable resistor element which is connected in series in the signal path, and a capacitor 9 may be connected in shunt with the signal path, as shown in FIG. 4. As a further alternative, FIG. 5 shows that the output from the detector 10 is compared against a reference voltage from a terminal 18 in a differential amplifier 19 so as to control the internal resistance of the transistor which is contained within the filter circuit 1 in accordance with a difference therebetween. Specifically, referring to FIG. 5, a source terminal 20 is connected through a resistor with a Zener diode 21, and the constant voltage thereacross is divided by a variable resistor 22 to constitute a reference voltage source 23. By adjusting the variable resistor 22 to change the reference voltage supplied to the terminal 18, the cut-off frequency of the filter circuit 1 can be automatically varied so that its output level becomes equal to any desired value chosen for the reference voltage level, again by utilizing the damping characteristic of the declining portion of the frequency response of the filter circuit 1. This is conveniently used to provide an optimum trigger level for the circuit 13 such as Schmidt trigger through the adjustment of the reference voltage when such circuit connected to the output of the filter circuit 1 has a different trigger level. Thus, the filter according to the invention can be used as a level regulator. Also in FIG. 5, a level regulator may be connected between the filter circuit 1 and the junction between the circuits 10 and 13, and in this instance, the reference voltage from the terminal 18 may be varied in accordance with a level change which results from the operation of the level regulator so as to modify the control signal to the variable element contained within the filter circuit 1.
The embodiment shown in FIG. 1 is suitable for use with a relatively low frequency, and difficulties may be experienced when it is used with an input signal of a higher frequency range. A filter suitable for use with higher frequencies is illustrated in FIG. 6 wherein the filter circuit 1 comprises an inductance element 25 connected in series with the signal path, and a pair of variable capacitance diodes 26, 27 connected between the opposite ends of the inductance element and ground, these diodes functioning as variable elements. An amplifier 28 is connected between the filter circuit 1 and the junction between the circuits 10 and 13, and the reference voltage from the terminal 18 is chosen in accordance with the gain of the amplifier 28. The output of the differential amplifier 19 is supplied as a control signal to the variable capacitance diodes 26, 27 through a resistor 29. Numerals 36 and 37 represent d.c. blocking capacitors. In the practical embodiment constructed in accordance with FIG. 6, the inductance element 25 had a value of 5 × 10 -9 henry, and each of the variable capacitance diodes 26, 27 had a capacitance which varies from 2 pF to 20 pF. FIG. 7 shows the resulting frequency responses when the control voltage is varied from 0 to 15 volts, and it will be noted that a substantial control over the cut -off frequency is enabled. Curves 30, 31, 32, 33 and 34 shown in FIG. 7 correspond to the control voltages of 0, 3, 5, 10 and 15 volts applied to the diodes 26, 27.
In another practical embodiment which is constructed according to FIG. 1, the amplifier 2 comprises an operational amplifier LM 301A manufactured by National Semiconductor Corporation of the United States, the transistor 8 is of the type 2N4393 manufactured by the same company, and the resistors 3, 4, 6 and 7 have resistance values of 10 kΩ, 330Ω, 10 kΩ, and 22 kΩ, respectively, and the capacitor 9 has a capacitance of 0.047μF. The filter circuit 1 has a cut-off frequency of 15 Hz when the output voltage of the detector 10 is -0.039 volt, and has a cut-off frequency of 3 kHz when the output voltage of the detector 10 is -5.00 volt.
While the invention has been described as applied to low pass filters, it should be readily apparent that the invention is also applicable to a high pass filter. This may be achieved, for example, by interchanging the position of the variable element 8 and the capacitor 9 in the embodiment of FIG. 4, and by substituting a variable capacitance diode for the inductance element 25 and replacing the variable capacitance diodes 26, 27 by inductance elements in the embodiment of FIG. 6. It should be also appreciated that the invention is not limited to the types of filters illustrated, but may be applied to any other type of filters. Additionally, while the field effect transistor and variable capacitance diodes have been illustrated as the variable element 8, various other elements can be used. For example, a photoconductive element such as CdS may be used to have its resistance varied by a control of light impinging thereon, or a coil wound on a core may be supplied with a d.c. current in superposition with the input signal so as to control the magnetic permeability of the core to change the inductance of coil. | A device for measuring the frequency or period of an input signal independent of different frequency noise signals which may be superimposed on the input signal includes a filter circuit having a variable cut-off frequency. The output level of the filter circuit is detected by a level detector, the output of which electrically controls a variable element such as a variable resistor, a variable capacitance diode or the like which is included in the filter circuit. This controls the cut-off frequency of the filter circuit, so as to maintain its output level at a given level. In this manner, an input signal frequency is converted into a corresponding level, utilizing a declining portion adjacent to the cut-off frequency of the frequency response of the filter circuit. The converted level is utilized to vary the cut-off frequency of the filter circuit to maintain its output level constant, thereby automatically changing the cut-off frequency in accordance with the input signal frequency. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a series of azaaspartic acid analogs which exhibit in vitro and in vivo inhibition of interleukin-1β convening enzyme, to compositions containing the novel aspartic acid analogs and to methods for therapeutic utility. More particularly, the interleukin 1β converting enzyme inhibitors described in this invention comprise novel azaaspartic acid α-substituted acetamides which possess particular utility in the treatment of inflammatory and immune-based diseases of lung, central nervous system, and connective tissues.
2. Reported Developments
Interleukin 1β (IL-1β) protease (also known as interleukin-1β converting enzyme or ICE) is the enzyme responsible for processing of the biologically inactive 31 kD precursor IL-1β to the biologically active 17 kD form (Kostura, M. J.; Tocci, M. J.; Limjuco, G.; Chin, J.; Cameron, P.; Hillman, A. G.; Chartrain, N. A.; Schmidt, J. A., Proc. Nat. Acad. Sci. (1989), 86, 5227-5231 and Black, R. A.; Kronheim, S. R.; Sleath, P. R., FEBS Let., (1989), 247, 386-391). In addition to acting as one of the body's early responses to injury and infection, IL-1β has also been proposed to act as a mediator of a wide variety of diseases, including rheumatoid arthritis, osteoarthritis, inflammatory bowel disease, sepsis, acute and chronic myelogenous leukemia and osteoporosis (Dinarello, C. A.; Wolff, S. M., New Engl. J. Med., (1993), 328, 106). A naturally occurring IL-1β receptor antagonist has been used to demonstrate the intermediacy of IL-1β in a number of human diseases and animal models (Hannum, C. H.; Wilcox, C. J.; Arend, W. P.; Joslin, G. G.; Ddpps, D. J.; Heimdal, P. L.; Armes, L. G.; Sommer, A.; Eisenberg, S. P.; Thompson, R. C., Nature, (1990), 343, 336-340; Eisenberg, S. P.; Evans, R. J.; Arend, W. P.; Verderber, E.; Brewer, M. T.; Hannum, C. H.; Thompson, R. C., Nature (1990), 343, 341-346; Ohlsson, K.; Bjork, P.; Bergenfeldt, M.; Hageman, R.; Thompson, R. C., Nature, (1990), 348, 550-552; Wakabayashi, G., FASEB, (1991), 338-343; Pacifici, R.; et al. Proc. Natl. Acad. Sci. (1989), 86, 2398-2402 and Yamamoto, I.; et al. Cancer Rsh (1989), 49, 4242-4246). The specific role of IL-1β in inflammation and immunomodulation is supported by the recent observation that the cowpox virus employs an inhibitor of ICE to suppress the inflammatory response of its host (Ray, C. A. et al, Cell, (1992), 69,597-604).
The importance of these observations is well recognized by those skilled in the art and several workers have proposed and demonstrated in vivo the utility of ICE inhibitors in modifying certain IL-1β mediated disease states. Some have suggested the development and therapeutic use of a small molecule inhibitor of mature IL-1β formation (See, e.g., Miller, D. K. et al. "The IL-1β Converting Enzyme as a Therapeutic Target" in Immunosuppressive and Antiinflammatory Drugs; Annals of the New York Academy of Sciences; Vol. 696, pp133-148, 1993). The following review of the current state of the art in ICE research further supports such utility of ICE inhibitors:
1) WO 9309135, published 11 May 1993, teaches that peptide-based aspartic acid arylacyloxy-and aryoxymethyl ketones are potent inhibitors of ICE in vitro. These compounds also specifically inhibited ICE in the whole cell (in vivo) by their ability to inhibit the formation of mature IL-1β in whole cells. These ICE inhibitors also demonstrated utility in reducing fever and inflammation/swelling in rats.
2) Patients with Lyme disease sometimes develop Lyme arthritis. B. Burgdorferi, the causative agent of Lyme disease, is a potent inducer of IL-1 synthesis by mononuclear cells. Miller et al. (Miller, L. C.; Lynch, E. A. Isa, S.; Logan, J. W.; Dinarello, C. A.; and Steere, A. C., "Balance of synovial fluid IL-1β and IL-1 Receptor Antagonist and Recovery from Lyme arthritis", Lancet (1993) 341; 146-148) showed that in patients who recovered quickly from Lyme Arthritis, the balance in synovial fluid of IL-1β and IL-1ra was in favor of IL-ra. When the balance was shifted in favor of IL-1β, it took significantly longer for the disease to resolve. The conclusion was that the excess IL-1ra blocked the effects of the IL-1 β in the patients studied.
3) IL-1 is present in affected tissues in ulcerative colitis in humans. In animal models of the disease, IL-1β levels correlate with disease severity. In the model, administration of 1 L-1ra reduced tissue necrosis and the number of inflammatory cells in the colon. See, Cominelli, F.; Nast, C. C.; Clark, B. D.; Schindler, R., Llerena, R.; Eysselein, V. E.; Thompson, R. C.; and Dinarello, C. A.; "Interleukin-1 Gene Expression, Synthesis, and Effect of Specific IL-1 Receptor Blockade in Rabbit Immune Complex Colitis" J. Clin. Investigations (1990) Vol. 86, pp, 972-980.
4) The IL-1 receptor antagonist, Antril (Synergen), possess significant antiinflammatory activity in patients with active rheumatoid arthritis. In a multicenter Phase II dose ranging study, 175 patients received subcutaneous doses of Antril at 20mg, 70mg and 200mg seven times, three times or once per week. The antagonist was found to be most effective when taken daily. After three weeks of daily treatment, patients showed a decrease in joint swelling and less disease activity (Scrip, NO 1873, 1993).
5) IL-1ra supresses joint swelling in the PG-APS model of arthritis in rats. See Schwab, J. H.; Anderie, S. K.; Brown, R. R.; Dalldorf, F. G. and Thompson, R. C., "Pro- and Anti-Inflammatory Roles of Interleukin-1 in Recurrence of Bacterial Cell Wall-Induced Arthritis in Rats". Infect. Immun. (1991) 59; 4436-4442.
6) IL-1ra shows efficacy in a small open-label human Rheumatoid Arthritis trial. See, Lebsack, M. E.; Paul, C. C.; Bloedow, C. C.; Burch, F. X.; Sack, M. A.; Chase, W., and Catalano, M. A. "Subcutaneous IL-1 Receptor Antagonist in Patients with Rheumatoid Arthritis", Arth. Rheum. ( 1991 ) 34; 545.
7) Soluble IL-1 receptor significantly reduces clinically the cutaneous late-phase allergic reaction. This was demonstrated in a prospective, randomized, double-blind, placebo-controlled study on 15 allergic subjects. See, Mullarkey, M. F. et al. "Human Cutaneous Allergic Late-Phase Response is Inhibited by Soluble IL-1 Receptor", J. of Immunology, (1994) 152; 2033-2041.
8) IL-1 appears to be an autocrine growth factor for the proliferation of chronic myelogenous leukemia cells. Both IL-1ra and sIL-1R inhibit colony growth in cells removed from leukemia patients. See, Estrov, Z.; Kurzrock, R.; Wetzler, M.; Kantarjian, H.; Blake, M.; Harris, D.; Gutterman, J. U.; and Talpaz, M., "Suppression of Chronic Myelogenous Leukemia Colony Growth by Interleukin-1 (IL-1) Receptor Antagonist and Soluble IL-1 Receptors: a Novel Application for Inhibitors of IL-1 Activity". Blood (1991) 78; 1476-1484.
9) As in 6) above, but for acute myelogenous leukemia rather than chronic myelogenous leukemia. See, Estrov, Z.; Kurzrock, R.; Estey, E.; Wetzler, M.; Ferrajoli, A.; Harris, D.; Blake, M.; Guttermann, J. U.; and Talpaz, M. "Inhibition of Acute Myelogenous Leukemia Blast Proliferation by Interleukin-1 (IL-1) Receptor Antagonist and Soluble IL-1 Receptors". (1992) Blood 79; 1938-1945.
An effective therapy has yet to be fully developed commercially for the treatment of IL-1β mediated inflammatory diseases. Consequently, there is a need for therapeutic agents effective in the treatment and prevention of these diseases.
SUMMARY OF THE INVENTION
It is known that aspartic acid is the P1 specificity determinant for ICE. This is exemplified by the potent irreversible inhibitor i (structure 1) which contains a P1 aspartic acid residue. In this invention we describe inhibitors where the traditional aspartic acid residue is substituted with an azaaspartic acid residue as indicated by ii (structure 1). In these novel agents, the α-carbon atom which bears the aspartic acid side chain has been replaced by a nitrogen atom. ##STR3##
Aspartic Acid-Based ICE Inhibitor (Dolle, R. E. et al., J. Med. Chem. 37, 563 (1994)) ##STR4##
Azaaspartic Acid-Based ICE Inhibitor (Present Invention)
According to the present invention, there is provided a compound of the formula (A) or a pharmaceutically acceptable salt thereof: ##STR5## wherein: R 2 =H or alkyl;
R 3 =halo, O(CO) 0-1 aryl, OPOR 4 R 5 ; ##STR6## where R 4 and R 5 =aryl;
R 6 =H, aryl or aralkyl;
R 7 =independently selected from R 6 , CF 3 and CF 2 CF 3 ;
R 1 =R 6 -CO, heteroaryl-CO, heteroaralkyl-CO and amino acid.
"Alkyl" is defined as a saturated aliphatic hydrocarbon which may be either straight- or branched-chain. Preferred groups have no more than about 12 carbon atoms and may be methyl, ethyl and structural isomers of propyl, butyl, pentyl, hexyl, octyl, nonyl, decyl, undecyl, dodecyl.
"Aryl" is defined as a phenyl or naphthyl ring which may be substituted or unsubstituted wherein one or more of the hydrogen atoms has been replaced by the same or different substituents including halo, alkyl, aryl, nitro, cyano, amino, hydroxyl, alkoxy or haloalkyl.
"Aralkyl" means an alkyl radical substituted with an aryl ring, For example, benzyl. 4-chlorobenzyl.
"Heteroaryl" means pyridyl, thienyl or furanyl and structural isomers thereof.
"Heteroaralkyl" means an alkyl radical substituted by a heteroaryl ring. For example, 2-thienyl ethyl.
"Halo" means iodo, bromo, chloro, and fluoro.
"Amino acid" is defined as a commercially available natural or unnatural amino acid or dipeptide where the α-amino group in the amino acid or dipeptide has been protected with an N-protecting group. Such groups include, amides, sulfonamides, carbamates, and ureas as described in The Peptides, E. Gross and J. Meienhofer, Eds., Vol. 2, (1981) Academic Press, NY. N-Benzyloxy carbonyl-L-valine-L-alanine is an example.
The present invention also concerns the pharmaceutical composition and method of treatment of IL-1β protease mediated disease states or disorders in a mammal in need of such treatment comprising the administration of IL-1β protease inhibitors of formula (A) as the active agent. These disease states and disorders include: infectious diseases, such as meningitis and salpingitis; septic shock, respiratory diseases; inflammatory conditions, such as arthritis, cholangitis, colitis, encephalitis, endocerolitis, hepatitis, pancreatitis and reperfusion injury, immune-based diseases, such as hypersensitivity; auto-immune diseases, such as multiple sclerosis; bone diseases; and certain tumors and leukemias.
The present invention has particular utility in the modulation of processing of IL-1β for the treatment of rheumatoid arthritis. Levels of IL-1β are known to be elevated in the synovial fluid of patients with the disease. Additionally, IL-1β stimulates the synthesis of enzymes believed to be involved in inflammation, such as collagenase and PLA2, and produces joint destruction which is very similar to rheumatoid arthritis following intra-articular injection in animals.
In the practice of this invention an effective amount of a compound of the invention or a pharmaceutical composition thereof is administered to the subject in need of, or desiring, such treatment. These compounds or compositions may be administered by any of a variety of routes depending upon the specific end use, including orally, parenterally (including subcutaneous, intraarticular, intramuscular and intravenous administration), rectally, buccally (including sublingually), transdermally or intranasally. The most suitable route in any given case will depend upon the use, the particular active ingredient, and the subject involved. The compound or composition may also be administered by means of controlled-release, depot implant or injectable formulations as described more fully herein.
In general, for the uses as described in the instant invention, it is expedient to administer the active ingredient in amounts between about 0.1 and 100 mg/kg body weight, most preferably from about 0.1 to 30 mg/kg body weight for human therapy, the active ingredient will be administered preferably in the range of from about 0.1 to about 20-50 mg/kg/day. This administration may be accomplished by a single administration, by distribution over several applications or by slow release in order to achieve the most effective results. When administered as a single dose, administration will most preferably be in the range of from about 0.1 to mg/kg to about 10 mg/kg.
The exact dose and regimen for administration of these compounds and compositions will necessarily be dependent upon the needs of the individual subject being treated, the type of treatment, and the degree of affliction or need. In general, parenteral administration requires lower dosage than other methods of administration which are more dependent upon absorption.
A further aspect of the present invention relates to pharmaceutical compositions comprising as an active ingredient a compound of the present invention in admixture with a pharmaceutically acceptable, non-toxic carrier. As mentioned above, such compositions may be prepared for use for parenteral (subcutaneous, intraarticular, intramuscular or intravenous) administration, particularly in the form of liquid solutions or suspensions; for oral or buccal administration, particularly in the form of tablets or capsules; or intranasally, particularly in the form of powders, nasal drops or aerosols.
When administered orally (or rectally) the compounds will usually be formulated into a unit dosage form such as a tablet , capsule, suppository or cachet. Such formulations typically include a solid, semi-solid or liquid carrier or diluent. Exemplary diluents and vehicles are lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, mineral oil, cocoa butter, oil of theobroma, alginate, tragacanth, gelatin, syrup, methylcellulose, polyoxyethylene sorbitar monolaurate, methyl hydroxybenzoate, propyl hydroxybenzoate, talc, and magnesium stearate.
DETAILED DESCRIPTION OF THE INVENTION
As shown in Scheme 1, t-butyl hydrazine acetic acid (Formula 1, prepared according to Niedrich, H. et al., Chem. Ber. 102, 1557-1569 (1969)) was acylated with either an N-protected amino acid or dipeptide acid or any desired non-peptide carboxylic acid. The acylation reaction was carried out using a peptide coupling reagent such as an acid chloride, mixed anhydride and other methods described in The Practice of Peptide Synthesis (M. Bodanszky, Ed., 1984 Springer-Verlag, NY) to yield an acyl hydrazone (Formula 3). The acyl hydrazone in turn was reacted with an α-halo acetyl chloride (Formula 4) in the presence of a base such as N-methylmorpholine. This reaction afforded compounds of Formula 5. When compounds of Formula 5 were treated with trifluoroacetic acid (TFA) in methylene chloride (25% TFA solution) for 3 hrs. at 25° C., the t-butyl ester was hydrolyzed and the inhibitors of Formula 7 were obtained. Alternatively, when the acyl hydrazide of Formula 5 (W═Br) was treated with a phenol, arylcarboxylic acid, diarylphosphinic acid, a tetronic acid derivative or a 5-hydroxy-pyrazole derivative in dimethylformamide containing potassium fluoride, the compounds of the type described by Formula 6 were obtained. These t-butyl esters were then treated with TFA as before (Formula 5→7) to furnish inhibitors of Formula 7. ##STR7## where W=halo;
HO-Y=phenol, carboxylic acid, diarylphosphinic acid, tetronic acid derivative or 5-hydroxypyrazole derivative;
R 1 and R 3 are as defined previously.
The following examples further illustrate the compounds of the invention.
EXAMPLE 1 ##STR8## Z=N terminal protecting group N-benzyloxycarbonyl
N-Benzyloxycarbony-L-valine-L-alanine-azaaspartic acid 2.6-dichlorobenzoyloxymethyl ketone ##STR9## Part A
Z-Val-Ala-OH(2) (4.00 g, 12.4 mmol), hydrazine(1) (2.18 g, 14.9 mmol) and HOBT (2.09 g, 13.6 mmol) were dissolved in 25 mL of DMF. 1-(3-Dimethyl-aminopropyl)-3-ethyl carbodiimide hydrochloride (EDC, 2.61 g, 13.6 mmol) was then added in one portion at 0° C. and the reaction solution stirred for 6 h. The reaction solution was then poured into 800 mL of water and the product extracted into ethylacetate (3×). The organic layer was washed (water, 0.3 NaKHSO 4 (2×), 5% NaHCO 3 (2×), brine) and dried over Na 2 SO 4 . Evaporation of solvent yielded.sup.(3) as a fine white powder of sufficient purity: 5.34 g, 95%, MP 115°-157° C. ##STR10## Part B
Bromoacetyl chloride(4) (0.71 mL, 8.66 mmol) was added dropwise to a 0° C. solution of hydrazide(3) (3.00 g, 6.66 mmol) and N-methylmorpholine (1.1 mL, 9.99 mmol) in dichloromethane (80 mL). After stirring for 5 h at 0° C., the reaction mixture was poured into water (600 mL) and the product extracted into ethylacetate (3×). The organic phase was then washed (water, 0.3 NaKHSO 4 (2×), 5% NaHCO 3 (2×), brine), dried with Na 2 SO 4 , filtered and concentrated. Recrystallization from warm ethylacetate/hexanes provided the bromoacetyl derivative(5) (3.11 g, 82%) as a white crystalline solid, MP 136°-138° C. ##STR11## Part C
Powdered HF (0.128 g, 2.18 mmol) was added to a homogeneous solution of bromoacetyl derivative(5) (0.500 g, 0.874 mmol) and 2,6-dichlorobenzoic acid(8) (0.234-g, 1.20 mmol) in 5 mL of DMF. The reaction was then warmed at 60° C. for 10 hrs. The reaction mixture was poured into 100 mL of water and the products extracted into ethylacetate (3×). The ethylacetate layer was then washed (water, 0.3 NKHSO 4 (2×), 5% NaHCO 3 (2×), brine), dried with Na 2 SO 4 , filtered and concentrated. Recrystallization from warm EtOAc/hexanes provided dichlorobenzoate derivative(9) as a white crystalline solid (0.510 g, 86%, MP 176°-178° C.) ##STR12## Part D
Toluene (5 mL) and a 25% solution of TFA/CH 2 Cl 2 (100 mL) were added to a 250 mL flask containing tBu ester(9) (0.450 g, 0.66 mmol). After stirring for 1 hr at RT, additional toluene (50 mL) was added and all solvents evaporated under reduced pressure. Two additional 100 mL portions of toluene were added and evaporated. Concentration of a homogeneous solution of the product in dichloromethane and hexanes (2×) produced a fine white powder. After two-fold trituration with several mL of hexane, Example 1 was collected on a filter and dried under high vacuum: 0.411 g, 95% amorphous. Anal. calcd. for C 27 ,H 30 Cl 2 N 4 O 9 : C, 51.85; H, 4.83; N, 8.46. Found C, 51.66; H, 5.14; N, 8.51.
Following the procedure described in Scheme 1 and by analogy to Example 1, the following compounds were prepared.
EXAMPLE 2 ##STR13##
N-Benzyloxycarbonyl-L-valine-L-alanine-azaaspartic acid bromomethyl ketone
Anal. calcd. for C 20 H 27 BrN 4 O 7 .O 2 H 2 O: C, 46.29; H, 5.32; N, 10.80. Found: C,46.6, H, 5.50; N, 10.45.
EXAMPLE 3 ##STR14##
N-Benzyloxycarbonyl-L-valine-L-alanine-azaaspartic acid 4-(3-phenyl)tetronyloxymethyl ketone
Anal. calcd. for C 30 H 34 N 4 O 10 .1H 2 O: C, 57.32; H, 5.77; N, 8.91. Found: C, 57.28; H, 5.67; N, 9.02.
EXAMPLE 4 ##STR15##
N-Benzyloxycarbonyl-L-valine-L-alanine-azaaspartic acid 5-(1-phenyl-3-trifluoromethyl)pyrazoloxymethyl ketone
Anal. calcd. for C 30 H 33 F 3 N 6 O 8 .O0.5H 2 O: C, 53.65; H, 5.10; N, 12.51. Found: C, 53.94; H, 5.17; N, 12.24.
EXAMPLE 5 ##STR16##
N-Benzyloxycarbonyl-L-valine-L-alanine-azaaspartic acid diphenylphosphinyloxymethyl ketone
Anal. calcd. for C 32 H 37 N 4 O 9 P.0.25 H 2 O: C, 58.49; H, 5.75; N, 8.53. Found: C, 58.23; H, 5.87; N, 8.41.
EXAMPLE 6 ##STR17##
N-Benzyloxycarbonyl-L-valine-L-alanine-azaaspartic acid chloromethyl ketone
mass spectrum m/z=471 (M+H)
EXAMPLE 7 ##STR18##
N-(2,6-Dichlorobenzoyl)-azaaspartic acid chloromethyl ketone
mass spectrum m/z=338 (M+H)
In Vitro Testing
Second order rates for inactivation were obtained by using the enzyme assay described in Dolle, R. E. et al., J. Med Chem. 37,563 (1994).
The compounds in examples 1-7 possess IL-1β protease inhibition (kobs/I were>5,000M -1 s 1-1 ).
In Vitro
In vitro inhibition (IC 50 ) was determined as follows:
Human monocytes were isolated from heparinized leukopheresis units obtained through Biological Specialty Corporation (Lansdale, Pa). Monocytes were purified by Ficoll-Hupaque (Pharmacia Fine Chemicals, Piscataway, N.J.) gradient centrifugation and more than 95% pure monocyte populations obtained by centrifugal elutriation. The assay was performed on duplicate samples of freshly isolated human monocytes, cultured in suspension at 37° C. and rotated gently in conical bottom polypropylene tubes (Sardstedt Inc., Princeton, N.J.). Human monocytes at a concentration of 5×10 6 cells/mL were resuspended in 1 mL of RPMI 1640 (a common tissue buffer from M.A. Bioproducts, Walkersville, Md.) containing 1% fetal calf serum (FCS) (HyClone, Logan, Utah) and 50 μg/mL gentamycin (Gibco, Grand Island, N.Y.). The cells were treated either with a compound of the invention (i.e. test compound) or with a non-inhibitor (control compound, typically 0.03% DMSO) for 15 minutes and then activated with 0.01% fixed Staphylococcus aureus (The Enzyme Center, Malden, Mass.) for 1 hour. The cells were then centrifuged and resuspended in 1 mL of cysteine, methionine-free RPMI media containing 1% dialyzed FCS (Hyclone). The cells were pretreated with a test compound or control compound for 15 minutes after which 0.01% fixed S. aureus plus 100 μCi Tran 35-S label (ICN, Irvine, Calif.) was added and the cells incubated at 37 ° C. for 1 hour. After incubation, cells were centrifuged, washed once in phosphate buffer saline and resuspended in 1 mL RPMI containing 1% fetal calf serum. The cells were again pretreated with a test or control compound for 15 minutes and then 0.01% S. aureus for 2 hours. At the end of the incubation, cells were centrifuged and supernates saved for immunoprecipitation. Cells were washed once in phosphate buffer saline and then lysed in RIPA, a continuous cell media buffer containing 2 mM phenyimethylsulfonyl fluoride, 10 mM iodoacetate, 1 μg/mL pepstatin A, 1 μg/mL leupeptin and 0.5 TIU aprotinin.
For the immunoprecipitations, an equal volume of 1% dry milk in RIPA buffer plus 50 μL of resuspended protein A sepharose CL-4B (Pharmacia, Piscataway, N.Y.) was added to supernates and 1 mL of 4% dry milk containing protein A sepharose CL-4B to cell lysates and samples rotated for 30 minutes at 4° C. Beads were then centrifuged down, samples transferred to fresh tubes and incubated overnight with 40 82 g rabbit anti-human IL-1β polyclonal antibody (Genzyme, Cambridge, Mass.). The IL-1β proteins were then precipitated with 70 μL protein A sepharose, resuspended in 60 μL SDS sample buffer and run on 15% SGD-PAGE gels. Autoradiography was performed on dried gels and the amount of radioactivity (counts per minute, cpm) quantitated using a Betascope 603 analyzer.
Data Analysis
In the monocyte pulse chase assay, each test parameter was run in duplicate. Data was collected from the Beta Scope using a personal computer, then transferred to the VAX system for calculation of mean cpm and standard deviation of the mean. When test compounds were evaluated, the percent inhibition of release of mature IL-1β was calculated as follows: ##EQU1##
These % inhibition values were then used to calculate IC 50 value for each compound. Since the human monocyte pulse chase assay uses primary cells from different donors, each test compound was run in 2-3 separate experiments, using monocytes from 2-3 different donors.
For examples given above, the in vitro IC 50 's ranged from approximately 0.1 up to approximately 10 μM. | Disclosed are compounds, compositions and methods for inhibiting interleukinprotease activity. The compounds, α-substituted acetamides a ##STR1## wherein: R 2 =H or alkyl;
R 3 =halo, O(CO) 0-1 aryl, OPOR 4 R 5 ; ##STR2## where R 4 and R 5 =aryl;
R 6 =H, aryl or aralkyl;
R 7 =independently selected from R 6 , CF 3 and CF 2 CF 3 ;
R 1 =R 6 -CO, heteroaryl-CO, heteroaralkyl-CO and amino acid. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of Invention
[0005] This invention relates to the construction of post-framed buildings and the methods of erecting a building that ensure a structure's precision and integrity.
[0006] 2. Prior Art
[0007] The traditional process of constructing post frame buildings consists of placing a wooden columnar structure into a hole drilled in the earth or onto a concrete foundation. The column must then be braced and spaced to assure accurate post spacing and plumb alignment. The holes are then filled with soil and compacted to keep the column in place. Dimensional lumber is then used to create a sidewall either by nailing long “girts” to the exterior face of the column or in between the columns to create a cavity to later be filled with insulation and be a framing for interior finishes. This framing method is tedious and requires much checking and rechecking to keep walls plumb and square. It also requires field cutting of lumber, which is more prone to error than framing materials produced in a manufacturing environment. After the wall framing is complete, a prefabricated roof truss is attached to the columns and lumber “purlins” are used to frame the roof. These “purlins” can either be nailed longitudinally on to the top of truss top chord or mounted in between the top chords of the truss using a metal hanger. Much bracing, measuring and labor is required to construct buildings in this manner and often results in imperfections in diaphragm load distribution and framing accuracy.
BRIEF SUMMARY OF THE INVENTION
[0008] 1. This new invention solves many of the problems associated with the prior art.
The bookshelf building panel is reinforced with high tensile steel cross-bracing to ensure that the panel remains square and true during transport and construction. This strength allows the roof panels, trusses, columns, and wall panels to be assembled on the ground as one unit and raised into place, where it is attached to previously-raised sections, thus completing the wooden structure of the building. This reduces the time needed for construction, assures perfectly square and plumb buildings, and increases safety for workers as most work is done on the ground instead of in the air.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 depicts the bookshelf building panel and the steel strapping cross bracing required to keep it in square and increase the finished building's diaphragm strength.
[0011] FIG. 2 depicts the gable wall assembly with the wall panels attached to the columns and the gable truss attached to the columns.
[0012] FIG. 3 depicts the wall panel/column/truss/roof panel assembly in the raised position relative to grade.
DETAILED DESCRIPTION OF THE INVENTION
[0013] 1. The description of this invention begins with the building panel itself. The panel in FIG. 1 is designed to fit between the columns of the post frame structure. This method allows for the attainment of high r-values in the resulting building because of the increased area for insulation between the exterior wall and the interior wall. The panel is composed of wooden vertical and horizontal members, mechanically fastened to each other, which may be composed of dimensional lumber from 2×4 to 2×12 depending on the engineering requirements of the building. The most common application would be composed of 2×6 dimensional lumber. Typically the panels would then be 5.5 inches thick. The height of the panel would be the distance from the grade board to the top of the building support columns, and the width of the panel would be the required spacing of the building columns minus the width of the column itself. The panel would also be braced from each corner to its opposite corner with a medium gauge steel strapping in order to keep the panels square during transport and construction and to provide tension bracing to distribute building diaphragm loads. These panels would also be used to compose the roof structure in the same way they are used to compose the sidewall structure. The roof panel application simply requires changing the length and width of the panel to match up with the specific trusses and posts used on any job so that when the wall panel/column/truss/roof panel assembly is constructed they are all the same width. The edge of the roof panel, which matches up with its counterpart at the building peak, would be mitered so that these edges match flush when they are assembled. Multiple combinations of roof panels may be used to obtain any desired length to match the truss top chord length. During assembly their outer edges must be locked together so that they cannot sag when raised into place.
[0014] 2. Many customer-demanded options could be included in the panels such as framing for windows and doors, wainscoting for the bottom of wall sections, venting options for roof peaks, and joist hanger reinforcements for the connection of the horizontal and vertical members. Sheathing could also be applied to the panels in the manufacturing process, saving time and labor on the jobsite, reducing waste, and increasing accuracy of the finished product.
[0015] 3. The wall panels, wooden support columns, trusses, and roof panels may then be assembled by the following method.
3A. The building's exterior walls are laid out and holes for the posts are dug or a concrete foundation is poured. 3B. Starting from one of the gable wall ends, the entire gable wall assembly may be constructed on the ground. Each gable wall panel will be screwed and bolted to the columns and the gable end truss will be mounted to the columns after the columns are notched to accept the thickness of the truss. The bottom of the columns would also be cut to match the elevation of the foundation. The entire gable wall/column/truss assembly ( FIG. 2 ) could then be raised with a crane or other suitable lifting device and lowered into the holes in the earth or onto the concrete foundation. The gable wall-post-truss assembly would then be straightened, plumbed and braced. 3C. After the gable wall is braced the next truss in order is attached to the next support columns while still on the ground. The bottoms of the columns are cut to length to match the foundation. Wall panels may then be attached to the posts. Roof panels are then attached to the truss and to the wall panel next to it. The roof panels are then attached to each other where they meet in the middle of the truss. Knee braces are added from the column to the truss to keep the column perpendicular to the truss bottom chord during raising. The diagonal steel bracing of the roof and wall panels then allows the entire wall panel/column/truss/roof panel assembly ( FIG. 3 ) to be raised into position without buckling. The assembly is then attached to the gable wall assembly with screws and bolts. 3D. The process of step 3 is repeated until the length of the building is completed, finishing with the opposite gable end wall. 3E. Steel siding and roofing or other suitable building materials are then added to complete the structure. | 1. A post frame bookshelf style steel reinforced building panel and the construction method thereof to form a building structure. | 4 |
TECHNICAL FIELD
The present invention relates to a drainage mat and mortar blocker. More particularly, it a drainage mat which acts as a continuous drainage medium and a barrier to construction debris when inserted into a wall cavity.
BACKGROUND
The concept of placing drainage systems and debris inhibiting systems in wall cavities is well-known. For instance, U.S. Pat. No. 5,860,259 illustrates a planar insulating board constructed of an insulated section and a drain structure for use in masonry walls. The insulated section is constructed of extruded or expanded polystyrene and the drain structure is fabricated of a matted material such as strands of polymer, i.e., polyethtylene, nylon or polyester. The drain structure is attached to the insulated section by an adhesive.
U.S. Pat. No. 4,704,048 illustrates a panel assembly inserted on the exterior surface of a wall. The assembly includes an insulating board with channels on one side of the board. A water-pervious fabric is attached to the channelled side of the board. The panel assembly collects water and channels it downward and away from the wall.
U.S. Pat. No. 5,857,297 describes an elastomeric, water-impervious coating which is applied to the outer surface of a foundation wall. Sheets of water-impervious protection board, formed from thermoplastic resin, are then bonded to the elastomeric coating. The proctection boards function to protect the elastomeric coating from damage during backfilling. Further, the protection boards contain holes and channels that serve to facilitate the movement of water downward away from the wall.
U.S. Pat. No. 6,238,766 illustrates a high-strength geomembrane constructed from a blend of polyethylene copolymers. The geomembrane is installed on a foundation wall and serves to protect wall waterproofing systems from impact of debris from backfilling, earth movement and cracks.
U.S. Pat. No. 5,598,673 describes a masonry cavity wall construction which prevents water damage to building foundations and blocks construction debris from entering the cavity. The air space, bewteen the masonry cavity wall and the interior wythe, contains board insulation to which is attached a polymeric fluiding conducting mesh. The mesh allows gases and water to pass through but prevents solid materials, such as construction debris, from passing through it.
U.S. Pat. No. 5,615,525 illustrates a thermoplastic foam board containing channels which extend into the board. The panel is installed on the exterior surface of a foundation wall with the channels abut and open toward the backfill soil. The channels vary in width so as to prevent backfill soil from entering the channels while still providing effective water drainage.
All of the above patents teach methods and apparatus for providing drainage for walls and/or blocking debris from entering wall cavities and/or providing insulation for walls. However, none of the prior art specifically addresses an apparatus for providing wall insulation, water drainage and preventing substantially all debris from blocking the drainage of water from the wall cavity. Further, none of the prior art suggest providing a gap, free of debris, between the interior and exterior wall and below the drain material, to permit water to exit the wall cavity.
None of the prior art teach or suggest a product that utilizes a folded flap that remains out of a contractor's way while he/she constructs an exterior wall. The prior art does not teach or suggest a product that completely blocks the cavity of a wall to permit drainage and collect construction debris. Further, none of the prior art suggest an adjustable product that can be applied to wall cavities that are small in size, i.e., one inch to three inches across.
Thus, there is a need for a drainage mat that provides superior water drainage, debris-blocking capability and insulation in a simple product that can be easily installed in a wall cavity.
SUMMARY
The present invention relates to a method and apparatus to provide insulation, drainage and debris blocking capability. More particularly, the invention relates to a drainage mat and mortar blocker including a panel and polymeric drainage mat which includes protrusions on the front side and indentations, corresponding to the protrusions, on the back side of the mat. A filter fabric is affixed the protrusions. The top portion of the back side of the drainage mat is affixed to the panel and the bottom portion of the mat is folded upward so as to form a U-shape. The U-shape is held in place by connections extending from the back side of the bottom portion of the drainage mat and into the front side of the drainage mat.
It is an object of the present invention to provide an apparatus that provides drainage and debris-blocking capabilities in a single product.
It is an object of the present invention to provide an apparatus that utilizes a folded flap that remains out of a contractor's way while he/she constructs an exterior wall.
It is an object of the present invention to provide an apparatus that completely blocks the cavity of a wall to permit drainage and collect construction debris.
It is an object of the present invention to provide an adjustable product that can be applied to wall cavities that are small in size, i.e., one inch to three inches across.
It is an object of the present invention to provide an apparatus that blocks debris so that the gap at the bottom of a wall cavity is open for drainage.
It is another object of the present invention to provide a drainage and debris-blocking apparatus that is easy to install.
It is a further object of the present invention to provide a drainage and debris-blocking apparatus that may be conveniently installed on an insulation panel.
The foregoing and other advantages of the invention will become apparent from the following disclosure in which one or more preferred embodiments of the invention are described in detail and illustrated in the accompanying drawings. It is contemplated that variations in procedures, structural features and arrangement of parts may appear to a person skilled in the art without departing from the scope of or sacrificing any of the advantages of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the drainage and mortar blocker affixed on an insulation panel.
FIG. 2 is a side view of the drainage and mortar blocker as installed in a typical wall cavity.
FIG. 3 is a perspective view of the front side of the drainage mat.
FIG. 4 is a perspective view of the front side of the drainage mat.
FIG. 5 is a front view of the back side of the drainage mat.
In describing preferred embodiments of the invention, which are illustrated in the drawings, specific terminology is resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
Although preferred embodiments of the invention are herein described, it is understood that various changes and modifications in the illustrated and described structure can be affected without departure from the basic principles that underlie the invention. Changes and modifications of this type are therefore deemed to be circumscribed by the spirit and scope of the invention, except as the same may be necessarily modified by the appended claims or reasonable equivalents thereof.
DETAILED DESCRIPTION OF INVENTION
FIG. 1 is a perspective view of the drainage mat and mortar blocker 4 , in accordance with an embodiment of the present invention. The drainage mat and mortar blocker includes a drainage mat 4 and filter fabric 18 .
Drainage mat 4 is more clearly illustrated in FIGS. 3 and 4. FIG. 4 shows the front side 5 of the drainage mat 4 . Drainage mat 4 may be constructed of any flexible material that is impervious to water including thermoplastic materials. The preferred material used for the drainage mat is high density polystyrene. Drainage mat 4 contains protrusions 12 with apertures 10 randomly positioned between the protrusions 12 . FIG. 5 shows the back side 3 of drainage mat 4 . Depressions 16 on the back side 3 of the drainage mat 4 correspond with the protrusions 12 of the front side 5 of the drainage mat 4 (FIG. 4 ). As shown in FIGS. 1 and 3, filter fabric 18 is affixed, by an adhesive, to protrusions 12 on the front side 5 of the drainage mat 4 . Filter fabric 18 may be any suitable material which is pervious to water but impervious to solids. In a preferred embodiment, the filter fabric is constructed of polypropylene however, other materials suitable for a filter fabric include polyester and polyethylene. In FIG. 3, filter fabric 18 is pulled back for illustration purposes only. As illustrated in FIG. 1, the filter fabric 18 extends over the edge 11 of the bottom portion 20 on the back side 3 of the drainage mat.
As shown in FIGS. 1 and 2, drainage mat 4 may be affixed to a panel 2 . The panel may be constructed of any suitable material that can be easily affixed to a wall and/or provide insulation to a wall including, but not limited to, fibrous material such as glass fibers and cellulose fibers, composite materials, plywood or gypsum sheathing, expanded polystyrene rigid insulation, extruded polystyrene rigid insulation or polyisocyanurate rigid insulation. In the present invention, the preferred panel is an expanded polystyrene foam insulation board, such as that found in commonly-owned U.S. Pat. No. 6,268,046, which is hereby incorporated by reference.
Turning to FIGS. 1, 3 and 4 , drainage mat 4 includes a top portion 22 and a bottom portion 20 . As illustrated in FIG. 1, the top portion 22 is affixed a panel 2 by any conventional means, such as an adhesive. It should be noted, however, that the drainage mat does not have to be affixed to a surface, the mat may simply rest in a wall cavity. The bottom portion 20 of the back side 3 of drainage mat 4 is folded upwardly adjacent from said top portion 22 of the panel 2 . For the purposes of this invention, the term “adjacent” has the meaning close to, next to, lying near, contiguous or adjoining. In a preferred embodiment, the bottom portion 20 forms a U-shape. Connections such as sewing, staples, string, tape, ties, weak adhesives and any other material capable of retaining the fold, which may be easily severed, may be used. Preferably clips 6 are used, which are inserted during manufacture of the mat, extend through the filter fabric 18 on back side 3 of the bottom portion 20 and through the filter fabric 18 and into the front side 5 of the drainage mat 4 thereby retaining the U-shape.
Turning now to FIG. 2, the wall system 7 shows the drainage mat and mortar blocker as it is typically installed in a wall cavity. The drainage mat and mortar blocker may be installed on a panel 2 , affixed to the interior wythe 26 itself or simply placed into the wall cavity. The wall system includes an exterior wythe 28 , drainage mat and mortar blocker 4 , an exterior sheathing 24 , flashing 34 and interior wythe 26 . All of the components of the wall system 7 are supported by studs 32 .
In FIG. 2, the drainage mat and mortar blocker 4 is installed between an interior wythe 26 and exterior wythe 28 . In a preferred embodiment, interior wythe 26 may have an exterior sheathing 24 affixed to its exterior surface to prevent water from entering the interior wythe 26 . Exterior sheathing 24 can be constructed of any suitable material that is impervious to water including, but not limited to, laminated polymeric material, polymeric films, plywood, gypsum sheathing, and oriented strand board (OSB) sheathing. The interior wythe 26 is typically constructed of wood, plastic, steel, or masonry. In a preferred embodiment, panel 2 is affixed to the exterior sheathing 24 on the interior wythe 26 with the drainage mat 4 facing the exterior wythe 28 . The interior and exterior wythe define a wall cavity 36 which may be any width. The present invention can used utilized in any width of wall cavity. In a preferred embodiment, the wall cavity is between about one to about three inches wide. The bottom portion 20 of the drainage mat extends into the bottom of cavity 36 between the exterior wythe 28 panel 2 . Flashing 34 extends under exterior wythe 28 , the bottom surface of the cavity 36 and under the panel 2 .
As shown in FIG. 2, the exterior wythe 28 is partially constructed prior to installing the drainage mat and mortar blocker 4 . After the mat and mortar blocker 4 has been installed, construction of the exterior wythe 28 is completed and clips 6 are broken or cut, allowing the bottom portion 20 to release and at least partially abut exterior wythe 28 . Alternatively, the drainage mat and mortar blocker can be installed prior to constructing the exterior wythe however, the exterior wythe should be installed one or two courses high before the clips are severed allowing the bottom portion 20 to release.
The exterior wythe in a preferred embodiment is a brick facing, however the drainage mat and mortar blocker will work with any type of facing such as, concrete block or precast concrete panels. As the exterior wythe is being completed, the filter fabric 18 on the drainage mat 4 contains any mortar and debris (not shown) that falls into the cavity 36 . The majority of the debris is collected in the bottom, U-shaped, portion 20 of the mat 4 .
Although the drainage mat 4 is impervious to debris, water from construction, weather, condensation, and the like, is able pass through the filter fabric 18 and the apertures 10 in the drainage mat. Protrusions 12 permit water from the filter fabric to be pulled by gravity through the apertures 10 into the bottom of the cavity 36 and onto the flashing 34 . The water then exits the cavity through weep holes (not shown) in the exterior wythe.
The drainage mat 4 is manufactured in continuous, flat sheets which may be cut according to the amount required for a wall application. The drainage mat 4 is pre-manufactured with filter fabric 18 affixed to the protrusions 12 with adhesive material on the front side 5 of the mat (see FIG. 3 ). FIG. 5 illustrates the back side 3 of the drainage mat 4 as it is manufactured showing depressions 16 and apertures 10 . Filter fabric 18 extends from the front side 5 (not shown) to the back side 3 and is affixed to the edges of the back side of the mat with adhesive. After filter fabric 18 is applied to the drainage mat 4 , the drainage mat 4 is folded and secured with clips 6 . The mat may be folded either by hand or by mechanical means. The clips 6 may be inserted into the mat by a hand-held device or by mechanical means such as an automated machine. In a preferred embodiment, drainage mat 4 is adhered to the panel 2 with an adhesive during the final step of manufacture. However, the mat may be affixed to the panel during installation of the mat into the wall cavity as well.
It is possible that changes in configurations to other than those shown could be used but that which is shown is preferred and typical. It is therefore understood that although the present invention has been specifically disclosed with the preferred embodiment and examples, modifications to the design concerning sizing and shape will be apparent to those skilled in the art and such modifications and variations are considered to be equivalent to and within the scope of the disclosed invention and the appended claims. | A drainage mat and mortar blocker system including a panel and polymeric drainage mat which includes protrusions on the front side and indentations on the back side of the mat. A filter fabric is affixed to the side of the mat containing the protrusions. The top portion of the back side of the drainage mat is affixed to the panel and the bottom portion of the mat is folded upward so as to form a U-shape. The U-shape is held in place by connections extending from the back side of the bottom portion of the drainage mat and into the front side of the drainage mat. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to earlier filed U.S. provisional application Ser. No. 60/600,455 filed on Aug. 11, 2004, the entire contents of which is incorporated herein by its reference.
GOVERNMENTAL RIGHTS
[0002] This invention was made with Government support under Contract No. DAAE30-03-C1077, awarded by the U.S. Army. The Government may have certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates generally to power supplies, and more particularly, to power supplies for projectiles, which generate power due to an acceleration of the projectile.
[0005] 2. Prior Art
[0006] All existing and future smart and guided projectiles and those with means of one-way or two-way communications with a command or tracking station or with each other require electric power for their operation. In addition, as munitions are equipped with the means of communicating their type and characteristics with the firing system to ensure that the intended round is being used and for fire control purposes, and for health monitoring and diagnostics runs before loading, they would require a low level of power supply minutes and sometimes even seconds before being loaded into the gun system. The amount of power required for the proper operation of such smart and guided munitions or those equipped with the aforementioned health monitoring and diagnostics capabilities, is dependent on their mode of operation and the on-board devices that have to be powered. The amount of power requirement is fairly small if the projectile is required to only receive a RF or other similar signal and to power sensors such as MEMs types of accelerometers and rate gyros or health monitoring and diagnostics related electronics. The power requirement is increased if the projectile is also required to communicate back to the ground or some mobile station. The power requirement, however, becomes significant when the projectile has to be equipped with electric or smart materials based actuation devices for guidance and control, particularly if the projectile is required to become highly maneuverable over long traveling times and while traveling at relatively high speeds such as supersonic speeds.
SUMMARY OF THE INVENTION
[0007] Accordingly, an apparatus for generating an electrical power upon an acceleration of the apparatus is provided. The apparatus comprising: a piezoelectric member having at least a portion thereof formed of a piezoelectric material for generating an output power upon an impact; and a spring element configured to have at least one of a portion thereof and a portion attached thereto impact the piezoelectric material upon the acceleration.
[0008] The apparatus can further comprise a mass associated with the spring element for increasing a magnitude of the impact. The mass can be a portion of the spring element. The mass can be a separate portion from the spring and attached thereto.
[0009] The apparatus can further comprise means for preloading the piezoelectric material in compression. In which case, the apparatus can further comprise means for adjusting an amount of the preloading.
[0010] The apparatus can further comprise a housing having an internal cavity for containing the piezoelectric member and spring element in the internal cavity. The housing can comprises means for collapsing in a direction of the acceleration to limit an amount of movement of the spring member. The means for collapsing can comprise the housing being an additional spring member having a greater spring coefficient than the spring element. The means for collapsing can comprise the housing having a curved shape for facilitating collapse thereof where the acceleration is greater than a predetermined limit.
[0011] The apparatus can further comprise limiting means for limiting a loading on the piezoelectric member due to the impact. The limiting means can comprise sandwiching the piezoelectric member between the spring element and an intermediate member, wherein one of the spring element and intermediate member have a stop for contacting the other of the spring element and intermediate member where the acceleration reaches a predetermined limit. The limiting means can comprise an intermediate element having a tapered surface, wherein the spring element has an opposing tapered surface for mating with the tapered surface of the intermediate element where the acceleration reaches a predetermined limit. The limiting means can comprise the spring element having a flange for contacting a surface of an intermediate element where the acceleration reaches a predetermined limit. The intermediate element can have first and second surfaces and wherein the flange contacts the first surface where the acceleration reaches a predetermined limit and the flange contacts the second surface where a deceleration reaches another predetermined limit.
[0012] The spring element can comprise fist and second spring elements and the piezoelectric member can comprise first and second piezoelectric members corresponding to the first and second spring elements, respectively, wherein the acceleration causes a vibration in the first and second spring members in the direction of the acceleration to cause an reciprocating impact of the first and second piezoelectric members. In which case, the apparatus can further comprise a mass positioned between the first and second spring elements. The first spring element, second spring element and mass can be a single integral member.
[0013] Also provided in an apparatus for generating an electrical power upon an acceleration of the apparatus in which the apparatus comprises: a housing; a piezoelectric member positioned within the housing; a spring element disposed with the housing; and a mass configured to impact the piezoelectric material upon the acceleration. The mass can be a portion of the spring element.
[0014] Still provided is a method for generating an electrical power upon an acceleration of an apparatus. The method comprising: accelerating the apparatus; and impacting a piezoelectric material upon the acceleration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other features, aspects, and advantages of the apparatus and methods of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0016] FIG. 1 illustrates a schematic cross section of a power generator according to a first embodiment.
[0017] FIG. 2 illustrates a variation of the power generator of FIG. 1 .
[0018] FIG. 3 illustrates a schematic cross section of a power generator according to a second embodiment.
[0019] FIG. 4 illustrates a schematic cross section of a power generator according to a third embodiment.
[0020] FIG. 5 a illustrates a schematic cross section of a power generator according to a fourth embodiment.
[0021] FIG. 5 b illustrates a first variation of the power generator of FIG. 5 a.
[0022] FIG. 5 c illustrates a second variation of the power generator of FIG. 5 a.
[0023] FIG. 5 d illustrates a third variation of the power generator of FIG. 5 a.
[0024] FIG. 5 e illustrates a fourth variation of the power generator of FIG. 5 a.
[0025] FIG. 5 f illustrates a fifth variation of the power generator of FIG. 5 a.
[0026] FIG. 5 g illustrates a sixth variation of the power generator of FIG. 5 a.
[0027] FIG. 6 illustrates a schematic cross section of a power generator according to a fifth embodiment.
[0028] FIG. 7 illustrates a schematic cross section of a power generator according to a sixth embodiment.
[0029] FIG. 8 illustrates a schematic cross section of a power generator according to a seventh embodiment.
[0030] FIG. 9 illustrates a variation of the power generator of FIG. 8 .
[0031] FIG. 10 illustrates a variation of the power generator of FIG. 9 .
[0032] FIG. 11 illustrates a schematic cross section of a power generator according to a eighth embodiment.
[0033] FIG. 12 illustrates a variation of the power generator of FIG. 11 .
[0034] FIG. 13 illustrates a schematic cross section of a power generator according to a ninth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] In the methods and apparatus disclosed herein, the spring end of a mass-spring unit is attached to a housing (support) unit via one or more piezoelectric elements, which are positioned between the spring end of the mass-spring and the housing unit. A housing is intended to mean a support structure, which partially or fully encloses the mass-spring and piezoelectric elements. On the other hand, a support unit may be positioned interior to the mass-spring and/or the piezoelectric elements or be a frame structure that is positioned interior and/or exterior to the mass-spring and/or piezoelectric elements. The assembly is provided with the means to preload the piezoelectric element in compression such that during the operation of the power generation unit, tensile stressing of the piezoelectric element is substantially avoided. The entire assembly is in turn attached to the base structure (e.g., gun-fired munitions). When used in applications that subject the power generation unit to relatively high acceleration/deceleration levels, the spring of the mass-spring unit is allowed to elongate and/or compress only within a specified limit. Once the applied acceleration/deceleration has substantially ended, the mass-spring unit begins to vibrate, thereby applying a cyclic force to the piezoelectric element, which in turn is used to generate electrical energy. The housing structure or the base structure or both may be used to provide the limitation in the maximum elongation and/or compression of the spring of the mass-spring unit (i.e., the amplitude of vibration). Each housing unit may be used to house more than one mass-spring unit, each via at least one piezoelectric element.
[0036] In the following schematics of the various embodiments, the firing acceleration is considered to be upwards as indicated by arrow 113 .
[0037] In a first embodiment, power generator 100 includes a spring 105 , a mass 110 , an outer shell 108 , a piezoelectric (stacked and washer type) generator 101 , one socket head cap screw 104 and a stack of Belleville washers 103 (each of the washers 103 in the stack is shown schematically as a single line). Piezoelectric materials are well known in the art. Furthermore, any configuration of one or more of such materials can be used in the power generator 100 . Other fasteners, which may be fixed or removable, may be used and other means for applying a compressive or tensile load on the piezoelectric generator 101 may be used, such as a compression spring. The piezoelectric generator 101 is sandwiched between the outer shell 108 and an end 102 of the spring, and is held in compression by the Belleville washer stack 103 (i.e., preloaded in compression) and the socket head cap screw 104 . The mass 109 is attached (e.g., screwed, bonded using adhesives, press fitted, etc.) to another end 106 of the spring 105 . The piezoelectric element 101 is preferably supported by a relatively flat and rigid surface to achieve a relatively uniform distribution of force over the surface of the element. This might be aided by providing a very thin layer of hard epoxy or other similar type of adhesives on both contacting surfaces of the piezoelectric element. The housing 108 may be attached to the base 107 by the provided flange 111 using well known methods, or any other alternative method commonly used in the art such as screws or by threading the outer housing and screwing it to a tapped base hole, etc. The mass 109 is provided with an access hole 110 for tightening the screw 104 during assembly. Between the free end 106 of the spring and the base 107 (or if the mass 109 projects outside the end 106 of the spring, then between the mass 109 and the base 107 ) a gap 112 is provided to limit the maximum expansion of the spring 105 . Alternatively, the gap 112 may be provided by the housing 108 itself. The gap 112 also limits the maximum amplitude of vibration of the mass-spring unit.
[0038] During firing of a projectile (the base structure 107 ) containing such power generator 100 , the firing acceleration is considered to be in the direction 113 . The firing acceleration acts of the mass 109 (and the mass of the spring 105 ), generating a force in a direction opposite to the direction of the acceleration that tends to elongate the spring 105 until the end 106 of the spring (or the mass 109 if it is protruding from the end 106 of the spring) closes the gap 112 . For a given power generator 100 , the amount of gap 112 defines the maximum spring extension, thereby the maximum (tensile) force applied to the piezoelectric element 101 . As a result, the piezoelectric element is protected from being damaged by tensile loading. The gap 112 also defines the maximum level of firing acceleration that is going to be utilized by the power generator 100 .
[0039] In applications where high levels of acceleration (deceleration) are present in both directions (direction 113 and in its opposite direction), then similar stops may be provided to limit spring compression. This can be achieved by providing flanges on the end 106 of the spring 105 and stops to prevent compression of the spring element 105 over a predetermined limit, for example as shown in FIG. 2 . FIG. 2 shows a partial cross-section of the side of the power generator assembly that is connected to the base structure 107 , with the remaining part of the assembly being identical to that shown in FIG. 1 . A free end 122 of the spring unit (with or without the mass 121 ) is provided with a flange 127 . A flanged ring 123 is then positioned around the flange 127 before assembling the unit inside the housing 124 . Once attached to the base structure 107 , a housing lip 128 keeps the flanged ring 123 in contact with the base structure 127 , thereby limiting the motion of the free end 122 of the spring unit within the distances 125 and 126 , up and down, respectively.
[0040] When the firing acceleration has ended, i.e., after the projectile has exited the gun barrel, the mechanical (potential) energy stored in the elongated spring is available for conversion into electrical energy. In all the present power generators, this is accomplished by harvesting the varying voltage generated by the piezoelectric element 101 as the mass-spring element vibrates. The spring rate and the maximum allowed deflection determine the amount of mechanical energy that is stored in the spring 105 . The effective mass and spring rate of the mass-spring unit determine the frequency (natural frequency) with which the mass-spring element vibrates. By increasing (decreasing) the mass or by decreasing (increasing) the spring rate of the mass-spring unit, the frequency of vibration is decreased (increased). In general, by increasing the frequency of vibration, the mechanical energy stored in the spring 105 can be harvested at a faster rate. Thus, by selecting appropriate spring 105 , mass 109 and gap 112 , the amount of electrical energy that can be generated and the rate of electrical energy generation can be matched with the requirements of a projectile.
[0041] In FIG. 1 , the spring 105 is shown to be a helical spring. The preferred helical spring, however, has three or more equally spaced helical strands to minimize the sideways bending and twisting of the spring during vibration. In general, any other type of spring may be used as long as they provide for vibration in the direction of providing cyclic tensile-compressive loading of the piezoelectric element.
[0042] In a second embodiment, as shown in FIG. 3 , the power generator is very similar to that of the previous embodiment, with the difference being that the socket head cap screw 104 ( FIG. 1 ) is eliminated, and the preloading of the piezoelectric element 101 is achieved by means of a pin 116 , which is attached to or an integral part of a cap 115 . The cap 115 is connected to the housing 118 , for example by means of threads, potting, press fitting, flange or other methods known in the art. The cap 115 is in turn attached to the base structure using one of the means described in the previous embodiment. The gap 117 , which allows vibration of the mass-spring unit as described for the previous embodiment is provided between the free end 119 of the spring 105 and the cap 115 . In addition, the mass 109 is preferably eliminated and a required mass is added to the free end 119 of the spring by making it larger. Alternatively, and if it is allowed by the size of the power generator, the hole 110 in the mass 109 ( FIG. 1 ) is made large enough to accommodate the pin 116 . The hole 110 must obviously be large enough to allow vibration of the mass-spring unit without the interference of the pin 115 . This embodiment has the advantage of eliminating the possibility of failure of threads of the screw 104 as a result of high firing accelerations or fatigue during vibration, and the possibility that the screw loosening up as a result of acceleration and decelerations and vibration of the mass-spring unit.
[0043] In a third embodiment, as shown in FIG. 4 , the power generator is very similar to that of the first embodiment, with a difference being that the housing 131 is provided with a significant flexibility in the axial direction, i.e., along the length of the housing 131 . In FIG. 4 , the housing 131 is shown as a helical spring (preferably with three or more strands). However, any other housing design that provides the desired axial flexibility may also be used. By providing a housing that is flexible in the axial (parallel to the spring 105 ) direction, the electric power generator 130 has the ability to collapse in the axial direction due to the firing acceleration and limiting the stretching of the spring 105 . By making the housing spring 131 much stiffer than the spring 105 , the electric power generator 130 can still vibrate and generate electricity at lower acceleration levels and collapse and protect the spring 105 and the piezoelectric element at extremely high accelerations. In FIG. 4 , a washer 132 is shown to be positioned between the piezoelectric element and the housing 131 . Such washers are preferably bonded to one or both surfaces of the piezoelectric element 101 to better distribute load over its top and bottom surfaces.
[0044] In the embodiment shown in FIG. 4 , the housing 131 is providing the axial flexibility that is desired in the axial direction. Alternatively, the pin 116 ( FIG. 3 ) may be provided with the desired axial flexibility while keeping the housing 131 rigid.
[0045] In a fourth embodiment, as shown in FIG. 5 a , the housing shell or support (frame) structure 141 is designed to buckle when the firing acceleration increases beyond a certain predetermined range, thereby helping to provide added protection against damage to the piezoelectric and/or mass-spring and/or other elements of the power generation unit 140 . The housing shell or support structure 141 may be designed to be prone to buckling instability in any of the ways known in the art. In FIG. 5 a , the buckling instability of the power generator 140 is due to a bowed geometry in its housing shell or support structure 141 . At low accelerations and during vibration of the mass-spring unit, the instability will not be noticeable. However, if the acceleration exceeds a critical value, the housing shell (support structure) 141 will become unstable and buckle. The buckling of the housing shell or support structure 141 can be designed to provide protection for the mass-spring unit, piezoelectric element, assembly screw and other elements of the assembly from excessive loading. The buckling may be limited to its elastic range, in which case the housing shell or support structure returns to its original shape once the critical acceleration level has subsided. Alternatively, the housing shell or support structure could be designed to permanently deform during buckling. The housing shell or support structure could also be designed to achieve a combination of elastic and plastic deformation.
[0046] In either one of the above cases, the total amount of buckling deformation must be limited to prevent a total collapse of the housing shell or support structure during high acceleration (firing) periods and excessive loading of the piezoelectric and/or the mass-spring and/or the assembly screw or other elements of the assembly. In addition, the total amount of buckling deformation must be limited to prevent a total and permanent collapse of the housing shell or support structure, in order to allow the mass-spring unit to vibrate with the desired amplitude following the high acceleration period(s).
[0047] The means of limiting the maximum buckling deformation of the housing shell or support structure 141 may be an integral part of the housing shell or support structure as shown in FIG. 5 b . In the embodiment of FIG. 5 b , the housing shell or support structure is provided with pairs of axially positioned steps 142 (preferably three or more that are positioned symmetrically around the periphery of the housing shell or support structure) are used to limit the axial buckling of the housing shell or support structure 141 to the provided gap 143 . The steps 142 may be internal and/or external to the housing shell or support structure 141 . The steps 142 are preferably integral to the housing shell or the support structure.
[0048] Alternatively, the means of limiting the maximum buckling deformation of the housing shell or the support structure 141 may be provided by a space 148 between a head of the assembly screw 144 and a pin 145 attached to the base structure 107 as shown in FIG. 5 c (the pin may also be attached to the housing shell or the support structure base 141 , not shown).
[0049] Alternatively, the means of limiting the maximum buckling deformation of the housing shell or the support structure 141 may be provided by a space 149 between the head of the assembly screw 144 and the mass 147 (of the mass-spring unit) and the space 150 between the mass 147 and the base structure 107 as shown in FIG. 5 d (the space 150 may also be between the mass 147 and the base of the housing shell or the support structure 141 , not shown).
[0050] Alternatively, the means of limiting the maximum buckling deformation of the housing shell or the support structure 141 may be provided by a space 152 between the head of an assembly screw 151 and the base structure 107 as shown in FIG. 5 e (the space 152 may also be between the head of an assembly screw 151 and the base of the housing shell or the support structure 141 , not shown).
[0051] Alternatively, the means of limiting the maximum buckling deformation of the housing shell or the support structure 141 may be provided by a space 153 between a cylindrical sleeve 154 and the base structure 107 as shown in FIG. 5 f (the space 153 may also be between the sleeve 153 and the base of the housing shell or the support structure 141 , not shown). In FIG. 5 f , the sleeve 154 is shown to be press fitted into the top portion of the housing shell or support structure 141 . Alternatively, the sleeve 154 may be press fitted to the bottom portion of the housing shell or support structure 141 or even be loosely assembled inside of the housing shell or support structure 141 .
[0052] Alternatively, the sleeve 154 may be positioned exterior to a housing shell or support structure 155 that has a top flange 156 as shown in FIG. 5 g , and limit its maximum buckling by either the space 157 between the flange 156 and the sleeve 154 or by limiting the outward radial expansion of the housing shell or support structure 155 .
[0053] In the FIGS. 5 a - 5 g , the buckling under high (firing) acceleration is shown to be in the housing shell or the support structure (columns of a support structure frame) in the axial direction. However, the buckling may be designed to occur in other modes, and in other elements of the structure of the power generation assembly. For example, the pin 116 of the embodiment shown in FIG. 3 may be designed to buckle in the elastic range to reduce the peak loading of the piezoelectric element 101 during peak acceleration period(s), and return to essentially its original shape and position to allow unhindered operation of the power generator.
[0054] In other apparatus and methods disclosed herein, a mass-spring unit is attached directly or via an intermediate element to the base structure. A piezoelectric element is positioned between the spring of the mass-spring unit and the base structure or between the mass-spring unit and an intermediate element. The means of attaching the spring of the mass-spring unit to the base structure (or the aforementioned intermediate element) is preferably provided with the means to preload the piezoelectric element in compression so that during the vibration of the mass-spring unit, the piezoelectric element is not subjected to tensile loading. When an intermediate element is present, it may be attached directly to the base structure by any one of the methods commonly used in the art, e.g., by constructing the intermediate element as a cylinder and threading it and the base structure; or by using screws or bonding using various methods known in the art, including adhesives; by providing a flange on the intermediate element and then attaching the flange to the base structure using methods known in the art, including the use of clamps; etc.
[0055] An advantage of this method is that it leads to designs that are very simple and easy to manufacture, assemble and mount on the base structure. However, a disadvantage of this method is that during acceleration of the base structure (in the axial direction), the force generated by the entire mass of the mass-spring unit, the attachment means (e.g., screw), the preloading means (e.g., Belleville washers), etc., act directly on the piezoelectric element. As a result, the piezoelectric element has to be designed to resist the maximum possible (shock) loads, thereby leading to a power generator that is difficult to be optimally designed for the actual (working) acceleration levels of the base structure and produce the maximum possible power for a specified (available) power generator volume. This shortcoming of the present method can, however, be substantially overcome using a number of modifications that are described in the following embodiments.
[0056] A schematic of the fifth embodiment 160 is shown in FIG. 6 . The unit 160 primarily consists of a spring 161 , preferably made of 3 or more helices to minimize bending and other rotations and lateral displacement during vibration; mass 162 , which may have a top piece 163 to prevent it from traveling into the spring element 161 , and noting that the free (top) portion 168 of the spring 161 may partly or wholly constitute the mass 162 and 163 ; and a piezoelectric element 165 . The mass 168 is preferably press fitted and/or potted into the open end of the spring 161 . A screw 167 is used to attach the spring 161 to an intermediate element 166 , with the piezoelectric element 165 being positioned between the two. One or more stacks of Belleville washers 164 are positioned between the screw head and the spring 161 to provide the required preloading force on the piezoelectric element 165 . The preloading load is adjusted by adjusting the tightness of the screw 167 . The intermediate element 166 may then be attached to the base structure 107 using any one of the aforementioned means, including by a longer assembly screw 167 that taps into the base 107 .
[0057] In an alternative embodiment of the electrical power generator 160 , the intermediate element 166 can be eliminated and the piezoelectric element can be attached directly to the base structure 107 .
[0058] The embodiment 160 provides a very simple design, which, however, does not offer any protection for the piezoelectric 165 against excessive high accelerations of the base structure. The spring 161 is preferably designed such that during firing it is compressed until it reaches its solid height, which indicates the total potential energy that is stored in the spring 161 . Once the firing (high) acceleration period has ended, the spring-mass unit is free to oscillate. Meanwhile the mechanical energy stored in the spring element 161 can be converted into electrical energy by the piezoelectric element.
[0059] In yet other methods and apparatus disclosed herein, a mechanical mechanism is provided to limit the deformation of the spring element of the mass-spring units in compression, tension or both tension and compression. The purpose of such spring deformation limiting mechanisms is to limit the compressive and/or the tensile loading applied to the piezoelectric elements and also prevent overloading of the spring element when the base acceleration and/or deceleration passes certain limits. The embodiments of this method are otherwise similar to those presented for the fifth embodiment.
[0060] A sixth embodiment, generally referred to by reference numeral 170 , is shown in FIG. 7 . The power generator 170 of the sixth embodiment is very similar to the previous embodiment 160 , with the addition of a protective stop 172 located around a base of the spring 171 . The stop 172 is designed to bottom out against the intermediate element 174 , closing the gap 173 , if the vertical acceleration of the base structure 107 exceeds a specified level. As a result, by proper selection of the amount of the gap 173 , the piezoelectric element 175 is protected from overloading in compression. The gap 173 must still be large enough to allow the piezoelectric generator 175 to deform during the oscillations of the spring 171 .
[0061] For a realistic thickness of the piezoelectric stack 175 , for example for heights of around 5 mm, the gap 173 needs to be less than 10 microns, depending on the level of the working acceleration, which requires precision manufacture of the spring element or employment of a simplifying manufacturing/assembly technique. As an example, the gap 173 may be made larger than required without requiring high precision, then during the assembly, the gap 173 is filled with hard epoxy, while taking steps to allow the epoxy to bond to only one of the surfaces of the gap 173 . The unit is then loaded in compression to the desired compression limit of the piezoelectric element and the epoxy is allowed to cure. This assembly procedure ensures that the desired gap height is achieved.
[0062] A seventh embodiment is similar to the embodiment of FIG. 7 , with the difference being in the method of stopping the spring element against the intermediate element. The schematic of such an embodiment 180 is shown in FIG. 8 . The spring element 183 is made with a tapered outer diameter, while the intermediate element 181 is provided with a matching tapered surface 182 . As the base structure 107 accelerates upward, e.g., during firing by a gun, the spring 183 begins to compress, until it comes to rest against the tapered surface 182 of the intermediate element 181 when a specified acceleration level is reached. If the acceleration of the base structure exceeds the specified level, the contacting tapered surfaces prevent overloading of the piezoelectric element 186 , and also protects the spring element 183 from excessive deformation axially and in other modes such as bending or lateral displacement, thereby protecting it from failure. Similar to the previous embodiments, the spring element 183 is attached to the intermediate element 181 with the screw 187 and with the Belleville washers 188 to provide the means to preload the piezoelectric element for its protection from tensile loading during vibration of the mass-spring unit. The intermediate element 181 is in turn attached to the base structure 107 using one of the means previously described. This embodiment therefore provides protection against over-stressing of both the spring element 183 and the piezoelectric element 186 .
[0063] In a variation of the seventh embodiment, the spring element 183 is also provided with a top flange 184 . In the absence of the acceleration of the base structure 107 , a gap 189 is provided between the flange 184 and a top surface 185 of the intermediate element 181 . When the acceleration of the base structure 107 reaches a certain specified level, the spring 183 is compressed enough to close the gap 189 , thereby preventing the top flange 184 of the spring element to move down any further. As a result, the maximum compressive load of the piezoelectric element 186 can be limited, thereby providing the means to protect it from failure.
[0064] In another alternative of the seventh embodiment, no taper is provided on either the spring element 183 or the intermediate element 181 . The spring element is provided with the flange 184 , FIG. 8 , which comes to a stop against the top 185 of the intermediate element 181 at a specified level of the acceleration of the base structure 107 , thereby providing protection for both the piezoelectric element 186 and the spring 183 .
[0065] In another alternative of the seventh embodiment, the spring flange 184 can be positioned along the length of the spring. Such an embodiment 190 is shown in FIG. 9 . The intermediate element 191 of this embodiment is shown to have an internal groove 192 , in which the flange 194 of the spring element 193 is positioned. The flange 194 may be an integral part of the spring 193 , in which case to make the unit assembly possible, either the intermediate element has to be made out of two parts with a common surface at the groove 192 (the two parts, longitudinal or transverse, have to be then joined using any one of the methods known in the art); or the flange 194 may be a retaining ring, which is assembled in a groove (not shown) in the spring 193 . The spring element 193 is then attached to the intermediate element 191 by a screw 196 as shown for the previous embodiments, with the piezoelectric element 195 positioned between the two as shown in FIG. 9 . Preloading Belleville washers (not shown) are preferably used with the screw 196 as shown in FIG. 8 . As can be appreciated, the total axial compressive and tensile deformation of the spring is thereby protected at high accelerations and decelerations of the base structure 107 . The total amount of compressive and tensile deformation of the spring is determined by the gaps 198 and 197 , respectively, between the lower and upper surfaces of the flange 194 and the lower and upper surfaces of the groove 192 . The piezoelectric element 195 and the spring element 193 are thereby protected from overloading due to high levels of base structure acceleration and deceleration.
[0066] In a variation of the embodiment shown in FIG. 10 , the spring element 203 has a flange 204 at its free (upper) end. The intermediate element 201 is the provided with a counter bore 202 , in which the flange 204 is positioned in the assembled unit 200 . A cap 205 is then fixed to the top of the intermediate element 201 , for example by screws 206 (shown schematically by dashed lines). The remaining elements of this embodiment are the same as those of the embodiments shown in FIGS. 8-9 . The flange 204 , thereby, protects both the piezoelectric element and the spring element 203 as was described for the previous embodiment.
[0067] In the embodiments shown in the FIGS. 8-10 , the spring deformation limiting taper surfaces and spring flanges are positioned external to the spring element. Alternatively, the taper surfaces and/or flanges may be positioned internal to the spring, with the mating taper surfaces and/or flange accommodating grooves positioned on an internal pin (such as a pin similar to the pin 151 in the embodiment of FIG. 5 e , with an external taper surface and/or groove used in place of the screws 187 or 196 in the embodiments of FIGS. 8-10 ).
[0068] In the embodiments shown in FIGS. 9 and 10 , the spring deformation limiting flanges are provided on the spring elements and the mating grooves are provided on the intermediate elements. Alternatively, the flanges may be provided on the intermediate elements and the mating grooves on the spring elements.
[0069] In all the above embodiments of this method, one part of the spring deformation limiting mechanism (for example a groove or its mating flange, or one of the tapered mating surfaces) is provided on the intermediate element, which is in turn fixedly attached to the base structure. It is, therefore, possible for the intermediate element to be an integral part of the base structure.
[0070] In still yet further apparatus and methods disclosed herein, double spring-mass (mass positioned in between two springs) unit(s) are packaged such that: (a) there is no need for separate preloading elements; (b) the internal attachment screws or the like are eliminated; (c) fewer internal components are needed; and (d) the assembly process is greatly simplified and the need for a preload adjustment step is eliminated. The electric power generators using this method can be constructed with three basic parts; a double spring and mass unit, which can be constructed as a single integral unit; piezoelectric generator(s); and an outer (or inner) support structure, which may be in the form of a shell housing. In this method, the mass-spring unit is compressed and positioned within a gap provided with a relatively rigid housing shell or support structure. Piezoelectric elements are positioned between at least one of the springs and the gap surfaces. The unit is then attached to the base structure using one of the methods described for the previous embodiments.
[0071] A schematic of an eighth embodiment 210 is shown in FIG. 11 . It comprises a mass 212 , which is positioned between two springs 213 and 214 . In FIG. 11 , the mass 212 and the two springs 213 , 214 are constructed as a single unit, however, they may also be individual components. The mass-spring unit is then positioned inside a relatively rigid shell housing 211 . Piezoelectric elements 215 are placed between each spring 213 , 214 and the housing on one or both ends. In the embodiment shown in FIG. 11 , the opening through which the mass and spring unit and the piezoelectric elements 215 are entered into the housing shell 211 is positioned on a side of the housing shell 211 . Alternatively, all internal elements may be entered from a top or bottom opening, and then sealed by a cap. When the loading opening is on the bottom of the housing, which is directly attached to the base structure 107 , no cap may be required.
[0072] The mass 212 or the spring elements 213 and/or 214 (preferably only one of the two) can be provided with a flange similar to the flange 194 in FIG. 9 , and the housing shell can be provided with a mating groove 192 (alternatively, the position of the flange and the mating groove may be exchanged). As a result, the total deformation of the springs, thereby the compressive and tensile force exerted on the piezoelectric element(s) is limited. This provides protection for both piezoelectrics 215 and the spring elements 213 , 214 when the acceleration or deceleration of the base structure 107 exceeds the specified amount.
[0073] The spring 213 and/or spring 214 can be provided with outside taper and mating taper surfaces on the inner surfaces of the housing shell, both similar to that shown in FIG. 8 . As a result, the compressive and/or tensile deformation of the springs 213 and 214 is/are limited. This provides protection for both piezoelectric 215 and the spring elements 213 , 214 when the acceleration or deceleration of the base structure 107 exceeds the specified amount.
[0074] Instead of an exterior shell housing or support structure, an interior structure can be used to keep the distance between the top surface of the interior assembly (top surface of the spring or the piezoelectric element, if any) and the bottom surface of the interior assembly (bottom surface of the spring or the piezoelectric element, if any) relatively constant.
[0075] The schematics of a typical such embodiment 220 is shown in FIG. 12 . The support structure is shown as a cylinder 221 , with top 222 and bottom 223 ends (one of the ends 222 or 223 , alone or with certain portion of the cylinder 221 , is a separate piece and is fastened to the main piece to allow assembly). Two springs 224 and 225 , with a mass 226 that is positioned between the two springs are assembled as shown around the interior cylinder 221 . The mass and the two springs are preferably constructed as a one integral piece. Piezoelectric elements 227 are positioned on at least one side of the mass and spring unit. The spring is preferably preloaded to prevent the piezoelectric element(s) from being loaded with a considerable tensile loading to prevent its failure.
[0076] In the above embodiments, the springs are preloaded to prevent excessive loading of the piezoelectric elements in tension. Alternatively, by providing little or no preloading, and by firmly attaching the piezoelectric element(s) to the housing shell, the spring is allowed to bounce back and forth inside the housing shell cavity. The advantage of such a design is that the piezoelectric elements are never subject to tensile loads, which can easily fracture such brittle materials. However, the resulting impact loading can cause problems. In addition, the impulsive loading of the piezoelectric element(s) result in high but short duration charges that has to be harvested rather quickly, which can be difficult to accomplish efficiently.
[0077] In still yet other apparatus and methods disclosed herein, the piezoelectric based power generators are constructed with two modular units. The first module is a mass-spring unit and the second module is a packaged preloaded and high acceleration and shock resistant piezoelectric unit. The two modules are then connected to each other by a screw or by using any one of the methods known in the art.
[0078] The spring of the mass-spring unit is preferably designed such that it could compress essentially elastically to a solid length, thereby providing a means of protecting the spring from failure in compression. When necessary, relatively solid stops (provided by a housing shell or internal or external support structure) are preferably provided to limit tensile deformation (elongation) of the spring, thereby providing a means of protecting the spring from failure in tension. As a result, the spring of the mass-spring unit can readily be protected from excessive acceleration and/or deceleration of the base structure.
[0079] The piezoelectric unit (module) comprises a housing or support structure, within which the piezoelectric element is assembled with two sets of preloading springs (preferably of Belleville washer type), separated by a relatively solid separating element, to which the spring-mass module is attached. The piezoelectric element is positioned between the base of the housing and one of the two sets of preloading springs, opposite to the separating element.
[0080] By assembling mass-spring units with various equivalent masses and spring rates with various piezoelectric unit modules with appropriate preloads and piezoelectric elements, a wide range of power generator units that can operate in various acceleration/deceleration and shock loading environment and various power generation requirements can be constructed. When subjected to higher than operating base structure accelerations, the spring of the mass-spring can be made to come in contact with the piezoelectric unit housing or support structure, thereby preventing the piezoelectric from damage. When subjected to higher than operating base structure deceleration, the mass-spring unit pulls the aforementioned separating element away until it is stopped by the housing element. By having provided enough of a preloading force and by matching the deformation of the preloading springs to the allowed displacement of the separating element, the preloading spring stays in contact with the piezoelectric element at all times, thereby preventing any impact loading of the piezoelectric element during subsequent acceleration (or significant reduction in the deceleration level) of the base structure.
[0081] A schematic of a ninth embodiment 230 is shown in FIG. 13 , and comprises the mass-spring module 231 and a piezoelectric assembly module 232 . In the schematic of FIG. 13 , the mass of the mass-spring module is incorporated into the mass of the spring element 233 . However, additional mass may also be added (preferably to the free end) of the spring element 233 to vary (decrease) the natural frequency of the mass-spring module 231 . The two modules ( 231 and 232 ) are attached together by the screw 234 . The two modules may be attached together in numerous ways known in the art. For example, a stem may be provided on the attaching side of the spring, which can then be press fit into a provided hole in the attachment element 235 , or the stem may be threaded and screwed in a tap provided in the element 235 , instead of the screw 234 .
[0082] The piezoelectric assembly module 232 consists of a housing 236 , at the bottom of which the piezoelectric 242 (preferably stack) element is positioned (preferably adhered by a relatively hard epoxy or other similar material to help to distribute the load more uniformly on the piezoelectric element surface at its interface with the housing 236 ). A washer 241 is positioned (preferably similarly adhered) to the piezoelectric element 242 . The separating element (plunger) 238 with at least one preloading (preferably of Belleville washer type) springs 239 and 240 , above and below its flange 238 , respectively, is positioned above the piezoelectric washer 241 . The preloading springs 239 are held in place by the retaining ring 237 . To prevent the retaining ring 237 from being dislodged during impact loading or high acceleration/deceleration of the base structure, a sleeve (not shown) may be placed on the piston 235 , between the piston 235 and the retaining ring (with a slight clearance between the sleeve and the retaining ring).
[0083] In the piezoelectric module 232 shown in FIG. 13 , the preloading assembly is held in place by the retaining ring 237 . Alternatively, the retaining ring may be integral to the housing 236 , i.e., a step may have been provided to seat the preloading springs 239 . The piezoelectric module is then assembled from the bottom (constructed open) end and is then capped following the assembly.
[0084] In another alternative, at least one side of the housing 236 is open and the parts are assembled from this open side of the housing.
[0085] The piston 235 is designed to be long enough (alternatively, the spring 233 may have been constructed with an appropriate shoulder or a space may be used) to provide the gap 243 between the spring 233 and the top surface of the housing 236 . During acceleration of the base structure 107 , once a specified design acceleration limit is reached, the gap 243 is closed, thereby preventing further loading of the piezoelectric element 242 . During deceleration of the base structure 107 , once a specified design acceleration limit is reached, the gap 245 between the top surface of the spring 233 and the outer shell or frame 244 (which together with the housing 236 is fixed to the base structure using one of the aforementioned methods), is closed, thereby preventing further elongation of the spring 233 and its damage. Meanwhile, the piston 235 is pulled away from the piezoelectric element until the preloading springs 239 are have reached their near rigid (compressed) length, thereby preventing further movement of the piston. As a result, the piezoelectric element is protected from tensile loading.
[0086] In an alternative embodiment, the spring 233 may be protected from excessive levels of deceleration by elongating the head of the screw 234 past the top of the spring 233 , and providing it with a head with the gap 245 with the top surface of the spring to act as a stop against excessive elongation of the spring.
[0087] Other variations of the embodiments disclosed above are also possible. For example, in all cases, the housing may be integral to the structure of the base structure (projectile); the housing may be a structure to support the generated loads or may encapsulate most or all the components of the generator and may even be hermetically sealed; the mode of vibration may be essentially axial, in torsion, in bending or in any of their combination; the piezoelectric element(s) may be of any shape and geometry and may or may not be of stacked construction (however, by using a stacked piezoelectric element, a lower voltage level but larger current can be achieved); the electrical characteristics of the piezoelectric element are also desired to be selected such that it allows efficient transfer of electrical energy to collection circuitry (such collection circuitry being well known in the art and not shown herein) which can mean that the impedance of the piezoelectric element is matched with the collecting circuitry to maximize the rate of energy transfer, e.g., to the storage capacitors; the taper and flange stops shown in FIGS. 8-10 may also be incorporated into any of the other embodiments; in all cases, the spring element may be designed to elastically (or partly elastically and partly plastically) collapse to its solid length in compression, thereby being protected from higher acceleration/deceleration that produces spring elongation.
[0088] While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims. | An apparatus for generating an electrical power upon an acceleration of the apparatus is provided. The apparatus includes: a piezoelectric member having at least a portion thereof formed of a piezoelectric material for generating an output power upon an impact; and a spring element configured to have at least one of a portion thereof and a portion attached thereto impact the piezoelectric material upon the acceleration. | 5 |
FIELD OF THE INVENTION
The present invention relates to decreasing frictional wear and degradation in products, typically orthopaedic implants, in which components made from ultra-high molecular weight polyethylene (UHMWPE) come into frictional contact with components, e.g., made of a metal alloy, such as cobalt-chromium.
BACKGROUND OF THE INVENTION
The replacement of destroyed or damaged human joints is one of the great achievements of twentieth century orthopaedic surgery. However, total joint prostheses, composed of various combinations of metal, ceramic, and polymeric components, continue to suffer from distressingly limited service lives. For example, the current generation of high-load bearing prostheses for the hip and knee have a typical lifetime on the order of 6-12 years. Generally, failed implants can be replaced once or twice, which means that current technology provides a solution for--at most--about 25 years.
With human life expectancies steadily increasing, there is a driving need to increase significantly the effective lifetime of a single implant. One of the problems encountered in designing such prostheses is the difficulty of finding materials which are both biocompatible and also durable enough to replace a human joint. In use, a human joint is exposed to substantial, repetitive loads and frictional stresses.
Although the geometric details may vary, a natural human hip, knee, or shoulder joint generally includes: (a) a more-or-less spherical ball; (b) an attachment to a long bone; and, (c) a hemispherical socket (the "acetabular cup") in a contiguous bony structure which retains the spherical ball so that the long bone may pivot and articulate. In a healthy joint, nature minimizes the friction between the joint components and prevents bone-on-bone wear and destruction by using mating porous cartilaginous layers that provide "squeeze-film" synovial fluid lubrication. This lubrication results in a low coefficient of friction on the order of 0.02.
When a human joint has been destroyed or damaged by disease or injury, surgical replacement (arthroplasty) normally is required. A total joint replacement includes components that simulate a natural human joint, typically: (a) a more-or-less spherical ceramic or metal ball, often made of cobalt-chromium alloy; (b) attached to a "stem," which generally is implanted into the core of the adjacent long bone; and (c) a hemispherical socket which takes the place of the acetabular cup and retains the spherical ball. This hemispherical socket typically is a metal cup affixed into the joint socket by mechanical attachments and "lined" with UHMWPE so that the ball can rotate within the socket, and so that the stem, via the ball, can pivot and articulate.
One of the difficulties in constructing any device for implantation into the human body is the need to avoid an adverse immune response. The possibility of an adverse immune response is reduced when certain synthetic materials are used. Cobalt-chromium alloy, titanium, and UHMWPE are examples of such synthetic materials. Unfortunately, the use of UHMWPE in the bearing of a total joint replacement may be the cause of at least one type of failure of such devices.
Three basic problems may cause a total joint replacement to fail or to have a limited service life. The first problem, which manifests itself at the bone-stem interface, is not the focus of the present application. Because the elastic modulus of the stem greatly exceeds that of the bone, flexural loading caused by walking creates local cyclic stress concentrations due to the non-compliance of the stem. These stresses can be intense and even severe enough to cause death of local bone cells. If this occurs, pockets of non-support are created, and the stem may loosen or fail.
The two other basic problems, which are coupled, are the subject of the present application. One of these problems, known as ball-cup friction and wear, results from frictional wear between the hemispherical bearing (which is "lined" with UHMWPE) and the polished spherical ceramic or metal ball attached to the stem. The other problem, known as sub-surface fatigue, results from brittleness of the UHMWPE bearing and the resulting tendency of the UHMWPE bearing to fail under reciprocating applied loads.
For many years, the acetabular cup in joint implants has been "lined" with UHMWPE, or other materials, in order to decrease the coefficient of friction of the socket or bearing. Unfortunately, clinical experience has shown that, at least when UHMWPE is used to line the bearing, either the surface of the UHMWPE "bearing" and/or the surface of the metal/ceramic ball ultimately is destroyed by friction-induced wear. Alternately, the acetabular cup loosens after a period of use, greatly increasing ball-cup friction and wear.
Some insight into the cause of failure due to ball-cup friction and wear has been gleaned from histological studies of the surrounding tissue. These histological studies show that the surrounding distressed tissue typically contains extremely small particles of UHMWPE which range from sub-micrometers to a few micrometers in size. Larger particles of UHMWPE appear to be tolerated by the body, as is the solid bulk of the UHMWPE bearing. However, the body apparently does not tolerate smaller particles of UHMWPE. In fact, these small particles of UHMWPE cause powerful histiocytic reactions by which the body unsuccessfully attempts to eliminate the foreign material. Agents released in this process attack the neighboring bone to cause "wear debris-induced osteolysis" which, in turn, leads to a loss of fixation and loosening of the prosthesis due to "remodeling" of the bone.
The first step in the generation of the small particles of UHMWPE appears to be the formation of a very thin layer of polyethylene between the spherical ball and the UHMWPE lining of the bearing. This thin film of polyethylene adheres to the "ball" and serves as a soft, shearable, solid lubricant composed of millions of submicrometer particles. Adhesive wear between the ball and the bearing produces strong, adhesive junctions on the ball. When exposed to further friction, fibrils of the polymer shear off of these adhesive junctions and are drawn into slender connecting ligaments, eventually producing ligament rupture.
This ligament rupture apparently produces the lubricous, extremely small particles of UHMWPE which eventually migrate to the bone-acetabular cup bond line. The reason for migration of these particles into the "crevice" between the ball and the cup are the microcurrents that are generated in the synovial fluid by joint motion. Once a sufficient number of small particles enter the bone-cup crevice, the bone tissue begins to degrade and the joint replacement eventually loosens and fails.
One way to reduce friction between the metal and UHMWPE components would be to coat one or both of the components with diamond-like carbon (DLC), which is chemically inert, biocompatible, and is known to have a low coefficient of friction. Unfortunately, the very properties of DLC that make it a desirable coating for parts that will be frictionally engaged make it difficult to achieve strong adhesion of the DLC coating to the substrate, particularly where deposition temperatures must be low. This limited adhesion problem can be exacerbated by very high compressive stress, such as that found in a plasma-deposited DLC (up to 8 GPa). Therefore, some have concluded that DLC--or at least plasma-deposited DLC--cannot be used in orthopaedic applications.
Energetic ion beam-associated DLC has a far lower residual stress than plasma-deposited DLC, and is a better candidate for a high integrity DLC. The substrate material to which all forms of carbon adhere most successfully is silicon. This is because strong covalent Si--C bonds are easily formed between the coating and the silicon substrate. Some have attempted to improve the adhesion of DLC to other materials, such as metal alloys, by forming an interposed silicon bond-coat to which the DLC will adhere more strongly.
Unfortunately, this simple approach does not result in adhesion that survives in applications, such as orthopaedic applications, where the DLC coating is subjected to substantial friction and stress. The simple formation of a silicon bond-coat on a metal alloy appears to create another relatively weak interface between the silicon and the metal or alloy.
Therefore a method is needed by which a DLC coating can be strongly adhered to a metal surface, and by which the shearing of polymer fibrils from an UHMWPE component can be prevented. The method would be most efficient if it rendered the UHMWPE compound less brittle so that sub-surface fatigue failure was reduced.
FIGURES
FIG. 1 is a diagrammatic representation of a mixed prospective and cross sectional side view of the wear test machine used in the following experiments.
FIG. 2 is a chart of the number of wear cycles against the volume (mm 3 ) lost during those cycles.
SUMMARY OF THE INVENTION
The present invention provides a method for modifying the surfaces involved, typically a metal alloy spherical ball and an UHMWPE bearing, to reduce: (1) frictional wear between such surfaces; (2) shearing of fibrils from the UHMWPE bearing; and (3) sub-surface fatigue in the UHMWPE component. The method involves solvent immersion of the UHMWPE component to remove short chains of polyethylene at or near the surface of the component, and to swell and strengthen the subsurface of the component. The method also involves treating the metal alloy spherical ball to create a metal-silicide interface which permits firmer adhesion of DLC and thereby reduces the coefficient of friction of said surface. Although the methods of the present invention are particularly useful in orthopaedic applications, the methods also can be used to treat similar components used in other applications.
DETAILED DESCRIPTION OF THE INVENTION
The present invention has two aspects. The first aspect is solvent immersion treatment of the UHMWPE component. The second aspect is a method for creating strong adhesion of the DLC coating to the spherical ball.
Solvent Immersion of UHMWPE Component
Solvent immersion according to the present invention may be used to treat any UHMWPE component that will be exposed to friction during use in order to increase the life of such a component. Solvent immersion particularly is useful in connection with medical devices, and most particularly with medical devices such as total joint replacements, which contain UHMWPE bearings that will be exposed to friction during use.
Methods of manufacturing components made of UHMWPE are known. The process of the present invention preferably is performed after the component has been formed, but before insertion into an end product, such as the metal cup of a total joint prosthesis. The apparatus used to immerse the UHMWPE component is not critical to the present invention. For example, if desired, the UHMWPE component may be immersed in the solvent using a simple hand-held instrument.
A preferred solvent for immersion according to the present invention is decahydronaphthalene (C 10 H 18 , anhydrous), also known as Decalin™. However, other organic solvents which are capable of dissolving short chain polyethylenes and of swelling the microstructure of the component also may be used. Such solvents include aromatic hydrocarbons, such as benzene, toluene, xylene, and o-dichlorobenzene; other alicyclic hydrocarbons, such as cyclohexane and tetrahydronaphthalene, also known as Tetralin™; and, aliphatic hydrocarbons such as n-paraffin, isoparaffin, and mixtures thereof.
The solvent chosen should be placed in an appropriate container for immersion of the UHMWPE component under controlled conditions of time and temperature. The solvent should be heated to a temperature that will maximize the dissolution of short polyethylene chains, typically between about 30°-100° C. A temperature of between about 30°-50° C. is preferred because temperatures above about 50° C. result in excessive swelling of the polymer. Once a stable solvent temperature has been reached, the UHMWPE component should be immersed and retained in the solvent for a period sufficient to dissolve any short chain polyethylenes and to swell the microstructure of the component. This typically should require about 30-180 seconds, preferably about 30 seconds. The time of immersion generally should decrease as the temperature of the solvent is increased.
After the UHMWPE component has been immersed in the solvent for an appropriate period of time, the component should be removed from the solvent and allowed to dry. A "naked" UHMWPE component generally should be dried for about 24 hours at room temperature. The conditions under which the UHMWPE component is dried are not critical; however, if the UHMWPE component has areas that are difficult to dry, some relatively mild form of heat or air flow may be helpful to dry the component.
After the UHMWPE component has been dried, the UHMWPE component should be placed in a standard vacuum chamber and exposed to a vacuum of between about 10 -1 -10 -5 torr, preferably about 10 -3 torr, for a time sufficient to remove residual solvent, preferably at least 8 hours. Thereafter, the UHMWPE component is ready for assembly into an end product and/or for any further treatment(s) that may be required before use, e.g., sterilization.
DLC COATING OF METAL COMPONENT
The method for treating a metal alloy to provide a diamond-like coating (DLC) uses ion beam assisted deposition of silicon, followed by deposition of DLC. This method is believed to form strong interatomic bonds across the DLC coating-substrate interface. In order to knit the successive layers of metal-silicon-DLC together effectively, it is necessary to supply a bond-interface for the metal-silicon bond as well as for the silicon-DLC bond. Without limiting the present invention, it is believed that the present method achieves this result by forming strong interatomic bonds having a character that is intermediate between the type of bond that exists between the atoms in the metal and the type of bonds in the silicon. Preferably, a metal substrate is used that forms a strongly-cohesive silicide--that is, an intermetallic compound in which the bonding is partially metallic and partially covalent. Metal substrates that form strongly-cohesive silicides include cobalt, nickel, titanium, zirconium, chromium, molybdenum, tungsten, platinum, and palladium.
After conventional cleaning of the component to remove superficial contaminants, such as grease, the component is placed in a vacuum chamber that has been evacuated to a base pressure of preferably less than 10 -5 torr. The component then is bombarded with ions, preferably argon ions, at an energy range between about 10-100 keV, preferably around 10 keV. This ion bombardment provides an effective means to remove some of the remaining adsorbed atoms from the surface.
The component is heated, preferably to a temperature of about 300° C., or, if the material is temperature sensitive, to the highest temperature acceptable for that material. Silicon then is deposited onto the component using known means. A preferable means is to position the workpiece directly over the volatilization hearth which is maintained at a preferred temperature of about 750° C. (1382° F.), until a preferred coating thickness of between 100-200 nm has been achieved. The thickness of the coating may be monitored by standard methods, e.g., using the frequency charge of a quartz crystal oscillator.
The component preferably is simultaneously bombarded with an energetic beam of ions, preferably argon ions, at an energy range between 500 eV to 100 keV, preferably between 10-20 keV, in order to form a layer of metal silicide at the metal-silicon interface. Although argon ions are preferred, other suitable ions may be used, such as nitrogen, argon, hydrogen, silicon, methane, helium, or neon, having an energy between 500 eV to 100 keV, preferably 10-30 keV. The ion-to-atom ratio should be sufficient, preferably at least 1 ion to 10 silicon atoms, to form a layer of metal silicide at the metal-silicon interface.
Thereafter, the component is cooled to about 80° C., preferably without removing the component from the vacuum chamber, and the diamond-like carbon (DLC) is deposited, preferably using energetic ion beam deposition techniques. The DLC preferably should be deposited by vaporizing a precursor, such as polyphenyl ether, and condensing the precursor onto the surface of the component using known means. At the same time, the component should be bombarded, either in a continuous or interrupted fashion, with an energetic beam of ions. Preferable ions are nitrogen, argon, hydrogen, silicon, methane, helium, or neon, having an energy between 500 eV to 100 keV, preferably 10-30 keV. The procedure is continued until a thickness of DLC between about 100 nm-10 microns is achieved.
EXAMPLES
GENERAL EXPERIMENTAL PROCEDURES
Wear Test Machine
The wear test machine used in the following examples provided a versatile means for material wear testing. The machine, which is shown in FIG. 1, was capable of applying user defined load profiles in a temperature controlled environment. Briefly, the wear test machine included a reciprocating table 10 controlled by a drive 11. On the reciprocating table 10 was a water bath 12 which held the plate 14 to be tested. A pin 16, described more fully below, was retained stationary adjacent to or abutting the plate 14 or sample to be tested. The movement and weight exerted on the plate 14 by the pin 16 was controlled by a force transducer 18 and a dead weight 20, as described more fully below.
Reciprocating Motion
Linear reciprocating motion was accomplished by means of the DC servo motor drive 11 (configured in velocity mode) directly coupled to a ball screw driven rail table 10. Stroke length was determined by two magnetic control switches mounted on the front of the machine. A trapezoidal velocity profile was sent to the motor as a voltage from a Mackintosh IIci equipped with a data acquisition board and software using a LabVIEW software development system (National Instruments, Austin, Tex.). This trapezoidal velocity profile was under closed loop control using the magnetic control switches as position feedback. The speed of reciprocation was controlled by the magnitude of the trapezoidal voltage signal sent from the Mac IIci.
Load Profiles
Static loads were applied using dead weights 20 placed on the end of a stainless steel beam 22. The normal force on the pin 16 was calculated to be 1.9 times the weight of the dead weights 20 on the end of the beam 22. The maximum static normal force was 43.7 pounds (194.4 N) on the pin [23 pounds (102.3 N) located at the end of the beam 22].
Force Measurements
Frictional force recordings between the pin and the plate were obtained from a piezoelectric, voltage mode force transducer. Since the capacity of the force transducer was 100 lbs (444.8 N), very small force measurements could be inaccurate. Normal force recordings on the pin 16 were obtained from a piezoelectric, voltage mode force transducer 18. Its capacity also was 100 lbs (444.8 N).
Cycle Count
The number of cycles was counted in two places. On the Mac IIci, a software counter was incremented each time the left magnetic control switch was closed. As a hardware backup mechanism, a separate magnetic switch (which used the same power supply as the control switches) was located on the back of the wear machine to increment an electronic counter.
Temperature
The temperature of the wear environment could be regulated by means of a water bath 12 which surrounded the stainless steel wear chamber 24. The water bath 12 was heated by a stainless steel immersion heater controlled by a temperature controller. Water temperature was measured with an RTD probe placed in the bath.
Safety
Since it was desirable for the wear machine to operate overnight and on weekends without supervision, a number of safety mechanisms were used.
Software Control
The computer program which drove the system had a "stop switch" on the screen which enabled the program to be manually stopped at any time. Also, the program continually sampled from two additional magnetic stop switches inside the reciprocating rail table. Therefore, in the event of the stroke length being exceeded, one of these switches would close and the program would be stopped. These two stop switches were located slightly outside of the desired stroke length of the wear test (which was determined by the two magnetic control switches previously discussed).
Hardware Control
Located outside of these stop switches were two industrial mechanical push button switches placed in series between the main power source and the motor drives. These switches normally were closed.
If the reciprocating table 10 traveled too far beyond the desired stroke length of the wear test, one of the magnetic stop switches closed, which caused the computer program to send zero volts to both DC motors 11, stopping the wear test. However, a very small voltage still was sent to the motors 11 from the computer, to which the velocity-configured motor 11 could respond. Therefore, the wear chamber 24 continued slowly to drift and soon engaged one mechanical stop switch. This engagement turned off the main power to the motors 11.
Evaluation of Wear
Evaluation of wear resistance and the associated coefficient of sliding friction was performed under realistic environmental but static loading conditions. Two types of wear were measured. First, the wear represented by loss of the coating from the substrate, which was quantified in terms of the number of cycles required to expose the substrate, or major portions thereof. This determination was most effectively made by microscopic observation, rather than by weight loss.
In cases where no coating was involved, it was useful to monitor weight loss; however, it was imperative to compensate for environmental fluid uptake (gain in mass) of the wear sample by using a dummy sample presoaked and exposed to the test bath simultaneously alongside the wear specimen. To ensure that trends observed in the data represented a steady state situation, data was obtained over a period approaching 10 6 cycles (corresponding to about one year of normal ambulation). Later tests completed about 1.25×10 6 cycles.
Simulation of Joint Environment
The environment of a natural joint (with synovial fluid) was simulated using bovine serum. Pin/plate materials were chosen based on a judgment that the constraints of the total joint design cause a localized sector of the femoral ball to describe a wide path within the socket of the acetabular component. Eventually, as seen in joint simulator experiments, a millimeter or more of polymer may be worn away, with no measurable loss of material by the metal or ceramic ball. Therefore, these tests utilized metal, ceramic, or coated metal pins run against coated or uncoated polymeric plates.
Polyethylene
The virgin UHMWPE that was used in the following examples was obtained from Westlakes Plastics, Lenni, Pa. For purposes of the present study, gamma-ray sterilization was not performed. If such sterilization had been performed, then the sterilization process should have produced a marginal improvement of mechanical performance, as a consequence of cross-linking. Because the surface of polyethylene is scratched easily, all of the surfaces and materials were kept scrupulously clean using a laminar air-flow cabinet. A Struers Rotopol polisher with a Pedamat head was used to polish the samples according to the procedure given in Table I:
TABLE I______________________________________Polishing of PolyethyleneStep Abrasive Applied Load Duration______________________________________1. 400 grit SiC 100 N 2 min. repeat once2. 600 grit SiC 100 N 2 min. repeat once3. 1200 grit SiC 100 N 2 min. repeat once4. 2400 grit SiC 100 N 2 min. repeat once5. 4000 grit SiC 100 N 2 min. repeat once6. 1 μm Diamond Spray 80 N 5 min. repeat untilon Pan-w Cloth* scratches are gone______________________________________ *Pan-w is a cardboard like cloth made by STRUERS.
The alloy was manufactured by Carpenter Technology, Houston, Tex., and had the following composition: cobalt 70/chromium 30, with a minor addition of molybdenum. After machining, the 10 mm diameter test pins were contoured at one end to a radius of 20 mm and polished by standard metallurgical techniques. The curvature was designed to prevent the edge of the pin from cutting into the surface of the polyethylene flat.
Wear testing was performed using the wear test machine described above. The temperature was maintained within the test chamber at 23±1° C. by means of an external water bath 12. The chamber containing the sample plate 14 was reciprocated beneath the stationary pin 16 at 1 Hz over a sliding distance of 50.8 mm per cycle; both sliding speed and distance approximate that which obtains during service within a total hip joint. Cobalt-chromiummolybdenum and alumina pins 16 were machined to a 20 mm radius (similar to that of typical femoral balls) and polished metallographically to obtain a surface finish of less than 0.05 um R a .
Samples were soaked in pairs (wear specimen plus dummy) for one week in bovine serum buffered with sodium azide in a 0.1 vol. % solution, the latter to prevent bacterial growth. Subsequent wear testing was performed in the same solution, and the soaked control specimen was used to correct for fluid weight gain in the wear sample. Samples were weighed periodically during testing, and corresponding associated friction coefficients (ratio of linear force to normal load) were measured during sliding.
The desired test load, and that used for most experiments, corresponded to a stress level induced by normal body loads at a total hip interface. Since the articulating pin-on-plate wear surfaces did not conform to the degree of the actual prosthesis, the required equivalent stress loads were lower. In particular, using the measured plastic impression within a UHMWPE plate as a measure of contact area, the approximate equivalent (stress) load was 33.4 N.
Tests generally were run for 10 6 cycles, with wear defined in terms of cumulative mass (volume) loss. Samples were examined by scanning electron microscopy (SEM) at the conclusion of the test.
Solvent Immersion
The polished samples were treated with Decalin™ for between 30 seconds at 120° C. and 3 minutes at 50° C., as shown in Table II. The higher temperatures resulted in excessive swelling of the polymer. From the following results, it was concluded that it might be possible to use Decalin™ at room temperature to achieve adequate selective dissolution of the low molecular weight polyethylene fraction.
For CoCr--DLC against Decalin™-treated polyethylene, as well as for CoCr--DLC against untreated polyethylene, wear virtually was zero for more than one million cycles; however, major wear was observed for CoCr against untreated UHMWPE. In addition, it was observed that wear of CoCr on highly polished UHMWPE only occurred following an incubation period of approximately 500,000 cycles, versus the immediate wear measured for CoCr against rough polished (commercial quality finish) polyethylene. Unfortunately, once wear begins, the wear can be so rapid that the cumulative wear volumes for rough and smooth surfaces are essentially equal by approximately 1.5 million cycles. Therefore, the advantage achieved by polishing alone is short-lived, and ultimately inconsequential, due to the devastating wear rate associated with fibrillar pullout/failure. In both cases, wear surfaces exhibited fibrillar pullout and microfailure. These observations are quantified in FIG. 2, which shows actual wear rate and wear factors (wear volume normalized for load) for all cases. These wear rates and wear factors for the CoCr-UHMWPE cases are in close agreement with data generated under similar conditions and reported in H. A. McKellop, et al., "Wear Characteristics of UHMWPE," J. Biomed. Mater. Res., 12 (1978) 895.
For the minimal wear cases, a groove caused by creep deformation was produced in the plates, but no weight loss was measured. At 10 6 cycles, sliding contact surfaces of the Decalin™-treated UHMWPE had become gently undulating, with fine-scale, very flat deformation (but not wear) markings superimposed on the undulations. The original surface was flat (no undulations) and covered with fine-scale polish markings. The latter contrasts with the original polished surface of untreated polyethylene, which was characterized by fibrillar structures similar to those observed during equilibrium wear.
Although likewise characterized by zero measured wear for at least 1.25×10 6 cycles, the contact microtopography for smooth-polished DLC against CoCr--DLC had a markedly different appearance. Undulations were not so apparent, and material appeared to have been pulled out of the surface. However, high magnification study of these structures indicated that they were fairly flat, unlike the sharply-peaked, tensile-failure, fibrillar structures observed for uncoated CoCr against UHMWPE. This suggested that the forum landmarks probably did not yet correspond to wear (detachment from the substrate).
The results of the test, given in Table II, show that after 10 6 cycles, no fibrils were present at the wear surface of Decalin™ treated polyethylene:
TABLE II__________________________________________________________________________Pin Plate Load (N) μ N (cycles) Wear__________________________________________________________________________CoCr-DLC UHMWPE 33.4 0.12 537,498 ˜0 Decalin ™ Pretreat 30 s at 100° C.CoCr-DLC UHMWPE 33.4 0.135 1,000,610 ˜0 Decalin ™ Pretreat 30 s at 100° C.CoCr-DLC UHMWPE 33.4 0.11 1,000,000 ˜0 Decalin ™ Pretreat 180 s at 50° C.CoCr-DLC UHMWPE 33.4 0.08 1,000,000 ˜0CoCr UHMWPE 33.4 0.09 1,000,000 major (rough polish)CoCr UHMWPE 33.4 0.14 1,000,000 major, (smooth polish) following incubation period of ˜5 × 10.sup.5 cyclesCoCr-DLC UHMWPE 33.4 0.09 1,205,000 ˜0__________________________________________________________________________
Similar results were obtained at 1.25×10 6 cycles.
DLC Coating
Example 1
A DLC coating of approximately 1 micron in thickness was prepared by nitrogen ion bombardment of a polyphenyl ether precursor. The alloy was cleaned in isopropyl alcohol prior to coating. Isopropyl alcohol was chosen because it leaves few, if any, residues. Wear testing revealed that, under some circumstances, there could be a loss of adhesion of the coating.
Example 2
A later batch of four CoCr pins was treated using a bond-coat of silicon. Silicon was chosen because (a) DLC is known to adhere better to silicon that any other substrate, which is attributed to strong SiC bonds formed at the interface, and (b) cobalt and, to a lesser extent, chromium are known to form silicides (CoSi, CoSi 2 , CrSi 2 ) at the interface if the temperature exceeds about 300° C. This solid state reaction is known to be enhanced by ion assisted deposition, probably because energetic ions disrupt the surface oxide or other barriers to interdiffusion at the metal-silicon interface.
Therefore, a coating process was chosen which was an argon ion-assisted deposition of approximately 100 nm of silicon at 300° C. The silicon was evaporated from an electron-beam heated hearth and the thickness was controlled by means of a quartz crystal film thickness monitor (Intellimetrics Ltd.). DLC was deposited, in a separate run. After initial ion bombardment in the vacuum chamber to remove the remaining adsorbed atoms from the surface, the alloy was heated to a temperature of 300° C. The DLC thickness achieved was approximately 0.5 microns.
In prolonged wear tests, at a contact pressure of 6.9 MPa against UHMWPE under serum, i.e., load and environmental conditions equivalent to walking, no decohesion or loss of DLC was observed after 1.25 million reciprocated wear cycles.
Conclusions
DLC coated CoCr against polyethylene clearly represents a considerable advantage over uncoated CoCr against polyethylene. Moreover, pretreatment of the UHMWPE with Decalin™ provides additional wear resistance. Clearly, the pre-wear damage mechanisms have been altered, and it is believed that wear may be further postponed and, possibly, reduced in rate once it begins by use of the present methods.
From the appearance of the DLC-UHMWPE contact surface, it appears that localized adhesion takes place as the DLC rider passes over the polyethylene surface, possibly pulling out the soft (lower molecular weight) constituent on a gradual cyclic basis. However, the adhesive contact force is insufficient to fail the pulled out microstructure, at least before 1.25×10 6 cycles. The prewear structures shown above do not resemble the individual "mountain peak" topography associated with submicrometer particle production; therefore, it is possible that a different particle generation mechanism, hence a different particle size distribution, will prevail. Since osteolytic destruction of the bone-biomaterial interface is induced principally by submicrometer particles, the production of larger average size particles may result in reduced osteolytic destruction. The possibility for improvement seems greatest for DLC against solvent-immersed UHMWPE. Here, soft-phase fibrillation was eliminated, there is a high likelihood that wear can be postponed further, that the eventual wear mechanism and rate will be altered, and that the wear particle size distribution will correspond to larger particles, i.e., on the order of the hard semicrystalline domains. Moreover, since Decalin™ penetrates a significant fraction of a millimeter into the UHMWPE, these effects should persist throughout the wear process.
One of skill in the art will recognize that many modifications may be made to the present invention without departing from the spirit and scope of the present invention. The embodiment described herein is meant to be illustrative only and should not be taken as limiting the invention, which is defined in the following claims. | The present invention provides methods for modifying surfaces made from metal alloy and/or UHMWPE, preferably surfaces which are frictionally engaged, e.g., in an orthopaedic implant. The methods of the present invention reduce the coefficient of friction of the metal alloy component, reduce the shearing of fibrils from the UHMWPE component, and reduce sub-surface fatigue in the UHMWPE component. The method involves solvent immersion of the UHMWPE component to remove short chains of polyethylene at or near the surface of the component, and to swell and toughen the subsurface of the component. The method also involves firmly coating the surface of the metal alloy component with an adherent layer of diamond-like carbon ("DLC") by creating a metal-silicide interface at the surface of the metal alloy to permit firmer adhesion of DLC. Although the methods of the present invention are particularly useful in orthopaedic applications, the methods also can be used to treat similar components used in other applications. | 0 |
BACKGROUND
[0001] 1. Field
[0002] The following relates to mobile telephony, and more particularly to optimization of calls that are terminated or initiated by mobile devices.
[0003] 2. Related Art
[0004] Although much emphasis has been placed, of late, on providing data communication capabilities on mobile phones, voice services and voice communications remain an important feature to be made available on mobile devices.
[0005] Mobile devices in many cases continue to be tariffed differently than PSTN-based devices. For example, a mobile device may accrue charges for outgoing calls (e.g., minutes for outgoing calls will be counted against an allocation), while incoming calls do not accrue such charges. Other aspects of a user experience of voice calling on mobile devices include how much delay there is in call establishment. It would be beneficial to continue to improve such user experiences and tailor mobile device voice telephony usage to reduce unnecessary charges.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 depicts an example system view in which aspects described herein can be practiced;
[0007] FIG. 2 depicts an example mobile device view in which aspects described herein can be practiced;
[0008] FIG. 3 depicts a schematic example of a switching network that can implement voice channels, which can be used for voice calls, according to the description herein;
[0009] FIG. 4 depicts an example method;
[0010] FIGS. 5-9 depict example methods which can be used for call acceptance prediction, as depicted in FIG. 4 ;
[0011] FIG. 10 depicts a method of maintaining information to be used in call acceptance prediction; and
[0012] FIG. 11 depicts an example composition of a mobile device, such as that illustrated in FIG. 2 .
DESCRIPTION
[0013] The following description provides examples and other disclosure, which teach those of ordinary skill in the art how to practice implementations of inventive aspects described herein. As such, the description is not limiting, but rather is exemplary.
[0014] For convenience, in this description, the terms “mobile phone” and “mobile communications device” generally can be used to refer to any portable or mobile network-enabled device that has capabilities to send and receive voice calls and may also be able to send and receive data, such as data generated by web browsing, e-mail, SMS, instant messaging, and the like. As will become clear, a variety of devices in a variety of form factors can meet such a definition, including, for example, phones, smartphones, laptops configured with appropriate network connections and user input devices, tablet computers, navigation devices embedded in automobiles, and netbooks.
[0015] In one example, aspects of this description relate to optimization of mobile terminated/mobile initiated (MTMI) calls. In one system architecture, a system (e.g., a server) can function as a Private Branch eXchange (PBX) for mobile devices, and provide functions such as call forwarding to mobile devices. In one example, the system can receive a call that is to be forwarded to a mobile device. The system can signal, over a data channel to the mobile device, that the system has a call to be forwarded to the mobile device. The mobile device can respond by beginning to initiate a voice channel before the user of the mobile device has indicated that the call is to be accepted (an early call). Alternatively, the mobile device can begin initiation of the voice channel responsive to the user indicating that the call is to be accepted (a late call). In the former case, a delay perceived by the user will be shorter, or possibly even zero. However, the former case also can incur fees and charges, even if the user ignores or rejects the call.
[0016] Devices may be pre-configured to perform either early or late calls. However, further optimizations may be available. In one example, information about the calling party (i.e., the party that called the PBX, or more generally, any entity that can receive such calls) and prior history of how the user responded to calls from that party is used to predict whether the user will answer the call. If the prediction is that the user will answer the call, then an early call strategy is used. If the prediction is that the user will not answer the call, a late call strategy is used. A variety of example approaches to making such predictions will be described below.
[0017] In the above manner, these aspects can improve user experience, by reducing call setup delay, while avoiding increased costs of early call setup in situations where the user may ultimately not want to have the call established at all.
[0018] In a more-specific example, FIG. 1 depicts a system architecture 100 in which a data and voice-enabled mobile device 107 can operate. A Radio Access Network (RAN) 105 provides broadband wireless access to device 107 . RAN 105 communicates wirelessly with device 107 , and connects device 107 via a circuit 122 with a voice-quality network channel 103 . Voice-quality network 103 can serve as a bearer channel for voice calls in which mobile device 107 participates, and can comprise portions of the Public Switched Telephone Network (PSTN).
[0019] RAN 105 also can connect through an IP link 124 to private network(s) 112 and through an IP link 126 to public network(s) 111 . Usage of IP is exemplary and other addressing systems can be provided. For example, private networks 112 can use X.25 addressing and also can be implemented using Virtual Private Network (VPN) technology to carry data over public networks 111 .
[0020] Mobile device 107 also can have an interface for communication using local area wireless network technologies, such as 802.11 series technologies. When using such technologies for communication, mobile device 107 typically interfaces with a wireless LAN access point 114 , which can communicate over public network(s) 111 , such as through a router (not depicted). Communications on this medium also can be addressed using IP, as depicted by labeling the link IP link 128 .
[0021] Each voice call in which mobile device 107 participates can be terminated at the PBX, or the device 107 . A router 119 can communicate with a firewall 115 . Firewall 115 can directly communicate to and receive communication from public network(s) 111 and private network(s) 112 that originate from PBX 118 , or which otherwise involve signaling concerning voice calls that travels over the data network (such as the data network elements depicted in FIG. 1 ).
[0022] FIG. 1 also depicts the existence of other networks 193 and other devices 192 , which can call into PBX 118 . The existence of such other devices 192 is for setting context that PBX 118 may be getting any number of incoming voice calls at a given time. For example, a larger PBX, for a company or company site with several thousand employees would be expected to have a large number of calls incoming to the PBX in any given period of time.
[0023] Referring to FIG. 2 , there is depicted an example of mobile device 107 . Mobile device 107 comprises a display 212 and the cursor or view positioning device 214 , shown in this implementation as a trackball 214 , which may serve as another input member and is both rotational to provide selection inputs and can also be pressed in a direction generally toward housing to provide another selection input. Trackball 214 permits multi-directional positioning of a selection cursor 218 , such that the selection cursor 218 can be moved in an upward direction, in a downward direction and, if desired and/or permitted, in any diagonal direction. The trackball 214 is in this example situated on a front face (not separately numbered) of a housing, to enable a user to manoeuvre the trackball 214 while holding mobile device 107 in one hand.
[0024] The display 212 may provide that selection cursor 218 depicts generally where the next input or selection will be received. The selection cursor 218 may comprise a box, alteration of an icon or any combination of features that enable the user to identify the currently chosen icon or item. The mobile device 107 in FIG. 2 also comprises a programmable convenience button 215 to activate a selected application such as, for example, a calendar or calculator. Further, mobile device 107 can include an escape or cancel button 216 , a camera button 217 , a menu or option button 224 and a keyboard 220 . Camera button 217 is able to activate photo-capturing functions when pressed preferably in the direction towards the housing. Menu or option button 224 loads a menu or list of options on display 212 when pressed. In this example, the escape or cancel button 216 , menu option button 224 , and keyboard 220 are disposed on the front face of the mobile device housing, while the convenience button 215 and camera button 217 are disposed at the side of the housing. This button placement enables a user to operate these buttons while holding mobile device 107 in one hand. The keyboard 220 is, in this example, a standard QWERTY keyboard.
[0025] FIG. 3 depicts a simplified example of how a voice channel may be setup, over the voice network 103 depicted in FIG. 1 . FIG. 3 depicts that voice network 103 may comprise a number of switches (e.g., SS7 switches 192 a - f ), which, based on signaling, can be used to establish a circuit between an ingress point and an egress point from network 103 . As depicted, a selection of the switches, such as SS7 switches 192 b, 192 c and 192 e are used in making circuit 122 . The selection of appropriate switches, allocation of resources at those switches, and the establishment of connections among the switches can take time, which can result in a perceived delay to begin using the circuit 122 for voice communication.
[0026] FIG. 4 depicts a method in which a predictive setup of such a voice channel is begun for a call incoming to a mobile device, before there has been an actual disposition of the incoming call (e.g., an ignore or answer disposition). In particular, FIG. 4 depicts that an indication of an available incoming call destined for a mobile device is received ( 402 ). For example, when PBX 118 has received a call (an “incoming call”) to be forwarded to mobile device 107 , PBX 118 can arrange for an indication of such incoming call to be sent to device 107 over a data channel, such as through router 119 and over any of the networks depicted in FIG. 1 (such as public network 111 or private network 112 ).
[0027] Information about the incoming call is accessed ( 404 ). For example, ANI or caller-ID information, which identifies a calling party placing the incoming call, can be accessed. This data can be presented over a data channel that signaled the availability of the call.
[0028] Information about history of call disposition is then accessed ( 406 ). Such information can include information about a number of calls that have been placed by the calling party to the mobile device, a number of calls from the calling party that have been answered at the mobile device, a number of calls in total that have been placed to the mobile device, and a number of calls in total that have been answered at the mobile device, for example. Based on this stored information and the calling party information, a prediction ( 408 ) whether the user at the mobile device is likely to answer the incoming call is made. Further aspects of such prediction are described with respect to FIGS. 5-9 ; however, by way of brief example, if a ratio of the calls answered versus the total number of calls incoming from the calling party is low (i.e., the user rarely answers the phone when this calling party calls), then the prediction would be that the user will not answer the phone at this time.
[0029] Based on the prediction, a decision ( 410 ) is made as to whether to begin establishing ( 412 ) a voice channel to be used for the voice call or not. In particular, if the user was predicted to answer, then the voice channel establishment will be started. Otherwise, FIG. 4 depicts that the method will await a disposition of the call by the user. Such disposition, in this example, can comprise a determination whether the user has answered ( 420 ) the call, and if so, then voice channel establishment can begin ( 423 ). If the user has not yet answered, then a decision can be made as to whether the user selected to ignore/reject ( 421 ) the call. If the user rejected the call, then the method can stop ( 418 ), or take another suitable action. A timeout decision ( 422 ) can be made, which in the occurrence of a timeout, can also cause the method to stop ( 418 ). Otherwise, a loop to again determine whether user has answered ( 420 ) can be provided.
[0030] Returning to the response to predicting that the user will answer ( 408 , 410 , 412 ), the method also can check whether the call has been answered ( 414 ), and if so, then the call can proceed ( 416 ). If the call has been rejected/ignored ( 470 ) or there was a timeout ( 472 ), then the voice channel which was begun can be torn down ( 471 ). Otherwise, there can be a loop to again determine whether user has answered ( 414 ).
[0031] The method of FIG. 4 depicts an example approach to implementing the predictive aspects disclosed herein. A logically equivalent method may be provided by those of ordinary skill in the art that would differ from an order or arrangement of the elements depicted in FIG. 4 .
[0032] The methods depicted in FIGS. 5-9 relate to more specific examples of how call disposition predictions can be made. These examples also are by way of explanation, rather than limitation, as those of ordinary skill in the art would be able to provide other call disposition predictive mechanisms based on these disclosures.
[0033] FIG. 5 depicts that one approach to call disposition prediction can include accessing ( 502 ), such as from a memory, data representative of a number of times that calls from the calling party were answered, and predicting ( 504 ) whether the user will answer based on such number. For example, if there were prior calls from the calling party, but none were answered, then the prediction can be that the user will not answer this call either.
[0034] FIG. 6 depicts that another method can involve accessing a number of times that the calling party has called ( 506 ), accessing a number of times that the user answered when the calling party called ( 508 ), producing a ratio between the answers and the total ( 510 ) and predicting ( 512 ) whether the user will answer the call based on the ratio. For example, if the ratio indicates that more than half of the calls were answered, then this call will be predicted to be answered.
[0035] FIG. 7 depicts another prediction method, in which stored information concerning a number of times calls from the calling party were answered can be accessed ( 518 ). Other information that can be accessed ( 520 ) relates to a number of times, in total, that the user answered the phone. A ratio between the number of calls answered from the calling party to the total number of answered calls can be produced ( 522 ), and a prediction is made ( 524 ) based on that ratio.
[0036] FIG. 8 depicts another prediction method in which a number of times that calls were answered is accessed ( 514 ); a number of incoming calls in total is accessed ( 516 ), a ratio between such total number of calls answered and number of incoming calls in total is produced ( 525 ), and a prediction made based on that ratio ( 527 ).
[0037] Each of the above ratios, and more generally, the comparisons between the data elements described, can be viewed as a statistic that can be used in predicting whether the user will answer the phone for a given incoming call. FIG. 9 depicts that multiple such statistics can be used in forming such a prediction.
[0038] In particular, FIG. 9 depicts that a statistics 1 . . . n can be produced (steps 530 , 532 , and 534 ) and those statistics can be used in making a prediction ( 536 ) about whether the call will be answered. For example, each of the ratios described with respect to FIGS. 6-8 can be a statistic used in the method of FIG. 9 .
[0039] FIG. 10 depicts that the data that can be used in producing the statistics or otherwise making the predictions described with respect to FIGS. 4-9 can be gathered and maintained. In particular, a number of incoming calls can be updated ( 554 ), and a number of calls from the calling party can be updated ( 558 ), regardless of disposition of the incoming call. If the call was answered, then a total number of calls answered can be updated ( 552 ), as can a total number of calls answered from the calling party ( 556 ). These updated numbers can then be used for predictive purposes during for future incoming calls. The data can be stored as raw numbers, or some of the ratios described can be precomputed and stored. Still further, the prediction can be made in advance based on the data, and the prediction stored. For example, a flag can be stored with identifying information for a particular calling party that indicates to answer or ignore the next call from this particular calling party. Such data can be stored on the mobile device, in the network, on PBX 118 , or in another suitable location.
[0040] FIG. 11 depicts an example composition of a device which can perform the method aspects described above in processing resources, as well as store, or otherwise have access to a computer readable medium that stores code for configuring processing resources to perform such methods.
[0041] By particular example, FIG. 11 depicts that device 107 can be provided with components as follows. Device 107 can have a variety of components by which user input can be received, including a camera 825 , a keyboard 827 , a touch screen 829 , and a microphone 831 that can be used for speech recognition, for example (collectively, input sources 816 ). These ways of receiving user input can be processed and ultimately coupled with processing resource 819 that can be comprised of a plurality of components, such as a programmable processor 845 , one or more ASICs 847 , as well as other co-processors 849 . For example, an ASIC or co-processor may be provided for implementing graphics functionality, encryption and decryption, audio filtering, and other such functions that often involve many repetitive, math-intensive steps. Processing resource 819 also may interface with one or more network interfaces 817 , each of which may be comprised of one or more Media Access Controllers (MACs) 851 , which in turn interface with physical layers 853 .
[0042] Processing resource 819 also may interface with a memory resource 818 which may be comprised of a plurality of memories, including a RAM 855 , and a non-volatile memory 857 , which can be implemented with one or more of Flash memory, PROM, EPROM, and so on. Non-volatile memory 857 can be implemented as flash memory, ferromagnetic, phase-change memory, and other non-volatile memory technologies. Non-volatile memory 857 also can store programs, device state, various user information, one or more operating systems, device configuration data, and other data that may need to be accessed persistently. Such memory 818 can be used for storing the call history, statistics, and/or flags, which were described with respect to the method aspects above.
[0043] Processing resource 819 also may interface with user output 820 components, which can include a display 841 , as well as a speaker 843 , which can be used for text to speech or for performing audio, more generally.
[0044] A battery interface 888 interfaces a battery 889 with processing resource 819 . Battery interface 888 can provide battery status updates and manage recharging of the battery, for example. Processing resource 819 also can couple, through an interface 890 , with a SIM/RUIM/USIM 891 , to enable communication over protocols that would use each.
[0045] Aspects described above can be implemented as computer executable code modules that can be stored on computer readable media, read by one or more processors, and executed thereon. Such computer readable media can be read by such processors over a network, which can be implemented using wired and wireless network technologies. In addition, separate boxes or illustrated separation of functional elements of illustrated systems does not necessarily require physical separation of such functions, as communications between such elements can occur by way of messaging, function calls, shared memory space, and so on, without any such physical separation.
[0046] Although certain disclosures were provided with respect to certain portions of the figures and in certain examples, the structures or functions disclosed therein can be used or adapted for use with the structures or functions disclosed with respect to other portions of the disclosures and figures. More generally, a person of ordinary skill would be able to adapt these disclosures to implementations of any of a variety of communication devices. Similarly, a person of ordinary skill would be able to use these disclosures to produce implementations on different physical platforms or form factors without deviating from the scope of the claims and their equivalents. | A PBX can receive a call for a mobile device, and can send a message over a data channel to the mobile device indicating such. The mobile device can open a voice channel for the call. The mobile device inspects information about the call, such as calling party information, and using historical information, such as statistics relating to acceptance of calls from that calling party to predict whether a user of the mobile device is likely to answer the call or not. If the mobile device predicts that the user is probably going to answer the call, then the mobile device begins establishing the voice channel before the user answers the call (e.g., by accepting through the user interface). However, if the mobile device predicts that the user is not going to answer the call, then the mobile device waits until the user actually answers the call to begin establishing the voice channel. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit of U.S. Provisional Application No. 60/706,758 filed on Aug. 10, 2005, which is incorporated herein by reference.
STATEMENT OF GOVERNMENT INTEREST
The present invention may be made or used by or for the Government of the United States without the payment of any royalties thereon.
FIELD OF THE INVENTION
Localizer antenna arrays are provided at the end of major runways at major airports. Their correct operation is critical to air traffic safety. The present invention relates to the detection of cable faults in the Localizer antenna array.
BACKGROUND
The Localizer is part of the Instrument Landing System (ILS). The ILS is a ground based precision approach system that provides course and vertical guidance to landing aircraft. The Localizer is the component of the ILS that provides course guidance to the runway. The Localizer is located at the end of the runway. The Localizer equipment has 8, 14, or 20 antenna elements wired in an array. The number of antennas in the array depends on whether the airport has close or parallel runways, or if there are building obstructions near the runways. In these cases, the radiated signal pattern must be narrowed. Increasing the number of antennas in the array narrows the radiated signal pattern. All the proper signals have to be radiated from all the antennas to give a pilot the correct left-to-right indication on his instruments. A fault in the cable feeding an antenna will cause the Localizer system to shut down, and the pilot will lose the Localizer signal that could possibly result in an unsafe condition during final approach to landing.
The Localizer equipment generates a DC voltage that is present at all times in all the antenna lines in the antenna array. When the Localizer equipment is operating normally, a cable fault card in the equipment generates an audio tone and sends it back to the Localizer equipment shelter. When a cable fault occurs, the DC voltage on that particular antenna line goes to zero, and the cable fault card has group of circuits that detect this condition. When the DC voltage goes to zero on any of the antenna lines, the audio tone is inhibited and the Localizer monitor generates a cable fault alarm. However, the Localizer monitor does not identify which antenna in the array caused the fault.
Troubleshooting to find the fault requires the technician to measure voltages at a test point with a voltmeter to determine which antenna or feed line is has the fault which caused the Localizer system to shut down. The problem is compounded if the fault is intermittent. An intermittent fault can take hours or even days to troubleshoot. The technician has to be on the proper test point and actually see the voltage drop with a voltmeter to identify the antenna. The technician must start at one end of the antenna array and check every connector. In a 20-element antenna array there are 80 connectors. There have been instances where an antenna array was completely recabled, and upon the completion, the problem was still present.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an example embodiment of the present invention, a Localizer cable fault analyzer.
FIG. 2 is a schematic diagram of an example embodiment of the present invention configured for use on a 20-antenna Localizer antenna array.
FIG. 3 is an example block diagram of a LED inhibiting circuit for a 20-antenna embodiment of the present invention.
FIG. 4 is a photograph of a 20-antenna example embodiment of the present invention.
FIGS. 5 through 10 are illustrations of case layouts for a 20-antenna example embodiment of the present invention.
FIGS. 11 through 13 are circuit board layouts for a 20-antenna example embodiment of the present invention.
FIGS. 14 through 18 are photographs of a 20-antenna example embodiment of the present invention.
SUMMARY OF THE INVENTION
The present invention is capable of memorizing which antenna in the Localizer antenna array caused a fault. The Localizer equipment monitors the antenna transmit and monitor cables for continuity using a DC voltage. This DC voltage is present along with RF signals to and from all the antennas in the antenna array. If there is an open or short circuit condition or a faulty antenna, the DC voltage goes to zero and the Localizer equipment generates a cable fault alarm. The present invention connects to the Localizer equipment before the circuitry that generates the cable fault alarm.
The present invention comprises 20 separate detection and capture circuits for monitoring up to 20 antennas in a Localizer antenna array. Each detection and capture circuit comprises a buffer circuit coupled to a digital latch circuit and an indicator device such as a light emitting diode (LED), light bulb, breaker button, etc. When connected to the Localizer equipment, the present invention senses the voltage drop on the antenna circuit when a fault occurs and causes the indicator device to signal the occurrence of the fault in that particular antenna circuit. The indicator device continues to signal the occurrence of a fault until a reset switch is activated.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention is a diagnostic Localizer cable fault analyzer that automatically detects and memorizes which antenna in a Localizer antenna array has caused a fault. The present invention allows troubleshooting to be focused on the particular antenna and related transmit and monitor cables causing the fault. This results in shortened outage times and allows the Localizer system to be returned to service faster.
The existing Localizer equipment in the field typically has 8, 14, or 20 antennas wired in pairs. Referring to FIG. 1 , the present invention includes a separate detection and capture circuit 100 to monitor each respective antenna in the Localizer antenna array to detect and memorize which antenna in the Localizer antenna array caused a fault. For example, an 8 antenna Localizer antenna array would require 8 detection and capture circuits, a 14 antenna Localizer antenna array would require 14 detection and capture circuits, and a 20 antenna Localizer antenna array would require 20 detection and capture circuits. FIG. 2 is a schematic diagram of an example embodiment of the present invention configured for use on a 20-antenna Localizer antenna array.
The example detection and capture circuit 100 in FIG. 1 may include a light emitting diode (LED) 110 to act as an indicator device to indicate that a fault has been detected. If the LED lights during a detection and capture operation, it would indicate that a fault has occurred in the antenna associated with that detection and capture circuit. Any other type of indicator such as a light bulb, breaker button, etc. may also be used as an indicator device.
The example detection and capture circuit 100 depicted in FIG. 1 uses a digital latching circuit 120 comprising a pair of cross coupled NAND gates. One input (i.e., upper) to the latching circuit 120 is coupled to the common terminal of a reset switch 130 which can be selected to a normally open (NO) terminal to apply ground to reset the latch, or, alternatively, selected to a normally closed (NC) terminal to apply a predetermined voltage, V cc , through a resistor 140 to bias the latch into the select and capture mode. An opposite (i.e., lower) input to the latching circuit 120 is coupled to a suitable monitoring point on the Localizer equipment. A buffer circuit 150 is included between the input to the latching circuit 120 and the monitoring point on the Localizer equipment. The buffer circuit 150 prevents the present invention from causing alarms in the Localizer equipment.
In operation, the Localizer equipment monitors the antenna transmit and monitor cables for continuity using a DC voltage. This DC voltage is present on the cables along with the RF signals to and from all the antennas. If there is an open or short circuit, or a faulty antenna, the DC voltage goes to zero and the Localizer equipment generates a cable alarm. The present invention connects to the Localizer equipment before the circuitry that generates the cable fault alarm. When the DC voltage at the monitoring point on the Localizer equipment goes to zero (i.e., ground), the LED 110 instantly lights and stays lit to indicate that a fault has been detected in the antenna associate with that particular LED. The LED can be extinguished using the reset switch 130 .
The present invention can be connected “on-the-fly” while the Localizer is transmitting without interfering with the Localizer's operation. Also, the present invention may remain connected to the Localizer for extended periods and act as a long term monitor. With this long term monitoring capability, the present invention will immediately detect and report an intermittent cable fault. The present invention can also be used proactively to rule out an antenna array if a cable fault occurs and no LEDs light.
As mentioned previously, typical pre-existing Localizers have 8, 14, or 20 antennas wired in pairs. While three separate (8, 14, and 20-antenna) versions of the present may be constructed, it is more advantages to construct a single twenty antenna version of the present invention which can be used to fault analyze any of the 8, 14, or 20 antenna Localizers. FIG. 2 is a schematic diagram for a 20 antenna version of the present invention.
When a 20-antenna version of the present invention is connected to diagnose an 8-antenna Localizer such as a Wilcox Mark 1F, it is best to inhibit the LEDs of any of the extra unused circuits to prevent confusion and save battery power. FIG. 3 shows a block diagram of an example LED inhibiting circuit where a switch 310 can be selected to disable LEDs 9 through 20 when fault analyzing an 8-antenna localizer, or alternatively enable LEDs 9 through 20 when fault analyzing a 14 or 20-antenna such as a Wilcox/Thales Mark 20/20A. This example configuration is battery powered allowing portability and includes a main power switch 320 . When the power switch 320 is closed, buffer device U 1 and latch device U 2 receive steady power.
FIG. 4 shows an example embodiment of a 20-antenna version of the present invention. The top panel of the enclosure has a power switch, a reset switch, a selector switch to select between 8-antenna and 14/20-antenna Localizers, and 20 LEDs arranged in a double row of 10. A self-test function is included on the side of the enclosure to check all of the digital gates and LEDs. Inside, the enclosure contains a printed circuit board with 14 integrated circuits, one resistor, and the internal wiring.
The following is a parts list for construction a 20-antenna example embodiment of the present invention:
(extended
quantity
Quantity
Mouser part #
for 10)
1
Chassis box
537-TF-782
10
1
Battery Holder, 4 D cells
12BH146
10
2
Toggle switch, SPST
10TC320
20
1
Push button switch, SPST
10PA322
10
4
Standoff, nylon, 1″
561-K61.00
100
1
Grommet, rubber
534-739
10
4
Standoff, nylon .5″
561-K6.50
100
4
Bumper, rubber
534-721
40
1
clip (ground)
548-46A-B
10
1
sub D connector (plug)
538-DEU 9P
10
1
sub D connector (socket)
538-DEU 9S
10
8
spade tongue terminal (red)
538-19144-0003
80
(#6 spade
lug terminal)
Flat cable, .050″ 20 c stranded
566-9L28020
100 ft. roll
(4 foot flat cable per analyzer)
SEMICONDUCTORS
10
Quad 2-Input NAND Gate CMOS
512-MM74HC00N
100
4
Hex Converter High Speed CMOS
512-MM74HC4050N
40
(extended
Allied
quality
Quantity
part #
for 10)
20
LED, 5 V red, 6″ wire leads
265-5031
200
1
Header, shrouded, 20 pin
512-2630
10
1
IDC connector, dual row 20 pin
618-8906
10
1
IDC connector strain relief
618-8932
10
Quantity Texas Circuitry Inc. part # 1 Printed Circuit Board 200306-SE ($45 ea, $60 for 2, $200 for 10)
Miscellaneous Parts
1 breadboard. RadioShack Dual PC Board part #276-148 (breaks in half making 2). 1 Wire Markers (self-adhesive) RadioShack part #2781650A (or equivalent) 1 handle, (3 inch length) Home Depot part #P604BAC
Lowe's part #PW353-26D (The supplied screws are too long. Either cut them in half or replace with ½″ #8 screws.)
1 ea 100 ohm 5%, ¼ watt resistor. 2 ea Velcro cable ties (6 per pack) Walmart #F8B024-WM (in electronics department) Screws, washers, nuts
14 ea 4/40×⅜″ Phillips head machine screw with flat, split and hex nut.
4 ea 6/32×2″ Phillips head machine screw with flat, split and hex nut.
4 ea #8×⅜″ pan head sheet metal screw. When completed, discard the 4 screws supplied with the metal enclosure and force these into the 4 cover mounting holes.
2 ea terminal solder lug #4 screw size
1 ea terminal solder lug (yellow) #8 screw size #12 wire size.
1 ea support clamp, ¼″ size, ¼″ diameter ACE Hardware part #CLC-4. Used to secure the Mark 1F harness to the case so it won't get lost.
Wiring, internal to unit, 22 ga. stranded.
Brown 8″×8 wires (for Mark 1F pad connections on card to sub D connector) Red, VCC, Mark 20/Mark 1F switch, 20″ Black GND, 12″ Yellow, RESET switch, 8″
External Mark 1F cable uses 24 feet. (8 wires 3 feet long) 22 ga stranded wire.
External Ground wire for unit is 4 feet of 12 ga stranded wire.
20 conductor stranded ribbon cable (listed in Mouser parts above) 4 feet length.
The example embodiment of a 20-antenna version of the present invention may be assembled as follows:
Case layouts ( FIGS. 5-10 ), circuit board layouts ( FIGS. 11-13 ), and photographs ( FIGS. 14-18 ) of the example embodiment of the present invention are included. There is a manufactured circuit card (See parts list, above) that may dictate the size of the sheet metal case, and the circuit card must be mounted and connected in the case as described below to insure correct operation of this embodiment of the present invention and to prevent damage to the Localizer equipment.
Drawings of all sides of the box are included in FIGS. 5-10 . These figures may be scanned, resized as desired, and printed-out. Cut around the border, and tape the drawings to the metal case. Mark with a scribe then drill and de-burr all holes, and cut all openings in the case. The two slots on the right hand side need to be drilled first and filed to size. Suggest using a 9-pin sub D connector to check the fit to prevent filing too far. The slot for the 20-pin header also needs to be cut here.
One hard part is to cosmetically get the 20 LEDs lined up in a straight double row. One way is to mark the holes on the drawing, drill a small hole, and then drill a bigger hole using a 0.156″ drill bit. A better method is to take a piece of breadboard wide enough to reach from the handle to the LED holes. Mount it under the handle then mark off 20 holes and use the breadboard for a drill guide for a 0.060″ drill bit or smaller, followed by a 0.156″ bit. Install the top handle and all three switches. The RESET switch may have a plastic tab that needs to be filed off so it will sit flush. Install the sub D connector socket on the right side using two each 4/40×⅜″ screws with flat, split, and hex nut.
The artwork for the front side of the circuit card is shown in FIGS. 11 and 13 with the IC positions, resistor, and all wire connection identifiers added in. Orientation is with part number 200306 SE near the bottom right. FIG. 15 is a picture of the finished circuit card. All pin 1 locations are marked with a white dot.
Install all 14 ICs and the resistor on the circuit card. Mount all the components of the front side of the card. There are two different types of ICs on the board, ten ICs having 14-pins and four having 16-pins. The 16-pin ICs go on the outside edges next to the inputs. All of the 14-pin ICs line up in the center next to the outputs. Verify the notch at pin 1 on each IC is in accordance with FIG. 11 . After all the components have been soldered, clean the board with alcohol and set it aside.
LED test port. Mount the 20-pin header (Allied part no. 512-2630) on the breadboard in the location shown in FIG. 12 with the pins coming through the solder pad side. Solder a piece of bus wire around all 20 pins and solder to the ground lug in the position shown in FIG. 12 . Mount the breadboard on the inside of the analyzer with the 20-pin header protruding through the slot using four each 4/40×⅜″ screws with flat, split, and hex nut.
All input wires, switch wires, output LED wires pass through the backside and solder to the front side of the circuit card. When complete, the circuit card is mounted in the enclosure with the component side showing and all the wires gathered and hidden behind the circuit card. as shown in FIG. 15 .
D-cell battery holder. Hold the end with the wires and using a pair of dikes, snip some plastic from the slot at the end of the center separation, and pass the red lead through to the negative compartment. Loosely mount the plastic case to the analyzer with four each 4/40×⅜″ machine screws. Mark the case then remove it, and drill a hole in the plastic in the same place as the hole in the analyzer box. Pass both black and red leads through the hole to the inside of the case. Mount the battery holder to the case with a machine screw, flat washer, flat, split, and hex nut. Place a ground lug on the inside of the analyzer case under the flat washer on one of the screws. On the reverse side, slip a small one inch long piece of heat shrink over the leads and up through the hole and shrink to prevent the leads from shorting to the case. Solder the black lead to the ground lug, and solder the red lead to one of the POWER switch terminals.
POWER switch. From the second terminal, solder an eight-inch 22-gauge stranded wire to the V cc pad on the circuit card. Solder a second four-inch wire from the same switch terminal to one terminal on the 14/20-antenna (Mark 20)/8-antenna (Mark 1F) switch. (See FIG. 16 )
14/20-antenna (Mark 20)/8-antenna (Mark 1F) switch. Solder an eight-inch red 22-gauge stranded wire from the other terminal to the 14/20-antenna/8-antenna pad on the circuit card. Position this switch on the analyzer where the ON position is pointing to the 14/20-antenna (Mark 20) position.
RESET switch. This is a momentary contact push button switch that grounds all of the input pins with the RESET function. Solder a black wire from one terminal of the switch to a ground lug. Solder a yellow eight-inch 22-gauge stranded wire to the other terminal and to the RESET pad on the circuit board. (See FIG. 16 .)
Ground wire. Cut a four-foot length of black 12-gauge stranded wire. Crimp and solder one end to a solder lug (yellow). Mount this lug under one of the screws on the handle. Pass the other end of the wire completely through the rubber grommet and crimp (remove the black plastic insulators from the clip before soldering and be sure to put one over the wire before crimping) and solder the ground clip (Mouser part #548-46A-B) to the other end. Connect an eight-inch piece of 22-gauge black wire from a ground lug to the GND pad near the top left of the circuit card. (See FIG. 16 .)
LEDs. Install the twenty LEDs into the case using a ¼″ nut driver pushing only on the rim of the LED.
Ribbon cable installation. Cut a four-foot length of 20-wire flat ribbon cable. On one end, separate all wires six inches back and strip ¼″ from the end. Beginning with wire #1 (marked with either a red or black stripe) solder to the circuit board as follows. (Pass the wires through the back and solder to the front of the circuit board.) Notice each side uses every other wire, i.e.,
LED 90
1
1 (wire marked in red or black)
2
3
3
5
4
7
5
9
6
11
7
13
8
15
9
17
10
19
LED 150
1
2
2
4
3
6
4
8
5
10
6
12
7
14
8
16
9
18
10
20
Pass the other end of the ribbon cable through the rubber grommet on the right side of the analyzer box then slip a Velcro® cable tie over the end of the cable. Take a black marker and mark UP ↑ on both sides of the ribbon cable pointing to wire #1 about two inches from the end. Next, install a UDC connector to the end of the ribbon cable. Position the cable inside the connector, and then put it in a vise and force the connector together. Fold the ribbon cable back over the connector and snap the strain relief on the connector. (See FIG. 17 .)
For the 8-antenna (Mark 1E/F) function, cut eight 22-gauge stranded cables eight inches in length. Strip and solder one end to pads 1 - 8 on the top row on the 90 input side. Terminate each wire with a female pin and then insert into holes 1 - 8 on the sub D connector on the right side of the analyzer. Verify that the sub D pins 1 - 8 connect to pads 1 - 8 on the 90 input side. (See FIG. 16 .)
Now the LED wires can be soldered. The LED black wire locations are numbered on the circuit card drawings, FIGS. 11 and 13 . As shown in FIG. 16 , all LED wires pass through the backside of the circuit board and solder to the front. The output portion from the center of the circuit card is shown in FIG. 13 . The LED red wires solder to the pads as shown.
Start with the 1/90 and solder the black 90 LED outputs first, the red 90s, then the red 150s, and then the black 150s. After the LED leads are soldered, solder the VCC, GND, RESET and Mark 20(14/20-antenna)/Mark 1F(8-antenna) switch wires from the chassis then mount the circuit card into the enclosure using four 6/32×2″ screws. On the back, install 1″ and 0.5″ Teflon® spacers on each screw, then the circuit card, and then a flat, split, and hex nut. (See FIG. 15 .) Clean the front side of the circuit card with alcohol.
Mount the four rubber feet on the bottom of the case using four 4/40 screws with flat, split, and hex nut. One may put a flat washer under the screw before going through the rubber feet. Assemble the case using four #8×⅜″ sheet metal screws.
8-antenna (Mark 1E/F) cable instructions: Cut eight lengths of 22-gauge stranded wire three feet long. Crimp and solder one end to a red spade terminal. Attach a wire number 1 - 8 on each terminal. Cover each terminal with a half-inch length of ¼-inch clear heat shrink to protect the number. Insert all eight wires into a 32-inch long ¼-inch heat shrink. Terminate the other end of the wires with a male end of a 9-pin sub D connector (plug), and insert the wires into the proper holes on the D connector. Slip a Velcro® tie over harness at the spade lug end then slide to the sub D connector end. Roll up the harness and attach it to the case with a clip. (See FIG. 18 .)
Validation. Connect a 20-pin connector to the LED test port and apply power. Verify the 14/20-antenna (Mark 20)/8-antenna (Mark 1F) switch is in the 14/20-antenna (Mark 20) position. This tests the IDC connector, ribbon cable, inner connections, logic gates, and LEDs. If all the LEDs light, the unit is validated and ready for use. | A Localizer cable fault analyzer that memorizes which antenna in a Localizer antenna array caused a fault. The Localizer equipment monitors the antenna transmit and monitor cables for continuity using a DC voltage. The present invention senses the voltage drop on the antenna circuit when a fault occurs and causes an indicator device to signal the presence of the fault in that particular antenna circuit. The indicator device continues to signal the presence of a fault until a reset switch is activated. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority benefit of Taiwan Patent Application Serial Number 095125989, filed on Jul. 17, 2006, the full disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to a detection circuit, and more particularly to a jack detection circuit.
2. Description of the Related Art
The majority of the present electronic products, e.g. personal computers or multimedia products, provide at least two jacks as the transmission interface of analog signals. When a user plugs a jack or key device into the jacks, an information unit, e.g. central processing unit, recognizes the device or its signal in accordance with a jack or key state of the device or the signal outputted therefrom. A keyboard module is widely used as a jack (or key) device. When a user presses any keys on the keyboard module, it will send out an analog signal such that an information unit can recognize the keys which are pressed. Conventionally, the analog signal is utilized to control switching states of a switching circuit 90 , as shown in FIG. 1 , so as to change an equivalent resistance of the switching circuit 90 and further to generate a voltage signal V in1 . Afterward, the voltage signal V in1 is converted to a digital signal by an analog-to-digital converter (AD converter) and then outputted from an output bus N such that the information unit (not shown) can perform corresponding activities according to the outputted digital signal.
FIG. 1 shows a conventional switching module having a switching circuit 90 connected to an AD converter 80 in series, and an input voltage of the AD converter 80 is V in1 . The switching circuit 90 includes four switches SW 4 , SW 3 , SW 2 and SW 1 , and the conducting states of these switches are determined by a jack state or a key state of a jack or key device or its signal. In addition, the conducting priority of the switches SW 4 , SW 3 , SW 2 and SW 1 of the switching circuit 90 is SW 4 >SW 3 >SW 2 >SW 1 . When the switch SW 4 is turned on (conduction), then Vin 1 =0 volt; when the switch SW 3 is turned on, then Vin 1 =V CC ×/(R 5 +R 4 ) volt; when the switch SW 2 is turned on, then Vin 1 =V CC ×(R 4 +R 3 )/(R 5 +R 4 +R 3 ) volt; when the switch SW 1 is turned on, then Vin 1 =V CC ×(R 4 +R 3 +R 2 )/(R 5 +R 4 +R 3 +R 2 ) volt; and when all the switches are OFF, then Vin 1 =V CC ×(R 4 +R 3 +R 2 +R 1 )/(R 5 +R 4 +R 3 +R 2 +R 1 ) volt. Generally, the input voltage V in1 is non-linearly varied in accordance with different conducting states; therefore, the interval of comparison voltage of the AD converter 80 has to be non-linear, or a higher bit rate AD converter has to be utilized.
FIG. 2 shows another conventional switching circuit 91 cascaded with an AD converter 80 . In this case, the switches SW 4 , SW 3 , SW 2 and SW 1 of the switching circuit 91 have identical conducting priorities, i.e. their ON and OFF states are determined by the jack or key state or the signal from the jack or key device. Normally, under different conducting states of the switches, an input voltage V in2 of the AD converter 80 various non-linearly. In this manner, the interval of comparison voltage of the AD converter 80 has to be non-linear, or a higher bit rate AD converter has to be utilized. However, this will increase the complexity of signal recognition.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a jack detection circuit so as to solve the above mentioned problems.
It is a further object of the present invention to provide a jack detection circuit so as to provide linearly varied input signals for an AD converter.
In order to achieve above objects, a jack detection circuit of the present invention is utilized for detecting a jack or key state of an analog device and/or its analog signal so as to generate a digital signal, and the jack detection circuit includes a switching circuit, a transition circuit and an AD converter (analog-to-digital converter). The switching circuit forms an equivalent resistance in accordance with the jack or key state of the analog device or its analog signal. The transition circuit is coupled to the switching circuit and generates a reference current in accordance with a first reference voltage and the equivalent resistance. The AD converter is coupled to the transition circuit and generates the digital signal according to the reference current.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, advantages, and novel features of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
FIG. 1 shows a circuit diagram of a conventional jack detection circuit.
FIG. 2 shows a circuit diagram of another conventional jack detection circuit.
FIG. 3 shows a block diagram of the jack detection circuit according to the first embodiment of the present invention.
FIG. 4 shows a circuit diagram of the jack detection circuit according to the first embodiment of the present invention.
FIG. 5 shows a circuit diagram of the jack detection circuit according to the second embodiment of the present invention.
FIG. 6 shows a circuit diagram of the jack detection circuit according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 3 , it illustrates a block diagram of a jack detection circuit according to the first embodiment of the present invention. The jack detection circuit is utilized for detecting a jack or key state of an analog device and/or its analog signal so as to generate a digital signal. The jack detection circuit includes a switching circuit 91 , a transition circuit 10 and an analog-to-digital converter 20 (AD converter for abbreviation hereinafter). The transition circuit 10 transfers a first signal inputted from the switching circuit 91 to a second signal, wherein one embodiment of the first and the second signals includes an analog current signal. The AD converter 20 converts and outputs the second signal to a digital output signal.
Referring to FIG. 4 , it depicts a circuit diagram of the jack detection circuit in accordance with the first embodiment of the present invention including the switching circuit 91 , the transition circuit 10 , the AD converter 20 and a resistor R 5 . The resistor R 5 has a first end and a second end, wherein the first end is coupled to a second signal output terminal of the transition circuit 10 , and the second end is coupled to a reference voltage, e.g. a ground end. In this embodiment, the switching circuit 91 has four resistor units and each of the resistors has one of the four switches SW 1 , SW 2 , SW 3 and SW 4 and a corresponding resistance element, e.g. resistors R 1 , R 2 , R 3 and R 4 . The switches SW 1 , SW 2 , SW 3 and SW 4 can be controlled by an analog device so as to be in an ON state or in an OFF state. For example, if the analog device is a keyboard, each key on the keyboard corresponds to one switch or a group of switches. When a user presses a key on the keyboard, its corresponding switch or switches will be conducted (turned on). In another example, if an analog device is plugged to the jack detection circuit shown in FIG. 3 , the switches can be impressed to conduct by a plugging force from a user. In this embodiment, assume R 1 =R ohm, R 2 =2R ohm, R 3 =4R ohm and R 4 =8R ohm. In addition, depending on different applications, the number of resistor units of the switching circuit 91 could be four as well as any other number.
Referring to FIG. 4 again, the transition circuit 10 according to the first embodiment of the present invention includes a first reference voltage generator 11 and a first current mirror 12 . The first reference voltage generator 11 has an operational amplifier 111 and a first transistor 112 . The positive input terminal of the operational amplifier 111 receives a first reference voltage V ref , its negative input terminal is connected to the source of the first transistor 112 and coupled to the switching circuit 91 and its output terminal is coupled to the gate of the first transistor 112 . If the operational amplifier 111 is an ideal amplifier, the voltage on the negative input terminal V ref ′ is substantially identical to the first reference voltage V ref on the positive input terminal. Therefore, a corresponding current I in3 can be determined by the voltage V ref ′ divided by the equivalent resistance of the switching circuit 91 , and their relationships are shown in Table 1.
The first current mirror 12 includes a second transistor 121 and a third transistor 122 having their gates connected with each other. If the ratio aspect of the transistor 121 is identical to that of the transistor 122 , a current aI in3 proportional to the current I in3 can be formed. Because the operation and implementation of a current mirror are well known by the person skilled in the art, their detailed descriptions will not be described herein.
TABLE 1
digital
output
SW 1
SW 2
SW 3
SW 4
I in3
V in3
signal
Off
Off
Off
Off
0
0
0000
Off
Off
Off
On
V ref /8R
aI in3 × R 5 = X
0001
Off
Off
On
Off
V ref /4R
aI in3 × R 5 = 2X
0010
Off
Off
On
On
(V ref /8R + V ref /4R)
aI in3 × R 5 = 3X
0011
Off
On
Off
Off
V ref /2R
aI in3 × R 5 = 4X
0100
Off
On
Off
On
(V ref /8R + V ref /2R)
aI in3 × R 5 = 5X
0101
Off
On
On
Off
(V ref /4R + V ref /2R)
aI in3 × R 5 = 6X
0110
Off
On
On
On
(V ref /8R + V ref /4R + V ref /2R)
aI in3 × R 5 = 7X
0111
On
Off
Off
Off
V ref /R
aI in3 × R 5 = 8X
1000
On
Off
Off
On
(V ref /8R + V ref /R)
aI in3 × R 5 = 9X
1001
On
Off
On
Off
(V ref /4R + V ref /R)
aI in3 × R 5 = 10X
1010
On
Off
On
On
(V ref /8R + V ref /4R + V ref /R)
aI in3 × R 5 = 11X
1011
On
On
Off
Off
(V ref /2R + V ref /R)
aI in3 × R 5 = 12X
1100
On
On
Off
On
(V ref /8R + V ref /2R + V ref /R)
aI in3 × R 5 = 13X
1101
On
On
On
Off
(V ref /4R + V ref /2R + V ref /R)
aI in3 × R 5 = 14X
1110
On
On
On
On
(V ref /8R + V ref /4R + V ref /2R + V ref /
aI in3 × R 5 = 15X
1111
R)
wherein X = (aV ref × R 5 )/8R
Referring to FIG. 4 again, an input end of the AD converter 20 , according to the first embodiment of the present invention, is connected between the first current mirror 12 and the first end of the resistor R 5 . The AD converter 20 is a voltage AD converter and its input voltage V in3 equals a multiplication of the current aI in3 and the resistor R 5 , i.e. V in3 =R 5 ×aI in3 as shown in Table 1, and hence the input voltage V in3 has linear characteristics. After the input voltage V in3 is converted by the AD converter 20 , a corresponding digital output signal will be outputted from the output bus N. The relationships between the conducting states of the switching circuit 91 , the input voltage V in3 of the AD converter 20 and the digital output signals are also shown in Table 1. In this embodiment, since the switching circuit 91 has four switches, the outputted digital signals are four-bit digital signals.
Referring to FIG. 5 , it illustrates a jack detection circuit according to the second embodiment of the present invention. The jack detection circuit also includes the switching circuit 91 , the AD converter 20 and the resistor R 5 , and the jack detection circuit also has a transition circuit 30 which has a reference voltage generator 31 and a current mirror 32 . This embodiment differs from the first embodiment in the types of the transistors, i.e. the transistors in the transition circuit 30 of the second embodiment are P-type transistors while the transistors in the transition circuit 10 of the first embodiment are N-type transistors. A negative input terminal of the operational amplifier 311 receives the first reference voltage V ref , its positive input terminal is connected to the source of the transistor 321 and coupled to the switching circuit 91 , and its output terminal is connected to the gate of the transistor 321 . In this manner, the transition circuit 30 can also transfer a first signal I in4 to a second signal aI in4 which varies linearly in accordance with the conducting states of the switching circuit 91 . Therefore, the AD converter 20 receives an input voltage V in4 =R 5 ×aIin 4 and can have linearly varied interval of comparison voltage.
Referring to FIG. 6 , it shows a jack detection circuit according to the third embodiment of the present invention. The jack detection circuit also includes the transition circuit 10 , the resistor R 5 and the switching circuit 91 . The differences herein with respect to the first embodiment are that the third embodiment further includes a comparison current circuit 40 and the type of the AD converter 50 is different. The transition circuit 10 also transfers a first signal I in5 to a second signal aI in5 , as described above. The comparison current circuit 40 comprises a second reference voltage generator 41 and a second current mirror 42 . The second reference voltage generator 41 has an operational amplifier 411 and a transistor 412 . A positive input terminal of the operational amplifier 411 receives a second reference voltage V ref ″ (in this embodiment the second reference voltage V ref ″ equals the first reference voltage V ref ), its output terminal is coupled to the gate of the transistor 412 , and its negative input terminal is connected to the source of the transistor 412 and coupled to a first end of the resistor R 5 . The second end of the resistor R 5 is coupled to a reference voltage, e.g. a ground end, so as to form a reference current I ref =V ref ″/R 5 flowing through the transistor 412 . In this embodiment, the second current mirror 42 maps the reference current I ref to a comparison current I c which is inputted, together with the second signal aI in5 of the transition circuit 10 , into the AD converter 50 to be compared, and finally a digital output signal will be outputted from the output bus N. The AD converter 50 in this embodiment is a current AD converter, which is utilized for comparing the second signal aI in5 outputted from the transition circuit 10 with the comparison current I c outputted from the comparison current circuit 40 , and the second signal aI in5 varies linearly in accordance with conducting states of the switching circuit 91 .
In addition, embodiments shown in FIG. 4 , FIG. 5 and FIG. 6 can be varied and implemented by other circuit structure, for example but not limited to, interchanging the V CC and the ground shown in all figures.
Although the invention has been explained in relation to its preferred embodiment, it is not used to limit the invention. It is to be understood that many other possible modifications and variations can be made by those skilled in the art without departing from the spirit and scope of the invention as hereinafter claimed. | A jack detection circuit includes a transition circuit and an AD converter. The transition circuit linearizes analog signals sent from a switching circuit. The AD converter converts the linearized analog signals to digital output signals thereby decreasing the complexity of signal recognition. | 7 |
FIELD OF THE INVENTION
The present invention relates to a seat elevating mechanism for chair designed to provide a supporting force that helps old men and patients to get up from or sit on a chair effortlessly.
BACKGROUND OF THE INVENTION
An old man or a patient with weak legs and slow movement has difficulty in sitting on a chair safely and effortlessly, and therefore frequently needs help of an attendant to sit on the chair. It is even more laborious for the old man or the patient having injured or weak legs to get up from the chair, particularly when there is not an attendant.
There are chairs with an elevating seat available in the market designed for the aged and some patients. The elevating seats of these conventional chairs are slightly higher than that of other normal chairs, and are therefore not comfortable for sitting. Since the conventional elevating seats are normally elevated using an air pump, the users still need to exert strength at two legs to get up from the elevated seats. Another disadvantage of the conventional elevating seats is the seats are forward and downward inclined when being elevated, preventing the users from stably sitting thereon. The conventional chairs with elevating seats are therefore not safe and inconvenient for use.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a seat elevating mechanism for chair, in which the seat of the chair is electrically driven to elevate, so that a user may stably sit thereon while the seat is gradually elevated and horizontally moved forward, and may get up from the chair effortlessly when the elevated seat reaches at a desired height.
The seat elevating mechanism for chair according to the present invention includes a chair, a two-piece seat, a seat support, and a telescopic lifter. The seat support includes a mounting bracket fixedly mounted to a front side of the chair, and a seat-board supporting frame having front and rear portions for supporting front and rear seat boards, respectively, to a top thereof. The front and the rear portion of the seat-board supporting frame are pivotally connected to one another at two laterally spaced pivoting points. The telescopic lifter may be actuated to push the rear portion of the seat-board supporting frame upward, so that the seat-board supporting frame and the seat boards thereon are elevated and horizontally moved forward, allowing a user stably sit thereon to get up easily.
In the seat elevating mechanism for chair according to the present invention, the rear portion of the seat-board supporting frame is always in a horizontal position in the course of elevating or lowering, allowing the user to stably sit thereon.
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 a front perspective view of a chair with a seat elevating mechanism according to the present invention, wherein the seat is in a fully lowered position;
FIG. 2 is a partially phantom view showing the structure of the seat elevating mechanism of the present invention, wherein the seat elevating mechanism is in an elevated position;
FIG. 3 is a partially sectioned side view showing the seat elevating mechanism of the present invention in the elevated position;
FIG. 4 is a partially sectioned side view showing the seat elevating mechanism of the present invention in a fully lowered position; and
FIG. 5 is a front perspective view of the chair of FIG. 1 with the seat in the elevated position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Please refer to FIGS. 1 and 2 . The present invention relates to a seat elevating mechanism for a chair 10 . As shown, the set elevating mechanism mainly includes a two-piece seat 20 consisting of a front and a rear seat board 21 , 22 , a seat support 30 , and a telescopic lifter 40 .
The seat support 30 includes a mounting bracket 31 fixedly mounted to a front side of the chair 10 at a predetermined position, a seat-board supporting frame 32 for supporting the two seat boards 21 , 22 to a top thereof, two laterally corresponded horizontal arms 33 fixedly connected at one end to the fixed mounting bracket 31 , and two links 34 .
The whole seat-board supporting frame 32 is pivotally connected at a front side to the fixed mounting bracket 31 , so as to pivotally turn about two pivoting points 51 relative to the mounting bracket 31 . The seat-board supporting frame 32 includes a front and a rear portion 321 , 322 that are pivotally connected to one another at two laterally spaced pivoting points 52 , and respectively support the front and the rear seat boards 21 , 22 thereon.
Each of the two links 34 has a first end pivotally connected to a free end of one of the horizontal arms 33 to turn about a pivoting point 53 , and a second end pivotally connected to the rear portion 322 of the seat-board supporting frame 32 to turn about a pivoting point 54 , such that the pivoting points 51 for the front side of the seat-board supporting frame 32 and the fixed mounting bracket 31 , the pivoting points 52 for the front and the rear portion 321 , 322 of the seat-board supporting frame 32 , and the pivoting points 53 , 54 for the two ends of the links 34 together form four points of a parallelogram.
The telescopic lifter 40 includes a base 41 pivotally connected to the rear portion 322 of the seat-board supporting frame 32 at a predetermined point, and an extendable pipe 42 having an outer end pivotally connected to a rear bottom crossbar 11 of the chair 10 at a predetermined point. When the telescopic lifter 40 is actuated, it pushes the rear portion 322 of the seat-board supporting frame 32 upward and thereby elevates the seat 20 supported on the seat-board supporting frame 32 while moving the seat 20 forward, enabling a person sitting on the seat 20 to get up easily.
Please refer to FIG. 3 . When the extendable pipe 42 of the telescopic lifter 40 is extended, the seat-board supporting frame 32 is elevated. Since the above-mentioned four pivoting points 51 , 52 , 53 , and 54 form four points of a parallelogram, the rear portion 322 of the frame 32 is always in parallel with the horizontal arms 33 , which are fixedly connected to the mounting bracket 31 . And, since the horizontal arms 33 are horizontally fixedly mounted on the chair 10 , the rear portion 322 of the seat-board supporting frame 32 is always in a horizontal position, allowing a user, particularly an old man to sit on the seat 20 stably. When the telescopic lifter 40 gradually pushes the seat 20 upward, the front portion 321 of the seat-board supporting frame 32 is turned about the pivoting points 51 at the front side of the seat-board supporting frame 32 , bringing the rear portion 322 to gradually move forward while being elevated, and enabling the old man to get up from the seat more easily.
In practical use of the chair 10 , a back cushion 12 is attached to a back of the chair 10 , and front and rear seat cushions 13 , 14 are separately attached to the two seat boards 21 , 22 of the seat 20 , so that the chair 10 is more comfortable for sitting. To help an old man to sit on the rear seat cushion 14 , first elevate the seat-board supporting frame 32 to a desired height, as shown in FIG. 5 , so that the old man's hips are in contact with and slightly seated on the rear seat cushion 14 . Then, the telescopic lifter 40 is operated to retract the extendable pipe 42 , so that the seat-board supporting frame 32 and the rear seat cushion 14 are gradually lowered for the old man to sit down effortlessly.
The telescopic lifter 40 is a known mechanism, and the extendable pipe 42 is driven to move by an electric motor. When the extendable pipe 42 of the telescopic lifter 40 is caused to retract, a weight must be applied to the telescopic lifter 40 to lower the seat-board supporting frame 32 . This design makes the seat elevating mechanism of the present invention safer for use. This type of telescopic lifter 40 is referred to as a passively retractable telescopic lifter 40 and has been widely supplied in the market for many years. More specifically, when the extendable pipe 42 of the telescopic lifter 40 is gradually retracted, a distance by which the seat-board supporting frame 32 is elevated with the telescopic lifter 40 is gradually reduced at the same time. At this point, an overall weight of the user, the frame 32 , and the base 41 of the telescopic lifter 40 would cause the seat-board supporting frame 32 to move downward and finally reach a fully lowered horizontal position, as shown in FIG. 4 . However, in practical design of the chair 10 , it is possible for the seat-board supporting frame 32 to lower under only the weight of the supporting frame 32 and the base 41 when the extendable pipe 42 is operated to retract.
It is preferable to have two laterally corresponded links 34 , so that the whole seat elevating mechanism of the present invention may be moved in a stable manner. A switch 15 is provided to a lower front of one armrest 16 of the chair 10 for conveniently controlling the operation of the telescopic lifter 40 by a user.
In brief, the seat elevating mechanism for a chair according to the present invention uses simple linkage for the seat to gradually elevate while maintaining in a horizontal position, so that an old man or a patient may be stably and effortlessly moved to an almost upright position. Moreover, the seat is moved forward while being elevated, allowing the old man or the patient to stand up more easily. Therefore, the present invention actually provides a power-controlled elevating chair very suitable for the aged. | A seat elevating mechanism for chair particularly designed for old men and patients having weak legs mainly includes a seat that can be elevated or lowered using a power-actuated telescopic lifter. The seat is maintained in a horizontal position while being elevated or lowered, so that a user may stably sit thereon until the seat is fully elevated or lowered to enable the user to get up or sit down effortlessly. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to syringe assemblies and particularly to syringe assemblies for use in I.V. flush procedures.
[0002] An I.V. catheter is a commonly used therapeutic device. Many patients, in accordance with their therapy, have an I.V. catheter connected to a vein ready for use in various procedures or in fluid communication with an I.V. system for infusing liquids and medication. Many I.V. sets have I.V. ports which are in fluid communication with a catheter and allow access for the purpose of injecting medication into the patient, and for use in flushing techniques to maintain catheter integrity. Healthcare facilities have flushing protocols which depend on the amount of time the catheter will remain in the patient and the type of catheter being used. For example, a peripherally inserted central catheter (PICC) is a long flexible catheter, which is typically inserted into the central venous system (optimally with the tip terminating in the superior vena cava) via the superficial veins of the antecubital fossa. PICC lines are designed for use when intermediate or long-term therapy is prescribed.
[0003] These catheter lines must be periodically flushed with saline flush solution and/or heparin lock flush solution depending on the protocol. Among other things, flushing saline solution removes blood from the catheter and heparin helps prevent the formation of future blood clots. The most common I.V. ports are covered by pierceable septums or pre-slit septums and are known in the art and sometimes referred to as “PRN” from the Latin pro re nata meaning “as the need arises”. The septum is preferably made of rubber or another elastomeric material which permits insertion of a sharp needle cannula in order to infuse fluids into or to withdraw fluids from the catheter. Upon withdrawal of the needle cannula the septum seals itself. Ports having pre-slit septums are used with blunt cannula. Typically, the blunt cannula is attached to a syringe and the syringe is moved to place a gentle pressure on the pre-slit septum which is forced open by the blunt cannula to establish fluid communication. Also, some I.V. sets have access valves which are responsive to the frusto-conically shaped tip of a syringe barrel for allowing fluid communication between the interior of the syringe and the catheter without the use of a cannula.
[0004] Catheters are flushed using syringe assemblies filled with various fluids. In some cases, different fluids are injected sequentially in accordance with the protocol. For example, a saline solution followed by an anticoagulant such as heparin. The size of the syringe used to flush I.V. lines varies by various factors including the size and length of the catheter. Typically syringes of 1 ml, 3 ml, 5 ml and 10 ml volume are used.
[0005] It is important in the flush procedure not to draw blood back into the catheter where it can clot and seal the catheter, commonly referred to as “reflux”. In order to prevent blood reflux into the catheter the user is encouraged to maintain a positive pressure in the line during the flush procedure. This may involve clamping the IV line and withdrawing the syringe and cannula from the I.V. port while still applying pressure to the syringe plunger rod during the flush procedure. When using a syringe with an elastomeric stopper, the stopper is often compressed when it contacts the distal end of the syringe barrel at the completion of the flush procedure. When a user relieves the pressure to the plunger after the flush procedure is completed, the stopper will expand back to its normal size drawing liquid from the catheter into the syringe barrel. This is undesirable, since it can cause blood to enter the catheter at the catheter distal end (reflux). Problems with reflux of blood into the catheter are on the rise because IV lines are now being flushed by a wide variety of health care workers not just those dedicated to catheter maintenance. These other health care workers, as a result of having many other aspects of patient care to be responsible for and who spend much less time flushing IV lines, are not as efficient as those dedicated to catheter maintenance.
[0006] Therefore there is a need for simple, straight forward easy-to-manufacture syringe assemblies which helps reduce or eliminate reflux of blood into the catheter during and after the flushing procedure has occurred even if flush protocols and procedures are not precisely followed. For example, prematurely releasing the compressive force on the stopper, which may cause reflux of blood into the catheter.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a syringe assembly for use in flush applications. The syringe assembly reduces or eliminates reflux of blood into the catheter by providing a proximally facing annular boss on the inside surface of the distal wall of the syringe barrel. The boss projects into the fluid containing chamber of the barrel and surrounds the passageway in the barrel tip through which flush solution is discharged. The annular boss is positioned so that it contacts the distal surface of the stopper and seals the passageway before other portions of the inside surface of the distal wall of the barrel surrounding the boss contact the stopper. Further compression of the stopper will be independent of this seal so that reflux is reduced or eliminated.
[0008] An I.V. flush syringe assembly comprises a barrel including a cylindrical sidewall having an inside surface defining a chamber for retaining fluid. The barrel includes an open proximal end and a distal end having a distal wall with an elongate tip extending distally therefrom. The tip includes a passageway therethrough in fluid communication with the chamber. The plunger having an elongate body portion includes a proximal end, a distal end and a stopper slidably positioned in fluid-tight engagement with the inside surface of the barrel for drawing fluid into and driving fluid out of the chamber by movement of the stopper relative to the barrel. The elongate body portion of the plunger extends outwardly from the open proximal end of the barrel. The stopper has a distal surface. Anti-reflux structure is provided for controlling stopper deflection when fluid has been delivered from the chamber and the stopper is in contact with the distal wall of the barrel. Anti-reflux structure may include a stopper preferably having a conically shaped distal surface and a proximally-facing annular boss in the barrel for sealing the passageway in the distal tip of the barrel.
[0009] The syringe assembly may further include at least one projection on the distal surface of the stopper positioned mostly in the space between the distal surface of the stopper and the conically shaped inside surface of the distal wall of the barrel when the distal surface of the stopper first contacts the conically shaped inside surface.
[0010] The syringe assembly may also include flush solution in the chamber and a tip cap releasably connected to the tip of the syringe barrel for sealing the passageway. The flush solution may be selected from the group consisting of saline flush solution and heparin lock solution.
[0011] The syringe assembly may further include a needle assembly including a cannula having a proximal end, a distal end, and a lumen therethrough. A hub having an open proximal end containing a cavity and a distal end attached to the proximal end of the cannula so that the lumen is in fluid communication with the cavity of the hub. The needle assembly is removably attached to the tip of the barrel through engagement of the tip to the cavity of the hub so that the lumen is in fluid communication with the chamber of the barrel.
[0012] Another embodiment of the I.V. flush syringe assembly of the present invention comprises a barrel including a cylindrical sidewall having an inside surface defining a chamber for retaining fluid. The barrel includes an open proximal end and a distal end having a distal wall with an elongate tip extending distally therefrom having a passageway therethrough in fluid communication with the chamber. A plunger includes an elongate body portion having a proximal end, a distal end and a stopper slidably positioned in fluid-tight engagement with the inside surface of the barrel for drawing fluid into and driving fluid out of the chamber by movement of the stopper relative to the barrel. The elongate body of the plunger extends outwardly from the open proximal end of the barrel. The stopper includes a distal surface. A tip cap is releasably connected to the elongate tip of the barrel for sealing the passageway. A quantity of flush solution is in the chamber between the stopper and the distal wall. Anti-reflux structure for controlling stopper deflection when fluid has been delivered from the chamber and the stopper is in contact with the distal wall is provided. The anti-reflux structure may include an annular boss on the inside surface of the distal wall of the barrel surrounding the passageway. The boss is positioned so that it contacts the distal surface of the stopper and seals the passageway before portions of the inside surface of the distal wall surrounding the boss contact the distal surface of the stopper. The inside surface of the distal wall may be conically shaped and the annular boss raised from the conically shaped inside surface. The distal surface of the stopper may be conically shaped and projecting toward the annular boss. At least one projection on the distal surface of the stopper is provided. The at least one projection is positioned and/or sized so that when the stopper contacts the annular boss in the barrel, any deflection of the projection will not store enough energy to move the stopper proximally to the extent the stopper is disengaged from the inside surface of the distal end of the barrel near the passageway.
[0013] A method of flushing a catheter of the present invention comprises the steps of providing a syringe assembly having a barrel including a cylindrical side wall having an inside surface defining a chamber for retaining fluid, an open proximal end and a distal end including a distal wall with an elongate tip extending distally therefrom having a passageway therethrough in fluid communication with the chamber, a plunger including an elongate body portion having a proximal end, a distal end and a stopper having a distal surface wherein the stopper is slidably positioned in fluid-tight engagement with the inside surface of the barrel for drawing fluid into and driving fluid out of the chamber by movement of the stopper relative to the barrel, the elongate body portion extending outwardly from the open proximal end of the barrel, a quantity of flush solution in said chamber, and anti-reflux means in the barrel for minimizing stopper deflection when the flush solution has been delivered from the chamber and the stopper is in contact with and pressed against the distal wall. The method further includes providing a catheter having a proximal end, a distal end and a passageway therethrough and a housing having a hollow interior in fluid communication with the passageway, the housing having an access valve capable of engaging the elongate tip of the barrel for allowing fluid communication with the hollow interior of the housing. The method further includes the steps of placing the distal end of the catheter in a blood vessel; engaging the elongate tip of the barrel with the access valve so that the passageway in the tip is in fluid communication with the hollow interior of the housing; applying force to the plunger to move the plunger in a distal direction with respect to the barrel so that the flush solution in the chamber flows through the passageway into the hollow chamber of the housing and through the passageway of the catheter; continuing to apply force to the plunger until the stopper contacts and presses against the distal wall of the barrel; and disengaging said syringe assembly from said access valve.
[0014] An alternative method may include the step of attaching a needle assembly to the elongate tip of the barrel. The needle assembly includes a cannula having a proximal end, a distal end and a lumen therethrough and a hub having an open proximal end containing a cavity and a distal end attached to the proximal end of the cannula so that the lumen is in fluid communication with the cavity. The attachment of the needle assembly to the barrel is through frictional engagement between the cavity in the hub and the elongate tip. This alternative method is used with a catheter having a proximal end, a distal end and a passageway therethrough and a housing having a hollow interior connected to the catheter and in fluid communication with the passageway of the catheter. The housing further includes a septum for allowing fluid communication with the hollow interior. Fluid communication is established by forcing the distal end of the cannula through the septum so that the lumen of the cannula is in fluid communication with the hollow interior of the housing. Also, the cannula may be permanently attached to the barrel tip with or without the use of a hub. At completion of the flush procedure the cannula is withdrawn from the septum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a syringe assembly according to one embodiment of the invention.
[0016] FIG. 2 is a partially cross-sectioned side elevational view of the syringe assembly of FIG. 1 with a needle assembly attached.
[0017] FIG. 3 is a cross-sectional view of the syringe assembly of FIG. 1 taken along line 3 - 3 .
[0018] FIG. 4 is a partial perspective view of the stopper and distal end of the plunger of the syringe assembly of FIG. 1 .
[0019] FIG. 5 is an enlarged partial cross-sectional side elevation view of the distal end of the syringe assembly of FIG. 2 .
[0020] FIG. 6 is an enlarged partial cross-sectional side elevational view of the distal end of the syringe assembly shown at the completion of a flush procedure.
[0021] FIG. 7 is a side-elevational view illustrating the syringe assembly in use with a catheter injection site.
DETAILED DESCRIPTION
[0022] Referring to FIGS. 1-6 , a syringe 20 according to the present invention generally comprises a barrel 22 , and a plunger 24 . The barrel 22 has a generally cylindrical side wall 23 including an open proximal end 28 having finger grips 29 , a distal end 30 having a distal wall 31 and an inside surface 32 defining a chamber 33 for retaining fluid. The inside surface of the barrel at the distal wall is preferably conically shaped and includes a proximally facing annular boss 35 . Distal end 30 further includes a tip 36 having a passageway 38 in fluid communication with the chamber. The distal end of barrel 22 preferably, but not necessarily includes a locking luer type collar 40 concentrically surrounding tip 36 . The inside surface of the collar includes at least one thread 43 . A cannula 26 includes a proximal end 42 , a distal end 44 and a lumen 46 therethrough. The distal end may include a sharp tip or a blunt tip 48 as shown. The cannula may be connected directly to the tip of the syringe barrel to establish fluid communication between the lumen and the chamber. Also, the cannula may be part of a needle assembly 27 including a hub 34 having an open proximal end 37 containing a cavity 41 and a distal end 39 attached to the proximal end of the cannula so that the lumen of the cannula is in fluid communication with the cavity. The cavity of the hub can be removably frictionally engaged to the tip of the barrel as illustrated in FIGS. 2, 5 and 6 .
[0023] Plunger 24 includes an elongate body portion 25 , a proximal end 50 having a flange 51 , and a distal end 52 . A stopper 54 is disposed on projection 53 at distal end 52 of the plunger, preferably via threading engagement. Stopper 54 includes at least one rib and preferably a plurality of ribs 56 on its outside diameter. The stopper is slidably positioned in fluid-tight engagement with the inside surface of the barrel for drawing fluid into and drawing fluid out of the chamber, through the passageway, by movement of the stopper relative to the barrel. Stopper 54 includes a proximal end 55 having a cavity 57 therein for engaging projection 53 on the distal end 52 of the plunger. Stopper 54 further includes a distal end 58 having a distal surface 59 thereon. Distal surface 59 is preferably conically shaped.
[0024] Stopper 54 preferably includes at least one projection or lug 60 on distal surface 59 . Projection 60 keeps the stoppers from nesting or sticking to each other during the assembly process. For example, the distal surface of one stopper may position itself in the cavity of another stopper while the stoppers are together before assembly.
[0025] The stopper may be made of any material suitable for providing sealing characteristics while under compression. For example, the stopper may be made of thermoplastic elastomers, natural rubber, synthetic rubber or thermoplastic materials and combinations thereof. The plunger in this embodiment is preferably made of material which is more rigid than the stopper such as polypropylene, polyethylene and the like.
[0026] In operation, syringe 20 is connected to a needle assembly and filled with flush solution using known methods. The flush solution may be any solution intended for flushing. It is preferred that the flush solution be selected from the group consisting of saline flush solution and heparin lock flush solution. These solutions are known in the art and readily available. An example of a saline flush solution is 0.9% Sodium Chloride USP. An example of a heparin lock flush solution is 0.9% Sodium Chloride with 100 USP units of Heparin Sodium per ml or 10 USP units of Heparin Sodium per ml. The syringe with needle assembly attached is used to pierce the pierceable septum or a blunt cannula may be inserted into a pre-split septum of a vial containing flush solution and the flush solution is drawn into the syringe barrel by pulling plunger rod flange 51 in the proximal direction while holding barrel 22 , to draw fluid through the needle cannula into fluid chamber 33 .
[0027] Alternatively, the syringe may be filled with flush solution during the manufacturing of the syringe via a sterile filling method. Such prefilled syringes may be supplied with a tip cap, such as tip cap 45 releasably connected to tip 36 sealing passageway 38 . It is preferred that the tip cap is formed of material selected from the group of thermoplastic materials and elastomeric materials such as natural and synthetic rubber and thermoplastic elastomers.
[0028] The syringe is now ready for use in flushing a catheter of an I.V. set. I.V. sets can be very complicated and may include multiple injection ports, a valve and/or other components. For the purpose of illustrating the present invention a simplified I.V. set 64 is illustrated in FIG. 7 . I.V. set 64 comprises an I.V. site 65 which includes a housing 67 having a hollow interior 68 and a septum 69 at its proximal end. A catheter 70 having a conduit therethrough extends from the distal end of the housing. For this I.V. set septum 69 is pre-slit for use with blunt cannula. The I.V. site may be a valve having structure for accepting the syringe barrel tip and being activated by the insertion of the barrel tip to establish fluid communication with the catheter, such as the valve taught in U.S. Pat. No. 6,171,287.
[0029] Blunt tip 48 of cannula 26 may be inserted through pre-split septum 69 of I.V. set 64 . Alternatively, a sharp tip of a needle cannula may be used to pierce a septum that is not pre-split, or the tip of the barrel may be engaged with a valve in the I.V. site. This establishes fluid communication between the interior 68 of the I.V. set and the chamber of the syringe barrel. The syringe barrel 22 is preferably held via finger grips 29 . Pressure is then applied to flange 51 of the plunger, for example by a thumb, in the distal direction. This moves the plunger 24 having the stopper 54 on its distal end forcing the liquid such as flush solution 71 in the chamber 34 out of the chamber, through cannula 26 and into interior 68 of the I.V. set and then through catheter 70 .
[0030] Referring to FIG. 6 , the position of the plunger and stopper at the completion of the flush procedure is shown. At the completion of the flush procedure distal surface 59 of the stopper contacts annular boss 35 , inside the area of the stopper projection, sealing the passageway so that further deflection of the stopper will have little or no effect on liquid in the passageway and the catheter. Accordingly, stopper deflection caused by additional unnecessary force applied to the plunger, at this time, which could cause reflux of blood into the catheter using prior art syringes, is minimized or eliminated with the syringe of the present invention. The stopper may flex, however, this flexure will occur generally outside of the sealed area on the annular boss which surrounds the entrance to the passageway. In addition, projection 60 is shaped so that upon further deflection of the stopper through forces applied to the plunger, the projection will not be able to force the stopper to move proximally. That is, the projection cannot create enough force to move the stopper proximally to create reflux. It is preferred that the projection on the distal surface of the stopper be positioned mostly in space 61 between the distal surface of the stopper and the inside surface of the distal wall of the barrel as illustrated in FIG. 6 . The projection should be sized and positioned so that it cannot absorb enough energy during deflection to move the stopper proximally and break the seal between the stopper and the barrel at the annular boss. The projection can have a variety of shapes including the raised rectangular shape illustrated. The projection may also be angularly shaped having a distal surface at the same angle as the inside surface of the barrel.
[0031] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as disclosed. | An I.V. flush syringe assembly includes a barrel having an inside surface defining a chamber for retaining fluid, an open proximal end and a distal end including a distal wall with an elongate tip extending distally therefrom having a passageway therethrough in fluid communication with the chamber. A plunger having an elongate body portion and a stopper slidably positioned in fluid-tight engagement with the inside surface of the barrel is provided. Anti-reflux structure in said barrel is provided for controlling stopper deflection when fluid has been delivered from the chamber and the stopper is in contact with structure on the distal wall. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application claims priority on U.S. Provisional Patent Application No. 60/891,803, filed on Feb. 27, 2007, by the present applicant.
BACKGROUND OF THE APPLICATION
[0002] 1. Field of the Application
[0003] The present application relates to portable shelters used as alternatives to garages for vehicles, and more particularly to a door assembly for such portable shelters.
[0004] 2. Background Art
[0005] Portable shelters for vehicles have been developed as an alternative to garages. For car owners who do not have access to a garage, a portable shelter allows the car to be protected from snow and from the sun, amongst other elements. In severe winter climates, a portable shelter conveniently protects the car from snow, saving the car user some time, as the time required to shovel the driveway and brush the snow off the car is greatly reduced.
[0006] However, a garage has the advantage of being closeable. As such, snow cannot be blown into the garage in windy and snowy conditions, the garage can be heated, and items can be concealed in the garage.
SUMMARY OF APPLICATION
[0007] It is therefore an aim of the present application to provide a portable shelter that addresses issues associated with the prior art.
[0008] Therefore, in accordance with the present application, there is provided a retractable door assembly for an entrance/exit of a portable shelter comprising: a door having a panel of flexible material with a first edge and a second edge; at least one support rod, the door being connected to the support rod at the first edge and rolled onto the support rod; supports operatively connected to ends of the support rod and adapted to connect the support rod on a structure of the portable shelter with respect to the entrance/exit of the portable shelter, such that the support rod is rotatable about its longitudinal axis; and an actuator system operatively connected to the support rod to actuate a rotation of the support rod to deploy the door to close the entrance/exit and retract the door to free the entrance/exit of the portable shelter.
[0009] Further in accordance with the present application, there is provided a retractable door assembly in combination with a portable shelter comprising: a portable shelter having a structure and flexible panels secured to the structure to define a volume for accommodating at least one vehicle and at least one entrance/exit; and a retractable door assembly comprising a door having a panel of flexible material defining a first edge and a second edge, at least one support rod, the door being connected to the support rod at the first edge and rolled onto the support rod, supports operatively connected to ends of the support rod and adapted to connect the support rod on a structure of the portable shelter with respect to the entrance/exit of the portable shelter, such that the support rod is rotatable about its longitudinal axis, and an actuator system operatively connected to the support rod to actuate a rotation of the support rod to deploy the door to close the entrance/exit and retract the door to free the entrance/exit of the portable shelter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a portable shelter in accordance with the prior art;
[0011] FIG. 2 is a structure of the portable shelter of FIG. 1 ;
[0012] FIG. 3 is a schematic view of a retractable door assembly in accordance with a first embodiment of the present application, as used with the portable shelter of FIG. 1 ;
[0013] FIG. 4 is a perspective view of a structure of a portable shelter in combination with a retractable door assembly in accordance with a second embodiment of the present application;
[0014] FIG. 5 is an enlarged view of the structure and retractable door assembly of FIG. 4 ; and
[0015] FIG. 6 is an enlarged view of the structure and retractable door assembly of FIG. 4 , with a tool for manually retracting the door.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring now to the drawings, and more particularly to FIG. 1 , a portable shelter or vehicle shelter in accordance with the prior art is generally shown at 10 . The portable shelter 10 has a structure 12 upon which a covering 13 is tautened, so as to define the enclosure or volume in which the vehicle is stored. It is pointed out that the shelter 10 can be of different dimensions, for instance to be used to accommodate more than one car, lengthwise or widthwise. The covering 13 is typically made of panels of flexible material (e.g., plastic sheets, reinforced panels, tarp, etc.). The shelter 10 defines an entrance/exit 14 providing access to the portable shelter 10 .
[0017] Referring to FIG. 2 , a typical configuration for the structure 12 of the shelter 10 is illustrated. Amongst structural members, the structure 12 has columns 15 , longitudinal beams 16 and transverse beam 18 .
[0018] Referring to FIG. 3 , a retractable door assembly in accordance with a first embodiment is generally shown at 20 . The retractable door assembly 20 is suitably used with portable shelters such as the portable shelter 10 of FIGS. 1 and 2 .
[0019] In the embodiment of FIG. 3 , the retractable door assembly 20 has a support rod 22 . A door 24 consisting of a panel of flexible material is rolled around the support rod 22 , such that rotations of the support rod 22 about its longitudinal axis retract/deploy the door 24 , as illustrated by directions A.
[0020] Supports 26 are provided on opposed ends of the support rod 22 . In the embodiment of FIG. 3 , the supports 26 each enclose bearings so as to allow the rotation of the support rod 22 about its longitudinal axis, as illustrated by directions B. The supports 26 are secured to the structure 12 of the shelter 10 , and are, as an example, illustrated as being hooked to the longitudinal beams 16 . Fasteners are typically used to ensure that the supports 26 are removably anchored to the structure 12 . In another example, the supports 26 are secured to the transverse beam 18 or atop the columns 15 , with the rod 22 being spaced enough from the beam 18 to be operable.
[0021] An actuation system incorporates the motor 28 that is positioned adjacent to the support rod 22 , on the longitudinal beam 16 as well. The motor 28 actuates the rotation of the support rod 22 , by way of transmission 30 , in either direction. The transmission 30 is, in the embodiment of FIG. 3 , a belt with pulleys on the shaft of the motor 28 and on the rod 22 . Other transmissions are considered, such as gears or a chain with sprockets, amongst other possibilities. Considering the forces between the motor 28 and the rod 22 , the motor 28 must be anchored to the structure 12 to withstand the transmission of forces.
[0022] The motor 28 is connected to a power source, such as an adjacent power network. As alternatives, it is considered to provide the actuation system of the retractable door assembly 20 with a rechargeable battery, with for instance solar panels positionable on the outside of the shelter 10 to recharge the battery. The battery is selected so as to provide enough storage to be used as the single source of power for the actuation system.
[0023] The motor 28 is preferably provided with a remote control, such that the retraction/deployment of the door 24 can be performed from the vehicle. A remote control using RF signals can suitably be used for wireless communication with the motor 28 , such that the door 24 can be retracted from the vehicle.
[0024] A ballast 32 is optionally positioned on a bottom edge of the tarp door 24 . The ballast 32 provides stability to the door 24 once the door 24 is unrolled to close the entrance 14 of the shelter 10 . As an alternative, releasable connectors 34 in the form of Velcro™ strips are provided on the lateral edges of the door 24 , to releasably secure the door 24 to complementary strips on the periphery of the entrance 14 . The presence of connectors 34 must be taken into consideration if a remote control is used with the retractable door assembly 20 . More specifically, all necessary precautions must be taken so as to ensure that the door 24 is not retracted while being secured to the shelter 10 , or that the connection forces can be overcome by the action of the motor 28 without damaging the door 24 . The ballast 32 advantageously overcomes this problem.
[0025] When the ballast 32 is used, the selection of the sizing of the motor 28 must take into account the additional weight of the ballast 32 . The anchoring of the retractable door assembly 20 to the structure 12 of the shelter 10 must also be capable of sustaining this additional weight. The ballast 32 typically consists of a pocket in which a readily-accessible material is accommodated (e.g., sand, ice).
[0026] Referring concurrently to FIGS. 4 and 5 , a shelter in accordance with another embodiment is generally shown at 10 ′. The shelter 10 ′ is similar to the shelter 10 of FIGS. 1 and 2 , but is expandable/retractable in directions B. Accordingly, the shelter 10 ′ is readily deployed or put away in storage, or kept permanently on site in the retracted configuration. Anchoring devices are illustrated at C in FIG. 4 , so as to anchor the shelter 10 ′ to the ground or alternatively to surrounding structural walls. It is considered to have the roof be removable from a remainder of the structure, to facilitate storage of the shelter 10 ′. It is also considered to provide casters at the bottom of the structure 12 to facilitate the expansion or retraction of the shelter 10 ′.
[0027] The shelter 10 ′ is used in combination with retractable door assembly 20 ′. The retractable door assembly 20 ′ is similar to the retractable door assembly 20 , whereby like reference numerals represent like elements. The retractable door assembly 20 ′ has supports 26 ′ by which it is anchored atop the columns 15 , for instance by being bolted to the columns 15 . The supports 26 ′ support the rod 22 , the electric motor 28 , as well as gears 30 ′ which will transmit motion from the electric motor 28 to the rod 22 . The supports 26 ′ support the rod 22 by way of bearings or like member enabling rotation of the rod 22 .
[0028] A PCB controller 36 , a transformer 38 and emitter 40 /receiver 42 , and a manual switch are provided as part of the actuation system of the retractable door assembly 20 ′. More specifically, the PCB controller 36 controls the signals received from the remote control and from the detectors (i.e., the emitter 40 /receiver 42 ), so as to control the closing/opening of the door 24 . The transformer 38 is provided to ensure a suitable voltage is provided to the motor 28 and to the PCB controller 36 . For instance, the motor 28 preferably runs on 24 V voltage. It is pointed out that the transformer 38 may enclosed in the casing of the PCB controller 36 .
[0029] The retractable door assemblies 20 / 20 ′ may be provided in the form of retrofit kits that can be used with existing temporary shelters. In such a use, the support rod 22 is sized as a function of the width of the entrance 14 , or may be a telescopic rod adapting to different widths.
[0030] As the interior of the portable shelter 10 can be concealed with the door 24 , it is considered to provide heating in the portable shelter 10 . In such a case, all necessary precautions must be taken, considering that the tarp of the shelter 10 is made of a flammable material.
[0031] The retractable door assembly 20 / 20 ′ may suitably be used with other types of shelters that have an opened entrance. Moreover, the retractable door assembly 20 may be sold with the shelter 10 . Although the retractable door assemblies 20 / 20 ′ have been described with the door 24 moving upward/downward in retraction/deployment ( FIG. 3 ), it is considered to provide a retractable door assembly in which the door deploys from one side to another (e.g., left to right), similar to the lateral movement of an elevator door. In such a case, a rail is provided to support a free upper end of the door, so as to guide the door in its movement.
[0032] As illustrated in FIG. 6 , a manual override is optionally provided to actuate the motor 28 without the remote control. For instance, in the case of a power outage, the ratchet 44 or similar tool is used to open or close the door.
[0033] In another embodiment, the door (or doors) is a hinged door, pivoting about a vertical or horizontal axis as actuated by a motor. In the case in which the retractable door assembly has a hinged door, a frame is provided on the periphery of the door to maintain the tarp of the door tautened. | A retractable door assembly for an entrance/exit of a portable shelter comprises a door having a panel of flexible material. The door is rolled onto the support rod. Supports are operatively connected to ends of the support rod and are adapted to connect the support rod on a structure of the portable shelter with respect to the entrance/exit of the portable shelter, such that the support rod is rotatable about its longitudinal axis. An actuator system is operatively connected to the support rod to actuate a rotation of the support rod to deploy the door to close the entrance/exit and retract the door to free the entrance/exit of the portable shelter. | 4 |
FIELD OF THE INVENTION
This invention relates to a serial bus cable for connecting an external electronic apparatus such as a mobile phone with a serial bus port of a Personal Computer (PC) or other electronic or electrical device. More particularly the invention relates to a serial bus cable which is incorporated within and supported by an elongated strap, said strap being useful for one or more of a variety of purposes related to carrying, binding, and securing items.
BACKGROUND
Increasingly, PCs and other electronic devices have one or more serial bus ports as a standard specification. Peripherals of all types typically contain a serial bus port for connection to PCs, tablets, and other computing devices. Universal Serial Bus (USB) ports are increasingly standard for power and data connections to mobile telephones and other electronic devices. Power outlets and batteries are now commonly designed to contain USB ports and to use these USB ports to provide Direct Current (DC) power for mobile telephones and other electronic devices.
A method for supplying DC power to a display device through a USB port is disclosed in Japanese Patent Publication No. JP10-326128. A method for supplying DC power to a mobile phone through a USB port is disclosed in U.S. Patent Publication No. U.S. Pat. No. 6,211,649 B1. An adaptor for providing a source of DC power to a mobile device through a serial bus port is disclosed in U.S. Patent Publication No. U.S. Pat. No. 7,239,111 B2. A method for communicably connecting two electronic devices with a USB cable is disclosed in U.S. Patent Publication No. U.S. Pat. No. 7,525,046 B2. Methods and apparatus for providing automatic high speed data connection for portable devices with a FireWire (IEEE Standard 1394) serial bus are disclosed in U.S. Patent Publication No. U.S. Pat. No. 7,451,250 B2.
The ubiquitous nature of serial bus devices requires the routine use of dedicated serial bus connection cables, as these connection cables are typically not integral portions of the serial bus devices. Because many of these devices are designed to be mobile, this evolving serial bus standard therefore creates a need for users to routinely carry serial bus cables, or to repeatedly find or purchase serial bus cables.
Various approaches are used to solve the problem of conveniently carrying serial bus cables. One approach is to construct serial bus cables that have the size and shape of a commonly and conveniently carried item, such as a credit card, a collapsing pocket knife, or a door key. In some approaches, a serial bus cable is combined into another useful article, such as a key chain or a bracelet. U.S. Patent Publication No. U.S. Pat. No. 8,758,045 B2 combines a serial bus cable into a carabiner.
Utility straps are commonly used by persons who are traveling between locations. Utility straps are often used for carrying loads, such as to carry multiple bags, to attach loads to back packs, or to carry other accoutrements. Some utility straps are used to secure loads, such as to keep items safely within a bicycle's basket by connecting the utility strap across the top rails of the basket. Some utility straps are used to bind items together, such as to wrap a bundled electrical cable. Some utility straps contain features enabling them to be used for specific purposes such as attaching multiple luggage items to each other.
A multi-purpose utility strap is disclosed in U.S. Patent Publication No. U.S. Pat. No. 8,458,864 B1. A load-bearing utility strap for securing large articles and vehicles is disclosed in U.S. Patent Publication No. U.S. Pat. No. 6,637,077 B2. A utility strap for holding one piece of luggage to another is disclosed in U.S. Patent Publication No. U.S. Pat. No. 5,927,450 A. A method for connecting three luggage items with a utility strap is disclosed in U.S. Patent Publication No. US20060102672 A1.
Some practitioners have recognized some of the benefits of incorporating an electronic connector into a load-bearing higher assembly. U.S. Patent Publication No. U.S. Pat. No. 8,758,045 B2 is an example of this approach. A method for combining a portable electronic device lanyard with an earpiece cable is disclosed in U.S. Patent Application Publication 20140185856 A1. A method for integrating a cable with the webbing of a load-carrying vest is disclosed in U.S. Patent Application Publication No. 20120045929 A1.
As demonstrated by these samples of U.S. and international publications, the availability of serial bus cables remains a persistent problem in the state of the art of electronic and electrical devices. No device within the current art solves this problem through the innovative approach of combining the serial bus cable with a utility strap. Those skilled in the related arts will note that the approach of combining the functionality of a serial bus cable with a utility strap is particularly challenging as it requires developing a solution which will carry a tensile load along the elongated strap without over-stressing the serial bus connectors at the ends of the serial bus cable.
SUMMARY
The present invention provides a new and improved means for carrying a serial bus cable by combining that serial bus cable with a utility strap. It is a more particular object of the present invention for the serial bus cable to be enclosed within, incorporated within, or supported by a utility strap in such a way that the two form a single assembly. It is a still more particular object of the present invention that the serial bus cable wires extend along a significant portion of the length of the elongated strap. These serial bus wires combine with the serial bus electrical connectors to function as a serial bus cable of sufficient length for connecting electrical or electronic devices. The serial bus utility strap assembly of this invention is particularly suited to persons who frequently travel or change locations. This invention gives those persons a convenient method for carrying or securing objects while moving between locations, for carrying a serial bus cable between locations, and for accessing the serial bus cable for use at various locations.
The serial bus utility strap contains features which enable it to function as a common utility strap. These features specifically include a load-bearing elongated strap member and the provision of a fastening means at each end of the elongated strap. The elongated strap member enables the transfer of a tensile force along its length. This elongated strap member may comprise of one or more elements or layers. To facilitate the binding or carrying of objects, each of the two ends of the serial bus utility strap is provided with a load-bearing fastening means. The invention thus enables a person to carry an accoutrement or other load, to bind an object or group of objects, or to secure an item or group of items. Example loads which may be carried by a serial bus utility strap include luggage, bags, and boots. Examples of objects which may be bound by a serial bus utility strap include a bundled electrical power cord, a bundle of socks or stockings, or a rolled sleeping bag.
The serial bus utility strap also functions as a common serial bus cable. To perform this function, the serial bus utility strap is provided with electrically conductive wires and two electrical connectors. The electrical wires may be arranged individually and essentially in parallel with each other, as a single bundle held together within a protective cable core or cable jacket material, or as a combination of individual and bundled wires. The first of the two electrical connectors is electrically bonded to the first end of each of the electrical wires, and the second electrical connector is electrically bonded to the second end of each of the electrical wires. These electrical connectors are readily accessible for the user to connect to external electrical or electronic devices. In some embodiments, one or more of these electrical connectors complies in whole or in part with the USB design standards. In some embodiments, one or more of these electrical connectors complies in whole or in part with the FireWire design standard (IEEE Standard 1394).
A feature of the invention of a serial bus utility strap is that each fastening means is distinct from and separate from the electrical connectors of the assembly. Examples of these fastening means include but are not limited to rings, grommets, hooks, loops, button holes, buckles, and the hook-and-loop fastener system (e.g. Velcro®). The serial bus utility strap invention thus enables a tensile force to be carried along the length of the assembly without excessively stressing the necessary electrically conductive path between the assembly's electrical connectors and the assembly's electrical wires. This innovative combination of load-bearing and electrical features is thus arranged to provide a unique and practical means to combine two otherwise separate elements which are both commonly used by persons who travel between locations.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate three embodiments of the present invention. In the drawings:
FIG. 1A shows an isometric view of a first embodiment of a serial bus utility strap;
FIG. 1B shows a cross-sectional view of the serial bus utility strap assembly shown in FIG. 1A , with the cross-section taken along the line I-I;
FIG. 2A shows an isometric view of a second embodiment of a serial bus utility strap;
FIG. 2B shows a cross-sectional view of the serial bus utility strap assembly shown in FIG. 2A , with the cross-section taken along the line II-II;
FIG. 3 shows an embodiment of the serial bus utility strap utilized as a lanyard to hold an identification badge;
FIG. 4A shows an isometric view of a fourth embodiment of a serial bus utility strap;
FIG. 4B shows a partial side view of the fourth embodiment of a serial bus utility strap shown in FIG. 4A , with the side view corresponding to view III of FIG. 4A ;
FIG. 4C shows a partial side view of the fourth embodiment of a serial bus utility strap shown in FIG. 4A , with the side view corresponding to view IV of FIG. 4A ;
FIG. 5 shows an isometric view of a fifth embodiment of a serial bus utility strap;
FIG. 6A shows an isometric view of a sixth embodiment of a serial bus utility strap;
FIG. 6B shows an isometric view of an end of the sixth embodiment of a serial bus utility strap, with the view detailing the attachment of a button to the button hole of the serial bus utility strap.
DETAILED DESCRIPTION
The present disclosure is described more fully hereinafter with reference to the accompanying drawings, in which various aspects of six embodiments of a serial bus utility strap are shown. While six example embodiments of the invention may be described in the drawings and the following description, those skilled in the arts of serial bus cable design and flexible utility strap design will readily recognize that adaptations, modifications, alterations, and other implementations are possible. Therefore, the following detailed description does not limit the invention.
Where possible, the same reference numbers are used in the drawings and in the following description to refer to the same features or similar features. For example, the cross-sectional views use a common designator for an illustrative number of serial bus wires. The use of a common designator for serial bus wires is representative of any of the various number, type, and functions of electrical wires employed within serial bus cables or otherwise functioning as a serial bus cable. Likewise, the use of a common designator for serial bus connectors is representative of any of the various electrical connector designs specified by public or private serial bus specifications (e.g. Universal Serial Bus Revision 2.0 Specification and Universal Serial Bus Revision 3.1 Specification).
Relative terms such as “lower” and “upper” are used herein to describe one element's relationship to another element as illustrated in the drawings. These relative terms are intended to encompass different orientations of elements in the serial bus utility strap assemblies embodied herein, and not to be restricted to the orientations or embodiments depicted in the drawings.
The term “fastening means” is used herein to describe any suitable method for attaching items or connecting materials. These “fastening means” enable the serial bus utility strap to carry loads, to bind items, or to secure articles. The embodiments illustrated herein include loops, carabiners, a hook-and-loop fastening system (e.g. Velcro®), button holes, grommets, and D-Rings. These embodiments are not exclusive of other fastening systems, e.g. buttons, buckles, or other hook-like devices. Those skilled in the related arts will realize that embodiments of this invention may incorporate any suitable fastening means or combinations of fastening means, many of which are described in Cooperative Patent Classification (CPC) subclass A44B and in CPC group F16B45/00.
The term “cable core” is used herein to describe any method of collectively securing and protecting multiple wires in a single sub-assembly, such as for durability or ease of manufacturing. The cable core may also serve to electrically isolate the various wires from each other, especially if the wires are not separately insulated. While many current art cables use different materials for a cable's core and its jacket, most current art serial bus cables use the same material as both the cable core and the cable jacket. Thus, the use of the term “cable core” is appropriate to refer to the most common current art method of combining and protecting serial bus wires. However, those skilled in the related arts will recognize that wires assembled for use in a serial bus utility strap may be bundled, secured, and protected by various similar methods, such as using a jacket or a wrapping material. Likewise, those skilled in the related arts will recognize that these assemblies may have any cross-sectional shape, but are typically round or flat.
FIG. 1A and FIG. 1B show a first embodiment of a serial bus utility strap 100 . As shown in FIG. 1A and FIG. 1B , a serial bus utility strap 100 may incorporate individual electrical wires 110 encased in a strap material 120 . While FIG. 1B shows the serial bus utility strap having five wires 110 , consistent with embodiments of the invention, the serial bus utility strap may comprise any number of wires 110 .
Further considering the electrical properties of this first embodiment of a serial bus utility strap 100 , two serial bus connectors 130 are provided. The first ends of the serial bus wires 110 are each electrically bonded to a first serial bus connector 130 , and the second ends of the serial bus wires 110 are each electrically bonded to a second serial bus connector 130 . The connectors 130 and the wires 110 function together as a serial bus cable. While FIG. 1A shows the serial bus connectors 130 as USB-A style connectors, consistent with the embodiments of the invention, any USB, FireWire, or other serial bus connector may be connected to either end of the wires 110 in this serial bus utility strap 100 .
Further considering the structural properties of this first embodiment of a serial bus utility strap 100 , the strap material 120 may be a single piece of moldable plastic material, such as cross linked polyethylene or polyvinyl chloride. The serial bus cable connectors 130 are supported by and emerge from the strap material 120 in such a way as to make the connectors 130 easily accessible. To carry a load across the utility strap, each end of the strap contains a fastening means. In the embodiment in FIG. 1A , the fastening means shown at each end of the elongated strap is a loop 140 suitable for connecting to a hook, carabiner, or similar device. The loop 140 connects to the outer edges of the utility strap material 120 so that the inner portion of the utility strap material 120 experiences relatively little deformation when the serial bus utility strap 100 is under a tensile load. Because the deformation of the inner portion of the strap material 120 is limited, the strap material 120 does not excessively stress the interface between the wires 110 and the connectors 130 .
FIG. 2A and FIG. 2B show a second embodiment of a serial bus utility strap 200 . As shown in FIG. 2A and FIG. 2B , a serial bus utility strap 200 may comprise a serial bus cable core 210 enclosing serial bus wires 110 , an upper strap layer 220 , and a lower strap layer 230 . The serial bus utility strap may include padding 240 between the upper strap layer 220 and the lower strap layer 230 . In the embodiment illustrated in FIG. 2B , the serial bus wires 110 are bundled into and protected by a cable core 210 . While FIG. 2B shows the cable core 210 as enclosing five wires 110 , consistent with the embodiments of the invention, the cable core 210 may enclose any number of wires 110 and is not limited to five.
Further considering the electrical properties of this second embodiment of a serial bus utility strap 200 , two serial bus connectors 130 are provided. The first ends of the serial bus cable core 210 and its wires 110 are attached to a first serial bus connector 130 , and the second ends of the serial bus cable core 210 and its wires 110 are attached to a second serial bus connector 130 . While FIG. 2B shows a cable with a round cable core 210 , other embodiments may utilize other cable configurations, such as a ribbon cable or a flexible flat cable. Likewise, while FIG. 2A shows the serial bus connectors 130 as USB-A style connectors, consistent with the embodiments of the invention, any USB, FireWire, or other serial bus connector may be connected to either end of the wires 110 in this serial bus utility strap 200 .
Further considering the structural properties of this second embodiment of a serial bus utility strap 200 , the upper strap layer 220 and lower strap layer 230 may be constructed of, for example, leather, cotton, nylon, cross linked polyethylene, polyvinyl chloride, polyester, or any type of material commonly used to make utility straps. In the embodiment shown in FIG. 2A , the upper strap layer 220 and the lower strap layer 230 are stitched together in such a way as to make a single utility strap assembly and to secure the serial bus cable core 210 and connectors 130 within the assembly. To carry a load across the utility strap, each end of the strap contains a fastening means, which is shown in FIG. 2A as a D-ring 250 .
As shown in FIG. 2A , the upper strap layer 220 and the lower strap layer 230 separate from each other near the ends of the cable core 210 to allow the serial bus connectors 130 to protrude from the strap layers, thus enabling the serial bus connectors 130 to be readily accessible to the user. This separation of the upper strap layer 220 from the lower strap layer 230 also minimizes the elongation of the center of the upper strap layer 220 when the serial bus utility strap 200 is under a tensile load. Minimizing the elongation of the center of the upper strap layer 220 minimizes the load placed by the upper strap layer 220 on the interface between the wires 110 and the connectors 130 .
FIG. 3 shows a third embodiment of a serial bus utility strap 300 , and illustrates how a serial bus utility strap may be used to conveniently carry a common accoutrement such as an identity badge 320 . The embodiment of FIG. 3 is similar to that of FIG. 2A and FIG. 2B , in that it is a flexible strap with multiple strap layers and with D-rings 250 at each end. In FIG. 3 , a carabiner 310 is attached to each D-ring 250 to enable easy connection and removal of the serial bus utility strap 300 . The upper carabiner 310 enables attaching the assembly to a person, such as to a loop on an article of clothing. An identity badge 320 is hung on the lower carabiner 310 . The serial bus connectors 130 are easily accessible so that they may be used to connect electronics, especially when the serial bus utility strap 300 is removed from the carabiners 310 .
Those familiar with the related arts will notice two subtle but important aspects of this embodiment. First, this embodiment uses a combination of a D-ring and a carabiner, which illustrates that combinations of fastening methods may be used in creating the load-bearing fastening ends of the Serial Bus Utility Strap. For example, those familiar with the arts will recognize that a carabiner may be connected to a grommet or (as noted in the first embodiment) to a loop. Second, while each end of the embodiment shown uses a carabiner and a separate D-ring, those familiar with the arts will recognize that other styles exist in which the clasp-like mechanism of the carabiner attaches more permanently to the ring, either as a fixed or a flexible (e.g. a swivel) connection. These minor variations remain within the scope of the illustrated embodiment.
FIG. 4A shows a fourth embodiment of a serial bus utility strap. In this embodiment, the serial bus utility strap 400 utilizes parts of a hook-and-loop fastening system (e.g. Velcro®). The embodiment of FIG. 4A is similar to that of FIG. 2A and FIG. 2B in that it is a flexible strap with an upper layer 220 and a lower layer 230 which are stitched, glued, or fused together. As shown in FIG. 4A , the multi-hook portion 410 of a hook-and-loop fastening system is affixed to one end of the serial bus utility strap 400 . This multi-hook portion 410 is further illustrated in FIG. 4B . As is also shown in FIG. 4A , the multi-loop portion 420 of a hook-and-loop fastening system is affixed to the other end of the serial bus utility strap 400 . This multi-loop portion 420 is further illustrated in FIG. 4C . In the embodiment shown in FIGS. 4A-4C , the multi-hook portion 410 and the multi-loop portion 420 of the hook-and-loop fastening system are arranged such that the serial bus utility strap may be circled around and connected to itself, surrounding the intended load, objects to be bound, or objects to be carried. The locations and proportions of the hook-and-loop fastener elements in FIGS. 4A-4C are illustrative and do not exclude other configurations incorporating elements of a hook-and-loop fastening system. Similar to FIGS. 2A and 2B , two serial bus connectors 130 are provided, are connected together by wires contained in the Serial Bus Utility Strap assembly 400 , and are easily accessible so that they may be used to connect external electronic devices. For illustration, the serial bus connectors 130 are shown in FIGS. 4A-4C with proportions most like a USB-A or a USB-C connector. As with other embodiments herein described, these serial bus connectors 130 may be of any USB, FireWire, USB-derived, or FireWire-derived configuration.
FIG. 5 shows a fifth embodiment of a serial bus utility strap. In this embodiment, the serial bus utility strap 500 utilizes grommets 510 as the fastening means. The embodiment of FIG. 5 is similar to that of FIG. 2A and FIG. 2B in that it is a flexible strap with an upper layer 220 and a lower layer 230 which are stitched, glued, or fused together. As shown in FIG. 5 , one or more grommets 510 are affixed to each of the ends of the serial bus utility strap 500 . In FIG. 5 , one grommet 510 is affixed to one end of the serial bus utility strap 500 while two grommets 510 are affixed to the other end of the serial bus utility strap 500 . These quantities of grommets are illustrative and do not exclude other quantities arranged in other patterns. Similar to FIGS. 2A and 2B , two serial bus connectors 130 are provided, are connected together by wires contained in the Serial Bus Utility Strap assembly 500 , and are easily accessible so that they may be used to connect external electronic devices. As with other embodiments herein described, these serial bus connectors 130 may be of any USB, FireWire, USB-derived, or FireWire-derived configuration. FIG. 6A shows a sixth embodiment of a serial bus utility strap. In this embodiment, the serial bus utility strap 600 utilizes button holes 610 as the fastening means. The embodiment of FIG. 6A is similar to that of FIG. 2A and FIG. 2B in that it is a flexible strap with an upper layer 220 and a lower layer 230 which are stitched, glued, or fused together. As shown in FIG. 6A , the button holes 610 are located at either end of the device. The functionality of this button hole 610 is illustrated in FIG. 6B , which is a detail of either end of the serial bus utility strap 600 shown in FIG. 6A . As shown in FIG. 6B , a button 620 may be attached to some other device or object (omitted for clarity), then passed through the button hole 610 to transfer the load between the objects. Those familiar with the design of utility straps will readily recognize that utility straps may use one or more button holes, that buttons of various shapes or sizes may be slipped through or attached to these button holes in any of various fashions, and that the button holes may be reinforced or non-reinforced. Similar to FIGS. 2A and 2B , two serial bus connectors 130 are provided, are connected together by wires 110 contained in the Serial Bus Utility Strap assembly 600 , and are easily accessible so that they may be used to connect external electronic devices. As with other embodiments herein described, these serial bus connectors 130 may be of any USB, FireWire, USB-derived, or FireWire-derived configuration.
As stated, embodiment six is similar to embodiments two through five in the use of two layers of material surrounding wires 110 in a cable core. FIG. 6B shows additional detail of the upper layer of material 220 and lower layer of material 230 , and how these encase the wires 110 which carry data and/or power between the serial bus connectors 130 . Unlike the embodiment in FIG. 2B , the embodiment in FIG. 6B does not employ padding between the upper layer 220 and the lower layer 230 . Those familiar with the arts of utility strap design will readily understand that the inclusion (or non-inclusion) of padding in a utility strap is based upon factors such as the intended use of the utility strap, the shape of the utility strap, and the properties of the upper layer 220 and the lower layer 230 .
While certain embodiments of the serial bus utility strap invention have been described herein, other embodiments may exist without departing from the scope of the novel concepts of the invention. For example, various shapes, sizes, and proportions of rings and grommets exist, and those illustrated herein are not exclusive of these other configurations. Likewise, various lengths and proportions of straps and enclosed cables may be used. Consequently, other embodiments of the invention may provide a serial bus utility strap with application to a wide range of purposes and are not limited to the examples described in this specification. | A utility strap with embedded serial bus wires is provided. The utility strap is comprised of a flexible elongated strap member with each of the first and second ends having at least one of a ring, hook-and-loop fastening system, button hole, loop, grommet, and a carabiner. Serial bus wires are incorporated within said strap along a significant portion of the length of the strap, said wires forming a serial bus cable with exposed serial bus connectors for providing an electrical connection between two computer devices, peripherals, or other similar electronic devices. | 0 |
FIELD OF INVENTION
Various exemplary embodiments disclosed herein relate generally to policy and charging in telecommunications networks.
BACKGROUND
Bearer Control Mode (BCM) in a 3rd Generation Partnership Project (3GPP) mobile network Internet Protocol Connectivity Access Network (IP-CAN) session (or Gateway Control session) defines if it accepts network-initiated bearer establishment or modification. The 3GPP standard (specifically TS 29.212) states that the Bearer-Control-Mode AVP should be decided based on the Network-Request-Support (NRS) AVP in the Credit Control Request (CCR) message and the operator's policies defined in Policy Control and Charging Rules Function (PCRF) node.
However, the 3GPP specifications do not address certain scenarios, but which must to be addressed in real-world networks: such as how to handle a stored NRS value in a case where an operator's policy overrides BCM determination; how to handle a stored NRS value in a case of a failed message exchange; and how a PCRN should interact with PDN gateways which are non-standard, or do not support NRS and/or BCM.
In view of the foregoing, it would be desirable to provide a Policy and Charging Rules Node (PCRN) implementing a PCRF capable of handling some or all of the above scenarios.
SUMMARY
A brief summary of various exemplary embodiments is presented. Some simplifications and omissions may be made in the following summary, which is intended to highlight and introduce some aspects of the various exemplary embodiments, but not to limit the scope of the invention. Detailed descriptions of a preferred exemplary embodiment adequate to allow those of ordinary skill in the art to make and use the inventive concepts will follow in later sections.
Various exemplary embodiments relate to a method performed by a policy and charging rules node (PCRN). The method comprises: receiving at the PCRN, a service request message from an Evolved Packet Core (EPC) node; generating a response message to the service request message; and if the response message is a success message; determining whether the service request message includes a Network-Request-Support (NRS) attribute value pair (AVP) for an Internet Protocol Connectivity Access Network (IP-CAN) session or a gateway control session; and if the service request message includes the NRS AVP: storing the NRS value in a NRS buffer at the PCRN; determining a Bearer Control Mode (BCM) value for the IP-CAN session, based on the NRS value and policy rules at the PCRN; storing the BCM value in a BCM buffer at the PCRN; and sending the response message containing a BCM AVP containing the BCM value for the IP-CAN session or gateway control session.
In various alternative embodiments, the service request message comprises a Credit Control Request (CCR) message; and the response message comprises a Credit Control Answer (CCA) message.
In various alternative embodiments, if a value of a BCM-remove flag associated with the EPC node, stored at the PCRN, is true then sending the CCA message with no BCM AVP.
Various alternative embodiments, further comprise steps of: if the CCA message is a fail message then; not storing the NRS value in the NRS buffer at the PCRN; not storing the BCM value in a BCM buffer at the PCRN; and sending the CCA message with no BCM AVP.
Various other exemplary embodiments relate to a tangible and non-transitory machine-readable storage medium encoded with instructions thereon for execution by a policy and charging rules node (PCRN), wherein the tangible and non-transitory machine-readable storage medium comprises instructions for: receiving at the PCRN, a service request message from an Evolved Packet Core node; generating a response message; and if the response message is a success message; determining whether the service request message includes a Network-Request-Support (NRS) attribute value pair (AVP) for an Internet Protocol Connectivity Access Network (IP-CAN) session or a gateway control session; and if the service request message includes the NRS AVP: storing the NRS value in a NRS buffer at the PCRN; determining a Bearer Control Mode (BCM) value for the IP-CAN session or gateway control session, based on the NRS value and policy rules at the PCRN; storing the BCM value in a BCM buffer at the PCRN; and sending the response message containing a BCM AVP containing the BCM value for the IP-CAN session or gateway control session.
Various other exemplary embodiments relate to a policy and charging rules node (PCRN) for handling an incoming request message. The PCRN comprises: an interface for communicating with an Evolved Packet Core (EPC) node; a Network-Request-Support (NRS) buffer; a Bearer Control Mode (BCM) buffer; wherein the PCRN is configured to: receive a service request message on the interface from the EPC node; generate a response message to the request message; and if the response message is a success message; determine whether the request message includes a Network-Request-Support (NRS) attribute value pair (AVP) for an Internet Protocol Connectivity Access Network (IP-CAN) session or gateway control session; and if the request message includes the NRS AVP: store the NRS value in the NRS buffer; determine a Bearer Control Mode (BCM) value for the IP-CAN session, based on the NRS value and policy rules at the PCRN; store the BCM value in the BCM buffer; and send the response message containing a BCM AVP containing the BCM value for the IP-CAN session or gateway control session on the interface to the EPC node.
Various alternative embodiments further comprise a BCM-remove flag buffer associated with the EPC node, wherein if the BCM-remove flag is true, then the PCRN is further configured to send the CCA message with no BCM AVP.
In various alternative embodiments, if the CCA message is a fail message then the PCRN is further configured to: not store the NRS value in the NRS buffer; not store the BCM value in the BCM buffer; and send the CCA message with no BCM AVP.
Various other exemplary embodiments relate to a method performed by an Evolved Packet Core (EPC) gateway node. The method comprises: sending a service request message for an Internet Protocol Connectivity Access Network (IP-CAN) session or gateway control session to a policy and charging rules node (PCRN), the service request message including a Network-Request-Support (NRS) attribute value pair (AVP) containing an NRS value; receiving a response message from the PCRN in response to the service request message, determining if the response message is a success message; and storing the NRS value in a buffer at the EPC gateway node only if the response message is a success message.
In various alternative embodiments the sending step is preceded by a step of determining if the received NRS value is different from a NRS value stored in said NRS buffer and wherein the service request message only includes the NRS AVP containing the received NRS value if the received NRS value is different from a NRS value stored in the NRS buffer.
Various other exemplary embodiments relate to a tangible and non-transitory machine-readable storage medium encoded with instructions thereon for execution by an Evolved Packet Core (EPC) gateway node), wherein the tangible and non-transitory machine-readable storage medium comprises instructions for: receiving a NRS value from a downstream node; sending a service request message for an Internet Protocol Connectivity Access Network (IP-CAN) session or gateway control session to a policy and charging rules node (PCRN), the service request message including a Network-Request-Support (NRS) attribute value pair (AVP) containing the received NRS value; receiving a response message from the PCRN in response to the service request message, determining if the response message is a success message; and storing the received NRS value in a buffer at the EPC gateway node only if the response message is a success message.
Various other exemplary embodiments relate to an Evolved Packet Core (EPC) gateway node comprising: a first interface for communicating with a downstream node; a second interface for communicating with a policy and charging rules node (PCRN); a Network-Request-Support (NRS) buffer; wherein the EPC gateway node is configured to: send a service request message for an Internet Protocol Connectivity Access Network (IP-CAN) session or gateway control session to a policy and charging rules node (PCRN), the service request message including a Network-Request-Support (NRS) attribute value pair (AVP) containing an NRS value; receive a response message from the PCRN in response to the service request message, determine if the response message is a success message; and store the received NRS value in the NRS buffer at the EPC gateway node only if the response message is a success message.
In various alternative embodiments the EPC gateway node is further configured to determine if the received NRS value is different from a NRS value stored in the NRS buffer and wherein the service request message only includes the NRS AVP containing the received NRS value if the received NRS value is different from a NRS value stored in the NRS buffer.
BRIEF DESCRIPTION OF THE FIGURES
Some embodiments of apparatus and/or methods in accordance with embodiments of the present invention are now described, by way of example only, and with reference to the accompanying drawings in which:
FIG. 1 illustrates an exemplary topology of an EPS-compatible network;
FIG. 2 illustrates a PCRN aspect and a communicating EPS node aspect of an embodiment;
FIGS. 3A , 3 B illustrate a use case table for an embodiment; and
FIG. 4 illustrates an exemplary network element processor assembly according to an embodiment of the invention.
In the figures, like features are denoted by like reference characters.
DETAILED DESCRIPTION
Referring now to the drawings, in which like numerals refer to like components or steps, there are disclosed broad aspects of various exemplary embodiments.
FIG. 1 illustrates an exemplary topology of an EPS-compatible telecommunications network 100 . User Equipment (UE) 102 is connected through a radio access to S-GW node 104 which is connected to a P-GW node 106 and then through a Gx interface 110 to PCRN 108 . S-GW node 104 can also connect through Gxx interface 112 to PCRN 108 .
In operation and with reference to FIG. 2 , PCRN 204 communicates with EPC gateway node 202 (a P-GW or S-GW) via interface 206 (which can be a Gx interface in the case where EPC node 202 is a P-GW or can be a Gxx interface in the case where EPC node 202 is an S-GW).
EPC gateway node 202 implements a NRS buffer “NRS-gw” 212 to cache NRS values. PCRN 204 implements a NRS buffer “NRS-perf” 214 to cache NRS values in synchronization with the NRS-gw buffer 212 . PCRN 204 also implements a BCM buffer “BCM-perf” 216 and a BCM-remove flag 218 , as will be described below.
NRS-gw buffer 212 is empty (value=Null) on initialization of the EPC gateway node 202 . On receipt of a NRS value from a downstream node, EPC gateway node 202 determines if the NRS value is different from the value stored in NRS-pw buffer 212 , in which case EPC gateway node 202 sends a request message (such as CCR message 208 ) requesting a service such as an IP-CAN session establishment or modification request. Note that the NRS-pw buffer 212 is only updated after a success response to CCR message 208 .
PCRN 204 receives the service request message 208 and proceeds to evaluate the request and starts to generate a response message such as a CCA message according to available resources and policies defined within the PCRN 204 as is well known in the art. As is known in the art, CCA can be a CCA-I message indicating a session establishment request, CCA can be a CCA-U message indicating a session modification request. If PCRN 204 determines that the response message is a success message, (i.e.: the request can be fulfilled and the CCA message status is “success”) then PCRN 204 determines whether the request message includes a NRS AVP and if so, PCRN 204 stores the value of the received NRS (NRS value) in a NRS buffer 214 “NRS-perf”. PCRN 204 then transmits the CCA response message 210 to the EPC gateway node 202 with a success status. EPC gateway node 202 receives the response message 210 and determines whether it has a success status and if so, then updates the NRS-gw buffer 212 with the current NRS value. In this manner, NRS-gw buffer 212 and NRS-perf buffer 214 maintain synchronization.
In the case where PCRN 204 returns a fail status in the response message 210 (e.g.: a CCA message), neither NRS-gw buffer 212 nor NRS-perf buffer 214 are updated with the current NRS value. In this manner, NRS-gw buffer 212 and NRS-perf buffer 214 continue to maintain synchronization.
In response to receiving the request message 208 the PCRN 204 also determines a value of a Bearer Control Mode (BCM) for the IP-CAN session or gateway control session associated with the request message 208 , based on the received NRS value and on policy rules at the PCRN 204 , as is known in the art. The BCM value is stored in BCM buffer “BCM-perf” 216 at the PCRN 204 and is keyed to the associated IP-CAN session or gateway control session. In the case where PCRN 204 returns a fail status in the response message 210 (e.g.: a CCA message), PCRN 204 will not update BCM buffer “BCM-perf” 216 and will not send a BCM AVP in the response message 210 .
PCRN 204 additionally implements a BCM-remove flag 218 , keyed to specific gateways or Gx or Gxx interfaces, to indicate that a BCM AVP should not be transmitted to the associated gateway or over the associated Gx/Gxx interface. This is typically provisioned to indicate that the associated gateway cannot support BCM. This is valuable to allow interworking with non-standard-compliant gateways or other custom implementations. The value of the BCM-remove flag 218 can be populated via provisioning by the network operator and can be controlled dynamically via flexible rules at the PCRN 204 . In operation, the BCM-remove flag overrides any determination by the PCRN 204 to send a BCM AVP in response messages 210 .
FIGS. 3A , 3 B show a use case table 300 to illustrate example scenarios to describe the behavior of embodiments of the invention. Header 320 of table 300 describes contents of the respective columns as follows. Column 302 provides a use case reference number for convenience of discussion. Column 304 provides a brief description of the use case.
Column 306 “NRS-req” represents the NRS value in session request CCR 208 . Column 308 “NRS-gw” represents the value of the NRS in gateway buffer 212 (value is NULL when buffer is empty). Column 310 “NRS-perf” represents the value of the NRS in PCRF buffer 214 (value is NULL when buffer is empty). Column 312 “BCM-policy” represents the BCM value in PCRF operator policy rule action. This thus represents the BCM value as determined by PCRN 204 based on the policy rules within PCRN 204 and various inputs to the PCRN. Column 314 “BCM-remove” represents the value of the flag 218 indicating removal BCM from CCA response message (default value is false=do not remove). Column 316 “BCM-perf” represents the BCM value in PCRF internal IP-CAN session table 216 . Column 318 “BCM-cca” represents the value of BCM in Gx/Gxx response message CCA 210 .
Use case 1 illustrates the default NRS behavior. If NRS is absent in a CCR-I message 208 , PCRN 204 would return BCM=0 in CCA-I 210 (unless there is a PCRN operator policy rule action to override it).
Use case 2 illustrates a case where determination of the BCM by PCRN 204 overrides the NRS value received at the PCRN 204 . In the following event sequence: a) PCRN 204 receives a CCR-I message 208 (IP-CAN session establishment) containing a NRS AVP where NRS=1, PCRN 204 returns BCM=0in CCA-I message 210 , due to PCRN operator policy rule override (rule action sets BCM=0); b) followed by PCRN 204 receiving a CCR-U message 208 (IP-CAN session modification), where NRS AVP is absent, PCRN 204 then uses the last NRS value (NRS=1) stored at NRS-perf 214 , to determine that BCM=2 (provided no operator PDF rule in session update) and returns CCA-U message 210 with BCM AVP where BCM=1.
Use case 3 illustrates a case where an IP-CAN session update returns a failure response. In the following event sequence: a) PCRN 204 receives a CCR-I message 208 containing a NRS AVP where NRS=1, PCRF then returns CCA-I message 210 with BCM AVP where BCM=2; b) PCRN 204 then receives a first CCR-U message 208 where NRS=0, PCRN 204 then returns a first CCA-U message 210 with error code (i.e.: failed request), with no BCM AVP; c) PCRN 204 then receives a second CCR-U message 208 where NRS AVP is absent, PCRN 204 uses the last successful update (NRS=1), resulting in PCRN 204 determining that BCM=2. Since there is no change from the value stored at BCM-perf 216 , PCRN 204 then returns a second CCA-U message 210 with no BCM AVP.
Use case 4 illustrates a case where session establishment failure causes the PCRN to discard received NRS. In the following event sequence: a) PCRN 204 receives a first CCR-I message 208 containing a NRS AVP where NRS=1, PCRN 204 returns a first CCA-I message 210 with error code, rejecting the request (i.e.: failed request), with no BCM AVP; b) PCRN 204 then receives a second CCR-I message 208 with no NRS AVP (NRS absent), PCRN 204 considers NRS=0 (default value) and then returns a second CCA-I message 210 with success code and with a BCM AVP where BCM=0.
Use case 5 illustrates a case where NRS is cached at an IP-CAN session level. In the following event sequence: a) PCRN 204 receives a first CCR-I message 208 for a first IP-CAN session ID, containing a NRS AVP where NRS=1, PCRN 204 returns a CCA-I message 210 for the first IP-CAN session ID with a BCM AVP where BCM=2; b) PCRN 204 then receives a second CCR-I message 208 for a second IP-CAN session ID, with no NRS AVP (NRS absent), PCRN 204 considers NRS=0 (default value) and then returns a second CCA-I message 210 for the second IP-CAN session ID, with a BCM AVP where BCM=0.
Use case 6 illustrates a case where a gateway does not support NRS and BCM. A PCRN 204 operator policy rule action defines BCM-remove flag 218 =true in session establishment. This can be defined by the network operator by provisioning. In the following event sequence: PCRN 204 receives a first CCR message 208 , with no NRS AVP. PCRN 204 determines a success response CCA message. Because there is no NRS value stored in the NRS-perf buffer 214 , and there is no NRS value received in the CCR message 208 , then NRS-perf buffer 214 is not updated and left as null, and BCM-perf buffer 216 is determined as zero. PCRN 204 sends response CCA message with no BCM AVP.
Use case 7 illustrates a case where a vendor-specific legacy gateway partially supports 3GPP specifications. (e.g.: a vendor-specific gateway (P-GW/GGSN) supports only NRS, but not BCM). A PCRN 204 operator policy rule action defines BCM-remove flag 218 =true in session establishment. This can be defined by the network operator by provisioning. In the following event sequence: PCRN 204 receives a first CCR message 208 , containing a NRS AVP where NRS=1. PCRN 204 determines that a success CCA message 210 is to be returned, and then updates the NRS value in NRS-perf buffer 214 . BCM-perf 216 is also updated. PCRN 204 then sends response CCA message 210 but because the BCM-remove flag 218 is set, the BCM AVP is not included in the CCA message 210 .
Use case 8 illustrates a case where a UE handover causing bearer binding function is moved from Bearer Binding and Event Reporting Function (BBERF) such as a Serving gateway (S-GW) 104 to Policy and Charging Enforcement Function (PCEF) such as P-GW 106 in session modification. In the following event sequence: a) PCRN 108 receives a CCR message containing no NRS AVP on interface Gxx 112 from S-GW 104 for a gateway control session establishment. PCRN 108 establishes the gateway control session with BCM support (BCM is determined as 0, when NRS takes default value 0). Thus PCRN 108 responds on interface Gxx 112 with a CCA message with BCM=0; b) PCRN 108 receives a CCR-I IP-CAN session establishment on Gx interface. PCRN 108 identifies that the network is in Proxy Mobile IP (PMIP) mode, BCM is not supported on Gx interface and P-GW, therefore, it is not included in CCA-I. c) UE moved to another location, now the access to the network is via GTP, e.g., a SGSN node, then to the P-GW 106 . PCRN 108 receives a CCR-U message on interface Gx 110 from P-GW 106 for the same IP-CAN session, also with no NRS AVP. PCRN 108 detects that now the previous BBERF is no longer in the connection pass, therefore, P-GW 104 should resume bearer binding function. It responds with a CCA-U message on interface Gx 110 , confirming the handover. In this case, CCA-U messages contains a BCM AVP with BCM=0.
Use case 9 illustrates a Proxy Mobile IPv6 (PMIPv6) case where BCM is only supported on a Gxx interface, not on Gx interface.
Use case 10 illustrates a case where vendor-specific gateways support BCM on both Gx and Gxx interfaces. Similarly to the use cases described above, PCRN can receive CCR session request messages with no NRS AVP and determine appropriate BCM values and transmission of BCM values in CCA response messages based on BCM-policies defined at the PCRN.
FIG. 4 depicts a high-level block diagram of a network equipment processor assembly suitable for use in performing functions described herein.
As depicted in FIG. 4 , network equipment processor assembly 400 includes a network equipment processor element 402 (e.g., a central processing unit (CPU) and/or other suitable processor(s)), a memory 404 (e.g., random access memory (RAM), read only memory (ROM), and the like), a cooperating module/process 408 , and various input/output devices 406 (e.g., a user input device (such as a keyboard, a keypad, a mouse, and the like), a user output device (such as a display, a speaker, and the like), an input port, an output port, a receiver, a transmitter, and storage devices (e.g., a tape drive, a floppy drive, a hard disk drive, a compact disk drive, and the like)).
It will be appreciated that the functions depicted and described herein may be implemented in hardware, for example using one or more application specific integrated circuits (ASIC), and/or any other hardware equivalents. Alternatively, according to one embodiment, the cooperating process 408 can be loaded into memory 404 and executed by network equipment processor 402 to implement the functions as discussed herein. As well, cooperating process 408 (including associated data structures) can be stored on a tangible, non-transitory computer readable storage medium, for example magnetic or optical drive or diskette, semiconductor memory and the like.
It is contemplated that some of the steps discussed herein as methods may be implemented within hardware, for example, as circuitry that cooperates with the network equipment processor to perform various method steps. Portions of the functions/elements described herein may be implemented as a computer program product wherein computer instructions, when processed by a network equipment processor, adapt the operation of the network equipment processor such that the methods and/or techniques described herein are invoked or otherwise provided. Instructions for invoking the inventive methods may be stored in fixed or removable media, and/or stored within a memory within a computing device operating according to the instructions.
The functions of the various elements shown in the figures, including any functional blocks labeled as “processors”, may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” or “controller” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), and non volatile storage. Other hardware, conventional and/or custom, may also be included. Similarly, any switches shown in the FIGS. are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the implementer as more specifically understood from the context.
It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative circuitry embodying the principles of the invention. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in computer readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
It should also be understood that the steps of the exemplary methods set forth herein are not necessarily required to be performed in the order described, and the order of the steps of such methods should be understood to be merely exemplary. Likewise, additional steps may be included in such methods, and certain steps may be omitted or combined, in methods consistent with various embodiments of the present invention.
Although the elements in the following method claims, if any, are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those elements, those elements are not necessarily intended to be limited to being implemented in that particular sequence.
Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments necessarily mutually exclusive of other embodiments. The same applies to the term “implementation.”
The description and drawings merely illustrate the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventor(s) 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 equivalents thereof.
It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative circuitry embodying the principles of the invention. Numerous modifications, variations and adaptations may be made to the embodiment of the invention described above without departing from the scope of the invention, which is defined in the claims. | A method, apparatus, and machine readable storage medium is disclosed for handling Network-Request-Support (NRS) and Bearer Control Mode (BCM) at a Policy and Charging Rules Node (PCRN) and a Evolved Packet Core (EPC) gateway node. Embodiments maintain corresponding buffers for NRS values at the PCRN and the gateway and maintain synchronization between them. A gateway sends a credit control request (CCR) message to a PCRN and updates a local NRS buffer at the gateway when a successful credit control acknowledgement (CCA) response is received from the PCRN. Similarly, the PCRN updates a local NRS buffer at the PCRN when a successful credit control acknowledgement (CCA) response is sent to the gateway. | 7 |
CROSS REFERENCES
[0001] This application is a United States National Stage Application claiming priority under 35 U.S.C. 371 from International Patent Application No. PCT/NZ2009/000236 filed on Nov. 3, 2009, which claims the benefit of priority from New Zealand Patent Application No. 572477, filed on Nov. 3, 2008, the entire contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to improvements to work attachment assemblies and in particular work attachment assemblies for use with work machines such as excavators.
BACKGROUND OF THE INVENTION
[0003] Work machines such as excavators use a variety of work attachments. These attachments include buckets, graders, grapples or drilling attachments. It is desirable to have a releasable attachment between the construction vehicle and the work attachment to easily and rapidly change the work attachment. Generally a releasable attachment is provided by two or more jaws which engage pins on the work attachment. At least one of the jaws is moveable in a pivotal or sliding motion. The first jaw receives a pin and the second jaw moves to engage the second pin.
[0004] An actuator forces the jaw against the pin. This retains the pin in the jaw thereby securing the work attachment to the machine. It is known to use a locking portion as an added safety measure. This secures a pin in a jaw. In one form of coupling a person manually inserts a member to act as a locking portion. However, this involves the operator getting out of the excavator and getting close to the work attachment.
[0005] There are alternate embodiments where a locking portion is operatively coupled to the moveable jaw. In these, movement of the jaw controls movement of the locking portion to either retain or release a pin from another jaw.
[0006] An improvement to the commonly available coupling assemblies is that disclosed in PCT Application No. NZ2007/000320 to JR Sales International Limited. The JB Sales patent discloses a coupling having a body on an excavator arm with two jaws to receive pins on a work attachment. One of the jaws is slidable with respect to the body so that it can engage a pin on the work attachment.
[0007] The slidable jaw is configured to control a pivotally mounted retention member. This member therefore retains a second pin when the first jaw is not actuated to a position beyond that it assumes when receiving the first pin. Due to the opposite facing of the jaws, the mounting must be tilted to allow the second jaw to extend beyond the locking position.
[0008] However, the assembly disclosed by the JR Sales patent has a number of limitations. One of these disadvantages is the mounting of the retention member to the body. Over time the pressure exerted on the retention member by the moveable jaw causes wear and tear. The retention member may therefore be prone to failure.
[0009] In addition, the retention member only secures a second pin in the second jaw when the first jaw is in the correct position. Due to this securing the work attachment to the mounting is dependant on the position of the moveable jaw. Should the actuator or moveable jaw fail with the coupler in an inverted position, the effectiveness of the retention member is compromised and this could pose a safety risk.
[0010] A further disadvantage of the JR Sales patent is that the pin is not secured in the jaw immediately at being inserted into a jaw. Rather the operator must elect to retract an actuator so that the retention member secures the pin inside the jaw. This is an issue as research indicates that most accidents involving the accidental dropping of work attachments occur during the connection process. The JB Sales patent therefore does not address a major safety issue with releasably connected work attachments.
[0011] Further, more stringent safety regulations (presently in a draft form) would make it useful to have a release mechanism requiring more than three stages. This is because forcing an operator to take additional steps may help to ensure that work attachments are not accidentally released from an excavator. Ideally, this assembly should be more durable and less prone to mechanical failure than coupling assemblies available.
[0012] When in use, a boom arm controls the position and most of the operative movement of the work attachment. However additional actuators are used to provide more control over movement of the work attachment. This may include the tilting action of a bucket, or to operate a drilling machine.
[0013] These actuators are generally secured on the work attachment. Therefore, it is necessary to have a releasable connection between the actuators on a work attachment, and a control system. Generally this occurs using complementary hydraulic hose connectors on the work attachment and boom arm.
[0014] Connecting the complementary connectors is a manual process requiring an operator to switch off the excavator to relieve residual oil pressure and then climb out of the excavator to connect by hand.
[0015] Therefore, it would be an advantage to have an assembly which automatically aligns and locks connectors. Further, that assembly should allow them to release each other when required.
[0016] Yet another disadvantage of the available connectors in the prior art is that they are exposed when not in use. They can therefore be knocked causing damage, or contaminated by the ingress of dirt. This may result in sealing issues, leading to the escape of oil from the connectors. It can therefore affect the overall performance of the connectors. It would be an advantage to have a system to protect connectors from these types of damage.
[0017] All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.
[0018] It is acknowledged that the term ‘comprise’ may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, the term ‘comprise’ shall have an inclusive meaning—i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components or elements. This rationale will also be used when the term ‘comprised’ or ‘comprising’ is used in relation to one or more steps in a method or process.
[0019] It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice. Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.
DISCLOSURE OF THE INVENTION
[0020] According to one aspect of the present invention there is provided a coupler, including jaws to engage pins and thereby secure a work attachment to the coupler, wherein at least one of the jaws is moveable with respect to the coupler, characterized in that the coupler includes a safety link.
[0021] According to another aspect of the present invention there is provided a method of releasing a work attachment from a coupler, wherein the work attachment is secured to the coupler via two pins held within two jaws, the method including the steps of:
[0022] (a) moving a first jaw to release a first pin;
[0023] (b) changing the orientation of the coupler and work attachment relative to each other;
[0024] (c) moving the first jaw in the opposite direction to that in step (a);
[0025] (d) moving the first jaw in the opposite direction to that in step (c); the method characterised in that the action of step (c) causes a safety link to move to a release position so that the locking portion will release a pin from the second jaw in step (d).
[0026] According to another aspect of the present invention there is provided an assembly to provide a releasable connection between a device on a work attachment and a control system, wherein the work attachment is secured to a machine via a coupler, the assembly including: a first mounting having first set of connectors, and a second mounting having a second set of connectors corresponding to the first set of connectors, and at least one guard to protect one of the sets of connectors characterized in that the guard or the mountings can move with respect to each other to expose the first and second sets of connectors and allow these to engage.
[0027] According to another aspect of the present invention, there is provided a method of providing a releasable connection between a device on a work attachment and a control system, wherein the work attachment is secured to a work machine via a coupler, the method including the steps of
(a) orientating the coupler into a position to engage the work attachment and secure this to the machine, the method characterised by the step of (b) moving a guard or mountings with respect to each other to expose a first set of connectors and a second set of connectors so that these can engage with each other.
[0031] Preferably there is provided a mounting for use with connectors, the mounting including a plurality of connectors, a latch to secure the connectors to complementary connectors, the mounting characterized as having a release portion.
[0032] Preferably there is provided a method of releasing pairs of engaged connectors, the method including the steps of:
[0000] (a) moving two mountings with respect to each other, wherein the two mountings have pairs of engaged connectors, characterized in that the action of step (a) causes at least one of each pair of engaged connectors to abut a release portion thereby releasing the pairs of engaged connectors from each other.
[0033] The present specification discloses a number of inventions relating to improvements to the releasable attachment of work attachments to machines. In preferred embodiments the inventions disclosed are intended for use together and reference herein will be made as such. However, the present inventions could be used independently of the other and therefore the description herein should not be seen as limiting.
[0034] Preferably the machine may be an excavator or other construction vehicle. Reference herein will be made to the machine as an excavator. However, the present inventions can be used with other types of machines where releasable work attachments are utilised including graders and bulldozers, loaders, tractors and scrapers. Throughout the present specification reference to the term “work attachment” should be understood as meaning an implement for performing a task.
[0035] In a preferred embodiment the work attachment may be a digger bucket as known to those skilled in the art. Reference herein will be made to the work attachment as being a tilt bucket.
[0036] Alternatives for the work attachment include vibrating compactors and grapples used in the forestry industry for grasping and manipulating logs, hole boring augers, clamps, rotating screening buckets, work platforms, mowers, hedge cutters.
[0037] Throughout the present specification reference to the term “coupler” should be understood as meaning an assembly to secure a work attachment to an excavator.
[0000] In a preferred embodiment the coupler has two jaws that each engage a work attachment to thereby secure the work attachment to the coupler. Reference will be made accordingly. Preferably the jaws may face in opposite directions. However it is also envisaged that the jaws could face in the same direction.
[0038] In a preferred embodiment the moveable jaw is a slide as known to those skilled in the art. In this embodiment, movement of the jaw is in a sliding motion with respect to the coupler or bucket.
[0039] Alternatively the jaw may pivot about a fixed point on the coupler.
[0040] Preferably movement of the jaw is controlled by an actuator such as a hydraulic cylinder. Other types of actuators envisaged include a pneumatic cylinder, helical actuators, threaded manual actuators, springs, and chain drive assemblies. Reference herein will be made to the term “actuator” as being a hydraulic cylinder.
[0041] In a preferred embodiment the hydraulic cylinder is floatingly mounted within the body. Reference to the term “floatingly mounting” should be understood as meaning that the hydraulic cylinder is capable of moving in the coupler. That is, the hydraulic cylinder is not fixed at one or more points in the coupler. The hydraulic cylinder is able to contract and expand as per normal operation as should be known to those skilled in the art. However the hydraulic cylinder is also able to move up and down with respect to the coupler.
[0042] In a particularly preferred embodiment the mounting of the hydraulic cylinder allows both ends of the hydraulic cylinder to move in the coupler.
[0043] In a preferred embodiment the moveable jaw of the coupler is secured to one end of the hydraulic cylinder. Therefore expansion and contraction of the hydraulic cylinder moves the jaw with respect to the body.
[0044] In a preferred embodiment the present invention includes a track to guide movement of the hydraulic cylinder within the coupler.
[0045] In a particularly preferred embodiment the track guides movement of one end of the hydraulic cylinder so that the locking portion can release a pin from the jaw.
[0046] In one embodiment the track is a pin extending through the hydraulic cylinder and into channels on the coupler. The pin and channels allow the actuator to move within the coupler through a predetermined range of motion.
[0047] Alternatively, the hydraulic cylinder may be pivotally or slidably mounted to the coupler and therefore the foregoing should not be seen as limiting.
[0000] Throughout the present specification reference to the term “safety link” should be understood as meaning a component which controls whether the locking portion can be moved to release a pin from a jaw. In doing so, the safety link is important in forcing an operator to make several movements to release a pin from a jaw.
[0048] In a preferred embodiment the safety link may cause expansion and/or contraction of the hydraulic cylinder to move the locking portion and thereby release a pin from the jaw. Preferably, the safety link may be moveable between a safety position and a release position.
[0049] Throughout the present specification reference to the term “safety position” should be understood as meaning a position in which the safety link prevents a locking portion moving to release a pin from a jaw.
[0050] Throughout the present specification reference to the term “release position” should be understood as meaning a position in which the safety link does not prevent a locking portion moving to release a pin from a jaw.
[0051] In a preferred embodiment the safety link may be moved to the release position once the jaw is moved beyond the position in which it engages a pin. This may be achieved by extension of the hydraulic cylinder which moves the jaw and causes the safety link to contact a portion of the coupler, thereby moving the safety link into the release position. In a particularly preferred embodiment, when in the release position the safety link causes expansion or contraction of the hydraulic cylinder to move the locking portion and thereby release a pin from a jaw.
[0052] In one such embodiment, when in the release position the safety link abuts a stop. As the safety link abuts the stop it prevents the first end of the hydraulic cylinder (and also the moveable jaw) moving past a specific point in the coupler.
[0053] If the hydraulic cylinder continues to contract this causes the second end of the hydraulic cylinder to move in the couple. As the hydraulic cylinder is floatingly mounted within the coupler its second end moves with respect to the body and is guided by the track. This moves the locking portion, thereby releasing the pin from the jaw.
[0054] In the preferred embodiment when in the safety position the safety link does not abut the stop. Rather, the safety link moves within the coupler without contacting any obstructions—thereby allowing the hydraulic cylinder to fully contract by moving only its first end. This means that the hydraulic cylinder does not move the locking portion.
[0055] However the foregoing should not be seen as limiting and alternatives are envisaged including those where the safety link is moved to the release position by a second actuator. In a preferred embodiment the present invention includes a restricting portion.
[0000] In a preferred embodiment the coupler includes a restricting portion.
[0056] Throughout the present specification, the term “restricting portion” should be understood as meaning a component which controls and/or limits movement of the safety link. Preferably, the restricting portion may hold the safety link in the safety position. However, the hold on the safety link is not so great that it cannot be overcome by another force to allow the safety link to move to the release position.
[0057] In a preferred embodiment the restricting portion may be a spring biased detent. The detent may extend into a complementary recess on the safety link.
[0058] Alternatively, the restricting portion may be a rubber mounting block or washer. This provides a frictional resistance to movement of the safety link so that it only moves when pressure is applied.
[0059] Throughout the present specification reference to the term “locking portion” should be understood as meaning a component which can secure a pin in a jaw. In a preferred embodiment the locking portion may be formed in the hydraulic cylinder. In this embodiment the one end of the hydraulic cylinder is shaped to provide a recess or projection that can act as the locking portion. Alternatively, the locking portion may be a pin pivotally mounted on the coupler or the moveable jaw. Therefore the foregoing discussion of the locking portion should not be seen as limiting. In a preferred embodiment the coupling may have a snap lock mechanism.
[0060] Throughout the present specification the term “snap lock mechanism” should be understood as meaning a mechanism to bias the locking portion to a locking position. The locking position is that in which the locking portion secures a pin in a jaw.
[0061] In this embodiment a biasing means may force the locking portion towards the locking position. However, the biasing means is not so strong that it cannot be overcome by the motion of inserting a pin into the jaw. In this embodiment, the action of moving a pin into the jaw moves the locking portion sufficiently to allow insertion of the pin into the jaw.
[0000] When the pin is substantially inside the jaw the biasing means forces the locking portion into the locking position thereby securing the pin in the jaw. However the foregoing should not be seen as limiting and alternatives are envisaged.
[0062] In a preferred embodiment the coupling may include a reset portion. Throughout the present specification reference to the term “reset portion” should be understood as meaning a component which resets the safety link to the safety position.
[0063] In a particularly preferred embodiment the reset portion resets the safety link to the safety position after the locking portion has released a pin from a jaw. Preferably, the reset portion is a protrusion extending from the hydraulic cylinder. However, the protrusion may also be secured to the coupler or be formed integrally to the hydraulic cylinder. Therefore the foregoing discussion should not be seen as limiting.
[0064] In a preferred embodiment the relative orientation of the work attachment and coupling is changed by tilting the coupler. This can be achieved by an operator moving the excavators' arm.
[0065] In an alternate embodiment the coupler and work attachment slides relative to each other. The important aspect of moving the coupler and work attachment relative to each other is so that the moveable jaw can move yet does not engage a pin on the bucket. It can therefore move past the position in which it engages a pin.
[0066] Throughout the present specification the term “connection assembly” should be understood as meaning an assembly to provide a connection between a control system and a device on a work attachment.
[0067] Throughout the present specification reference to the term “mounting” should be understood as meaning a component to support a plurality of connectors. In a preferred embodiment the mountings may be housings that support and hold a set of connectors.
[0068] Preferably the present invention may include two mountings, one of which is secured to a coupler and one of which is secured to a work attachment with which the coupler is to be used.
[0069] Throughout the present specification reference to the term “guard” should be understood as meaning a component to protect connectors. In a particularly preferred embodiment the present invention includes two guards. The first guard may protect a set of connectors in a housing on a coupler. The second guard may protect a set of connectors in a housing on a work attachment. However the foregoing should not be seen as limiting and it is envisaged that the connection assembly could also include one or more guards. This may vary from application to application depending on factors such as the type of connectors or the conditions which they may encounter. In a preferred embodiment the guard(s) may close an open face of the housing (s) thereby protecting the connectors.
[0070] In a particularly preferred embodiment the guard can move to expose the sets of connectors. This action is preferably a pivot or slide. Causing the guard to pivot or slide may be achieved by the action of bringing a work attachment and coupler into alignment so that the coupler can secure the work attachment to a machine.
[0071] In a preferred embodiment the connection assembly may have an engagement portion to which pressure can be applied to move the guard. The application of pressure to the engagement portion causes the guard(s) and mounting to move with respect to each other. Due to this movement the sets of connectors are exposed allowing them to engage. However, it is also envisaged that the connection assembly may include an actuator to move a guard with respect to the mounting and thereby expose a set of connectors.
[0072] Throughout the present specification reference to the term “connector” should be understood as meaning components which can secure the parts of the control system to each other. Preferably the connectors are hydraulic hose connectors as should be known to those skilled in the art. The connectors may also secure electrical wires or pneumatic tubes to each other. Preferably, the connectors are complementary pairs of connectors which can engage. Once secured, the connectors provide a connection between controls in the excavator and an actuator on a work attachment.
[0073] In a preferred embodiment the connectors are Quick Release Connectors (QRCs) as known to those skilled in the art. In this embodiment the QRCs are complementary male and female connector halves. The female connector has a spring biased latch to secure the male and female halves relative to each other. Movement of the latch relative to the female connector causes engaged pairs of connectors to release each other. In some embodiments the connector halves include a spring release mechanism to force the connector halves apart when the latch is released. In a preferred embodiment, the housings include impact absorbers. In this embodiment, the mountings may be mounted on compressible supports. These compressible supports may be formed from rubber or plastics materials, springs or air cushions. The use of impact absorbers allows the present invention to better withstand knocks incurred during use of the work attachment or at engagement of the connectors. In a preferred embodiment the connection assembly may include guides.
[0074] Throughout the present specification the term “guides” should be understood as referring to components that may help to line up set of connectors so that these can engage. In a preferred embodiment, the guides may be tapered members extending from the first component of the hose connection assembly. In this embodiment, complementary recesses receive the tapered members. The mountings facilitate the sets of connectors engaging by helping to ensure that these align with each other.
[0075] In a preferred embodiment, the connection assembly may have a plurality of biasing mountings. The biasing mountings secure and support the connectors on the mountings. They also urge these forward to ensure that the connectors are secured to each other. This feature is particularly important when the present invention is used with hydraulic hose connectors where it is critical to ensure that hydraulic fluid cannot escape from the hoses. In a preferred embodiment the connection assembly may have a cleaning portion.
[0076] Throughout the present specification reference to the term “cleaning portion” should be understood as meaning a component which removes particulate matter from on or around the connectors and/or mounting. Preferably the cleaning portion is mounted on the guard. In a particularly preferred embodiment the mounting and housing move at an angle with respect to each other such that the mounting brushes across the cleaning portion. Having the mounting brush across the cleaning portion ensures that particulate matter is removed and cannot accidentally enter into the hose connectors. In a preferred embodiment the cleaning portion is made from a bristle or similar. Alternatives include ridges made from rubber or plastic materials.
[0077] The present invention has a number of advantages. Firstly, the configuration of the safety link and locking portion force an operator to move the coupler through four or more steps to release a work attachment. Therefore, this reduces the chances of a work attachment being accidentally dropped from an excavator. Further, the snap-lock mechanism makes it easier to secure a pin inside a jaw. This helps to remove uncertainty as to whether the work attachment is secured to the coupler. The connection assembly disclosed herein provides an automated system to easily align and connect complementary hose connectors. Further, the hose connection assembly helps to prevent damage of the hose connectors by eliminating knocks, and preventing particulate matter from entering the connectors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0078] Further aspects of the present invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings in which:
[0079] FIG. 1 is an exploded view showing the components of present invention;
[0080] FIG. 2 is a side cross-sectional view of a coupler;
[0081] FIGS. 3A-N are side cross-sectional schematics showing operation of the coupler;
[0082] FIGS. 4A and 4B are a side view showing the safety link in the safety position and release position;
[0083] FIGS. 5A and 5B are front and side perspective views of the first and second components of a connection assembly;
[0084] FIGS. 6A-F are a side cross-sectional schematic showing operation of a connection assembly;
[0085] FIGS. 7 A- 7 B are side cross-sectional views of an alternative embodiment of a coupler according to the present invention;
[0086] FIG. 8 is an exploded view of components of the alternate embodiment of the coupler; and
[0087] FIGS. 9 A & B are view of a tilt bucket having part of a connection assembly according to the present invention secured thereto.
DETAILED DESCRIPTION OF THE INVENTION
[0088] The present invention relates to improvements to work attachment assemblies ( 1 ) for use with excavators (not shown in the drawings). Like numbers refer to like components throughout the Figures.
[0089] Referring to FIG. 1 which is an exploded view showing the components of the work attachment assemblies, and FIG. 2 showing a side cross-sectional view of a coupler ( 2 ). The components of the coupler ( 2 ) will be discussed in the order in which they are assembled.
[0090] The coupler ( 2 ) has a body ( 3 ) to house its components. The body ( 3 ) facilitates attachment of the coupler ( 2 ) to an excavator arm (not shown). The attachment is via apertures ( 4 ) through which fasteners (not shown) can extend. This is as should be known to those skilled in the art. The body ( 3 ) has a first jaw ( 5 ) formed integrally at one end ( 6 ). A hydraulic cylinder ( 8 ) is positioned within the body ( 3 ). A second jaw ( 7 ) is secured to the hydraulic cylinder ( 8 ) at its first end ( 9 A). The hydraulic cylinder ( 8 ) is configured to slide the second jaw ( 7 ) relative to the body ( 3 ) by expanding and contracting.
[0091] Second end ( 9 B) of the hydraulic cylinder ( 8 ) is shaped to form a locking portion ( 10 ). The hydraulic cylinder ( 8 ) is floatingly mounted and is able to move within the body ( 3 ). This movement is additional to the expansion and contraction of the hydraulic cylinder ( 8 ). A snap lock mechanism ( 11 ) is formed from springs ( 12 ) and a pin ( 13 ). The pin ( 13 ) extends through the hydraulic cylinder ( 8 ) and into channels ( 15 ) in the body ( 3 ). The springs ( 12 ) provide a biasing force against the pin ( 13 ) and thereby the hydraulic cylinder ( 8 ). Nuts ( 16 ) allow the tension of the springs ( 12 ) to be adjusted. Safety links ( 17 ) are pivotally mounted to the second jaw ( 7 ). The body ( 3 ) has channels having a first section ( 19 ) and a second section ( 20 ). Stops ( 29 ) separate the first and second sections ( 19 , 20 ). Each channel ( 18 ) has a ridge ( 21 ) in the first section ( 19 ). Protrusions ( 22 ) extend from the side of the actuator ( 8 ) to provide reset portions.
[0092] A restricting portion ( 23 ) is formed from a recess ( 24 ) on the jaw ( 7 ), and a spring ( 25 ) biased detent ( 26 ) in the safety link ( 17 ). The restricting portion ( 23 ) can be better seen in FIGS. 4A and 4B . The relevance of the foregoing will become clearer from the following description of the coupler ( 2 ) in-use with reference to FIGS. 3 A-N. An excavator arm manipulates the coupler so that it will engage a work attachment having a first pin ( 27 ) and a second pin ( 28 ). The first and second pins ( 27 , 28 ) are parallel. The first and second pins ( 27 , 28 ) are shown in the Figures but the work attachment and excavator arm are not shown to simplify the Figures.
[0093] The first pin ( 27 ) presses against the locking portion ( 10 ). This overcomes the springs ( 12 ) to move the locking portion ( 10 ) and allow the pin ( 27 ) into the first jaw ( 5 ). Once the pin ( 27 ) is sufficiently inside the first jaw ( 5 ) the snap lock mechanism ( 12 ) forces the locking portion ( 10 ) into the locking position. This secures the pin ( 27 ) inside the first jaw ( 5 ). The body ( 3 ) is tilted to position the second jaw ( 7 ) between the first pin ( 27 ) and second pin ( 28 ). The hydraulic cylinder ( 8 ) expands to slide the second jaw ( 7 ) to engage the second pin. This is the position shown in FIG. 3E . The work attachment is now secured to the coupler ( 2 ) and can operate as should be known to those skilled in the art. It should be noted that the safety links ( 17 ) do not touch the ridges ( 21 ). To release the work attachment (not shown) the second jaw ( 7 ) is moved so that it releases the second pin ( 28 ). The coupling ( 2 ) is tilted with respect to the work attachment (not shown). This brings the second jaw ( 7 ) out of alignment with the second pin ( 28 ). The hydraulic cylinder ( 8 ) expands to move the second jaw ( 5 ). As the second jaw ( 7 ) is not in line with the second pin ( 28 ) the hydraulic cylinder can expand past the position in which the second jaw ( 7 ) engages the second pin ( 28 ). This movement is in the opposite direction to that in which the second jaw ( 7 ) moves to release the second pin ( 28 ). This action causes the safety links ( 17 ) to touch the ridges ( 21 ). The ridges ( 21 ) press against the safety links ( 17 ) forcing them into the release position.
[0094] FIG. 3I is the same as FIG. 3H but without the hydraulic cylinder ( 8 ) shown. This allows the safety links ( 17 ) to be clearly seen and that these are in the release position. The operator sends a signal to the hydraulic cylinder ( 8 ) to contract. This moves the second jaw ( 7 ) in the opposite direction i.e. the same direction that the second jaw ( 7 ) moves to release the second pin ( 27 ). The second jaw ( 7 ) is moved until the safety links ( 17 ) abut the stops ( 29 ). This prevents the hydraulic cylinder ( 8 ) moving the second jaw ( 7 ). The hydraulic cylinder ( 8 ) continues to contract. As the safety links ( 17 ) abut the stops ( 29 ) this causes the end ( 6 ) of the hydraulic cylinder ( 8 ) to move. The path of the end ( 6 ) is controlled by the pin ( 13 ) travelling in the channels ( 15 ). This causes the locking portion ( 10 ) to move out of the first jaw ( 5 ) thereby releasing the first pin ( 27 ) from the first jaw ( 5 ).
[0095] FIGS. 3K-3N show the hydraulic cylinder in dotted outline. The safety links ( 17 ) therefore cause contraction of the hydraulic cylinder ( 8 ) to move the locking portion ( 10 ). This releases the first pin ( 27 ) from the first jaw. The coupler ( 2 ) can then be moved away from the work attachment. The protrusions ( 22 ) press against to the safety links ( 17 ) forcing them to move away from the stops ( 29 ) and align with the second section ( 20 ) of the channels ( 18 ). This allows the hydraulic cylinder ( 8 ) to extend thereby forcing the locking portion ( 10 ) back into the first jaw ( 5 ). This resets the snap lock mechanism.
[0096] Referring now to FIGS. 1 , 5 A and 5 B which show the components of a connection assembly ( 30 ) to provide a connection between hydraulic actuators on a work attachment and a control system (not shown in the Figures for ease of reference).
[0097] The connection assembly ( 30 ) is formed from a first component ( 31 ) and a second component ( 32 ). The first component ( 31 ) is mounted on the second jaw ( 7 ) of the coupler ( 2 ). The second component ( 32 ) is mounted on a work attachment as is shown in FIGS. 9A & B. The first component ( 31 ) has a mounting ( 33 ) with a plurality of male hose connectors ( 34 ). A first guard ( 35 ) is pivotally attached to the mounting ( 33 ). A spring ( 36 ) biases the first guard ( 35 ) to a closed position in which it protects the male connectors ( 34 ). The second component ( 32 ) has a mounting ( 37 ) in the form of a housing and a second guard ( 38 ) slideably attached to the mounting ( 32 ). A spring (not shown) biases the second guard ( 38 ) to a closed position. A set of female hose connectors ( 40 ) are mounted inside the housing. The female connectors ( 40 ) and male connectors ( 34 ) are complementary and can engage each other to provide a connection between the control system and actuators on the work attachment. The second component ( 32 ) has a plate ( 43 ) with openings ( 44 ). The male connectors ( 34 ) can be inserted through the openings ( 44 ). The female connectors ( 40 ) have latches ( 41 ) which secure the male connectors ( 34 ) to them. The latches ( 40 ) release the male connectors ( 33 ) when moved along the length of the female connector ( 39 ).
[0098] Referring now to FIGS. 6A-6F which are side schematics showing the connection assembly ( 30 ) in use. The coupler ( 2 ) is positioned so that jaw ( 5 ) receives pin ( 27 ). The coupler ( 2 ) is tilted to move the second jaw ( 7 ) between pins ( 27 , 28 ). This action causes the coupler ( 2 ) to force guard ( 38 ) to slide down and expose the female connectors ( 40 ). The action of tilting the coupler ( 2 ) between the pins ( 27 , 28 ) also causes the guard ( 35 ) to move thereby exposing the male connectors ( 34 ). This is due to member ( ) on the guard ( 35 ) contacting a portion on the second component ( 32 ). This contact prevents the guard ( 35 ) tilting with the coupler ( 2 ) so that in effect the guard pivots with respect to the coupler ( 2 ) to expose the connectors ( 34 ). The second jaw ( 7 ) moves forward causing a corresponding movement in the first component ( 31 ). Tapered members ( 45 ) extend into openings ( 46 ). The members ( 45 ) help to ensure alignment of the hose connectors ( 34 , 40 ) so that they can engage.
[0099] The second jaw ( 7 ) continues moving causing the male and female connectors ( 34 , 40 ) to engage. This provides a connection between a hydraulic cylinder and a control system (neither shown in the FIGS. 6A-6F ). To release the connectors ( 34 , 40 ), the second jaw ( 7 ) is moved. This moves the first component ( 31 ) away from the second component ( 32 ) thereby causing the latches to abut the edges of the openings ( 44 ). The latches ( 39 ) are moved along the length of the female connector ( 38 ) thereby releasing the engaged connectors ( 34 , 40 ). Springs ( 36 ) force the guards ( 35 , 38 ) back to the closed position. The guards can therefore protect the connectors ( 34 , 40 ) when not in use.
[0100] Referring now to FIGS. 7A , - 7 G, and 8 which show an alternative embodiment of a coupler ( 46 ) according to the present invention. The coupler ( 46 ) has a body ( 47 ) with a first jaw ( 48 ) formed integrally at one end ( 49 ). A second jaw ( 50 ) is positioned inside the body ( 47 ). The second jaw ( 50 ) is able to slide with respect to the body ( 47 ). A hydraulic cylinder ( 51 ) is floatingly mounted in the body ( 47 ). The second jaw ( 50 ) is secured to the hydraulic cylinder ( 51 ) at its first end ( 52 ). The hydraulic cylinder's second end ( 53 ) is shaped to define a locking portion ( 54 ). Torsion springs ( 55 ) are mounted in the body ( 47 ) and abut against the hydraulic cylinder ( 51 ). The torsion springs ( 55 ) exert a biasing force that urges the hydraulic cylinder ( 51 ) and therefore the locking portion ( 54 ), towards a locking position. The locking portion ( 54 ) sits across the entrance ( 56 ) to first jaw ( 48 ). This is shown in FIG. 7A .
[0101] Safety links ( 57 ) are pivotally mounted to the body ( 47 ) above the second jaw ( 50 ). The safety links ( 57 ) have protrusions ( 58 ). In use, the coupler ( 46 ) is positioned so that a pin ( 59 ) presses against the locking portion ( 54 ). This overcomes the urging force of the torsion springs ( 55 ) and moves the locking portion ( 54 ) from the entrance ( 50 ) to first jaw ( 48 ). This allows the pin ( 59 ) to be inserted into the first jaw. When the pin ( 59 ) is inside the jaw ( 48 ) the torsion springs ( 55 ) force the locking portion ( 54 ) back across the entrance ( 56 ) to secure the pin inside the first jaw ( 48 ). The coupler ( 46 ) is tilted so that second jaw ( 50 ) is between pin ( 59 ) and a second pin ( 60 ). The hydraulic cylinder ( 51 ) is caused to expand which slides the second jaw ( 50 ) with respect to the body ( 47 ). The second jaw ( 50 ) receives the second pin ( 60 ) and thereby secures the work attachment (not shown) to the coupler ( 40 ). The work attachment can then be used as per normal operation.
[0102] To release the work attachment (not shown) the hydraulic cylinder ( 51 ) is caused to contract. This slides the second jaw ( 50 ) with respect to the body to release the second pin ( 60 ). The coupler ( 46 ) is tiled so that the second jaw ( 51 ) is brought of alignment with the second pin ( 60 ). The hydraulic cylinder ( 51 ) is caused to expand to move the second jaw ( 50 ) past the position in which it engages the second pin ( 60 ). This causes the second jaw ( 50 ) to move so that edge ( 61 ) is past the protrusions ( 58 ). This allows the safety links ( 57 ) to pivot downward. In this position the protrusions ( 58 ) are no longer above the top ( 62 ) of the jaw ( 50 ).
[0103] The hydraulic cylinder ( 51 ) contracts causing edge ( 61 ) to abut protrusions ( 58 ). This prevents first end ( 52 ) and the second jaw ( 50 ) moving further within the body ( 47 ). The hydraulic cylinder ( 51 ) continues to contract. As the hydraulic cylinder ( 51 ) is floatingly mounted within the body ( 47 ) the second end ( 53 ) is moved. This causes the locking portion ( 54 ) to be moved away from entrance ( 56 ) to the first jaw ( 48 ). First pin ( 59 ) therefore is released from the first jaw ( 56 ) and therefore the coupler ( 46 ). The coupler ( 46 ) can be moved away from the work attachment (not shown). Hydraulic cylinder ( 51 ) continues to contract. Safety links ( 57 ) abut against detents ( 63 ). This lifts the safety links ( 57 ) above edge ( 61 ) of the second jaw ( 50 ). The torsions springs ( ) force the locking portion ( 54 ) across entrance ( 56 ) to the first jaw ( 48 ). This allows hydraulic cylinder ( 51 ) to expand slightly towards the first jaw ( 50 ). Simultaneously the protrusions ( 58 ) are again above the top ( 64 ) of second jaw ( 50 ). This resets the safety links ( 57 ) to the safety position.
[0104] Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof. Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined in the appended claims. | A method of releasing a work attachment from a coupler ( 2 ), wherein the work attachment is secured to the coupler via two pins held within two jaws ( 5, 7 ), the method including the steps of: (a) moving a jaw ( 7 ) to release a first pin (b) changing the orientation of the coupler ( 2 ) and work attachment relative to each other (c) moving the jaw ( 7 ) in the opposite direction to that in step (a); characterised by the step of: (d) moving the jaw ( 7 ) in the opposite direction to that in step (c) characterised in that the action of step (c) moves a safety link ( 17 ) to a release position, thereby allowing a locking portion ( 10 ) to release a second pin from a jaw in step (d). | 4 |
This application is a continuation of application Ser. No. 07/943,485, filed Sep. 11, 1992, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image recording device for recording image information of the original such as, e.g., a check, an ordinary document, etc. on a recording medium such as a microfilm or the like.
2. Related Background Art
This type of prior art image recording device will be exemplified by FIG. 16. FIG. 16 is a side elevation illustrating one mode of a subject conveying system of a photographing device 1 serving as an image recording device.
When subjects S are placed on a paper feed tray 2 inclined downwards, the subjects S are moved in an arrowed direction by dint of the gravitational force. These subjects S are fed while being singly separated by a paper feed roller 3 rotating clockwise in the FIGURE and a separation roller 4 rotating clockwise in the FIGURE. Next, a lower belt 7 wound on belt rollers 6, 11 and on tension roller 10 is driven with rotations of a lower driving roller 9. The subjects S are conveyed from the horizontal direction to the vertical direction, while an idle roller 5 and a guide unit 8 depress the subjects S on the lower belt 7. The subjects S pass between a pair of guide glasses 22 serving as an exposure section.
Then, both surfaces of the subject S are simultaneously illuminated with beams of a pair of illumination lamps 21 during a passage between the guide glasses 22. Nip rollers 12, 13 are provided above and under the guide glasses 22. Further, an upper belt 18 wound on belt rollers 15, 17 and on a tension roller 16 is driven with rotation of an upper driving roller 19. A conveying route of the subjects S passing through the guide glasses 22 is changed from the vertical direction to the horizontal direction, while an idler roller 14 pushes the subjects S on the upper belt 18. The subjects S advance in an arrowed direction and are ejected into a stacker 20.
By the way, the following is a reason why the conveying speed of the subject S is constant in the conventional example explained above. If the conveying speed is made variable, an exposure time during photographing is also varied, and it is therefore required that a light quantity be adjusted. Besides, there differ the position of the stacker 20 and the way how the subject S springs out during the ejection in accordance with the speeds. A troublesome problem arises, wherein the positional adjustment is needed. However, the checks, etc. are quickly mass-processed, and hence the conveying speed is preferably high. While on the other hand, there exists a possibility that a relatively thin ordinary sheet-like document, etc. may be damaged by an impingement when feeding the document between the paper feed roller and the separation roller that are rotating at a high velocity. Therefore, the paper is fed preferably at a low speed during photographing thereof. As described above, there is such a defect that the paper feed speed can not be changed to a speed optimal to each subject.
SUMMARY OF THE INVENTION
It is a general object of the present invention, which obviates the defects inherent in the prior art described above, to provide an image recording device capable of effecting records suited to different types of subjects and eliminating the necessity for adjustments of respective sections even when adjusting a conveying speed of the subject.
To accomplish the foregoing object, according to one aspect of the present invention, there is provided an image recording device comprising: a conveying section for conveying sheet-like subjects; an illuminating section for illuminating the subjects with the light; and a recording section for recording image information given from the illuminating section, characterized by dividing a driving source for a paper feed section positioned upstream with respect to the illuminating section and an intra-device conveying section exclusive of the paper feed section and making variable a conveying speed of the paper feed section.
Further, the conveying speed of the paper feed section is made variable by providing a display section for displaying the conveying speed of the paper feed section and a setting switch capable of manually arbitrarily setting the conveying speed.
The thus constructed image recording device is capable of conveying the subjects at the paper feed speeds optimal to the respective subjects by adjusting the conveying speed of the paper feed section without adjusting the light quantity during the illumination and the position of the stacker in the ejecting section.
Furthermore, the conveying speed is recognizable by providing the display section and the setting switch. A degree of freedom to set the conveying speed increases, whereby a paper feeding state optimal to the subject can be developed.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent during the following discussion taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic block diagram illustrating a subject conveying system of an image recording device in the first embodiment of the present invention;
FIG. 2 is a schematic block diagram depicting a driving system thereof;
FIG. 3 is a block diagram showing how the operation thereof is controlled;
FIG. 4 is a block diagram illustrating a display section of the image recording device in the second embodiment of the present invention;
FIG. 5 is a block diagram showing how the operation thereof is controlled;
FIG. 6 is a diagram depicting the image recording device in the third embodiment of the present invention;
FIG. 7 is a block diagram showing a display section thereof;
FIG. 8 is a block diagram showing how the operation thereof is controlled;
FIG. 9 is a perspective view illustrating a photographing optical system;
FIG. 10 is a block diagram illustrating a shutter opening/closing control circuit;
FIG. 11 is a timing chart showing output signals thereof;
FIG. 12 is a timing chart showing the operation thereof;
FIG. 13 is a block diagram showing the second embodiment of the shutter opening/closing control circuit;
FIG. 14 is a block diagram showing the third embodiment;
FIG. 15 is a flowchart of assistance in explaining the operation thereof; and
FIG. 16 is a schematic block diagram illustrating a conventional image recording device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first embodiment of the present invention will hereinafter be described with reference to FIGS. 1 through 3.
FIG. 1 is a view illustrating a whole construction of a subject conveying system of a photographing device defined as an image recording device. Referring to the same FIGURE, a relatively thick subject (original) S 1 of, e.g. a check, etc. is, when placed on a paper feed board 31 inclined downwardly of a device body 30, moved in an arrowed direction by dint of the gravitational force. The subjects S 1 are singly separated by a paper feed roller 32 rotating anticlockwise in the FIGURE and a separation roller 33 rotating anticlockwise in the FIGURE, which constitute a paper feed section A. The subjects are thereafter conveyed onto a conveying belt 39 wound on belt driving rollers 37, 38 by means of paired conveying rollers 34, 35. The subjects S 1 are fed to a photographing upstream-side conveying section B by a driven roller 36 paired with the driving roller 37 through the conveying belt 39. This photographing upstream-side conveying section B is constructed of: belt rollers 40, 41; a tension roller 42; a conveying belt 44 wound on a lower large-diameter roller 43; and driven rollers 45, 46 paired respectively with the belt rollers 40, 41. The subjects S 1 fed from the paper feed section A are thereby conveyed to a photographing illumination section C.
The photographing illumination section C consists of a pair of transparent parallel glasses 47 and a pair of illumination lamps 48 disposed in front and in rear of the glasses. The upper and under surfaces of the conveyed subject S 1 are illuminated with beams of the illumination lamps 48 when passing between the pair of parallel glasses 47. Images on the upper and under surfaces of the subject S 1 are exposed onto films through unillustrated optical systems as well as through mirrors M 1 , M 2 .
The subjects S 1 are ejected outside the device body 30 by means of a photographing downstream-side conveying section D constructed of: belt rollers 49, 50; a conveying belt 53 wound on a tension roller 51 and an upper large-diameter roller 52; and a driven roller 54 paired with the belt roller 49. The ejected subjects S 1 impinge on a standing plate 55a of a stacker 55 and are thereby sequentially stacked in alignment on the stacker 55.
Next, in the case of photographing a relatively thin sheet-like subject (original) S 2 such as an ordinary document, etc., the subject S 2 is inserted along a horizontal manual feed board 56 disposed downwardly of the paper feed board 31 and slid on this board. The subject S 2 is, when fed in between the conveying belt 39 and a driven roller 57 paired with a driving roller 58, conveyed onto the conveying belt 39, while a conveying path changeover pawl 58 is rotated about a shaft 58a and is pushed up. The subject S 2 is thereafter imaged in the same way with the subject S 1 described above and then ejected.
Note that a subject detection sensor 59 is disposed downstream with respect to the conveying path changeover pawl 58. This sensor 59 controls opening/closing timings of a shutter (unillustrated) of a photographing section. A manual feed detection sensor 60 detects the fact that the subject is manually fed. Further, the conveying path changeover pawl 58 normally, as indicated by a solid line of FIG. 1, forms a conveying path of an automatic paper feed section. When the subject S 2 is fed from the manual feed board 56, however, the conveying path changeover pawl 58 forms a conveying path of a manual feed section, wherein the pawl rotates about the shaft 58a and is easily pushed up.
Next, FIG. 2 depicts a driving system of the above-mentioned subject conveying system.
Referring to the same FIGURE, a main motor 61 constituting a second conveying means rotates in an arrowed direction e (counterclockwise in the FIGURE). The power thereof is transferred from a coaxial motor pulley 62 via a belt 65 to a pulley 63 fixed to a shaft 43a of a lower large-diameter roller 43 and to a pulley fixed to a shaft 52a of an upper large-diameter roller 52. The above-mentioned conveying belts 44, 53 are thereby operated. The subject is conveyed to the photographing section through the conveying belt 44. The subject which has already undergone an imaging process is ejected from the device body through the conveying belt 53.
Further, a driving motor 66 constituting a first conveying means rotates in an arrowed direction f (counterclockwise in the FIGURE). The power thereof is transferred from a coaxial motor pulley 67 via a belt 70 to a pulley 68 fixed to a shaft 32a of a paper feed roller 32 and to a pulley 69 fixed to a shaft 33a of a separation roller 33. The paper feed roller 32 and the separation roller 33 are thereby rotated respectively. A gear 71 is mounted integrally coaxially on the pulley 69. This gear 71 meshes with a gear 72 so provided as to be integral and coaxial with a transfer pulley 73. This gear 72 is rotatably loosely fitted to a shaft 74. Then, rotations of the pulley 69 and the gear 71 are transferred to a manual feed belt roller pulley 75 fixed to a shaft 38a of a belt driving roller 38 via the gear 72, the transfer pulley 73 and the belt 76. Further, a conveying belt 39, etc. is operated by the belt driving roller 38, whereby the subject is conveyed at a speed v.
Additionally, the pulley 68 is so provided as to be coaxial and integral with a transfer pulley 77. Rotations of the pulley 68 and the transfer pulley 77 are transferred via a belt 78 to a pulley 79 fixed to a shaft 34a of the conveying roller 34 and therefore transferred further to the conveying roller 34.
Note that a unidirectional clutch is provided between the driving roller 38 and the shaft 38a.
Normally, the main motor 61 and the paper feed driving motor 66 rotate so that the conveying belt 39 and the belts 44, 53 move at the same speed v. On the verge of manual feed photographing after the subject has been placed on the manual feed detection sensor 60, however, as illustrated in a block diagram of FIG. 3, a signal is transmitted from the manual feed detection sensor 60 to a control circuit 80. A control signal is transmitted therefrom to the driving motor 66. The number of revolutions of the motor 66 decreases corresponding to a preset paper feed speed (lower than the paper feed speed during the automatic paper feed). The belt 39 is thereby moved at a speed v' (<v). When the subject S2 is conveyed at the speed v by the conveying belt 44, the conveying belt 39 moving at the speed v' follows up the movement of the subject S 2 owing to function of the unidirectional clutch described above, with the result that the belt 39 moves at the speed v. The subject is thus prevented from being damaged.
FIGS. 4 and 5 demonstrate the second embodiment of the present invention. For simplicity of explanation, a description will be given, wherein the same components as those in the first embodiment discussed above are marked with the like symbols.
The first embodiment discussed above has presented the 2-step changeover of the automatic paper feed and the manual paper feed. There is no such degree of freedom that the ordinary document is conveyed while reducing the paper feed speed in the automatic paper feed. Hence, in accordance with this embodiment, as shown in FIG. 4, a display 90 is provided with a feed speed display part 91 and a maximum speed display part 92 of the photographing device. Provided thereunder are a deceleration switch 93 and an acceleration switch 94 as manually manipulated speed setting switches capable of manually increasing and decreasing the paper feed speed by predetermined quantities. Other mechanical constructions are the same as those in the first embodiment described above. The paper feed speed can be increased and decreased every time switches 93, 94 are depressed.
FIG. 5 is a block diagram for the control thereof. When a signal is transmitted from the setting switch 93 or 94 to a control circuit 80, an indication on the feed display part 91 of the display is changed. The paper feed section driving motor 66 is controlled on one hand and rotated so that the paper feed section reaches the conveying speed displayed thereon.
With this operation, the user is able to freely set the paper feed speed in accordance the subject.
The third embodiment of the present invention will be demonstrated by FIGS. 6 to 8.
Give in this embodiment in an example where an automatic input unit such as a bar code reader or the like and a thickness detecting unit for detecting a thickness of the original are mounted. Referring to block diagram of FIG. 6 illustrating a subject conveying system, the numeral 98 designates a bar code reader, and the symbols 99A, 99B represent thickness detecting units. Other constructions are the same as those in FIG. 1 in the first embodiment.
Further, the configuration of the display of FIG. 7 is the same as that shown in FIG. 4 in the second embodiment discussed above.
FIG. 8 is a block diagram for the control thereof. A conveying speed arithmetic unit 100 calculates a conveying speed of the subject S at the bar code reader 98 in accordance with a read scan velocity and a bar code length of the bar code reader 98. The calculated conveying speed is inputted to a memory of the control circuit 80. When e.g., 40 m/min is inputted, as illustrated in FIG. 7, 40 is displayed in the maximum speed display part 92. This becomes the maximum speed of the device when the bar code reader is mounted. If read malfunctions are frequently caused in a printing state or the like of the bar code after conveying the subject, it is possible to make such an adjustment as to reduce the conveying speed by depressing the setting switch 93.
The thickness detecting units 99A, 99B include a pair of rollable roller disposed in the upper automatic paper feed path and in the lower manual paper feed path. When the sheet-like original is fed in between the pair of rollers, the upper roller moves upwards corresponding to a thickness of the original. The thickness of the original is detected by measuring the upward moving quantity of the upper roller.
Detected in this embodiment is whether or not the original has a thickness smaller than a predetermined thickness. When detecting the fact of being smaller than the predetermined thickness, the conveying speed of the paper feed section is reduced. As discussed above, there are eliminated the necessities for adjusting the exposure quantity in the illumination section and adjusting the stacker position in the ejecting section. Then, paper feeding states suitable for the subjects are selectable by changing over the conveying speed of the paper feed section, depending on the case where mass processing is to be quickly performed during the feed of paper and the case where recording is to be deliberately executed.
Provided further are a display for displaying a conveying speed of the paper feed section and a setting switch capable of arbitrarily setting a conveying speed. The conveying speed is thereby recognizable and settable as well. A degree of freedom of setting the conveying speed increases all the more. The paper feed state can be made optimal to the subject. Besides, even in the case of mounting the automatic input unit such as the bar code reader, etc., it can be set at a read optimum conveying speed.
FIG. 9 illustrates an optical system for photographing images of the two surfaces of the original on a film. The images of the two surfaces of the original S 1 are illuminated with beams of the illumination lamps 48. The images are then projection-exposed onto a film F through an image forming lens 113 after being reflected by a mirror 112 via mirrors M 1 , M 2 each disposed at 45° to the original and slits 111, 111'. Designated by 116 is a shutter for opening and closing a photographing light path.
Next, relations between signals from the subject detection sensor 59 and opening/closing timings of the shutter 116 will be explained with reference to FIGS. 10 to 12. FIG. 10 is a block diagram illustrating a shutter opening/closing control circuit. FIG. 11 is a timing chart of the output signals. FIG. 12 is a timing chart showing the operations. Referring to FIG. 1, let x be the length of the subject, let y be the distance from a detection position of the sensor 59 to the conveying speed constant-side inlet roller 45, and let z be the distance from the roller 45 to the photographing center. In FIG. 12, a point A 2 indicates a time when turning on the power supply; the top end of the subject is detected by the sensor 59 at a point B 2 ; and the rear end thereof is detected at a point C 2 . The shutter opens (point E 2 ) with a delay of time calculated by using the conveying speed v and the distance y+z from the sensor to the photographing center--i.e., the time being given by (y+z)/v--after detecting the top end of the subject at the point B 2 .
To begin with, a relation between the sensor 59 and the shutter will be explained in conjunction with FIG. 12. In the case of the automatic paper feed, the speeds v in the paper feed section and other conveying sections are equal, and hence the sensor 59 detects the top end of the fed subject at the point B 2 and detects the rear end of the subject at the point C 2 . On receiving detection signals thereof, a circuit which will be mentioned later adds allowance times D 2 E 2 , F 2 G 2 to a passing time B 2 C 2 of the subject which has passed under the sensor 59. The shutter 116 opens at a point D 2 and closes at a point G 2 . On the other hand, in the case of the manual paper feed, the conveying speed in the conveying section other than the paper feed section is constant. However, the conveying speed in the paper feed section is decreased down To v'. Hence, after the subject has passed under the sensor 59, a time B 2 E 3 until the photographing center is reached is later than B 2 E 2 in the automatic paper feed. Further, a time E 3 H 3 for which the subject passes through the photographing center is shorter by a conveying speed shown in the FIGURE than a time B 2 C 3 for which the subject passes under the sensor 59. Allowances times D 3 E 3 , H 3 G 3 are added to this E 3 H 3 . The shutter opens at D 3 and closes at G 3 .
A circuit for opening and closing the shutter corresponding to these two states will be described with reference to FIGS. 10 and 11.
Indicated by S1 in FIG. 10 is a signal inputted from the sensor 59 to a shift register 261. The symbol S2 represents a clock signal from a clock 260. The symbols S3-S6 represent preset output signals from a shift register 261.
The shift register 261 is intended to transmit a subject detection signal from the sensor 59 to a shutter control circuit 266 with a delay. A clock signal invariably having a constant pulse is inputted from a clock oscillator 260 to the shift register 261. The shift register 261 outputs the signals from the sensor with a predetermined time lag (several pulses).
A selector 262 is connected to an output-side of the shift register 261. An input terminal of a selector 265 is connected to an output terminal of the selector 262 via an OR circuit 263 and an AND circuit 264. An output terminal thereof is connected to the shutter control circuit 266. The terminals of the selectors 262, 265 are selected beforehand by signals S9, S10 from a conveying speed changeover switch 267.
In accordance with this embodiment having the construction discussed above, the selectors 262, 265 are at first connected to the terminals shown by broken lines in the case of the automatic paper feed. Signals S4, S5 are selected as output signals from the shift register 261. In the selector 265, an OR signal S7 of the OR circuit 263 is selected as an output signal and transmitted to the shutter control circuit 266. It is thus possible to open and close the shutter with an allowance time given to the time for which the subject passes under the sensor 59.
On the other hand, in the case of the manual paper feed, the selectors 262, 265 are connected to the terminals drawn by solid lines. Signals S3, S6 are selected as output signals from the shift register 261. In the selector 265, an AND signal S8 of the AND circuit 264 is selected as an output signal and transmitted to the shutter control circuit 266. It is thus feasible to open the shutter with a time lag longer than in the automatic paper feed and close the shutter in a shorter time than the time for which the subject passes under the sensor 59.
Note that the signals S3-S6 are arbitrarily set in accordance with the paper feed speed in the automatic or manual paper feed.
FIG. 13 shows the second embodiment of the shutter opening/closing control circuit.
The first embodiment described above presents the two-step speed changeover. This embodiment is arranged to correspond to stepless speed variations.
When inputting conveying speed data 380 to a control circuit 379, pulse widths of clock oscillators 381, 382 are set by output signals S13, S24. Selectors 373, 374 each selects one of output signals S16, S17 of shift registers 371, 372 by use of output signals S14, S25. A selector 377 selects an OR circuit 375 or an AND circuit 376 by use of an output signal S15. Signals S11 are transmitted from the sensor 59 to the shift registers 371, 372. Pulse signals are further inputted from the clock oscillators 371, 372 to the shift registers 371, 372. The selectors 373, 374 each selects one signal among signal groups S16, S17 of the shift registers 371, 372. The selected signals are inputted as signals S18, S19 to the OR circuit 375 and the AND circuit 376. A selector 377 selects an output signal S20 transmitted from the OR circuit or a signal S21 transmitted from the AND circuit 376. The selected signal is inputted to the shutter control circuit 378, thereby opening and closing the shutter.
Then, an opening/closing time of the shutter is adjusted by changing pulse widths of the clock oscillators 381, 382. The selectors 373,374 select outputs of the shift registers 371, 372, thereby making it possible to adjust a delay of the shutter opening/closing time after the subject has passed under the sensor 59.
FIGS. 14 and 15 show the third embodiment.
In this embodiment, the operation is performed without using the shift registers. An explanation will be given with reference to a block diagram of FIG. 14 and a flowchart of FIG. 15.
A signal S31 is inputted from the sensor 59 to a CPU 491 incorporating timers 492, 493. An output signal S32 thereof is inputted to a shutter control circuit 494. The timer 492 counts up a time for which the subject passes under the sensor 59. The timer 493 counts up a time until the photographing center is reached after the subject has passed under the sensor 59.
To start with, a carry-in speed of the subject is inputted in #1. Based on this numerical value, a constant for calculating a shutter opening time t' is computed from a time t required for the passage. Further, a time T of the timer 493 is determined in #2.
Next, when the subject begins to pass under the sensor 59, the timer 492 is actuated and starts counting up the subject passing time in #3 after the signal S31 has been inputted from the sensor 59 to the CPU 491. Simultaneously, the timer 493 starts subtracting the preset time in #4. When transmitting, to the CPU 491, a signal indicating that the subject has completely passed under the sensor 59, the timer 492 stops in #5. The shutter opening time t' is calculated from the time required for the passage in #6. After passing under the sensor 59, and when a timer 493's time T=0, an output signal S32 is transmitted to the shutter control circuit 494 in #7, thereby opening the shutter. Simultaneously, the timer 492 starts subtracting the time t required for the passage of the subject under the sensor 59 in #8. When the calculated shutter opening time t'=0, the output signal S32 is transmitted to the shutter control circuit 494 in #9, thereby closing the shutter.
In this manner, the control can be effected by deducing the shutter opening time and the shutter opening/closing timings from the conveying speed of the subject.
As discussed above, the shutter opening/closing timings can be varied corresponding to the conveying speeds with the passage of the subject in the paper feed section which is detected by the subject detection sensor provided in the paper feed section. The spacing between the images on the film is not influenced by variations in the conveying speed and can be made constant. A waste of the film can be eliminated.
Although the illustrative embodiments of the present invention have been described in detail with reference to the accompanying drawings, it is to be understood that the present invention is not limited to those embodiments. Various changes or modification may be effected by one skilled in the art without departing from the scope or spirit of the invention. | Disclosed is an image recording device having a conveying section for conveying sheet-like subjects, an illuminating section for illuminating the subjects with the light and a recording section for recording image information given from the illuminating section. A driving source for a paper feed section positioned upstream with respect to the illuminating section and an intra-device conveying section exclusive of the paper feed section is divided. A conveying speed of the paper feed section is made variable through a display section for displaying the conveying speed thereof and a setting switch capable of manually arbitrarily setting the conveying speed. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to modified opioids containing silicon.
BACKGROUND OF THE INVENTION
[0002] Opioids are psychoactive molecules that resemble morphine or similar molecules in their pharmacological effects. The primary therapeutic use of opioids is to produce an analgesic effect, otherwise referred to as a painkiller effect, whereby the perception of pain is decreased and the tolerance of pain is increased. Opioids are amongst the world's oldest known drugs, with examples of the morphine molecule being extracted from poppy flowers found in recorded history. Morphine, one of the most commonly known opioids, has the chemical formula C17H19NO3 and its molecular structure is well known.
[0003] Opioids operate on humans by binding to opioid receptors, which are primarily located in the central and peripheral nervous system and the gastrointestinal tract. Today, the primary clinical use of opioids is the treatment of severe pain such as post-operative pain. Although opioids are amongst the best known drugs for effective relief of severe pain, there are many undesirable side effects of opioids, which side effects include sedation, respiratory depression, constipation, nausea and vomiting, and addiction to the sense of euphoria it may induce. That is, ongoing administration of opioids may result in opioid dependence, leading to withdrawal symptoms upon abrupt discontinuation of opioids. Opioid dependence may also result in the need to increase the drug dosage over time to provide the same level of pain relief to the patient, which in turn may increase the unwanted side effects of the opioid.
[0004] A need has arisen for an opioid molecule that delivers effective pain reduction while decreasing or eliminating the undesirable side effects.
SUMMARY OF THE INVENTION
[0005] A modified opioid is provided comprising modified morphine molecules, wherein for each morphine molecule, one or more carbon atoms are replaced with silicon atoms.
[0006] A modified morphine molecule is further provided having the formula:
[0000]
[0007] Wherein one or more of A, B, C, D, E, F, G, H, I, J, K, L, M, P, Q, R and S are silicon and the remaining of A, B, C, D, E, F, G, H, I, J, K, L, M, P, Q, R and S are carbon; X is selected from the group consisting of lithium and hydrogen; and Y is selected from the group consisting of a single bond and an oxygen atom.
[0008] Further provided is a modified morphine molecule having the formula:
[0000]
[0009] Wherein one or more of A, B, C, D, E, F, G, H, I, J, K, L, M, P, Q, R and S are silicon and the remaining of A, B, C, D, E, F, G, H, I, J, K, L, M, P, Q, R and S are carbon; X is selected from the group consisting of lithium and hydrogen; and Y is selected from the group consisting of a single bond and an oxygen atom.
[0010] Finally, a method is provided for modifying an opioid comprising morphine molecules, said method comprising the step of replacing one or more carbon atoms with silicon atoms.
[0011] It is to be understood that other aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein various embodiments of the invention are shown and described by way of illustration. As will be realized, the invention is capable for other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A further, detailed description of the invention will follow by reference to the following drawings of specific embodiments of the invention. The drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. In the drawings:
[0013] FIG. 1 a is an illustration of the molecular structure of a first modified opioid of the present invention;
[0014] FIG. 1 b is an illustration of the molecular structure of a second first modified opioid of the present invention;
[0015] FIG. 2 is an illustration of the molecular structure of a third modified opioid of the present invention;
[0016] FIG. 3 is an illustration of the molecular structure of a fourth modified opioid of the present invention;
[0017] FIG. 4 is an illustration of the molecular structure of a fifth modified opioid of the present invention;
[0018] FIG. 5 is an illustration of the molecular structure of a sixth modified opioid of the present invention;
[0019] FIG. 6 is an illustration of the molecular structure of a seventh modified opioid of the present invention;
[0020] FIG. 7 is an illustration of the molecular structure of a eighth modified opioid of the present invention;
[0021] FIG. 8 is an illustration of the molecular structure of a ninth modified opioid of the present invention;
[0022] FIG. 9 is an illustration of a first chemical reaction to form the modified opioids of the present invention; and
[0023] FIG. 10 is an illustration of a second chemical reaction to form the modified opioids of the present invention.
DESCRIPTION OF THE INVENTION
[0024] The description that follows and the embodiments described therein are provided by way of illustration of an example, or examples, of particular embodiments of the principles of various aspects of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention in its various aspects.
[0025] The invention relates to novel opioid molecules that are similar in molecular structure to morphine, wherein selected carbon atoms in the known opioid molecular structure are substituted for silicon atoms.
[0026] Silicon based opioids are understood to synthetically mimic or enhance the functions of morphine. It is known that silicon can mimic the bioactivities of carbon and that carbon has similar valances and similar atomic vibrations to silicon, for example as seen in organosilanes and in silanediol. Silanediol peptic isosters have been used in the past an inhibitors of 4-Hydroxynonenal (HNE) an unsaturated hydroxyalkenal produced by the body. As well, decamethylcyclopenta siloxane (d5) has been seen to have an influence of the neurotransmitter dopamine.
[0027] It is also know that silanols can mimic a hydrated carbonyl and inhibit protease enzymes. It is also known that molecules having aromatic rings connected to 3 carbon atoms and a nitrogen atom have shown affinity in binding to opiate receptors.
[0028] In morphine, the cationic amine and anionic phenolic hydroxyl group bridge across the opiate receptor site with the alcohol being hydrogen-bonded to the cysteine sulfur. In this way, morphine molecules tend to occupy the space of met encephalin.
[0029] It is hypothesized by the inventor that based on the above observances; a synthetic silicon opioid would be able to mimic the naturally occurring opioid.
[0030] In a further preferred embodiment of the present invention, select hydrogen atoms in the known opioid molecular structure are substituted for lithium atoms. Lithium can substitute for hydrogen atoms since in many ways, the lithium-silicon bond is similar to a hydrogen-carbon bond.
[0031] In some embodiments of the invention, selected bonds between the silicon atoms are substituted with siloxane groups (Si—O—Si). In other embodiments of the invention, the double bonds between carbon atoms in the molecular structure of morphine are substituted with single bonds between silicon atoms. The modified opioid molecules of the present invention containing silicon and optionally also containing lithium, have molecular structures that are similar to the known morphine molecule. It is thus predicted that the silicon opioids will interact with the opioid receptors through similar pharmacokinetic mechanisms as the morphine molecule.
[0032] With reference to the figures, FIG. 1 a illustrates a structural analogue of the morphine molecule wherein four selected carbon atoms are substituted with four silicon atoms. This embodiment of the modified opioid is C 13 H 18 NO 3 Si 4 .
[0033] FIG. 1 b shows a structural analogue of the morphine molecule wherein four selected carbon atoms are substituted with four silicon atoms and one selected hydrogen atom is substituted with one lithium atom. This embodiment of the modified opioid is C 13 H 18 LiNO 3 Si 4 .
[0034] FIG. 2 illustrates the molecular structure for C 13 H 18 LiNO 6 Si 4 , a structural analogue of the morphine molecule wherein three siloxane groups are substituted for the three Si—Si bonds of the molecule illustrated in FIG. 1 .
[0035] FIG. 3 illustrates the molecular structure for C 3 H 9 Li 10 NO 3 Si 14 , a structural analogue of the morphine molecule wherein fourteen selected carbon atoms are substituted with fourteen silicon atoms and ten selected hydrogen atom are substituted with ten lithium atoms.
[0036] FIG. 4 shows a molecular structure for H 2 Li 17 NO 3 Si 17 , a structural analogue of the morphine molecule wherein all seventeen carbon atoms are substituted with seventeen silicon atoms and all of the hydrogen atoms other than the hydrogen atoms on the two hydroxyl groups are substituted with lithium atoms.
[0037] FIG. 5 illustrates a molecular structure for C 3 H 9 Li 18 NO 3 Si 14 , a structural analogue of the morphine molecule wherein fourteen selected carbon atoms are substituted with fourteen silicon atoms, the four double bonds between silicon atoms are substituted with single bonds, and eighteen selected hydrogen atoms are substituted with eighteen lithium atoms.
[0038] FIG. 6 illustrates a molecular structure for H 2 Li 25 NO 3 Si 17 , a structural analogue of the morphine molecule wherein all seventeen carbon atoms are substituted with silicon atoms, the four double bonds between silicon atoms are substituted with single bonds, and all of the hydrogen atoms other than the hydrogen atoms on the two hydroxyl groups are substituted with lithium atoms.
[0039] FIG. 7 shows a molecular structure for C 3 H 9 Li 18 NO 19 Si 14 , a structural analogue of the morphine molecule wherein all of the hydrogen atoms bonded to carbon atoms in the morphine molecule are substituted with lithium atoms, fourteen selected carbon atoms are substituted with fourteen silicon atoms and all of the Si—Si bonds are substituted for siloxane groups.
[0040] FIG. 8 illustrates a molecular structure for H 2 Li 25 NO 19 Si 17 , a structural analogue of the morphine molecule wherein all seventeen carbon atoms are substituted with silicon atoms, the four double bonds between silicon atoms are substituted with single bonds, all of the hydrogen atoms other than the hydrogen atoms on the two hydroxyl groups are substituted with lithium atoms and all of the Si—Si bonds are substituted for siloxane groups.
[0041] Because the mass of a silicon atom is greater than the mass of a carbon atom, it is predicted that the silicon opioids are more likely to have a stronger attraction to the opioid receptors in the human body. Furthermore, it is hypothesized that silicon-lithium bonds in the modified opioid of the present invention improve the stability of the overall molecular structure.
[0042] The silicon containing opioids of the present invention can be synthesized by any number of means that would be known to an ordinary person skill in the art.
[0043] As an example, but in no way limiting to the present invention, the silicon containing opioids of the present invention can by synthesized by mechanical means, such as by atomic manipulation. One mechanism using atomic manipulation is scanning tunneling microscope (STM) to manipulate single atoms through controlled, tunable interaction between the atoms at the end of an STM probe tip to create desired nanostructures on a surface that is being manipulated. STM manipulation of atoms may be used to induce disassociation of the carbon atoms from a morphine molecule spine and then bonding of the silicon atoms into the spine.
[0044] It is also possible to employ the use of ultra-short laser-pulses to heat and weaken carbon-hydrogen bonds and substitute in silicon or lithium at desired locations.
[0045] It is also possible to synthesize the silicon and lithium containing opioids of the present invention by chemical reactions such as by carbolithiation reaction of an organolithium reagent, in which a carbon-lithium bond is added to a carbon-carbon double or triple bond, forming new organolithium species. This can then be followed by a reaction with silanol or organosilicon. A quaternary ammonium cation can then be added to the resultant structure to develop the present silicon and lithium containing opioid shape. In a most preferred embodiment, a pre-synthesized organolithium is reacted with a pre-synthesized siloxane or silanol to form the resultant modified opioid. In a further embodiment, chemical reaction of silicon hydrides having silicon-hydrogen bonds may be implemented in hydrosilylation, a reaction commonly used to create organosilicon compounds.
[0046] Another chemical reaction means may use lithium-halogen exchange which could also include reactions of exchange with bromide, that is, a bromine-lithium exchange.
[0047] In a further embodiment, metalation, which results in a metal atom being attached to an often organic molecule, can be used. For example, lithium metal in contact with an organohalide tends to lithiate the organic molecule and results in an organolithium reagent and lithium halide.
[0048] With reference to FIG. 9 , this illustrates one example of how a tetracyclic core can be formed using disilabenzene as a substitute for benzene in the beginning stages of synthesis of morphine. The bromine and sulphur dioxide sulphates are then removed to form one of the modified opioids of the present invention. It is further possible to create silicon lithium bonds on the final molecular structure of FIG. 9 by using bromine for a lithium-hydrogen exchange. In this way, it is possible that one or more siloxane strands could be manipulated into hexagonal rings with an oxygen atom binding two organosilicon groups. Then bromine or iodine can be used to manipulate the hexagonal ring structures in to a tetracyclic core of the modified opioid of the present invention.
[0049] With reference to FIG. 10 , is an example of how a disilabenzene ring can replace benzene in the beginning stages of a Fukuyama total synthesis of morphine:
[0000]
[0000] from where the Fukuyama synthesis can be applied with a disilabenzene inner core. Furthermore, it is hypothesized that a hexasilane, a disilane or a trisilane may be attached to a siloxane strand. Then bromine or iodine can be used to manipulate the hexagonal ring structures in to a tetracyclic core of the modified opioid of the present invention.
[0050] In the embodiments above including siloxane groups, it is predicted that siloxane groups may be an effective means of counteracting the possible immunogenicity of the molecule, potentially resulting in the reduction of some undesirable side effects caused by known opioid molecules, including nausea and vomiting. Additionally, is hypothesized that silicon opioids may metabolize in the human body at an increased rate relative to the rate at which the corresponding carbon-containing opioid molecules metabolize in the human body, due to the increased size of a silicon atom relative to a carbon atom. This may result in a relatively lower dosage of the silicon-containing opioid molecules to achieve the desired analgesic effect.
[0051] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to those embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein, but is to be accorded the full scope consistent with the claims, wherein reference to an element in the singular, such as by use of the article “a” or “an” is not intended to mean “one and only one” unless specifically so stated, but rather “one or more”. All structural and functional equivalents to the elements of the various embodiments described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the elements of the claims. | A modified opioid is provided comprising modified morphine molecules, wherein for each morphine molecule, one or more carbon atoms are replaced with silicon atoms. A method is further provided for modifying an opioid comprising morphine molecules, said method comprising the step of replacing one or more carbon atoms with silicon atoms. | 2 |
FIELD OF THE INVENTION
The present invention is directed generally to cryptography, and more particularly to pseudo-random number sequencing.
BACKGROUND OF THE INVENTION
Pseudo-random number generators (PRNGs) are used in a wide variety of cryptographic applications. In particular, random outputs of PRNGs are relied upon in generating, for example, (1) unpredictable session identifiers or cookies for online client-server sessions, (2) key generation for symmetric, asymmetric encryption, the Diffie-Hellman key exchange algorithm and digital signature algorithms (DSA), (3) generating nonces in challenge-response authentication mechanisms, (4) producing random padding in cryptographic padding mechanisms such as public key cryptosystems (PKCS-1) and (5) providing random variables for accomplishing secure transmissions via wireless transport layer security (WTLS) and wireless application protocols (WAPs).
Common PRNGs are based on the American National Standards Institute (ANSI) X9.17 standard and are typically used with the Digital Encryption Standard (DES) or 3-DES block ciphers. Other block ciphers, such as Rivest Cipher-5 (RC-5) may also be used. In order to accomplish secure communications, it is desireable that the outputs from the PRNG be unpredictable. If the output of a PRNG becomes predictable, it will, in turn become easier to decipher any communications from a cryptography system employing such a PRNG. Thus, the random nature of a PRNG is an important aspect in maintaining secure communications.
Recently, several studies have determined that PRNGs using the ANSI X9.17 standard may be vulnerable to certain cryptographic attacks. In particular, it has been discovered that if the internal key used by an ANSI X9.17 PRNG becomes known, the PRNG becomes vulnerable to permanent compromise attacks. If an attacker can force input seed values to an ANSI X9.17 PRNG in an adaptive attack, it may be possible to force the PRNG to generate outputs in a partially-predictable manner. In addition, if an internal state of an ANSI X9.17 PRNG becomes known, a backtracking attack may be performed to discover previous secret outputs of the PRNG. See, e.g., Kelsey, J., et al., “Cryptanalytic Attacks on Pseudo-Random Number Generators,” ESORICS '98 Proceedings, Springer-Verlag, 1998, pp. 77–110 and Kelsey, J. et al., “Yarrow-160: Notes and the Design and Analysis of the Yarrow Cryptographic Pseudo-random Number Generator,” Proceedings of the Sixth Annual Workshop on Selected Areas in Cryptography.
Various methods for random number generation have been previously disclosed. See, for example, U.S. Pat. Nos. 6,141,668; 6,065,029; 6,061,703; 6,044,388; 5,983,252; 5,966,313; 5,961,577; 5,872,725; 5,864,491; 5,828,752; and 5,046,036. However, none of these systems provide a sufficient solution to the possible attacks noted above. Accordingly, there is a need for a method and apparatus for pseudo-random number generation which addresses certain deficiencies in prior technologies.
SUMMARY OF THE INVENTION
According to certain embodiments of the present invention, a method and apparatus for seeding a PRNG is presented in which a plurality of state variables in an output buffer for use by the PRNG in determining a random number. The PRNG receives successive input entropy signals. The output buffer is cleared upon receipt of each of the successive input entropy signals and new state variables are calculated thereafter.
In a further embodiment of the present invention, a method and apparatus for seeding a PRNG in an initial state is provided for securely generating a random number. In this embodiment, an input seed is received. New state variables are then calculated by concatenating the input seed with a first constant, determining a first output based on a hash of the concatenated input seed and the first constant, concatenating the input seed with a second constant and determining a second output based on a hash of the concatenated input seed and the second constant. A key for generating a random number is then determined based on at least a portion of the first output. A counter variable for generating a random number is determined based on a portion of the second output. The key and the counter variable are then stored in an output buffer.
According to another embodiment of the present invention, a method and apparatus for generating state variables for a PRNG, after an initial state, is provided for securely generating a random number. In such an embodiment, first state variables are stored in an output buffer. The first state variable include a first key, a first seed value and a first counter variable. A new input seed is the received. The output buffer is then cleared in response to the new input seed. Second state variables are then determined based on the new input seed and the first state variables.
According to still another embodiment of the present invention, a method and apparatus for determining a random number using a PRNG in an initial state are provided in which state variables for the PRNG are stored in an output buffer, the state variables include a first key, a first seed value, and a first counter variable. A second counter variable is determined by summing the first counter variable with a constant. The second counter variable is then encrypted using the first key and a block cipher to generate a first encrypted result. The first encrypted result is concatenated with the first seed value to generate a second encrypted result. The second encrypted result is the encrypted using the first key and the block cipher to generate a random number.
According to still another embodiment of the present invention, a method and apparatus for generating a random number is provided in which a key and a counter variable are stored in an output buffer. The counter variable is not a timestamp variable relating to a particular time. A first random number is the generated based on at least the key and the counter variable.
According to a further embodiment of the present invention, a method and apparatus for determining a sequential output of random numbers using a PRNG in an initial state is provided. Initial state variables are stored in an output buffer. The initial state variables include a first key, a first seed value, and a first counter variable Prior to receiving further input seed, a second counter variable is determined by summing the first counter variable with a constant. The second counter variable is encrypted using the first key and a block cipher to generate a first encrypted result. The first encrypted result is then concatenated with the first seed value to generate a second encrypted result. The second encrypted result is then encrypted using the first key and the block cipher to generate a random number. A second seed value may then be determined by: (1) encrypting the second counter variable using the key and the block cipher to generate a third encrypted result; (2) performing an exclusive-or operation of the third encrypted result with the random number to determine a fourth encrypted result; and (3) encrypting the fourth encrypted result using the key and the block cipher to determine the second seed value for generating a subsequent random number. A third counter variable is then determined by (1) summing the second counter variable with the constant, (2) encrypting the third counter variable using the key and the block cipher to generate a fifth encrypted result, (3) XOR-ing the fifth encrypted result with the second seed value to generate a sixth encrypted result, and (4) encrypting the sixth encrypted result using the first key and the block cipher to generate a second random number.
It is an advantage of the present invention, therefore, to have a method and apparatus for seeding a PRNG and determining random numbers using a counter variable in place of a timestamp variable in order to improve the security of PRNGs in a cryptographic system.
It is a further advantage of the present invention to implement the PRNG associated with the invention in either hardware or software, or in a combination of both hardware and software.
It is another advantage of the present invention to implement the inventive method of seeding and determining random numbers by using small amounts of random access memory (RAM) and Read-Only Memory (ROM) so that the invention may be embodied in mobile terminal, such as wireless cellular, satellite telephones and other wireless devices capable of two-way wireless communications, e.g. personal digital assistants (PDA's).
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects of the instant invention will be more readily appreciated upon review of the detailed description of the preferred embodiments included below when taken in conjunction with the accompanying drawings, of which:
FIG. 1 is a block diagram of a system employing a pseudo-random number generator implemented by hardware;
FIG. 2 is a flow chart depicting an exemplary re-seeding process for initializing a PRNG implemented in hardware or software;
FIG. 3 is a flow chart depicting an exemplary random number generation process for providing a random output in accordance with certain embodiments of the present invention;
FIG. 4 is a flow chart depicting an exemplary random number generation process for providing a random output in a series of rounds in accordance with certain embodiments of the present invention;
FIGS. 5A–5B are flow charts depicting exemplary processes for initiating re-seeding of a PRNG in accordance with certain embodiments of the present invention; and
FIGS. 6A–6B are flow charts depicting exemplary processes for storing and retrieving PRNG state information from persistent storage in accordance with certain embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a system and method for securing a PRNG against crypto-analytic attacks by which outputs from the PRNG may be guessed or determined. The PRNG may be enabled in hardware or software and may be employed by a mobile device, such as a mobile telephone using WAP/WTLS. The contemplated security features include: (1) reseeding the PRNG at each instance of input entropy in order to change the internal state of the PRNG, thereby generating a new internal key for each new seed input, and (2) replacing a timestamp variable with a running counter, the value of which is less likely to be known or determined outside the system. Specifically, input seeds are provided in sufficiently large increments to avoid iterative-guessing attacks. Upon the input of a new seed to the PRNG, two hash functions (employing either Secure Hash Algorithm-1 (SHA-1) or Message Digest-5 (MD5)) are used to generate a new internal key, a new seed variable and a new counter variable. These two hash functions each operate on the concatenation of a chosen constant value in base 16 , the current internal key K, the current seed value S, the current counter variable T and an input seed comprising a byte array of arbitrary length. The constant values chosen for each of the two hash functions may not be the same.
The results of these hash functions are then used in the following manner. The first 128-bit segment of the results of the first hash function are used to generate the next internal key. The first 64-bit segment of the results of the second hash function are used to generate a new seed value. The second 64-bit segment of the results of the second hash function are used to generate a new counter variable. A random number O i is generated from the results of encrypting the current counter variable and the previous seed value, according to a block cipher. The block cipher may be RC-5, although other block ciphers may also be used. Other available block ciphers include the Data Encryption Standard (DES), IDEA, Blowfish, CAST-n, MISTY, SKIPJACK and KASUMI. With come adjustments, the following block ciphers may likewise be used with the processes herein: Rivest Cipher 6 (RC-6), triple Data Encryption Satndard (3-DES), Advanced Encryption Standard (AES), and Twofish. Methods for encrypting using RC-5 are disclosed in U.S. Pat. Nos. 5,835,600 and 5,724,428, each being incorporated herein by reference. The output segments are received in an output buffer, which is purged upon the input of a new seed to the PRNG.
Referring now to FIGS. 1–6B , wherein similar components of the present invention are referenced in like manner, preferred embodiments of a method and apparatus for improved pseudo-random number generation are disclosed.
FIG. 1 discloses a cryptographic system 100 implemented in hardware and suitable for use with the present invention. The system 100 includes a central processing unit (CPU) 102 , a PRNG 104 , a persistent memory store 106 , ROM 108 , RAM 110 , a clock 112 , and an entropy input source 114 . These elements of system 100 may communicate over a common data bus or in any other equivalent manner.
The CPU 102 may be any available cryptographic processor capable of handling, for example, 128-bit encryption processes. It is contemplated that CPU 102 may be an ARM-7 CPU core manufactured by ARM, INC. However, other processing systems may likewise be used.
The PRNG 104 may be a physical PRNG by which input entropy signals are received and a string of random bits are generated and output. Such physical PRNG hardware is commonly available and known to one of ordinary skill in the art. Alternatively, the PRNG may be software code stored in a persistent memory 106 of the system 100 . The PRNG software may be implemented, for example, using ANSI-C programming code or JAVA programming languages to emulate a physical PRNG.
The persistent memory store 106 may be any memory device, such as semi-conductor memory device for storing binary instructions and data. The persistent memory store may be a CMOS storage device, or any other device in which such binary instructions and data may be maintained in the absence of power. Preferably, the persistent memory store 106 is suitable for operation with mobile terminals. The persistent memory store 106 may act as an output buffer for state variables and random numbers used by the system 100 .
ROM 108 may be any memory device, such as an electronically eraseable and programmable read-only memory (EEPROM) device suitable for providing processing instructions upon power-up of the system 100 .
RAM 110 may be any memory device, such as a Single In-Line Memory Module (SIMM) chip capable of temporary, power-dependent storage for storing processing instructions and data during operation of the system 100 .
Clock 112 may be any device for providing clocking signals to synchronize the communication between the elements of system 100 .
Input source 114 may be any device capable of providing input entropy signals to the PRNG 104 . Accordingly, the input source 114 may detect system events, capture noise signals from a microphone or particular radio frequencies, generate or receive random bits from other devices or components, or retrieve random data from memory allocation tables stored in persistent memory store 106 . The input source 114 may then transmit the input entropy signals received in any of these manners to the PRNG as an input seed.
Alternatively, the input entropy signals may be accumulated in an entropy accumulation pool as may be stored in persistent memory store 106 . When a predetermined amount of entropy signals are stored in such pool, the accumulated signals may then be provided to the PRNG 104 . Such process for providing accumulated signals is described further below in conjunction with FIG. 5B . The input entropy signals or accumulated entropy signals may be transmitted to the PRNG 104 at random or predetermined intervals in order to re-seed the PRNG. Such re-seeding is discussed further below in conjunction with FIG. 5A .
The system 100 is contemplated to be implemented within a mobile terminal, such as cellular telephone model nos. 6210, 6250, 7160 and 7190 manufactured by NOKIA CORPORATION.
Referring now to FIG. 2 , therein is depicted an exemplary re-seeding process 200 for initializing a PRNG implemented in hardware and/or software. The process 200 begins by initializing an output buffer, such as persistent memory store 106 , to store state variable for the PRNG 104 (step 102 ). A first constant C 1 is then appended to the output buffer (step 204 ). The constant C 1 may be, for example, 5555AAAA 16 , as a binary number expressed in base- 16 .
State variables representing a first key K o , a first seed value S o , a first counter variable T o and an input seed X may be appended to the output buffer (step 206 ). The state variables may each be set to be zero in an initial state of the PRNG. Methods for determining such state variables are described further below with respect to FIG. 3 . The input seed X may be a byte array of arbitrary length which may be generated by input source 114 .
The CPU 102 may then perform a cryptographic hash of the values in the buffer and may store the results as a first output A (step 208 ) in RAM 110 The hash may be a function such as a Secure Hash algorithm-1 (SHA-1) or a Message Digest-5 (MD-5) algorithm.
The output buffer may then be cleared upon receipt of new input seed X 1 (step 210 ). A second constant C 2 may then be appended to the output buffer (step 212 ). The constant C 2 may be, for example, AAAA5555 16 , a binary number expressed in base- 16 .
New state variables may then be appended to the output buffer, including a second key K 1 , a first seed value S 1 , a first counter variable T 1 and the input seed X 1 (step 214 ). The state variables may each be set to be zero in an initial state of the PRNG. Methods for determining such state variables are described further below with respect to FIG. 3 . The input seed X 1 may be a byte array of arbitrary length which may be generated by input source 114 .
The CPU 102 may then perform a cryptographic hash of the values in the buffer and may store the results as a first output A (step 216 ) in RAM 110 . The hash may be a function such as SHA-1 or MD-5.
A new key K may then be determined as the value of output A. The new seed value S may be determined as a portion of output B. The new counter variable T may be a second portion of output B (step 218 ). These new state variables may then be stored for use by the PRNG 104 , after which process 200 ends.
It is preferable that process 200 is performed upon each new receipt of input entropy from the input source 114 .
In mathematical terms, the above process 200 may be expressed as follows:
Let K 1 =a 128-bit key used by a block cipher; Let T 1 =a 64-bit counter variable; Let S 1 =a 64-bit chaining variable or seed value; Let X 1 =an input seed of arbitrary length; Let H(x) denote an SHA-1 or MD-5 hash of x, Let x∥y denote a concatentation of two byte strings x and y. Let C 1 and C 2 be constants (e.g. 5555AAAA 16 and AAAA5555 16 , respectively)
Then output variables A and B may be determined as follows:
A=H(C 1 ∥K 1 ∥S 1 ∥T 1 ∥X 1 ) B=H(C 2 ∥K 1 ∥S 1 ∥T 1 ∥X i )
It is contemplated that A and B may be determined as 128 bit strings. In such a case, a new key K will be determined as the entire 128 bit string of A. A new seed value S may be determined as the first 64 bits of B (i.e. bits 1.0.64) and the new counter variable T may be determined as the second 64 bits of B (i.e. bits 65 . . . 18 of B).
FIG. 3 is a flow chart depicting an exemplary random number generation process 300 for generating a random number O without new input seed in accordance with certain embodiments of the present invention. The process 300 begins by adding a constant C to the current counter variable T and place the result in the output buffer (step 302 ). The constant C may be a 64-bit odd constant, such as 2 64 log2 or B17217F7D1CF79AB 16 . The addition of T and C may be performed in little endian fashion modulo 2 64 .
The counter variable T is then encrypted with a block cipher using key K and stored as a first encrypted result (step 304 ). An exclusive-OR (XOR) operation is then performed on the first encrypted result and a previous seed value S. The result of the XOR operation is then encrypted using the block cipher and the current key K (step 306 ). The resulting value is the generated random number O. The first encrypted result from step 304 is then XOR-ed with the random number O and the result is encrypted to generate a current seed value S (step 308 ), after which process 300 ends. The current seed value S may then be used to generate subsequent random numbers.
In mathematical terms, the process 300 may be expressed as follows:
Let C=a 64-bit odd constant; Let O i =a 64-bit random number; Let K 1 =a 128-bit key used by a block cipher; Let T 1 =a 64-bit counter variable; Let S 1 =a 64-bit chaining variable or seed value; Let x (+) y denote an XOR operation between byte strings x and y; Let x [+] y denote the modulo 2 n sum of x and y; Let E k (x) denote the encryption of x with key K using a block cipher. (It is preferred that the block cipher uses a 64-bit block size in 16 rounds with a 128-bit key.)
State variables and pseudo-random numbers then may be generated as follows:
T 1 =T i-1 [+]C O 1 =E k (E k (T 1 )(+) S i-1 ) S 1 =E k (E k (T 1 )(+) O i )
FIG. 4 is a flow chart depicting an exemplary random number generation process for providing a random output in a series of rounds (3 rounds as shown) in accordance with certain embodiments of the present invention. As shown therein, T represents the counter variable, C represent a constant, E represents an encryption function, S represents a seed value, O represents a random number, [+] represent a modulo 2 n sum and (+) represents and XOR operation.
FIGS. 5A–5B are flow charts depicting exemplary processes 500 and 510 , respectively, for initiating re-seeding of a PRNG 104 in accordance with certain embodiments of the present invention. Referring to FIG. 5A , a process 500 for re-seeding upon each instance of new input entropy is shown. The process 500 begins upon receipt of a new entropy signal from input entropy source 114 (step 502 ). The PRNG is re-seeded by generating new state variables (step 504 ) as described above with respect to FIG. 2 . The process 500 then ends.
FIG. 5B depicts an exemplary process 510 for determining when to transmit new input entropy to the PRNG 104 when entropy signals are accumulated. The process 510 begins at step 512 when the CPU 102 determines whether new input entropy is available. This may be done by searching an input entropy accumulation pool stored in persistent memory store 106 . If there is no sufficient accumulation of input entropy (i.e. if a predetermined value of input entropy has not been stored), the process 510 continues to step 516 where entropy is further accumulated in the entropy pool. If, on the other hand, sufficient input entropy has been stored, the process 510 continues to step 518 where the PRNG 104 is re-seeded, where newly determined state variables are based at least in part on the accumulated input entropy signals. The process 510 then ends.
FIGS. 6A–6B are flow charts depicting exemplary processes for storing and retrieving PRNG state information from persistent storage in accordance with certain embodiments of the present invention.
FIG. 6A depicts an exemplary shutdown process 600 which may be performed by system 100 . When a shutdown of system 100 is detected (step 602 ), the CPU 102 may direct the storage in PRNG state variables in persistent memory store 106 (step 604 ), after which process 600 ends.
FIG. 6B depicts an exemplary power-up process 610 for the system 100 . Upon detection of a power-up condition (step 612 ), the CPU 102 determines whether the PRNG has been previously initialized (step 614 ), e.g. if previous state variables are stored in persistent memory store 106 . If so, the process 610 continues to step 618 where the previous state variables are retrieved from persistent memory store 106 for use by the PRNG 104 in generating new random numbers. If no previous state variables are stored, the process continues to step 616 where new state variables are generated based on input entropy signals from input source 114 , in accordance with process 200 above. The process 610 then ends.
The PRNG 104 as described herein may be bijective, e.g. it may be run backwards or forward in between seeding operations. The counter variable T, described above, does not include a timestamp value, i.e. denoting a particular time and/or date, which may be learned or guessed by an attacker by noting the particular time. Rather, the counter variable is a random variable that may be incremented by a constant between re-seeding processes. The counter variable may further be determined based on received input entropy upon re-seeding of the PRNG 104 . The use of the counter variable, therefore, increases the security of the cryptographic system 100 in a manner not contemplated in previous technologies.
Although the invention has been described in detail in the foregoing embodiments, it is to be understood that the descriptions have been provided for purposes of illustration only and that other variations both in form and detail can be made thereupon by those skilled in the art without departing from the spirit and scope of the invention, which is defined solely by the appended claims. | A pseudo-random number generator (PRNG) for a cryptographic processing system is disclosed in which the PRNG is reseeded at each instance of input entropy and in which a standard timestamp variable used in determining random sequence outputs is replaced with a running counter. The method employed by the PRNG demonstrates increased resistance to iterative-guessing attacks and chosen-input attacks than those of previous technologies. The PRNG is suitable for use in, for example, a mobile telephone system for accomplishing secure communications. | 7 |
This application is a continuation application of U.S. application Ser. No. 12/137,245 filed on Jun. 11, 2008 now U.S. Pat. No. 8,215,136 which claims the benefit of Korean Patent Application No. 10-2007-57876, filed on Jun. 13, 2007, which are hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a multiple laundry machine, and more particularly to a multiple laundry machine capable of separately washing a small amount of laundry.
2.Discussion of the Related Art
Generally, a laundry machine means an apparatus for washing, drying, or washing and drying laundry. One laundry machine can perform only a washing function or a drying function or can perform both the washing and drying functions. Recently, a laundry machine, which includes a steam supplier, to have a refresh function for, for example, removal of wrinkles, odor, static electricity, etc. from laundry, has been available.
Meanwhile, conventional laundry machines are classified into a front loading type and a top loading type in accordance with the direction that laundry is taken out. Also, conventional laundry machines are classified into a vertical-axis type, in which a pulsator or an inner tub rotates, and a horizontal-axis type, in which a horizontally-extending drum rotates. The representative example of such a horizontal-axis type laundry machine is a drum washing machine or a drum drying machine.
Such laundry machines have a tendency to have a large size, in order to meet the recent demand of users. That is, laundry machines used for domestic purposes have a tendency to have a large outer size.
Generally, only one large-capacity washing machine is equipped in a home. When it is desired to wash different kinds of laundry in an independent manner, using the washing machine, it is necessary to operate the washing machine several times. For example, when it is desired to wash laundry such as adult clothes and laundry such as underclothes or baby clothes in an independent manner, the washing machine operates two times to individually wash the two different kinds of laundry. For this reason, the washing time increases.
Furthermore, it is undesirable to use the large-capacity washing machine in washing a small amount of laundry, in terms of saving of energy, as in conventional cases. This is because the washing course set in the large-capacity washing machine is typical for the case, in which the amount of laundry to be washed is large, so that the amount of water to be consumed in the washing course is large. Also, a large amount of electricity is consumed because it is necessary to rotate a large-size drum or pulsator. In additional, since the washing course set in the large-capacity washing machine is typical for the case, in which the amount of laundry to be washed is large, the washing time is relatively long.
Also, the washing course set in the large-capacity washing machine is typical for general clothes. For this reason, the large-capacity washing machine may be unsuitable for the washing of delicate clothes such as underclothes or baby clothes.
In addition, the large-capacity washing machine is unsuitable in the case in which washing of a small amount of laundry should be frequently performed. Generally, users collect laundry for several days, in order to wash the collected laundry at one time.
However, leaving laundry, in particular, underclothes or baby clothes, without immediately washing them, is undesirable in terms of cleanliness. Furthermore, when such clothes are left for a long period of time, there is a problem in that they cannot be cleanly washed because dirt may be fixed to the clothes.
In this regard, it is necessary to use a small-size washing machine having a capacity much smaller than the conventional large-capacity washing machine. However, where two small-size washing machines are equipped in a home, and they are laterally arranged in parallel, there are problems associated with space utility and beauty, even though the size of the washing machines is small.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a multiple laundry machine that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a multiple laundry machine capable of achieving a washing operation for a small amount of laundry, and separately washing laundry in accordance with the kind of the laundry.
In accordance with one aspect of the present invention, a multiple laundry machine comprises: a casing; and a plurality of laundry machines arranged in the casing, to conduct washing operations in different manners, respectively.
The casing may comprise an accommodating space defined in the casing, to accommodate the plurality of laundry machines.
The accommodating space may be vertically partitioned into sub-spaces to receive the laundry machines, respectively.
The plurality of laundry machines may comprise a first laundry machine to conduct a washing operation for laundry while maintaining the laundry in a fixed state, and a second laundry machine to conduct a washing operation for laundry while applying a rotating force to the laundry.
The first laundry machine may comprise a drainage pipe, and the second laundry machine may comprise a water supply pipe connected to the drainage pipe of the first laundry machine.
The first and second laundry machines may be forwardly slidable from the casing. Alternatively, the first laundry machine may be of a top loading type, and the second laundry machine may be slidably installed.
The first laundry machine may comprise: a tub for providing a washing space; a rack for holding laundry in a fixed state; and a sprayer rotatably installed to spray wash water to the rack.
The tub may be formed to be partially opened at a front side of the tub.
The first laundry machine may further comprise a door for opening/closing the opened portion of the tub.
The rack may be provided with guide protrusions, and the tub may be provided with guide grooves engaged with the guide protrusions, to allow the rack to be outwardly ejectable through the opened portion of the tub, and to allow the rack to be adjusted in level.
The first laundry machine may comprise: a tub for providing a washing space; a rack for holding laundry in a fixed state in the tub; and a plurality of spray ports formed through a wall of the tub, to spray wash water to the rack.
The first laundry machine may comprise: a tub for receiving wash water; and an ultrasonic washer for vibrating the wash water received in the tub, to wash laundry.
The second laundry machine may comprise: a tub for receiving wash water; a pulsator rotatably mounted in the tub, to pulsate the wash water; and a motor for applying a rotating force to the pulsator.
The second laundry machine may comprise: an outer tub for receiving wash water; an inner tub rotatably installed in the outer tub, to pulsate laundry contained in the inner tub; and a motor for providing a rotating force to the inner tub.
The second laundry machine may comprise a steam generator for supplying steam to the tub.
Each of the laundry machines may comprise a heater for heating wash water, to achieve a laundry boiling function.
The multiple laundry machine may further comprise: a controller for controlling overall operation of each of the laundry machines such that the laundry machines are simultaneously controlled; a key input unit for inputting a user command associated with each of the laundry machines; and a display for displaying the user command input through the key input unit or an operation state.
The multiple laundry machine may further comprise: a controller for controlling operations of each of the laundry machines such that the laundry machines are independently controlled; a key input unit for inputting a user command associated with each of the laundry machines; and a display for displaying the user command input through the key input unit or an operation state.
At least one of the laundry machines may be forwardly slidable from the casing.
At least one of the laundry machines may comprise a door mounted to a portion of the casing corresponding to an upper portion of the laundry machine.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a perspective view illustrating a multiple laundry machine according to an exemplary embodiment of the present invention;
FIG. 2 is a perspective view illustrating a multiple laundry machine according to another embodiment of the present invention;
FIG. 3 is a sectional view illustrating a connecting pipe for re-use of wash water according to the present invention;
FIG. 4 is a sectional view illustrating a first laundry machine according to an exemplary embodiment of the present invention;
FIG. 5 is a perspective view illustrating a rack provided in accordance with the embodiment of FIG. 4 ;
FIG. 6 is a sectional view illustrating a first laundry machine according to another embodiment of the present invention;
FIG. 7 is a sectional view illustrating a first laundry machine according to another embodiment of the present invention;
FIG. 8 is a sectional view illustrating a second laundry machine according to an exemplary embodiment of the present invention; and
FIG. 9 is a sectional view illustrating a second laundry machine according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the present invention associated with a multiple laundry machine, examples of which are illustrated in the accompanying drawings.
FIG. 1 is a perspective view illustrating a multiple laundry machine according to an exemplary embodiment of the present invention.
As shown in FIG. 1 , the multiple laundry machine 10 according to the present invention includes a casing 20 , and a plurality of laundry machines arranged in the casing 20 , to conduct washing operations in different manners, respectively.
An accommodating space 30 is defined in the casing 20 , to accommodate the plural laundry machines therein.
The multiple laundry machine 10 according to the present invention includes a plurality of laundry machines to separately wash a small amount of laundry, different from conventional laundry machines. In detail, the plural laundry machines comprise a first laundry machine 100 capable of washing easily-deformable delicate clothes such as underclothes or baby clothes, and a second laundry machine 200 capable of washing laundry requiring a strong washing operation, for example, shoes, etc.
The first laundry machine 100 conducts a washing operation under the condition in which laundry is in a fixed state. On the other hand, the second laundry machine 200 conducts a washing operation under the condition in which a rotating force is applied to laundry.
Preferably, the accommodating space 30 is vertically partitioned, for efficient space utility. Since the second laundry machine 200 generates high vibration, as compared to the first laundry machine 100 , it is preferred that the second laundry machine 200 be arranged in an accommodating space defined in a lower portion of the accommodating space 30 , and the first laundry machine 100 be arranged in an accommodating space defined in an upper portion of the accommodating space 30 .
The first and second laundry machines 100 and 200 are slidably installed such that it is forwardly slidable along the casing 20 .
As shown in FIG. 2 , the first laundry machine 100 may be of a top loading type, in which a door 120 is mounted at a top side of the casing 20 , whereas the second laundry machine 200 may be slidably installed such that it is forwardly slidable.
The multiple laundry machine 100 may include a control panel 140 .
That is, as shown in FIG. 1 , the control panel 140 may comprise a plurality of control panels to independently control respective laundry machines.
Thus, the laundry machines 100 and 200 , which are installed at upper and lower positions, include control panels 140 , respectively. Accordingly, the laundry machines 100 and 200 are independently controlled to perform desired operations in an independent manner, respectively.
Preferably, each control panel 140 is arranged at a front side of the corresponding laundry machine 100 or 200 . Of course, each control panel 140 may be arranged at any position, as long as there is no restriction in arranging the control panel 140 at the position.
Meanwhile, as shown in FIG. 2 , for the control panel 140 , a single control panel may be provided at the multiple laundry machine 100 , to control both the overall operation of the first laundry machine 100 and the overall operation of the second laundry machine 200 .
In this case, the control panel 140 includes a controller (not shown) for controlling operations of the laundry machines 100 and 200 , a key input unit 141 for inputting a user command associated with each of the laundry machines 100 and 200 , and a display 142 for displaying the user command input through the key input unit 141 , and operation states.
The control panel 140 may also include a sound output unit (not shown) for audibly outputting information representing operation states of the laundry machines 100 and 200 .
When the laundry machines 100 and 200 simultaneously conduct washing operations, the multiple laundry machine 10 according to the present invention may be controlled such that wash water used for a rinsing operation in the first laundry machine 100 arranged at the upper position can be selectively re-used in the second laundry machine 200 arranged at the lower position.
Referring to FIG. 3 , the first laundry machine 100 arranged at the upper position includes a drainage pipe 101 connected to a water supply pipe 201 of the second laundry machine 200 arranged at the lower position.
A connecting pipe 102 is provided to connect the drainage pipe 101 of the first laundry machine 100 and the water supply pipe 201 of the second laundry machine 200 .
A first valve 101 is arranged in the drainage pipe 101 of the first laundry machine 100 . A second valve 112 is arranged in the connecting pipe 102 . A third valve 113 is arranged in the water supply pipe 201 of the second laundry machine 200 .
Since the drainage pipe 101 of the first laundry machine 100 arranged at the upper position and the water supply pipe 201 of the second laundry machine 200 arranged at the lower position are connected, wash water used to rinse delicate clothes contaminated in a low contamination degree can be re-used. Accordingly, there is an advantage in that saving of resources can be achieved.
When the first laundry machine 100 arranged at the upper position washes laundry contaminated in a high contamination degree, the first valve 101 is opened, and the second valve 112 is closed, to drain wash water used in the first laundry machine 100 , through the drainage pipe 430 , without re-use of the wash water. In this case, the third valve 113 is opened under the condition in which the second valve 112 is in a closed state, to supply water from an external water supply source to the second laundry machine 200 .
When it is desired to re-use, in the second laundry machine 200 , wash water used in the first laundry machine 100 , the first valve 111 and third valve 113 are closed, and the second valve 112 is opened. Accordingly, wash water used in the first laundry machine 100 is supplied to the second laundry machine 200 .
Hereinafter, an exemplary embodiment of the multiple laundry machine, in particular, each laundry machine, will be described in detail with reference to FIGS. 4 to 8 .
First, an exemplary embodiment of the first laundry machine 100 according to the present invention will be described with reference to FIG. 4 .
In the illustrated embodiment, the first laundry machine 100 may include a tub 121 for providing a washing space, a rack 128 for holding laundry in a fixed state, and a sprayer 126 rotatably installed to spray wash water to the rack 128 .
The tub 121 may be formed to be partially opened at a front side thereof. As shown in the drawings, it is preferred that the tub 121 be opened at an upper portion of the front side thereof, to receive wash water and to allow loading and unloading of laundry and insertion and ejection of the rack 128 .
It is also preferred that the first laundry machine 100 be provided with a door 129 for opening/closing an opening formed through the front side of the tub 121 .
The door 129 may be hinged to the casing such that it is vertically pivotable about a hinge in accordance with an operation of the user. The mounting of the door 129 may be achieved through various methods, as long as it does not interfere with the operation of the first laundry machine 100 .
The sprayer 126 functions to spray wash water at a high pressure toward laundry held by the rack 128 . A plurality of spray nozzles 126 a are mounted on a top surface of the sprayer 126 , to spray wash water. Lower nozzles (not shown) are mounted to a bottom surface of the sprayer 126 at opposite sides of the sprayer 126 , respectively, to cause the sprayer 126 to be rotated in accordance with the hydraulic pressure of the wash water.
The sprayer 126 may have a structure enabling the sprayer 126 to be movable in a vertical direction and in a forward/rearward direction.
As wash water is sprayed onto the laundry held by the rack 128 , a washing operation is carried out.
On the other hand, the washing operation may be carried out under the condition in which wash water is contained in the tub 121 such that laundry is sunk under the wash water. In this case, the washing operation is achieved through pulsation of the wash water generated by the rotating force of the sprayer 126 .
The first laundry machine 100 further includes a water supply pipe 122 connected to the external water supply source, to supply wash water to the tub 121 . As described above, the drainage pipe 101 is also included in the first laundry machine 100 , to drain wash water contaminated after being used in a washing operation.
When wash water is supplied via the water supply pipe 122 , a sump 125 collects the supplied wash water, and supplies the collected wash water to the tub 121 via the sprayer 126 .
Although not shown, a washing pump is arranged in the sump 125 , to pump the wash water collected in the sump 125 , and thus to supply the wash water to the sprayer 126 .
The first laundry machine 100 may further include a steam generator 124 a for supplying steam.
The steam generator 124 a may have the same structure as that of a steam generator used in a conventional washing machine.
In order to control the amount of wash water supplied to the tub 121 , the first laundry machine 100 preferably includes a tub-side valve 122 b for opening/closing the water supply pipe 122 , and a steam-side valve 124 b connected to the steam generator 124 a.
The rack 128 is configured such that laundry is seated on the rack 128 . The rack 128 is also configured such that it can be outwardly ejected through the opening of the tub 121 , and can be adjusted in level within the tub 121 .
The rack 128 will be described in detail with reference to FIG. 5 .
The rack 128 includes guide protrusions 128 a formed at opposite lateral ends of the rack 128 . Guide grooves 128 b are formed on an inner surface of the tub 121 at opposite sides of the tub 121 , in order to receive the guide protrusions 128 a such that the guide protrusions 128 a are movable along the guide grooves 128 b.
It is preferred that the guide grooves 128 b be inclined toward the bottom surface of the tub 121 as they extend inwardly from the opening of the tub 121 , as shown in FIG. 5 , such that the rack 128 can be forwardly ejected through the opening of the tub 121 , to allow the user to lay laundry on the ejected rack 128 , and the laundry laid on the rack 129 can be sunk under the wash water, to be effectively washed.
Thus, before the execution of a washing operation, the rack 128 is outwardly ejected through the opening of the tub 121 , to allow laundry to be laid on the rack 128 . Thereafter, the rack 128 is inserted into the tub 121 such that the laid laundry is sunk under the wash water in the tub 121 . In this state, the washing operation is executed.
Another embodiment of the first laundry machine 100 according to the present invention will be described with reference to FIG. 6 .
As shown in FIG. 6 , the first laundry machine 100 includes a tub 150 for receiving wash water therein, and an ultrasonic washer 160 for vibrating the wash water received in the tub 150 , to wash laundry.
Preferably, the first laundry machine 100 further includes a drawer 130 forwardly ejectable from the casing 20 .
The casing 20 of the first laundry machine 100 is opened at a top side thereof, to allow loading/unloading of laundry. A door is mounted to the top side of the casing 20 .
The tub 150 is opened at a top side thereof. A tub door 151 is mounted to the top side of the tub 150 around the opening of the tub 150 . Since the first laundry machine 100 has a relatively low height, wash water contained in the tub 150 may be splashed away from the tub 150 . The tub door 151 prevents such a phenomenon.
Although not shown, the ultrasonic washer 160 includes a vibrator for converting electrical energy into mechanical vibration energy, to generate ultrasonic waves, a booster coupled to the vibrator, to magnify the amplitude of the ultrasonic waves generated from the vibrator, and a horn coupled to the booster, to transfer the amplitude-magnified, namely, amplified, ultrasonic waves to the wash water contained in the tub 150 .
When an electrical signal is applied to the vibrator, piezoelectric ceramics arranged in the vibrator vibrate while repeating retraction and expansion. Since the vibration of the piezoelectric ceramics has a low amplitude, the booster coupled to the vibrator receives the vibration of the piezoelectric ceramics, and magnifies the amplitude of the vibration.
The amplified vibration is transferred to the wash water contained in the tub 150 , by the horn. As the vibration is transferred to the wash water, cavitating air bubbles are created in the wash water. The interior of the cavitating air bubbles is at a high temperature and under a high pressure, so that it is possible to sterilize bacteria existing in the wash water by the cavitating air bubbles.
The high temperature and pressure of the cavitating air bubbles are generated for a short time of several hundredths of a second to several thousandths of a second. By such a strong force, contaminants are dispersed and decomposed. Thus, a desired washing effect is obtained.
A drainage pipe 155 is connected to the bottom of the tub 150 , to drain wash water from the tub 150 .
It is preferred that the drainage pipe 155 include a longitudinally-extendable/contractible bellows tube 156 forming a portion of the drainage pipe 155 . When the drawer 130 is forwardly ejected, the bellows tube 156 is extended.
In place of the bellows tube structure, a telescopic structure may be used.
A water supply pipe 153 is connected to an upper portion of the tub 150 , to supply water. Similarly to the drainage pipe 155 , the water supply pipe 153 includes a bellows tube 154 .
Another embodiment of the first laundry machine according to the present invention will be described with reference to FIG. 7 .
As shown in FIG. 7 , the first laundry machine 100 includes a tub 131 for providing a washing space, a rack 138 for holding laundry in a fixed state in the tub 131 , and a plurality of spray ports 132 formed through a wall of the tub 131 , to spray wash water to the rack 128 .
Preferably, the first laundry machine 100 further includes a drawer 130 forwardly ejectable from the casing 20 .
The casing 20 of the first laundry machine 100 is opened at a top side thereof, to allow loading/unloading of laundry. A door is mounted to the top side of the casing 20 .
The tub 131 is opened at a top side thereof. A tub door 139 is mounted to the top side of the tub 131 around the opening of the tub 131 . Since the first laundry machine 100 has a relatively low height, wash water contained in the tub 131 may be splashed away from the tub 131 . The tub door 139 prevents such a phenomenon.
The spray ports 132 sprays wash water into the tub 131 at a high pressure. The sprayed wash water is again supplied to the spray ports 132 , so that the wash water is circulated. The sprayed wash water is used to achieve a washing operation.
In order to circulate the wash water, the first laundry machine 100 includes a circulating pump 134 a , a discharge pipe 134 connected to the circulating pump 134 a , and a supply pipe 133 connected to an outlet end of the circulating pump 134 a .The supply pipe 133 extends along the periphery of the tub 131 .
Preferably, the supply pipe 133 and discharge pipe 134 include longitudinally-extendable/contractible bellows tube 133 a and 134 b forming portions of the supply pipe 133 and discharge pipe 134 , respectively. When the drawer 130 is forwardly ejected, the bellows tubes 133 a and 134 b are extended.
In place of the bellows tube structure, a telescopic structure may be used.
A drainage pipe 135 is connected to the bottom of the tub 131 , to drain wash water. Similarly to the pipes 133 and 134 , the drainage pipe 135 includes a bellows tube 135 a.
A steam generator 137 may be provided to supply steam to the tub 131 . Although not shown, an air supplier may also be provided to spray air bubbles through the spray ports 132 , together with wash water.
Since wash water and air bubbles are simultaneously sprayed into the tub 131 , it is possible to perform a washing operation, using friction generated between the laundry and the wash water and air bubbles.
The washing operation may also be performed under the condition in which wash water is filled in the tub 131 . In this case, the wash water pulsates due to the air bubbles. Accordingly, the washing operation can be more effectively achieved by the sprayed wash water and the pulsation of the wash water.
The steam generator 175 and air supplier may have the same structures as those of a steam generator and an air supplier used in a conventional washing machine.
Hereinafter, a first embodiment of the second laundry machine 200 according to the present invention will be described.
In this embodiment, the second laundry machine 200 includes an outer tub 240 for receiving wash water, an inner tub 250 rotatably installed in the outer tub 240 , to pulsate laundry contained in the inner tub 250 , and a motor 290 for providing a rotating force to the inner tub 250 .
Preferably, the second laundry machine 200 further includes a drawer 220 forwardly ejectable from the casing 20 .
The outer tub 240 is supported by the drawer 220 . To support the outer tub 240 , supporters 260 and 262 are preferably provided.
Preferably, a gasket 222 , which is made of a flexible sealing material, is provided to prevent water and foreign matter from penetrating between the outer tub 240 and the drawer 220 .
The outer tub 240 is opened at a top side thereof. An outer tub door 241 is mounted to the top side of the outer tub 240 around the opening of the outer tub 240 . Since the second laundry machine 200 has a relatively low height, wash water contained in the outer tub 240 may be splashed away from the outer tub 240 . The outer tub door 241 prevents such a phenomenon.
The inner tub 250 is arranged within the outer tub 240 . A plurality of through holes are formed through the inner tub 250 , to allow wash water to enter and exit the inner tub 250 .
A motor 290 is fixedly mounted to a lower surface of the bottom of the outer tub 240 . The motor 290 includes a rotating shaft 291 extending through the bottom of the outer tub 240 so that it is directly connected to the bottom of the inner tub 250 .
A drainage pipe 270 is connected to the bottom of the outer tub 240 , to drain wash water. A drainage pump 272 is connected to the drainage pipe 270 .
It is preferred that the drainage pipe 270 include a longitudinally-extendable/contractible bellows tube 271 forming a portion of the drainage pipe 270 . When the drawer 220 is forwardly ejected, the bellows tube 271 is extended.
In place of the bellows tube structure, a telescopic structure may be used.
A water supply pipe 280 is connected to an upper portion of the outer tub 240 , to supply water. A water supply valve 282 is arranged in the water supply pipe 280 . Similarly to the drainage pipe 270 , the water supply pipe 280 includes a bellows tube 281 .
A steam generator 285 may be provided to supply steam to the outer tub 240 .
A heater 290 may also be provided to heat wash water contained in the outer tub 240 , and thus to achieve a laundry boiling function.
The steam generator 285 and heater 290 have the same structures as those of a steam generator and a heater used in a conventional washing machine.
Another embodiment of the second laundry machine 200 according to the present invention will be described with reference to FIG. 9 .
As shown in FIG. 9 , the second laundry machine 200 includes a tub 340 for receiving wash water, a pulsator 350 rotatably mounted in the tub 340 , to pulsate the wash water, and a motor 390 for applying a rotating force to the pulsator 350 .
Preferably, the second laundry machine 200 further includes a drawer 320 forwardly ejectable from the casing 20 .
The tub 340 is supported by the drawer 320 . To support the tub 340 , supporters 360 and 362 are preferably provided.
Preferably, a gasket 322 , which is made of a flexible sealing material, is provided to prevent water and foreign matter from penetrating between the tub 340 and the drawer 320 .
The tub 340 is opened at a top side thereof. A tub door 341 is mounted to the top side of the tub 340 around the opening of the tub 340 . Since the second laundry machine 200 has a relatively low height, wash water contained in the tub 340 may be splashed away from the tub 340 . The tub door 341 prevents such a phenomenon.
The pulsator 350 is arranged in the tub 340 such that it can wobble.
Preferably, a guide 345 having a concave shape is formed in the tub 340 .
The motor 390 is fixedly mounted to a lower surface of the bottom of the tub 340 . The motor 390 includes a rotating shaft 391 extending through the bottom of the tub 340 so that it is directly connected to the bottom of the pulsator 350 .
A drainage pipe 370 is connected to the bottom of the tub 340 , to drain wash water. A drainage pump 372 is connected to the drainage pipe 370 .
It is preferred that the drainage pipe 370 include a longitudinally-extendable/contractible bellows tube 371 forming a portion of the drainage pipe 370 . When the drawer 320 is forwardly ejected, the bellows tube 371 is extended.
In place of the bellows tube structure, a telescopic structure may be used.
A water supply pipe 380 is connected to an upper portion of the tub 340 , to supply water. A water supply valve 382 is arranged in the water supply pipe 380 . Similarly to the drainage pipe 370 , the water supply pipe 380 includes a bellows tube 381 .
A steam generator 3285 may be provided to supply steam to the tub 340 .
Although not shown, a heater 290 may also be provided to heat wash water contained in the tub 340 , and thus to achieve a laundry boiling function.
The steam generator 385 and heater have the same structures as those of a steam generator and a heater used in a conventional washing machine.
As apparent from the above description, the multiple laundry machine according to the present invention can perform a washing operation for a small amount of laundry, and can separately wash laundry in accordance with the kind of the laundry.
When the laundry machines of the multiple laundry machine operate simultaneously, it is possible to re-use wash water used for a rinsing operation, and thus to save resources.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A multiple laundry machine is provided. The multiple laundry machine may include multiple washing spaces capable of separately washing relatively small amounts of laundry in each. The multiple laundry machine may include a casing, and a plurality of individual laundry machines arranged in the casing. Each of the individual laundry machines provided in the casing may conduct washing operations in a different manner so as to provide washing capability of different sizes and types of loads. | 3 |
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