description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of copending application Ser. No. 07/816,025 filed on Dec. 30, 1991, now abandoned.
FIELD OF THE INVENTION
The present invention generally relates to apparatus for energizing fluorescent lamps, and more particularly relates to circuitry for controlling current level and light or lumen output level of a fluorescent lamp of a document scanner.
BACKGROUND OF THE INVENTION
A document scanner is an apparatus that converts printed text into digital data by illuminating the text with a fluorescent lamp and applying optical character recognition methods to the text. A problem with prior art document scanners is that the light intensity produced by their fluorescent lamps varies as both a function of age and temperature. For example, when a fluorescent lamp is first energized, light output increases to a maximum value as the lamp warms up, but then decreases as the lamp temperature continues to rise, .until equilibrium is reached. Moreover, darkening of the ends of the fluorescent lamp bulb causes lumen output to decrease as the lamp ages (lamps generally exhibit a significant decrease in lumen output after about 100 hours of operation). Further, lumen output may change with changes in power supply output. The need to correct these problems has increased with the advent of color document scanners, since constant light intensity is necessary for accurate reproduction of color documents.
Therefore, an object of the present invention is to provide methods and apparatus for automatically maintaining the light output of a fluorescent lamp at a substantially uniform and controlled level. A further object of the present invention is to reduce end darkening and effects thereof, particularly in a document scanner.
SUMMARY OF THE INVENTION
Fluorescent lamp current level controllers in accordance with the present invention comprise means for preheating the filaments of a fluorescent lamp by applying low voltage pulses of alternating polarity across the filaments. The low voltage pulses are sufficient to preheat the filaments but insufficient to cause the lamp to fluoresce (i.e., light up). Fluorescent lamp controllers in accordance with the invention further comprise high voltage means for applying high voltage pulses of alternating polarity across filaments of the lamp, the high voltage pulses being sufficient to cause the lamp to, fluoresce. Also included are control means for receiving a first signal indicative of a desired level of current in the filaments, sensing a current indicative of the actual level of current in the filaments, and controlling the high voltage means to cause the actual level of current to tend toward the desired level of current.
In preferred embodiments of the invention the first signal is a pulse signal of a prescribed frequency and the preheating means comprises means for receiving the first signal and a control signal and generating, in response to a prescribed state of the control signal, second and third signals of a frequency approximately half the prescribed frequency of the first signal. Also included are a first transformer comprising secondary coils adapted to be coupled to the filaments of the lamp and a primary coil adapted to be coupled to a DC voltage source, and switch means for controlling current through the primary coil in response to the second and third signals. In preferred embodiments the first transformer comprises a center tap on the primary coil adapted to be coupled to the DC voltage source. The first transformer is preferably arranged to provide approximately 3 to 4 volts across the filaments of the lamp when a DC voltage of approximately 24 volts is applied to the center tap.
The high voltage means preferably comprises a switch mode power supply regulator; power switch means, comprising a power input terminal, a power output terminal and a control input terminal and adapted to be coupled via the power input terminal to a source of DC power, for outputting via the power output terminal a DC current in response to a control signal received from the switch mode power supply regulator via the control input terminal; and a second transformer comprising secondary coils adapted to be coupled to at least one of the filaments of the lamp and a primary coil which is either directly or indirectly coupled to the power output terminal of the power switch means. In preferred embodiments the second transformer comprises a center tap on the primary coil and the power output terminal of the power switch means is coupled at least indirectly to the center tap. Moreover, the second transformer is preferably arranged to provide approximately 600 volts across the lamp (or across two lamps), and switch means for controlling current through the primary coil of the second transformer in response to the second and third signals are preferably included.
The control means, in preferred embodiments, comprises a current sense resistor and amplifier arranged to provide a signal indicative of current through the primary coil of the second transformer. In addition, in preferred embodiments, an inductor is coupled between the power output terminal of the power switch means and the center tap of the second transformer. The inductor provides a measure of noise suppression, which is particularly useful when the invention is employed in a document scanner.
The present invention also encompasses document scanners comprising a fluorescent lamp; scanning means for scanning a predefined area illuminated by the lamp and detecting light reflected therefrom, and for providing output signals indicative of light intensity levels detected; at least one reference surface of substantially uniform reflectivity for reflecting light emitted by the lamp to the scanning means; microprocessor means for receiving the output signals from the scanning means and generating a first control signal indicative of a desired level of light output by or current in the lamp and a second control signal for preheating the lamp; and a current level controller in accordance with the foregoing description coupled between the microprocessor means and the lamp.
The present invention also encompasses methods for controlling a fluorescent lamp. Methods in accordance with the invention comprise the steps of: preheating filaments of the lamp, for approximately one second, by applying low voltage pulses of alternating polarity across the filaments, the low voltage pulses sufficient to preheat the filaments but insufficient to cause the lamp to fluoresce; applying high voltage pulses of alternating polarity across filaments of the lamp, the high voltage pulses timed to create minimal noise effects and sufficient to cause the lamp to fluoresce; receiving a first signal indicative of a desired level of current in the filaments; sensing a current indicative of the actual level of current in the filaments; and controlling the high voltage pulses to cause the actual level of current to tend toward the desired level of current.
Other features and advantages of the invention are described below in connection with a detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a document scanner comprising a fluorescent lamp controller in accordance with the present invention.
FIG. 2 is a block diagram of a fluorescent lamp current level/light output control circuit in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like numerals represent like elements, FIG. 1 depicts a fluorescent lamp control system 10 in the context of a document scanner. The system comprises a fluorescent lamp 12 (typically including two tubular bulbs) for illuminating an area 14 to be scanned. Light reflected from the area 14 is focused by optical means 16 (e.g., a lens) onto light detection means 18 which provide analog output signals having magnitudes indicative of intensity levels of reflected light detected thereby. The analog output signals are converted to digital signals by an analog to digital (A/D) converter 20 and supplied to a microprocessor 22 for processing in a manner described below. Microprocessor 22 supplies control signals 24 (LAMPON -- L, PWM(D), PREHEAT -- L, see FIG. 2) to a fluorescent lamp control circuit 26 to adjust the input power or current supplied to lamp 12. The output light intensity produced by the lamp 12 will vary as input power (or current) is varied.
As mentioned, A/D converter 20 receives and digitalizes the analog output signals provided by the light detecting means 18. The lamp driver circuit 26 receives control signals from microprocessor 22 for controlling the input power to the lamp 12, so that the lamp intensity is altered with alterations in input power. In a preferred embodiment of the invention, the control signal 24 for controlling the light output level is a PWM (pulse width modulated) signal with a duty cycle D (accordingly, this signal is represented in FIG. 2 as PWM(D)). The operation of controller 26 is such that the input power, particularly the current, to the lamp 12 is varied in proportion to variations in the duty cycle D of control signal 24. Moreover, the control circuit 26 includes means for preheating the lamp filaments before the lamp is turned on, which has been found to prevent darkening of the ends of the bulb, and is synchronized in a manner that minimizes the effects of any noise generated.
The fluorescent lamp current level control circuit 26 is depicted in greater detail in FIG. 2. The control circuit 26 includes circuitry, referred to herein as preheating means, for applying approximately 3.6 V pulses of alternating polarity across filaments F1, F2, F3, F4 of the lamp 12 (the lamp includes two tubular bulbs, as shown). These low voltage pulses are sufficient to preheat the filaments but insufficient to cause the lamp to fluoresce. Preheating the filaments for approximately one second has been found to substantially reduce the darkening that typically occurs at the ends of the bulbs.
Preheating is effected by bringing the signal PREHEAT -- L low (this is an active low signal), which causes a divider circuit 50, which comprises a 74HCT74 IC, to output pulses onto its Q, Q output terminals at half the frequency of the PWM signal. In the preferred embodiment of FIG. 2 the frequency of the PWM signal is 100 kHz. The respective output signals of the divider 50 are amplified and inverted by FET drivers 48A, 48B (which are MC34151P ICs in the preferred embodiment). The output of FET driver 48A controls two FET power switches 32, 36 and the output of FET driver 48B controls FET power switches 34, 38.
As shown, a 24 VDC voltage is applied to a center tap of the primary coil of transformer T2; thus the pulses generated by the respective FET drivers 48A, 48B, which are out of phase with respect to each other, cause the respective halves of the primary coil to conduct alternating, oppositely directed current pulses. These alternating pulses cause a voltage of approximately 7.2 V to be induced across the topmost secondary coil of transformer T2 and a voltage of approximately 3.6 V to be induced across the other two coils (the topmost secondary coil of transformer T2 has twice as many turns as each of the other secondary coils). In addition, the topmost secondary coil of transformer T2 is coupled in series to the two filaments F2, F3, so a voltage of approximately 3.6 V will be applied across each filament. The center secondary coil is coupled to filament F1 and the by the primary of transformer T1, and the 60 volts is stepped up by the turns ratio of 10:1 (i.e., 10 turns of the secondary coil for each turn on each half of the primary coil) to 600 volts. (In other words, 120 volts are applied across the entire primary and stepped up 5 times to 600 volts across the secondary coil.) This 600 volts causes the lamp to fluoresce.
The amount of current through the primary coils of transformer T1 is proportional to the duty cycle of the PWM signal. A current sense element 40 (e.g., a current sense resistor) and a gain amplifier 44 are used to feed back the actual current level through the respective primary coils to the switch mode power supply regulator 28.
The output of amplifier/filter 52 is given by the expression
V.sub.52 =2V.sub.R -4D.
The output of the current gain amplifier 44 is given by
V.sub.44 =GR.sub.S I,
where R S represents the resistance of the current sense element 40 and G represents the amplifier's gain. The voltages V 52 , V 44 and V R are applied to the amplifier, labelled "AMP", in regulator 28 This amplifier (AMP), the resistors labelled 43, 45 and having a resistance R 2 and the loop compensator 46 perform the function of an integrator. A simplified expression of the output of the amplifier (AMP) is ##EQU1## where D represents the duty cycle, C represents the capacitance of the loop compensator 46 (i.e., the series capacitance in loop compensator 46), S represents the Laplace Transform operator and I represents the primary current of transformer T1. V OUT will become stable when the loop reaches a steady state, i.e., when
4D-IR.sub.S G=0,
or
I=4D/R.sub.S G.
This means that, if R S =0.05Ω and G=16.4, the current I will equal 4.88D, with 0≦D≦1. The secondary current of bottom secondary coil is coupled to filament F4, thus each of those filaments also receives approximately 3.6 V. This has been found to be sufficient to preheat the filaments without causing the lamp to fluoresce. The vertical bar to the left of the lamp 12 indicates that there must be a ground plane near the lamp (the specific ground plane spacing required for a particular lamp is typically specified by the lamp's manufacturer). The lamp of the preferred embodiment is a Sylvania part no. F13T5 fluorescent lamp.
Although the PWM pulses have a variable width, their trailing edges may be used to synchronize the entire circuit; therefore a pulse shaper 54 is employed to generate standardized pulses synchronized to the trailing edges of the PWM pulses. Once the preheat signal PREHEAT -- L goes low, the divider 50 is enabled and generates pulses at half the frequency of the signal output by the pulse shaper 24. The preferred procedure is to turn the preheat signal on (i.e., bring PREHEAT -- L low) about one second before the lamp is turned on. This simultaneously enables the FET power switches 32, 34, 36, 38, however FET power switch 30 controlling power to transformer T1 is not driven because the lamp has not been turned on yet. The lamp is instructed to turn on with the LAMPON -- L n signal (also an active low signal), which activates a switch mode power supply regulator 28.
The switch mode power supply regulator 28 of the preferred embodiment is a UC3524AN IC available from Unitrode Corporation. This device drives power switch 30, which in response to the drive pulses outputs 24 VDC pulses, which are smoothed by inductor L1 and applied to the center tap of transformer T1. Transformer T1 operates like transformer T2, except that transformer T1 generates high-voltage pulses across its secondary. When the LAMPON -- L signal goes low, the voltage generated across the secondary of transformer T1 is approximately 600 volts. This is due to the large voltage generated by the primary coil of transformer T1 and the avalanching of transistors (i.e. power switches) 32 and 34 at approximately 120 volts. This voltage is divided to 60 volts transformer T1 (the lamp current I LAMP ) will be one-tenth of the primary current, or 0.488 D, when the PWM signal varies between 0 and 5 volts. The voltage V OUT provides a signal that is used to control the output of regulator 28 to correctly set the on/off ratio of power switch 30, which in turn maintains the commanded level of current to the lamp 12.
Other aspects of the structure and operation of the circuit of FIG. 2 will be apparent to those skilled in the art, however a few important points regarding the circuit will be noted:
1. The fluorescent lamp current level controller maintains a commanded lamp current level using a closed loop current averaging technique. The lamp light output level is proportional to the commanded lamp current.
2. The lamp filaments are preheated to significantly reduce end darkening and effects thereof, and to extend lamp life.
3. The high voltage required to start the lamp is developed from the avalanche voltage of power switches 32 and 34. No other source of high voltage is necessary.
4. The current command signal can be either a DC voltage or a PWM signal. If the current command is a DC voltage, the pulse shaper 54 may be deleted and the oscillator (OSC) output of the switch mode power supply regulator 28 may be input to the CLK input of divider block 50.
5. The power switches 30, 32, 34, 36, 38 are synchronized with the PWM signal, which allows the switches to be triggered at times when the noise generated by the high voltage will least affect surrounding circuitry, e.g., at times when the light detectors are idle.
6. It is unnecessary to bring the signal PREHEAT -- L high after the lamp is turned on. Further, the lamp has been found to turn on quicker after it has been preheated, as compared to its turn on time without preheating. In an experiment, one bulb came on before the second bulb, taking a total of 6700 milliseconds. However, once the filaments were preheated, which cost approximately one second, the bulbs came on within 3 to 4 milliseconds. Further, there was no noticeable sequencing or flickering of the bulbs; both bulbs essentially came on instantaneously.
Many modifications, changes and variations of the preferred embodiments will become apparent to those skilled in the art after considering the specification and accompanying drawings. All such changes, modifications and variations within the true spirit and scope of the invention are intended to be covered by the following claims. | A method and apparatus for automatically adjusting the light intensity output of a fluorescent lamp of a document scanner. The fluorescent lamp current level control apparatus comprises preheating circuitry for applying low voltage pulses of alternating polarity across filaments of the lamp, the low voltage pulses sufficient to preheat the filaments but insufficient to cause the lamp to fluoresce; high voltage circuitry for applying high voltage pulses of alternating polarity across the lamp, the high voltage pulses sufficient to cause the lamp to fluoresce; and control circuitry for receiving a first signal (PWM (D)) indicative of a desired level of current in the filaments, sensing a current indicative of the actual level of current in the filaments, and controlling the high voltage circuitry to cause the actual level of current to tend toward the desired level of current. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention has to do with wellhead equipment used in connection with a pumping oil well, preferably one pumped with a rotated rod string. For years, a typical conventional pumping wellhead for a rotary pumping oil well has been constructed as shown in FIG. 1. The assembly comprises from the bottom up: a flanged casing head attached to the well casing; a flanged tubing head having an internal hanger from which the well tubing string is suspended; a tubing head adapter having a flanged connection at its bottom end and a threaded connection of smaller diameter at its top end; a production blow-out preventer (B.O.P) body having top and bottom threaded connections and including side openings for receiving the B.O.P. ram components; a flow tee body having threaded bottom and top connections and a threaded or flanged side opening for connecting with a flow line; a polished rod stuffing box; and a rotary drive assembly for rotating the well's rod string to power a downhole progressive cavity pump. These components, except for the rotary drive assembly, combine to form a vertical central bore extending therethrough. The polished rod of the rod string extends through this central bore.
[0002] The combination of the tubing head adapter, B.O.P. body and flow tee body components is commonly collectively referred to as a ‘pumping tree’.
[0003] The assembly of wellhead components above the tubing head is usually referred to collectively as the ‘Christmas tree’.
[0004] A recent improvement in the production wellhead art is disclosed in Canadian patent 2,197,584, issued Jul. 7, 1998 and re-issued May 16, 2000. This patent is owned by the present applicant. More particularly, this patent teaches integrating the tubing head adapter, B.O.P. body and flow tee body into a unitary structure, referred to as an ‘integral or composite pumping tree’, by forging, casting or machining a single steel body. The composite pumping tree is illustrated in prior art FIGS. 2 and 2 a and forms the lower end of the Christmas tree.
[0005] Another recent improvement in the production wellhead art is disclosed in Canadian patent application 2,280,581, filed by the present applicant. This patent application teaches integrating a tubing head adapter, shut-off valve body, B.O.P. body, and flow tee body into a composite pumping tree. This pumping tree is illustrated in prior art FIG. 3.
[0006] As previously stated, the rotary drive assembly usually has a stuffing box at its bottom end. The primary function of the stuffing box is to prevent upward leaking of fluid around the rotating polished rod. The stuffing box comprises a body or housing containing annular packing, which seals between the housing and the polished rod of the rod string.
[0007] Rotation of the polished rod eventually produces wear of the stuffing box packing. Therefore, changing the packing is part of the regular oilfield maintenance program.
[0008] Prior art FIGS. 1, 2 and 3 show a rotary drive assembly mounted to the stuffing box by an ‘open’ frame. The frame has side ‘windows’ which enable access to the stuffing box packing gland, so as to change out the packing. However this frame introduces significant vertical separation between the rotary drive assembly and the pumping tree. This is undesirable as the rotary drive assembly vibrates when operating and applies offset forces that can create damage to the wellhead below. It is desirable to minimize the spacing between the rotary drive assembly and the pumping tree.
[0009] A modified rotary drive assembly is shown in FIG. 4. In this unit, the stuffing box housing is now integral with the rotary drive assembly. This variation has had the benefit of shortening the distance between the rotary drive assembly and the pumping tree.
[0010] However, it is more difficult to change out the packing of the stuffing box illustrated in FIG. 4. This process now requires:
[0011] shutting off the rotary drive assembly;
[0012] closing the production B.O.P by rotating the ram screws to advance the B.O.P rams into engagement with the polished rod;
[0013] providing a service rig having a line which is attached to the polished rod to suspend the rod string;
[0014] disconnecting the rod clamp normally suspending the rod string from and drivably connecting it with the rotary drive assembly;
[0015] disconnecting the rotary drive assembly from the pumping tree;
[0016] lifting the rotary drive assembly up using a second line from the service rig;
[0017] securing a rod clamp to the polished rod below the rotary drive assembly, to secure the rod string;
[0018] then fully removing the rotary drive assembly;
[0019] replacing the packing; and
[0020] re-assembling the equipment.
[0021] This process can also be dangerous. Since the rod string is driven and rotated, it has a built-in torque. This torque can generate a back-spin force, which can cause injury to personnel in various situations.
[0022] With this background in mind, it is an objective of the present invention to provide a polished rod locking assembly, forming part of the pumping tree and preferably being an integral component of the tree, which locking assembly can be actuated to clamp onto the polished rod to prevent back-spin and to grip the polished rod with sufficient force so as to suspend the weight of the rod string.
[0023] It is another objective to provide a leverage assembly in conjunction with the locking assembly, which is operative to apply high axial torque to the locking means to better secure the rod string.
[0024] It is another objective to provide a locking means capable of functioning like a blind ram to seal off the vertical bore of the wellhead, when the polished rod has parted in the stuffing box.
SUMMARY OF THE INVENTION
[0025] In accordance with one aspect of the invention, a polished rod locking assembly (“PRL assembly”) is provided for inclusion as part of the pumping tree of a wellhead. This PRL assembly can be closed to clamp onto and frictionally engage the polished rod, to prevent back-spin, and to grip it with sufficient force so as to be able to suspend the rod string from the wellhead during stuffing box maintenance. These actions and results are hereafter collectively referred to as “securing” the polished rod.
[0026] More particularly, the PRL assembly comprises:
[0027] body means, which may be a separate component in a pumping tree formed of connected components or which preferably is integrated into a one piece integral pumping tree;
[0028] the body means forms a central bore (which forms part of the pumping tree vertical bore) and a pair of opposed, preferably horizontal, radial side openings. The side openings are internally threaded along part of their length and extend between the body means' outer peripheral surface and the central bore;
[0029] an externally threaded locking member is positioned in each body side opening. These locking members can be radially advanced to frictionally engage the polished rod. Each locking member preferally comprises an inner cylindrical member and an outer, rotatable, threaded shaft. The shaft functions, when rotated or screwed, to advance or retract the inner member. The cylindrical member and shaft are interconnected so that the inner member does not rotate while the rotating shaft pushes or pulls it. The inner member has a vertically grooved inner end face which will embrace the polished rod as it contacts and frictionally engages it. More preferably, the inner member is formed in two parts. The innermost part is horizontally pivotally connected to the outer part and there is a slight clearance between the two parts. The outer part closely fits the internal surface of the side opening and remains stationary. The innermost part can tilt to a limited extent to accommodate misalignment of the polished rod. Each locking member seals against the surface forming the side opening in which it is contained. The outer end of the locking member protrudes from the body means;
[0030] the inner end of an external lever arm is connected, preferably at right angle, with the protruding outer end of one of the locking members, for rotation or turning thereof. Movement of the outer end of the arm will cause the locking member to turn to a limited extent about its axis. Threaded means, such as a swing bolt having an annular head, is pivotally connected by means, such as a bolt, with the outer end of the arm. A post is anchored to the body means or tree. The post supports a rotatable sleeve at its outer end. The swing bolt extends through the opening formed by the sleeve. A nut, threaded on the end of the swing bolt, can be turned with relatively low torque to induce a relatively powerful lineal pull by the swing bolt on the arm. This causes relatively high torque to be applied to the locking member which in turn applies high lineal, inwardly directed force on the polished rod.
[0031] As a consequence, the locking members can be activated by hand turning their outer ends, to bring their inner end faces into firm contact with the polished rod. The arm and swing bolt assembly can then be introduced and operated to bias the locking member with considerable lineal force against the polished rod to ensure sufficient frictional engagement to secure the heavy rod string.
[0032] The specific described assembly provides a lever arm for turning the locking member and a mechanical means for biasing the arm's free end with a powerful lineal force to cause the locking member to secure the polished rod.
[0033] In another aspect, the PRL assembly is constructed so that it can operate as a “blind ram” to close the vertical bore of the pumping tree. More particularly, the body means and locking members are modified so that one locking member can retract sufficiently to enable the other locking member to extend across the vertical bore to close it. The other locking member carries seal means suitable for sealing the vertical bore from the radial openings when the locking member is in the closed position.
DESCRIPTION OF THE DRAWINGS
[0034] [0034]FIG. 1 is a side view of a prior art wellhead for a rotary pumping well comprising a pumping tree formed of interconnected separate components, the wellhead having a rotary drive assembly at its upper end;
[0035] [0035]FIG. 2 is a side view of a prior art wellhead for a rotary pumping well, incorporating an integral or composite pumping tree;
[0036] [0036]FIG. 2 a is a partly broken away perspective view of a prior art composite pumping tree;
[0037] [0037]FIG. 3 is a side view of a prior art wellhead incorporating an integral pumping tree having an integral shut-off valve;
[0038] [0038]FIG. 4 is a side view of a wellhead for a rotary pumping well comprising an integral pumping tree and having a PRL assembly constructed as an integral part of the tubing head adapter, the wellhead having a rotary drive assembly incorporating an integral stuffing box;
[0039] [0039]FIG. 5 is a side view of a wellhead incorporating an integral pumping tree having a shut-off valve and a PRL assembly constructed as an integral part of the tubing head adapter section of the tree;
[0040] [0040]FIG. 6 is a side view of a wellhead incorporating an integral pumping tree having a PRL assembly located above the production rod B.O.P.;
[0041] [0041]FIG. 7 is a side view in section of one embodiment of the PRL assembly;
[0042] [0042]FIG. 8 is a plan view in section of the assembly of FIG. 7;
[0043] [0043]FIG. 9 is a sectional side view showing part of the PRL assembly of FIG. 7, positioned within a partly shown housing or body and engaging a polished rod;
[0044] [0044]FIG. 10 is a sectional side view showing a self-aligning locking member positioned within a partly shown housing and engaging a polished rod;
[0045] [0045]FIG. 11 is a sectional plan view of the assembly of FIG. 10;
[0046] [0046]FIG. 12 is a sectional plan view showing a locking member connected with a leverage assembly;
[0047] [0047]FIG. 13 is a sectional side view showing an upper PRL assembly coupled with a leverage assembly, together with a lower production rod B.O.P.;
[0048] [0048]FIG. 14 is an external side view of part of the assembly of FIG. 13;
[0049] [0049]FIG. 15 is a sectional plan view of a PRL assembly, adapted to convert to a blind ram assembly covering the vertical bore, in an open position;
[0050] [0050]FIG. 16 is a sectional plan view of the PRL assembly of FIG. 15, in a closed rod-engaging position; and
[0051] [0051]FIG. 17 is a sectional plan view of the PRL assembly of FIG. 16, in a closed blind ram position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0052] One embodiment of the PRL assembly 1 is illustrated in FIGS. 4, 5, 7 , 8 and 9 . This PRL assembly 1 comprises a body means 2 having a vertical central bore 3 extending therethrough. The PRL assembly 1 forms part of the bottom connection 31 of an integral production pumping tree 4 . The bottom connection 31 is adapted to mate and connect with the top connection 5 of a wellhead tubing head 6 . The PRL assembly bore 3 forms part of the vertical internal bore 67 of the wellhead 7 , through which the polished rod 8 extends and through which fluid is produced.
[0053] The body means 2 forms a pair of opposed horizontal radial openings 9 extending between its outer peripheral surface means 10 and the bore 3 . Each radial opening 9 has inner and outer sections 11 , 12 . The opening sections 11 , 12 have offset centerlines 14 , 13 . The outer opening section 12 has a larger diameter than the inner opening section 11 , so that a shoulder 15 is formed at their junction.
[0054] A pair of cylindrical members 16 are positioned in the radial opening inner sections 11 and are slidable therealong. Each cylindrical member 16 has inner and outer ends 17 , 18 . The inner end 17 of the cylindrical member 16 has an end face 19 forming a vertical groove 100 , for conforming with and engaging the polished rod 8 .
[0055] A pair of tubular gland assemblies 20 are threaded into the opening outer sections 12 . The gland assemblies 20 form part of the body means 2 . In the embodiment of FIGS. 8 and 9, each gland assembly 20 comprises an externally threaded tube 21 , an outer ring 22 , packing 23 and an inner ring 24 abutting the shoulder 15 . The threaded tube 21 can be actuated to energize the packing 23 . The tube 21 is also internally threaded.
[0056] A pair of screws or shafts 26 , having externally threaded outer ends 27 , extend through the gland assemblies 20 and engage the outer ends 18 of the cylindrical members 16 . The outer end 27 of each shaft 26 protrudes out of its associated gland assembly 20 so that it is accessible for rotation. The shaft 26 and cylindrical member 16 together make up a unit referred to as a locking member 50 .
[0057] Each shaft 26 has a T-shaped head 25 at its inner end, which is received in a correspondingly T-shaped slot 28 formed in the outer end 18 of its associated cylindrical member 16 . As a result of this connection and the offset centerlines, the shaft 26 and cylindrical member 16 are connected for axial movement together but the shaft can be turned without rotating the cylindrical member.
[0058] As illustrated, the PRL assembly radial openings 9 are positioned between stud holes 30 of the bottom connection 31 of the pumping tree 4 .
[0059] It is to be noted that in this previously described embodiment:
[0060] the body means 2 forms part of the bottom flanged connection 31 of an integral pumping tree 4 ; and
[0061] the axial centerlines 14 , 13 of each associated shaft 26 and cylindrical member 16 are offset and the two elements are connected by a T-shaped head 25 and slot 28 arrangement, whereby the elements are tied together and move as a unit axially, but the threaded shaft 26 (which generates the lineal locking force) can rotate without turning the cylindrical member 16 (which will be locked with the vertical rod 8 ).
[0062] In operation, each gland tube 21 can be screwed in, to compress its packing 23 and provide a seal around the unthreaded inner end 29 of the contained shaft 26 . To lock the polished rod 8 , the shafts 26 are advanced inwardly, biasing the locking members 16 into firm contact with the polished rod 8 .
[0063] In a variant, the inner end portions of the polished rod locking members 16 can pivot to align with the polished rod 8 , to thereby prevent damage to the rod's surface.
[0064] When the B.O.P. rams are closed about the polished rod 8 , the latter can be tilted slightly. If the polished rod cylindrical members 16 are rigidly fixed and perpendicular to the axis of the bore 3 , they can damage the tilted polished rod.
[0065] In this alternative assembly, shown in FIGS. 10 and 11, each cylindrical member 16 is formed in two parts, an inner part 16 a and an outer part 16 b . The parts 16 a , 16 b are connected so that they move together axially as a unit, but inner part 16 a can pivot slightly to self-align with the polished rod 8 . More particularly the inner part 16 a has a spherical nose 40 which is received in a spherical cavity 41 formed in the inner end of outer part 16 b . There is a slight clearance 31 between the cylindrical member parts 16 a , 16 b . A horizontal bolt 43 holds the parts 16 a , 16 b together while allowing part 16 a to pivot when it is fully inserted into the vertical bore 3 and has cleared the inner surface 32 of the tree side wall 33 . To prevent the inner part 16 a getting separated should the bolt 43 break, it has a short thread 44 which can be threaded past a short thread 45 formed by the outer part 16 b . The shaft 26 has a centerline 46 and the cylindrical member 16 has a centerline 47 , which centerlines are offset one from the other.
[0066] O-rings 101 are mounted around each cylindrical outer part 16 b , for sealing against the adjacent inside surface 65 of the radial opening 9 in which the part is contained. It will be noted that the gland assembly 20 in this embodiment does not contain packing.
[0067] The PRL assembly 1 has been described in terms of a body means 2 which is provided by two partial segments of the bottom connection 31 , positioned between pairs of bolt holes 48 as shown in FIGS. 4, 5 and 18 . This design is useful when the radial openings 9 are of relatively small diameter, as are the contained components. When it is desirable to use components of greater diameter, then the body means 2 involves a complete transverse layer of the tree 4 , as shown in FIG. 6.
[0068] The PRL assembly 1 comprises a leverage assembly 51 which is designed with the following concept in mind:
[0069] the shafts 26 can be hand turned with a wrench to bring the cylindrical member end faces 19 into firm contact with the polished rod 8 —this is referred to as “hand tightening” the locking members 50 ;
[0070] the leverage assembly 51 can then be used to apply a much greater rotational torque to one of the shafts 26 to thereby increase the frictional force with which the end faces 19 secure the polished rod 8 .
[0071] The leverage assembly 51 is illustrated in FIGS. 12, 13 and 14 . It comprises a post 52 affixed to the tree 4 . The post 52 extends outwardly in parallel with the adjacent shaft 26 . A sleeve 53 is rotatably mounted on the outer end of the post 52 . The sleeve 53 can turn on the post 52 . The sleeve 53 forms a through-hole 69 . A horizontal, externally threaded swing bolt 54 extends through the through-hole 69 . At its inner end the swing bolt 54 has an annular head 55 . A nut 56 is screwed onto the outer end 57 of the swing bolt 54 . The nut 56 abuts the sleeve 53 . An arm 58 extends between the swing bolt's annular head 55 and the shaft 26 . The arm 58 has a hollow box-like section as shown in FIG. 12. At its lower end, the arm 58 has a transverse hexagonal opening 59 . A hexagonal nut 60 is fixed on the shaft's outer end 27 . When the arm 58 is added to the leverage assembly 51 , its lower end opening 59 receives the shaft nut 60 and the arm 58 engages the nut 60 , so that they will turn together. At its upper end, the arm 58 has a second transverse opening 61 . A bolt 62 extends through the arm upper opening 61 and through the opening 63 of the swing bolt annular head 55 . A nut 64 locks the bolt 62 in place, to effect a pivoting connection between the upper end of the vertical arm 58 and the inner end of the horizontal swing bolt 54 .
[0072] From the foregoing, it will be appreciated:
[0073] that the swing bolt nut 56 can be turned to cause the swing bolt 54 to linearly retract to the right (having reference to FIG. 14), thereby applying a powerful pull on the bolt 62 linking the arm 58 and swing bolt 54 ; and
[0074] this bias or pull applied to the upper end of the arm 58 applies powerful torque to the shaft nut 60 , causing the shaft 26 to advance to linearly bias the cylindrical member 16 into tight frictional engagement with the polished rod 8 .
[0075] In another embodiment shown in FIGS. 15 - 17 , the PRL assembly 1 comprises relatively long and short gland members 20 a , 20 b . One cylindrical member 16 c is longer than the other cylindrical member 16 d . One gland assembly 20 a is relatively longer than the other gland assembly 20 b . The gland assembly 20 a forms a longer cavity 70 a for accommodating the cylindrical member 16 c in the retracted or open position shown in FIG. 15. The gland assembly 20 b forms a cavity 70 b which is adapted to accommodate the cylindrical member 16 d in the ‘blind’ position shown in FIG. 17, thereby enabling the cylindrical member 16 c to cover or extend across the vertical bore 3 . The cylindrical member 16 c carries a suitable seal 68 for sealing the vertical bore 3 and the radial openings 9 .
[0076] From the foregoing it will be understood that the body means 2 and the locking members 50 co-operate to enable one cylindrical member 16 c to extend transversely across the vertical bore 3 to close and seal it. | The assembly functions to clamp onto and frictionally engage the polished rod of a well's rod string, with sufficient force to suspend the string from the wellhead. The assembly comprises an annular body forming opposed, radial, internally threaded side openings extending from its outer circumferential surface to its central vertical bore. An externally threaded locking member is positioned in each side opening and protrudes externally. The locking members can be manually threaded inwardly to engage the polished rod. An external leverage assembly is anchored to the body and engages one of the locking members. This leverage assembly can be manually turned to tighten the locking member against the polished rod with powerful axial force to provide enhanced gripping. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to bicycles having a front fork wheel suspension. More particularly, the present invention is directed to improvements which will enable a bicycle front fork wheel suspension to be more readily adapted to the needs of a wider variety of riders, and to modifications which are designed to improve handling characteristics of bicycles having front fork wheel suspensions.
2. Description of Related Art
In the present inventor's U.S. Pat. No. 4,971,344, a bicycle having a telescopic suspension system for the front wheel is disclosed which allows the bicycle to perform in the manner of one having a standard, rigid front fork under normal riding conditions, so that the pedaling energy of the rider is not absorbed by the suspension system, yet it is also able to compress and absorb high input impact shocks as occur when the front wheel contacts pot holes, tree roots or rocks, etc. This characteristic is achieved through the use of a fluid-containing circuit that acts to lock the telescoping suspension assembly against compression by resisting low input forces imposed upon the fork, via handlebar and frame portions of the bicycle, as a result of a pedaling action of a rider of the bicycle, while enabling compression of the suspension assembly for absorption of impact shocks imposed upon the front fork by a wheel carried thereby by reacting under the effect of high input forces. In accordance with a preferred embodiment, the fluid-containing circuit includes a valve with a valve body having at least one flow port and a displaceable valve plate. The valve plate is spring loaded into a position in which it blocks fluid flow through the port, and which opens to permit fluid flow when the spring force on the plate is overcome.
In another aspect of the front fork wheel suspension of the applicant's earlier U.S. patent, a cross member interconnects the lower tube of each of a pair of telescoping suspension assemblies to limit twisting and rotating motion of the suspension assemblies. This cross member also serves to provide a brake cable stop which enables a front brake cable to float with the lower tubes of the telescoping assemblies. Additionally, a wheel rim brake is carried by the lower telescoping tubes in areas at which the cross member connects to the lower telescoping tubes so as to enable the rim brake to travel with the lower telescoping tubes.
While this front fork wheel suspension of the present inventor has proved to provide excellent performance (having been used by professional riders to win championships), and has been commercially successful, areas for further improvement have been noted. In particular, in this earlier suspension assembly, the spring force for the spring preloading of the valve plate was set to be correct for riders of average weight and riding ability, but was either too stiff or soft for riders who varied from the norm. To adjust the suspension for riders of different weight, the suspension system was pressurized with air through an air valve, and this air pressure could be altered to compensate for different rider weights or riding conditions. However, because the extension damping performance of the suspension is directly related to the amount of air pressure in the system, adjusting the air pressure to compensate for a rider's weight could adversely impact on the extension damping characteristics of the suspension.
Additionally, while the inverted U-shaped cross member was designed to resist the torsional forces placed on the fork between the handlebars and the front wheel, to limit twisting and rotation of the lower telescoping tubes, other forces acting on the fork were not taken into consideration. In particular, subsequent research and testing has shown that side loading forces are imposed during cornering or when the rider is climbing hills out of the saddle ("jamming"). These forces tend to cause the individual telescoping legs to move independently of each other, which can detract from the bicycle's handling characteristics.
SUMMARY OF THE INVENTION
In view of the foregoing, it is a general object of the present invention to further develop the bicycle front fork wheel suspension of the above-noted patent so as to render it more adaptable to a wider variety of riders, without affecting its extension damping characteristics, and to further strengthen its ability to resist the effects of outside forces which can adversely affect handling characteristics.
More specifically, it is an object of the present invention to provide a bicycle with a front fork wheel suspension which utilizes a hydraulic valve to control flow between tubes of a telescopic suspension assembly in which the opening characteristics of the valve are adjustable.
It is a further object of the present invention to provide a bicycle with a front fork wheel suspension which includes a cross member between the telescoping tubes which will increase fork stiffness, not only with respect to torsional forces, but also side loading forces.
These and other objects of the invention are achieved in accordance with a preferred embodiment of a front fork wheel suspension of a bicycle having two telescoping suspension assemblies, one on each leg of the front fork. Each of the suspension assemblies includes a pair of telescoping tubes having a hydraulic fluid and an airspace therein, as well as a spring-loaded valve which regulates the flow of hydraulic fluid between the two tubes of the telescoping assembly. To control the point at which the assemblies change from a rigid, locked condition, in which the valve plate is closed, to a shock absorbing, telescopically displaceable condition, in which the valve plate is open, an adjustor rod is provided by which the degree of precompression of the valve spring can be changed. Furthermore, in order to improve the rigidity of the fork, the cross member interconnecting the lower tubes of the suspension assemblies has a compound cross-sectional shape which goes from circular cross section at a U-bend portion into a rectangular cross section at straight, leg portions thereof.
The foregoing and other objects, features and advantages of the present invention will become apparent from the following Detailed Description of the Preferred Embodiment when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a bicycle with a front fork wheel suspension in accordance with the present invention;
FIG. 2 is a front view of the front fork suspension in accordance with the present invention;
FIG. 3 is a cross-sectional side view of an upper telescoping tube for the telescoping suspension assembly of the front fork suspension of FIG. 2;
FIG. 4 is a rear elevational view of a cross member of the front fork illustrated in FIG. 2;
FIG. 4A is a cross-sectional view taken along line A--A in FIG. 4;
FIG. 4B is an enlarged cross-sectional view taken along line B--B in FIG. 4;
FIG. 4C is a cross-sectional view taken along line C--C in FIG. 4;
FIG. 5 is a bottom plan view of the cross member shown in FIG. 4;
FIGS. 6A-6C are schematic views of a core for use in producing a hollow within the legs of the cross member of FIG. 4;
FIG. 7 is an enlarged side elevational view of the cross member shown in FIG. 4;
FIG. 7A is a cross-sectional view taken along line 7A--7A in FIG. 7; and
FIG. 8 is a top view of the cross member shown in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As already mentioned, this invention represents a further development of that disclosed in the applicant's U.S. Pat. No. 4,971,344. Thus, to facilitate an understanding of the present invention, the disclosure of that patent is hereby expressly incorporated by reference. Furthermore, in order to facilitate reference to said earlier patent, to as great an extent as possible, the parts described herein are identified by the same reference numerals utilized to identify corresponding parts in this earlier patent.
In FIG. 1, a bicycle 1 is shown having a conventional frame 14. The improved front fork suspension 10 (shown in greater detail in FIG. 2) of the present invention has a steering pipe 16 which is mounted within a head tube 12 of the bicycle frame 14 for rotation along a steering axis in a pair of rotational bearings 18, together with the extension stem 34 of a standard handlebar 32.
The steering pipe 16 of the front fork suspension 10 is secured in a single upper crown 20, which also clamps two telescoping suspension assemblies 40 at an off angle relative to the steering axis, so as to place the front wheel 21 forward of the line of the steering axis in what is known as a rake on a standard bicycle fork.
Each of the telescoping suspension assemblies 40 of the front fork 10 is comprised of an upper telescoping tube 44 and a lower sliding tube 46. The axle 22 of the front wheel 21 is mounted in the bottom end of lower tubes 46. Also, as will be described in greater detail below, a standard wheel rim friction type brake 24 is mounted to the lower sliding tubes 46 in the areas where a cross member 48 is secured. This cross member 48, which serves to strengthen the front fork wheel suspension 10, also carries a cable stop 26 for the front brake Bowden cable 28, thereby allowing the front brake cable 28 to float with the lower sliding tubes 46 as the rim brakes 24 move up and down in unison with the rim 30 of the front wheel 21.
Inasmuch as the two telescoping suspension assemblies 40 are identical, and since the lower telescoping tube is constructed in the manner shown and described in U.S. Pat. No. 4,971,344 and can slidingly receive the upper telescoping tube 44 in the manner disclosed therein, with or without the hydraulic extension lock arrangement provided therebetween, the following discussion of the suspension assemblies 40 will be limited to a description of the upper telescoping tube 44. In this regard, specific reference can be made to FIGS. 3 & 4 and the description thereof in this prior patent.
In FIG. 3, upper telescoping tube 44 is shown as having a metering valve 60 threaded into its lower end for metering the flow of a viscous fluid medium 62 between the chamber 57 of the upper telescoping tube 44 and a similar chamber in a respective lower telescoping tube 46 during compression and extension of the suspension assembly 40. These chambers can be thought of as a single fluid chamber having a portion in each of the tubes with the metering valve 60 disposed therein to regulate flow of fluid between the portions of the chamber. To this end, the metering valve 60 is provided with ports 64 which extend through the body of the metering valve and open into a counterbore area 72 at their inner ends. A compression valve plate 66 is held in a closed position, covering the counterbore area 72, by a compression spring 68 that is held in place in a precompressed condition by an adjustment rod 70. The metering valve 60 has a threaded opening 65 into which a threaded end 67 of the adjustment rod 70 is screwed, and an intermediate counterbore 69 is provided for a cylindrical mounting shaft portion 71 of the adjustment rod 70. A sealing cap 55 is threaded into the upper end of tube 44 and an adjustment knob 73, that is provided at the top end of adjustment rod 70, passes through a central opening in the sealing cap 55. To prevent leakage, while enabling rotation of the adjustment rod 70 via the adjustment knob 73, an 0-ring seal 75 is incorporated into the sealing cap 55.
The lower tube 46 being filled with hydraulic fluid, it can be appreciated that the upper tube 44 cannot telescope into the lower tube 46 without fluid 62 being able to travel from the lower tube 46, through the ports 64, into the chamber 57 of the upper tube 44. However, so long as the compressive forces (such as those due to pedaling forces) are low, the preload imposed by the spring 68 will prevent valve plate 66 from opening so that the suspension assemblies 40 will be locked and function in the manner of a rigid fork. Furthermore, the preload imposed by the spring 66 can be adjusted to compensate for a full variety of rider weights and abilities by turning of the adjustment knob 73 so as to thread the adjustment rod more or less into the opening 65 of the metering valve 60. In the referenced patent, a preload spring force of approxiimately 7 lbs. was applied on the valve plate 66 with the system depressurized using a 40 to 50 lbs./inch spring. With the adjustment rod 70, a 100 lb./in. spring can be used to which as much as 15-20 lbs. of preload can be applied, (so as to enable compression of the suspension assemblies 40 only under the most rigorous of circumstances and/or heaviest of riders; as much as 40 lbs. of force being required to blow open the valve plate 66) or the preload could be decreased to a minimal value that is just sufficient to avoid absorption of pedaling forces on smooth roads (for use by the lightest and most inexperienced of riders).
As in the suspension assembly of the referenced patent, the counterbore area 72 allows the build up of fluid pressure force under the valve plate 66 to be greater than that of the ports 64, themselves, to facilitate the creation of a dampening characteristic that has much greater resistance at low input compressive forces than under high input forces for enabling the system to be locked to prevent absorbing of rider pedaling energy while rapidly opening under impact effects. However, in the illustrated embodiment, the counterbore 72 also houses an expansion check valve 82 which replaces the ball type arrangement previously provided in a return port located in the center of the spring retaining shoulder bolt.
Check valve plate 82 (which can be in the form of a thin washer), under the influence of compressive forces, is pressed against the underside of valve plate 66 by fluid attempting to exit the lower tube 46 via the ports 64. On the other hand, upon extension of the telescoping tubes 44, 46, the fluid medium 62 is able to enter the return port 80 and displace the check valve plate 82 out of its sealing position. In this regard, while the washer-like plate 82 can be permitted to simply float within the counterbore 72, preferably a thin wavy washer type spring is disposed between the check valve plate 82 and the bottom wall of the counterbore 72 so as to eliminate the effect of the check valve plate 82 having to, first, be displaced into its port-closing position during compression. If the preferred wavy-spring is utilized in conjunction with the check valve plate 82, it should have only enough strength to support the check valve plate 82 and should not affect the ability of viscous fluid 62 to shift the check valve plate 82 away from the port(s) 80 during extension. As an alternative, a very thin leaf spring could be mounted to the underside of the valve plate 66 instead of utilizing a check valve plate 82; however, such is not preferred for manufacturing reasons.
Also, as was done with the inventor's prior arrangement, the telescoping assemblies 40 are pressurized with air through an air valve to extend the system after it has been compressed and to provide a further ability to compensate for different rider weights or riding conditions. However, in this case, the air valve 90 is an elastomeric needle valve of the type commonly found on inflatable athletic balls, such as basketballs and footballs, and is incorporated into the adjustment knob 73 of the adjustment rod 70. In this regard, it can be seen from FIG. 3 that a needle insertion space 91 is formed into an upper end of the adjustment knob 73 and has an enlarged area 93 into which the elastomeric needle valve 90 can be snapped. Needle insertion space 91 communicates with chamber 57 through an air inlet port 95 at the bottom side of the adjustment knob 73.
Turning now to FIGS. 4-7, the improved cross member of the present invention will now be described. In the applicant's referenced patent, a cross member is provided between the two lower telescoping tubes to prevent the tubes from becoming skewed when the fork is loaded torsionally. That is, the cross member does not allow a twisting or rotating motion of the suspension assemblies at its attachment. Also, the rim brakes are mounted at the areas of connection between the cross member and lower tubes, thereby minimizing their influence by locating them at the strongest point of the lower tubes and, additionally, avoiding the need to provide a separate attachment means for the rim brakes. In the same way, in the illustrated preferred embodiment, a U-shaped cross member 48 is connected to the lower telescoping tubes 46 using a pair of bolts that mount through a pair of bolt hole bosses 47, 49 that are formed at the lower ends of legs 48L of cross member 48. Furthermore, the inner bosses 47, simultaneously, serve for mounting of the rim brakes 24 and can be provided with a flange 47a having a plurality of holes which can, selectively, be utilized to fix the end of a return spring of the brake device, as is conventional with bicycle wheel rim brakes.
However, it has been subsequently discovered, after further research and testing, that torsional forces placed on the fork, between the handlebars 32 and the front wheel 21 are not the only significant forces affecting the rigidity of a telescoping front wheel suspension. In particular, it has been determined that side loading forces, occurring while cornering or while the rider is climbing hills out of the saddle ("jamming") tend to cause the individual telescoping assemblies 40 to move independently of each other, resulting in adverse handling effects. Furthermore, it has been determined that, while a U-shaped cross member formed of a simple round tube will eliminate the effects of the torsional forces, a cross member of such a shape will not adequately cope with the noted side loading forces. More specifically, analysis of the side loading forces by the inventor has shown that a bending load is placed on the straight leg portions 48L of the U-shaped cross member 48 which a round tube cross section is not best suited to resist. On the other hand, a round cross section is best suited for resisting torsional forces, which the inventor has found to be concentrated in the U-bend portion 48B of the cross member 48. On the basis of this research and analysis, the new cross member 48, which is described relative to FIGS. 4-7, below, has been created.
The cross member 48 is formed of a cast metal part of a compound cross-sectional shape that is best suited for resisting all of the forces to which the front fork wheel suspension 10 will be subjected in use. As can be seen in FIG. 4A, the U-bend portion 48B is a solid rod of circular cross section, except for the provision of the mounting flat 48M (FIGS. 4 and 4B) upon which the brake cable stop 26 is mounted. However, in the area where the leg portions 48L merge into the U-bend portion 48B, the cross section of the cross member 48 undergoes a transformation from a round shape into the essentially square hollow cross-sectional shape shown in FIG. 4C, after which it flares outwardly into the larger rectangular hollow cross-sectional shape apparent from FIG. 5. From FIG. 4, it can be seen that the enlargement of the cross section of the legs 48L, from the square cross section of FIG. 4C to the rectangular cross section of FIG. 5, is produced solely through the flaring of the outer side wall of the straight leg portions 48L, the inner wall remaining essentially vertical.
By way of example, the flaring of the outer wall surface will produce an angle α of approximately 3.2°, and a U-bend portion 48B of approximately 0.55 inch diameter will blend into a square cross section with 0.55 inch long sides, and with the flaring resulting in a rectangular cross section that is about 0.55 inch by approximately 0.65 inch. Additionally, as a weight reducing measure, during the casting process for producing cross member 48, cores are utilized to render the straight leg portions 48L hollow, as represented by the broken lines in FIG. 4 and as can be seen from the views of FIGS. 4C and 5. FIGS. 6A-6C schematically depict the shape of a core which can be used for this purpose, and it is apparent from these figures that the core 100 is designed to produce a gradual reduction in the thickness of the outwardly flaring wall of the straight leg portion 48L while maintaining an essentially uniform wall thickness on the other three sides (although, a slight degree of taper is provided to the core at these sides simply to facilitate removal of the core from the finished cross member). The nominal thickness of the wall of the hollow portion of the cross member will be approximatel 0.05 inch at line C--C in FIG. 4. Tests with such a cross member have shown a dramatic increase in fork stiffness and improvement in handling characteristics.
As can be seen from FIGS. 7-8, the cable stop 26 is attached to the mounting area 48M at the top of cross member 48 and is comprised of a strut 26a and a cable stop receptacle 26b. The strut 26a slopes forwardly so that the cable stop receptacle 26b is oriented vertically with its center disposed approximately 0.9 inches forwardly of the apex of the U-bend portion, as viewed in FIG. 7.
From the foregoing, it should now be apparent how the present invention is able to achieve all of its initially stated objects, and more, so as to result in a bicycle front fork wheel suspension that is improved both with respect to versatility, strength, and handling performance without departing or detracting from the basic concepts and benefits associated with that of the inventor's earlier patent. Furthermore, while the present invention has been shown and described with reference to a specific preferred embodiment, it will be understood by those skilled in the art that various alterations and modifications in form and detail can be made within the scope of the present invention. For example, while the present invention shows the cross member 48 as being utilized in conjunction with the inventive hydraulic shock absorbing assemblies 40, it should be apparent that the benefits of this cross member can be achieved with any and all types of telescopic front fork shock absorbing assemblies whether utilizing hydraulic, elastomeric or spring damping mechanisms. Accordingly, the present invention is not intended to be limited to the specific details shown and described herein and encompasses the full scope of the appended claims. | In accordance with a preferred embodiment, a front fork wheel suspension of a bicycle has two telescoping suspension assemblies, one on each leg of the front fork. Each of the suspension assemblies includes a pair of telescoping tubes having a hydraulic fluid and an airspace therein, as well as a spring-loaded valve which regulates the flow of hydraulic fluid between the two tubes of the telescoping assembly. To control the point at which the assemblies change from a rigid, locked condition, in which the valve plate is closed, to a shock absorbing, telescopically displaceable condition, in which the valve plate is open, an adjustor rod is provided by which the degree of precompression of the valve spring can be changed. Furthermore, in order to improve the rigidity of the fork, the cross member interconnecting the lower tubes of the suspension assemblies has a compound cross-sectional shape which goes from circular cross section at a U-bend portion into a rectangular cross section at straight, leg portions thereof. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on Japanese Patent Application No.2000-090559 filed in Japan on Mar. 29, 2000, the entire content of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a liquid crystal display apparatus having a liquid crystal display element comprising multiple liquid crystal layers stacked together and to a driving method thereof, and more particularly, to a liquid crystal display apparatus that comprises multiple liquid crystal layers stacked together and that can display multi-color images, and to an interlace driving method thereof.
[0004] 2. Description of the Related Art
[0005] Liquid crystal apparatuses using so-called memory type liquid crystal (e.g., chiral nematic liquid crystal) have been proposed that can maintain a specific phase or molecular orientation even when no power is being supplied thereto. While a liquid crystal apparatus of this type can maintain the displayed images without the supply of power, it is slow in response (in other words, the required response time between the commencement of power supply and the appearance of the desired colors is long). In order to speed up to the extent possible redrawing of the display image in this liquid crystal apparatus, a drive method called dynamic driving has been proposed. Furthermore, in an effort to cause liquid crystal apparatuses of this type to display moving images, dynamic driving could be performed with the adoption of the scanning method generally adopted in the area of television image engineering (the interlaced scanning method). In the above dynamic driving, three different periods, i.e., a reset period, a selection period and a maintenance period, are needed in order to redraw display units on one scanning line. By sequentially selecting each scanning line, the entire display may be redrawn. In addition, by selecting only some scanning lines, the image corresponding to the selected area only may be redrawn as well.
[0006] However, during the above dynamic driving, while a scanning line is being accessed, i.e., during the above reset period, selection period and maintenance period, the display units on that scanning line cannot contribute to image display, and therefore the background color (normally black, which is the color of the light absorbing layer) is observed in this scanning line. Consequently, where the scanning lines are sequentially selected, a belt of the background color is observed over multiple scanning lines, and as the scanning progresses, this belt also moves. Where dynamic driving is performed using the interlaced scanning method, a belt having a width equivalent to multiple lines does not appear, but multiple belts each having a width equal to one line appear in the display. In particular, where the displayed images are continuously redrawn in order to reproduce moving images, the above-mentioned belts of the background color are observed at all times, significantly reducing the ease of image viewing.
SUMMARY OF THE INVENTION
[0007] Therefore, an object of the present invention is to provide a new liquid crystal display apparatus that can eliminate reduction in the ease of image viewing when dynamic driving is carried out.
[0008] Another object of the present invention is to provide a liquid crystal display apparatus that can prevent reduction in the ease of image viewing when driving is performed wherein image updating is continuously performed in order to reproduce moving images.
[0009] In order to attain at least one of these objects, a liquid crystal display apparatus reflecting one aspect of the present invention comprising: a liquid crystal display element having a plurality of liquid crystal layers each having a plurality of display units that are arranged in a matrix fashion and are defined by intersections of a plurality of scanning line electrodes and a plurality of data line electrodes, said liquid crystal layers being stacked each other such that said scanning line electrodes and said data line electrodes of any one of said liquid crystal layers match said scanning line electrodes and said data line electrodes of the other ones of said liquid crystal layers whereby a plurality pixels are formed by the display units of each liquid crystal layer that overlap with each other; and a controller for, when an image is drawn in said liquid crystal display element, selecting at least one of the matching scanning line electrodes of said liquid crystal layers at a different timing than that used for the other matching scanning line electrodes, such that the all of the matching scanning line electrodes of said liquid crystal layers are not simultaneously selected.
[0010] In this liquid crystal display apparatus, because the matching scanning line electrodes of the liquid crystal layers are prevented from being selected at the same time, if the pixels on a certain scanning line are viewed, at least one liquid crystal layer is contributing to the display, such that belts of the background color are no longer observed.
[0011] In the above liquid crystal display apparatus, the controller may include wiring that connects the drive circuits and the scanning line electrodes of each of the above liquid crystal layers.
[0012] In the above liquid crystal display apparatus, the controller may include a scanning driver that is shared by at least two of the liquid crystal layers. In this case, the above scanning driver may be shared by all of the liquid crystal layers.
[0013] In the above liquid crystal display apparatus, at least one of the liquid crystal layers may be placed such that it is offset from the other liquid crystal layers by one scanning line electrode in the direction of the alignment thereof.
[0014] In the above liquid crystal display apparatus, the controller may select each of the matching scanning line electrodes of the multiple liquid crystal layers at different timings.
[0015] In the above liquid crystal display apparatus, the controller may split the multiple liquid crystal layers into multiple fields for driving.
[0016] According to another aspect of the present invention, a liquid crystal display apparatus comprising: a liquid crystal display element comprising a plurality of liquid crystal layers that are stacked each other; a drive circuit for driving the liquid crystal layers; and a control unit that is connected to said drive circuit and is adapted to update information displayed on said liquid crystal display element by using an interlaced scanning method that divides each liquid crystal layer into a plurality of fields and sequentially drives the fields of each liquid crystal layer, wherein said control unit controls said driver so that a driven field of at least one of said liquid crystal layers different from those of the other of said liquid crystal layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other objects, advantages and features of the invention will become apparent from the following description thereof taken in conjunction with the accompanying drawings in which:
[0018] [0018]FIG. 1 is a cross-sectional view showing the basic construction of the liquid crystal apparatus pertaining to an embodiment 1;
[0019] [0019]FIG. 2 is a drawing showing in a simplified fashion the placement of the scanning line electrodes and the data line electrodes in the liquid crystal apparatus shown in FIG. 1;
[0020] [0020]FIG. 3 is a block diagram showing the basic construction of the liquid crystal apparatus shown in FIG. 1;
[0021] [0021]FIG. 4 is a block diagram showing the basic construction of the scanning line driver in the liquid crystal apparatus shown in FIG. 1;
[0022] [0022]FIG. 5 is a drawing to explain the interlace driving in the liquid crystal apparatus shown in FIG. 1;
[0023] [0023]FIG. 6 is a drawing showing the relationships among the scanning line shift clock, the scanning line latch signal and the data line drive signal in the liquid crystal apparatus shown in FIG. 1;
[0024] [0024]FIG. 7 is a cross-sectional view showing the basic construction of the liquid crystal apparatus pertaining to an embodiment 2;
[0025] [0025]FIG. 8 is a basic plan view of the liquid crystal apparatus shown in FIG. 7;
[0026] [0026]FIG. 9 is a drawing to explain the interlace driving of the liquid crystal apparatus shown in FIG. 7;
[0027] [0027]FIG. 10 is a block diagram showing the basic construction of the liquid crystal apparatus shown in FIG. 7;
[0028] [0028]FIG. 11 is a drawing showing the relationships among the scanning line shift clock, the scanning line latch signal and the data line drive signal in the liquid crystal apparatus shown in FIG. 7;
[0029] [0029]FIG. 12 is a cross-sectional view showing the basic construction of the liquid crystal apparatus pertaining to an embodiment 3;
[0030] [0030]FIG. 13 is a basic plan view of the liquid crystal apparatus shown in FIG. 12;
[0031] [0031]FIG. 14 is a drawing to explain the interlace driving of the liquid crystal apparatus shown in FIG. 12;
[0032] [0032]FIG. 15 is a block diagram showing the basic construction of the liquid crystal apparatus shown in FIG. 12; and
[0033] [0033]FIG. 16 is a drawing showing the relationships among the scanning line shift clock, the scanning line latch signal and the data line drive signal in the liquid crystal apparatus shown in FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Multiple embodiments of the present invention are explained below with reference to the accompanying drawings. In the accompanying drawings, the same or similar components are assigned the same numbers. In addition, in the following explanation, directional terms (such as ‘up’, ‘down’, ‘right’, ‘left’ and other terms including these terms) are used from time to time in order to facilitate understanding, but the scope of the present invention is not limited by these terms.
[0035] Embodiment 1
[0036] [0036]FIG. 1 is a simplified drawing to explain the basic cross-sectional construction of a reflection-type liquid crystal display apparatus. As shown in this drawing, the liquid crystal display apparatus 10 has a liquid crystal display element 12 . The liquid crystal display element 12 has three liquid crystal layers 14 (a blue liquid crystal layer 14 B, a green liquid crystal layer 14 G, and a red liquid crystal layer 14 R) and a light-absorbing layer 16 , arranged in this order from the observer side (the top side in the drawing). Each liquid crystal layer 14 has a top transparent substrate 18 , a bottom transparent substrate 20 that is aligned parallel to the top transparent substrate 18 with a prescribed distance therebetween, and liquid crystal 22 housed therebetween. In this embodiment, transparent glass plates are used for the transparent substrates, and memory type liquid crystal (such as chiral nematic liquid crystal) is used for the liquid crystal, but the application area of the present invention is not limited by this construction.
[0037] The top transparent substrate 18 has multiple (n number in this embodiment) belt-shaped transparent electrodes (scanning line electrodes, i.e., row electrodes) that are aligned parallel to each other and at prescribed intervals on the surface thereof that is in contact with the liquid crystal 22 . At the same time, the bottom transparent substrate 20 has multiple (m number in this embodiment) belt-shaped transparent electrodes (data line electrodes, i.e., column electrodes) that are aligned parallel to each other and at prescribed intervals on the surface thereof that is in contact with the liquid crystal 22 . Specifically, as shown in FIG. 2, the scanning line electrodes 24 and the data line electrodes 26 are aligned such that they are aligned in different directions, and in this embodiment, as seen by an observer, the scanning line electrodes 24 extend in the right/left direction and are aligned at prescribed intervals in the top/down direction, while the data line electrodes 26 extend in the top/down direction and are aligned at prescribed intervals in the right/left direction. The transparent electrodes are formed of indium tin oxide (ITO), as generally known to vendors in the art.
[0038] In this embodiment, the three liquid crystal layers 14 are stacked together such that the scanning line electrodes 24 and the data line electrodes 26 of each liquid crystal layer 14 are not offset from one liquid crystal layer 14 to another in either the right/left or top/down directions. In other words, the first to n-th scanning line electrodes of the blue liquid crystal layer B are respectively located on the first to n-th scanning line electrodes of the green liquid crystal layer G, which are in turn respectively located on the first to n-th scanning line electrodes of the red liquid crystal layer R. Similarly, the first to m-th data line electrodes of the blue liquid crystal layer B are respectively located on the first to m-th data line electrodes of the green liquid crystal layer G, which are in turn respectively located on the first to m-th data line electrodes of the red liquid crystal layer R.
[0039] As shown in FIG. 3, each liquid crystal layer 14 has its own scanning line driver (scanning line drive circuit) 28 and data line driver (data line drive circuit) 30 . The scanning line electrodes 24 and the data line electrodes 26 of each liquid crystal layer 14 are connected to their corresponding scanning line driver 28 and data line driver 30 . These multiple scanning line drivers 28 and data line drivers 30 are connected to a common controller (control circuit) 32 .
[0040] As shown in FIG. 4, each scanning line driver 28 comprises a shift register 34 , a level shifter 36 , and a driver 38 . In response to a shift clock pulse 40 and a latch signal 42 transmitted from the controller 32 , a prescribed voltage (a scanning line drive voltage 46 ) supplied from the liquid crystal drive power supply 44 is impressed to a desired scanning line electrode 24 . The specific operation of the scanning line driver 28 is explained in detail below.
[0041] The interlace driving of the liquid crystal display element 12 will now be explained with reference to FIGS. 5 and 6. In order to simplify the explanation, each liquid crystal layer 14 is assumed to have nine scanning line electrodes. In addition, in the explanation below, the expression (N, M) indicates a pixel that is displayed at the point at which the N-th scanning line electrode and the M-th data line electrode intersect. Further, in this interlace driving, one frame is divided into three fields (each representing ⅓ of the frame). The scanning lines (the first to ninth scanning lines) of each liquid crystal layer 14 are assigned to the three fields F1, F2 and F3, such that they have the relationships shown in Table 1 below.
TABLE 1 Field Liquid F1 scanning F2 scanning F3 scanning crystal line row line row line row layer number number number Red: R 1, 4, 7 2, 5, 8 3, 6, 9 Green: G 2, 5, 8 3, 6, 9 1, 4, 7 Blue: B 3, 6, 9 1, 4, 7 2, 5, 8
[0042] (a 1 ) through (a 3 ) and (b 1 ) through (b 3 ) of FIG. 5 show the scanning lines that are driven (i.e., are impressed with a scanning line drive voltage 46 ) in the three fields F1, F2 and F3. The hatched area indicates a driven scanning line. Specifically, as shown in (a 1 ) and (b 1 ) of FIG. 5, in the first field F1, the first, fourth and seventh scanning line electrodes are sequentially driven in the red liquid crystal layer R, the second, fifth and eighth scanning line electrodes are sequentially driven in the green liquid crystal layer G, and the third, sixth and ninth scanning line electrodes are sequentially driven in the blue liquid crystal layer B. Therefore, for example, where a data line drive voltage is being impressed to the first data line electrodes 26 ( 26 - 1 ) from the data line drivers 30 , the molecular orientation of the liquid crystal areas corresponding to the pixels (1, 1), (4, 1) and (7, 1) at which the data line electrode 26 and the first, fourth and seventh scanning line electrodes 24 of the red liquid crystal layer R intersect changes, causing these areas to become transparent. When this occurs, the first, fourth and seventh lines of the green liquid crystal layer G and the blue liquid crystal layer B are in the reflection state, such that when seen from the side of the observer, the first, fourth and seven scanning lines selectively reflect green and blue. The molecular orientation of the liquid crystal areas corresponding to the pixels (2,1), (5, 1) and (8, 1) at which the data line electrode 26 and the second, fifth and eighth scanning line electrodes 24 of the green liquid crystal layer G intersect changes, causing these areas to become transparent. When this occurs, the second, fifth and eighth lines of the red liquid crystal layer R and the blue liquid crystal layer B are in the reflection state, such that when seen from the side of the observer, the second, fifth and eighth scanning lines selectively reflect red and blue. Furthermore, the molecular orientation of the liquid crystal areas corresponding to the pixels (3, 1), (6, 1) and (9, 1) at which the data line electrode 26 and the third, sixth and ninth scanning line electrodes 24 of the blue liquid crystal layer B intersect changes, causing these areas to become transparent. When this occurs, the third, sixth and ninth lines of the green liquid crystal layer G and the red liquid crystal layer R are in the reflection state, such that when seen from the side of the observer, the third, sixth and ninth scanning lines selectively reflect green and red.
[0043] Next, as shown in (a 2 ) and (b 2 ) of FIG. 5, in the field F2, the second, fifth and eighth scanning line electrodes are sequentially driven in the red liquid crystal layer R, the third, sixth and ninth scanning line electrodes are sequentially driven in the green liquid crystal layer G and the first, fourth and seventh scanning line electrodes are sequentially driven in the blue liquid crystal layer B. Therefore, where a data line drive voltage is being impressed to the first data line electrodes 26 from the data line drivers 30 , for example, the molecular orientation of the liquid crystal areas corresponding to the pixels (2, 1), (5, 1) and (8, 1) at which the data line electrode 26 and the second, fifth and eighth scanning line electrodes 24 of the red liquid crystal layer R intersect changes, causing these areas to become transparent. When this occurs, the second, fifth and eighth lines of the green liquid crystal layer G and the blue liquid crystal layer B are in the reflection state, such that when seen from the side of the observer, the second, fifth and eighth scanning lines selectively reflect green and blue. The molecular orientation of the liquid crystal areas corresponding to the pixels (3, 1), (6, 1) and (9, 1) at which the data line electrode 26 and the third, sixth and ninth scanning line electrodes 24 of the green liquid crystal layer G intersect changes, causing these areas to become transparent. When this occurs, the third, sixth and ninth lines of the red liquid crystal layer R and the blue liquid crystal layer B are in the reflection state, such that when seen from the side of the observer, the third, sixth and ninth scanning lines selectively reflect red and blue. Further, the molecular orientation of the liquid crystal areas corresponding to the pixels (1, 1), (4, 1) and (7, 1) at which the data line electrode 26 and the first, fourth and seventh scanning line electrodes 24 of the blue liquid crystal layer B intersect changes, causing these areas to become transparent. When this occurs, the first, fourth and seventh lines of the green liquid crystal layer G and the red liquid crystal layer R are in the reflection state, such that when seen from the side of the observer, the first, fourth and seventh scanning lines selectively reflect green and red.
[0044] Subsequently, as shown in (a 3 ) and (b 3 ) of FIG. 5, in the field F3, the third, sixth and ninth scanning line electrodes are sequentially driven in the red liquid crystal layer R, the first, fourth and seventh scanning line electrodes are sequentially driven in the green liquid crystal layer G, and the second, fifth and eighth scanning line electrodes are sequentially driven in the blue liquid crystal layer B. Therefore, for example, where a data line drive voltage is being impressed to the first data line electrodes 26 from the data line drivers 30 , the molecular orientation of the liquid crystal areas corresponding to the pixels (3,1), (6, 1) and (9, 1) at which the data line electrode 26 and the third, sixth and ninth scanning line electrodes 24 of the red liquid crystal layer R intersect changes, causing these areas to become transparent. When this occurs, the third, sixth and ninth lines of the green liquid crystal layer G and the blue liquid crystal layer B are in the reflection state, such that when seen from the side of the observer, the third, sixth and ninth scanning lines selectively reflect green and blue. The molecular orientation of the liquid crystal areas corresponding to the pixels (1,1), (4, 1) and (7, 1) at which the data line electrode 26 and the first, fourth and seventh scanning line electrodes 24 of the green liquid crystal layer G intersect changes, causing these areas to become transparent. When this occurs, the first, fourth and seventh lines of the red liquid crystal layer R and the blue liquid crystal layer B are in the reflection state, such that when seen from the side of the observer, the first, fourth and seventh scanning lines selectively reflect red and blue. Further, the molecular orientation of the liquid crystal areas corresponding to the pixels (2,1), (5, 1) and (8, 1) at which the data line electrode 26 and the second, fifth and eighth scanning line electrodes 24 of the blue liquid crystal layer B intersect changes, causing these areas to become transparent. When this occurs, the second, fifth and eighth lines of the green liquid crystal layer G and the red liquid crystal layer R are in the reflection state, such that when seen from the side of the observer, the second, fifth and eighth scanning lines selectively reflect green and red.
[0045] The processing for the fields F1, F2 and F3 described above is thereafter repeatedly carried out.
[0046] The driving of the scanning line drivers 28 in the above interlace driving will be explained with reference to FIG. 6. In the drawing, the scanning line shift clock comprises pulses that are input to the shift registers 34 of the red liquid crystal layer R, the green liquid crystal layer G and the blue liquid crystal layer B. In each frame, one shift clock pulse is input to the shift register 34 of the red liquid crystal layer R, two shift clock pulses are input to the shift register 34 of the green liquid crystal layer G and three shift clock pulses are input to the shift register 34 of the blue liquid crystal layer B. A scanning line latch signal 42 is then input to the shift registers 34 of each liquid crystal layer 14 . Consequently, the scanning line driver 28 of the red liquid crystal layer R impresses a scanning line drive signal 46 to the scanning line electrode 24 having the row number corresponding to the number of shift clock pulses input before the input of the scanning line latch signal 42 . In other words, a scanning line drive signal 46 is impressed to the first scanning line electrode 24 in the red liquid crystal layer R while a scanning line drive signal 46 is impressed to the second scanning line electrode 24 in the green liquid crystal layer G and to the third scanning line electrode 24 in the blue liquid crystal layer B, respectively. Furthermore, in accordance with the image signals, a data line drive signal 48 is impressed to the data line electrodes 26 in each liquid crystal layer 14 .
[0047] Three shift clock pulses are then input to the shift registers 34 of the red liquid crystal layer R, the green liquid crystal layer G and the blue liquid crystal layer B, respectively. A scanning line latch signal 42 is also input to the shift register 34 of each liquid crystal layer 14 . Consequently, the scanning line driver 28 of each liquid crystal layer 14 impresses a scanning line drive signal 46 to the scanning line electrode 24 having the row number corresponding to the number of shift clock pulses input before the input of the scanning line latch signal 42 . In other words, a scanning line drive signal 46 is impressed to the fourth scanning line electrode 24 in the red liquid crystal layer R while a scanning line drive signal 46 is impressed to the fifth scanning line electrode 24 in the green liquid crystal layer G and to the sixth scanning line electrode 24 in the blue liquid crystal layer B, respectively. Furthermore, in accordance with the image signals, a data line drive signal 48 is impressed to the data line electrodes 26 in each liquid crystal layer 14 .
[0048] Three shift clock pulses are then input once more to the shift registers 34 of the red liquid crystal layer R, the green liquid crystal layer G and the blue liquid crystal layer B, respectively. A scanning line latch signal 42 is also input to the shift register 34 of each liquid crystal layer 14 . Consequently, a scanning line drive signal 46 is impressed to the seventh scanning line electrode 24 in the red liquid crystal layer R while a scanning line drive signal 46 is impressed to the eighth scanning line electrode 24 in the green liquid crystal layer G and to the ninth scanning line electrode 24 in the blue liquid crystal layer B, respectively. Furthermore, in accordance with the image signals, a data line drive signal 48 is impressed to the data line electrodes 26 in each liquid crystal layer 14 .
[0049] As described above, using the liquid crystal apparatus 10 of the above embodiment, in each field when the interlace method is adopted in the liquid crystal apparatus, the scanning line to which a scanning line drive signal is being impressed becomes transparent, but because the scanning lines of the other liquid crystal layers (the scanning lines of the other liquid crystal layers located above or below the scanning line to which a scanning line drive signal is being impressed) are not being impressed with a scanning line drive signal, they are in the reflection state. In other words, two colors are reflected in all areas corresponding to the scanning lines, so that the color (usually black) of the light absorbing layer, which is supporting the three liquid crystal layers, does not appear in the background, and high-quality, easily viewable images may be obtained.
[0050] Embodiment 2
[0051] [0051]FIGS. 7 through 11 show a liquid crystal apparatus 10 A comprising an embodiment 2. In this liquid crystal apparatus 10 A, the three liquid crystal layers 14 are placed such that they are offset from each other by one scanning line electrode 24 . Specifically, the first to nth scanning line electrodes of the bottommost red liquid crystal layer R are located below the second to n+1th scanning line electrodes of the middle green liquid crystal layer G, and the first to nth scanning line electrodes of the middle green liquid crystal layer G are located below the second to n+1th scanning line electrodes of the topmost blue liquid crystal layer B. In addition, as shown in FIG. 10 in particular, the three liquid crystal layers 14 are connected to a single scanning line driver 28 .
[0052] Using the liquid crystal apparatus 10 A of the embodiment 2, one frame is divided into three fields, as shown in FIG. 9. In the first field, a scanning line shift clock pulse 40 is first supplied to the scanning line driver 28 from the controller 32 , and a scanning line latch signal 42 is then supplied. Consequently, the scanning line driver 28 sequentially impresses a scanning line drive voltage to the first scanning line electrodes of the three liquid crystal layers 14 , as shown in FIG. 9( a ). Because the three liquid crystal layers 14 are offset from each other by one scanning line electrode, in the green liquid crystal layer G, a scanning line drive voltage is impressed to the scanning line below the second line of the blue liquid crystal layer B. In the red liquid crystal layer R, a scanning line drive voltage is impressed to the scanning line below the third line of the blue liquid crystal layer B.
[0053] Three scanning line shift clock pulses 40 are then supplied to the scanning line driver 28 from the controller 32 , followed by a scanning line latch signal 42 . Consequently, the scanning line driver 28 impresses a scanning line drive voltage 46 to the fourth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the fifth line of the blue liquid crystal layer B and the red liquid crystal layer's scanning line below the sixth line of the blue liquid crystal layer B.
[0054] Three scanning line shift clock pulses 40 are then supplied to the scanning line driver 28 from the controller 32 , followed by a scanning line latch signal 42 . Consequently, the scanning line driver 28 impresses a scanning line drive voltage to the seventh scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the eighth line of the blue liquid crystal layer B and the red liquid crystal layer's scanning line below the ninth line of the blue liquid crystal layer B.
[0055] In the second field, the scanning line driver 28 impresses a scanning line drive voltage to the second scanning line of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the third line of the blue liquid crystal layer B and the red liquid crystal layer's scanning line below the fourth line of the blue liquid crystal layer B, as shown in FIG. 9( b ).
[0056] The scanning line driver 28 then impresses a scanning line drive voltage to the fifth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the sixth line of the blue liquid crystal layer B and the red liquid crystal layer's scanning line below the seventh line of the blue liquid crystal layer B.
[0057] The scanning line driver 28 then impresses a scanning line drive voltage to the eighth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the ninth line of the blue liquid crystal layer B and the red liquid crystal layer's scanning line below the tenth line (which is a virtual line that does not exist in actuality) of the blue liquid crystal layer B.
[0058] In the third field, the scanning line driver 28 impresses a scanning line drive voltage to the third scanning line of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the fourth line of the blue liquid crystal layer B and the red liquid crystal layer's scanning line below the fifth line of the blue liquid crystal layer B, as shown in FIG. 9( c ).
[0059] The scanning line driver 28 then impresses a scanning line drive voltage to the sixth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the seventh line of the blue liquid crystal layer B and the red liquid crystal layer's scanning line below the eighth line of the blue liquid crystal layer B.
[0060] The scanning line driver 28 then impresses a scanning line drive voltage to the ninth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the tenth line (which is a virtual line that does not exist in actuality) of the blue liquid crystal layer B and the red liquid crystal layer's scanning line below the eleventh line (which is a virtual line that does not exist in actuality) of the blue liquid crystal layer B.
[0061] An image for one frame is displayed in this manner, and the above processing is repeatedly carried out for the subsequent frames as well. As described above, because in the liquid crystal apparatus 10 A of the embodiment 2, the three liquid crystal layers 14 are offset from each other by one scanning line, the three liquid crystal layers 14 may be simultaneously driven by a single scanning line driver, and the construction of the drive circuit may be made simpler than that in the liquid crystal apparatus 10 A of the embodiment 1.
[0062] Embodiment 3
[0063] [0063]FIGS. 12 through 16 show a liquid crystal apparatus 10 B comprising an embodiment 3. In this liquid crystal apparatus 10 B, as shown in FIGS. 12 through 14, the blue liquid crystal layer B that comprises the first group is placed such that it is offset from the green liquid crystal layer G by one scanning line electrode 24 . However, the green liquid crystal layer G and the red liquid crystal layer R comprising the second group match, i.e., are perfectly aligned with each other. As shown in FIG. 15, the blue liquid crystal layer B and the green liquid crystal layer G are connected to one scanning line driver 28 A, while the red liquid crystal layer R is connected to a different scanning line driver 28 B.
[0064] Using this liquid crystal apparatus 10 B of the embodiment 3, as shown in FIG. 14, one frame is divided into three fields (shown in (a) through (c) of FIG. 14). During driving, in the first field, a scanning line shift clock pulse is supplied to the scanning line driver 28 A from the controller 32 , as shown in FIG. 16. Two scanning line shift clock pulses are also supplied to the scanning line driver 28 B from the controller 32 . A scanning line latch signal is then supplied to the scanning line drivers 28 A and 28 B, respectively, from the controller 32 . Consequently, the scanning line driver 28 A impresses a scanning line drive voltage to the first scanning line of the blue liquid crystal layer B, as shown in FIG. 14( a ). At the same time, the scanning line driver 28 A also impresses a scanning line drive voltage to the green liquid crystal layer's scanning line below the second line of the blue liquid crystal layer B. The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the third line of the blue liquid crystal layer B.
[0065] Three scanning line shift clock pulses are then supplied to the scanning line drivers 28 A and 28 B, respectively, from the controller 32 , followed by a scanning line latch signal. Consequently, the scanning line driver 28 A impresses a scanning line drive voltage to the fourth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the fifth line of the blue liquid crystal layer B. The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the sixth line of the blue liquid crystal layer B.
[0066] Three scanning line shift clock pulses are then supplied to the scanning line drivers 28 A and 28 B, respectively, from the controller 32 , followed by a scanning line latch signal. Consequently, the scanning line driver 28 A impresses a scanning line drive voltage to the seventh scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the eighth line of the blue liquid crystal layer B. The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the ninth line of the blue liquid crystal layer B.
[0067] In the second field, the scanning line driver 28 A impresses a scanning line drive voltage to the second scanning line of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the third line of the blue liquid crystal layer B, as shown in FIG. 14( b ). The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the fourth line of the blue liquid crystal layer B.
[0068] Three scanning line shift clock pulses are then supplied to the scanning line drivers 28 A and 28 B, respectively, from the controller 32 , followed by a scanning line latch signal. Consequently, the scanning line driver 28 A impresses a scanning line drive voltage to the fifth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the sixth line of the blue liquid crystal layer B. The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the seventh line of the blue liquid crystal layer B.
[0069] Three scanning line shift clock pulses are then supplied to the scanning line drivers 28 A and 28 B, respectively, from the controller 32 , followed by a scanning line latch signal. Consequently, the scanning line driver 28 A impresses a scanning line drive voltage to the eighth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the ninth line of the blue liquid crystal layer B. The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the tenth line (which is a virtual line that does not exist in actuality) of the blue liquid crystal layer B.
[0070] In the third field, the scanning line driver 28 A impresses a scanning line drive voltage to the third scanning line of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line under the fourth line of the blue liquid crystal layer B, as shown in FIG. 14( c ). The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the fifth line of the blue liquid crystal layer B.
[0071] Three scanning line shift clock pulses are then supplied to the scanning line drivers 28 A and 28 B, respectively, from the controller 32 , followed by a scanning line latch signal. Consequently, the scanning line driver 28 A impresses a scanning line drive voltage to the sixth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the seventh line of the blue liquid crystal layer B. The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the eighth line of the blue liquid crystal layer B.
[0072] Three scanning line shift clock pulses are then supplied to the scanning line drivers 28 A and 28 B, respectively, from the controller 32 , followed by a scanning line latch signal. Consequently, the scanning line driver 28 A impresses a scanning line drive voltage to the ninth scanning line electrode of the blue liquid crystal layer B, as well as to the green liquid crystal layer's scanning line below the tenth line (which is a virtual line that does not exist in actuality) of the blue liquid crystal layer B. The scanning line driver 28 B impresses a scanning line drive voltage to the red liquid crystal layer's scanning line below the eleventh line (which is a virtual line that does not exist in actuality) of the blue liquid crystal layer B.
[0073] An image for one frame is displayed in this manner. The above processing is repeatedly carried out for the subsequent frames as well. Because the two liquid crystal layers B and G are offset from each other by one scanning line in this liquid crystal apparatus 10 B of the embodiment 3, the two liquid crystal layers B and G may be simultaneously driven by a single scanning line driver, and the construction of the drive circuit may be made simpler than in the liquid crystal apparatus 10 of the embodiment 1.
[0074] As is clear from the above description, because the liquid crystal apparatuses pertaining to the embodiments 1 through 3 are constructed such that different fields of the three display layers are redrawn at a given time, even during redraw of the display image, an area corresponding to any particular scanning line is in a state in which two colors are reflected. Consequently, even during redraw of the display image, the color (usually black) of the light absorbing layer that supports the three liquid crystal layers does not appear in the background, and thereby images that are easy to view may be obtained.
[0075] Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be construed as being included therein. | Disclosed is a liquid crystal display apparatus comprising: a liquid crystal display element having a plurality of liquid crystal layers each having a plurality of display units that are arranged in a matrix fashion and are defined by intersections of a plurality of scanning line electrodes and a plurality of data line electrodes, said liquid crystal layers being stacked each other such that said scanning line electrodes and said data line electrodes of any one of said liquid crystal layers match said scanning line electrodes and said data line electrodes of the other ones of said liquid crystal layers whereby a plurality pixels are formed by the display units of each liquid crystal layer that overlap with each other; and a controller for, when an image is drawn in said liquid crystal display element, selecting at least one of the matching scanning line electrodes of said liquid crystal layers at a different timing than that used for the other matching scanning line electrodes, such that the all of the matching scanning line electrodes of said liquid crystal layers are not simultaneously selected. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to retainers and, more particularly, to systems and methods for mounting devices using dovetail grooves and expanders.
[0003] 2. Description of Related Art
[0004] Network devices commonly include non-compliant retainers, such as wedge locks, that lock circuit boards or other devices into position. These non-compliant retainers, however, do not allow for mounting of the circuit boards or other devices in a cantilevered state, such that the plane of the circuit board assembly or other device is supported only at one end or edge. Moreover, the network devices are not configured to allow for multiple wedge locks to be implemented in a coplanar fashion.
[0005] Accordingly, there is a need in the art for systems and methods that improve the retention of circuit boards or modules in a network device.
SUMMARY OF THE INVENTION
[0006] Systems and methods consistent with the present invention address this and other needs by using an expanding device, such as a wedge lock, to retain a processing module having a dovetail portion within a frame.
[0007] In accordance with the principles of this invention as embodied and broadly described herein, an optical processing device includes a group of processing modules, a frame, and an expanding device. A portion of each of the processing modules is configured in a dovetail shape. The frame is configured to receive the dovetail end of the processing modules. The expanding device is configured to lock the dovetail end of the processing modules to the frame.
[0008] In another implementation consistent with the present invention, a retainer includes a device having a dovetail-shaped portion, a frame configured to receive the dovetail-shaped portion, and at least one expanding device configured to compress the dovetail-shaped portion against the frame.
[0009] In yet another implementation consistent with the present invention, a method for retaining a device, having a dovetail portion, in a frame is provided. The method includes attaching at least one expanding device to the dovetail portion or the frame, sliding the dovetail portion into the frame, and expanding the at least one expanding device to retain the dovetail portion in the frame.
[0010] In a further implementation consistent with the present invention, a method for dissipating heat from a processing module, having a dovetail portion, to a frame is provided. The method includes attaching at least one expanding device to the dovetail portion or the frame, inserting the dovetail portion into the frame, and expanding the at least one expanding device to bring the dovetail portion into contact with the frame and allow for heat dissipation from the processing module to the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, explain the invention. In the drawings,
[0012] [0012]FIG. 1 illustrates an exemplary system in which systems and methods consistent with the present invention may be implemented;
[0013] [0013]FIG. 2 illustrates an exemplary configuration of the line unit of FIG. 1;
[0014] [0014]FIG. 3 illustrates an exemplary cross sectional view of the processing module/frame interface in an implementation consistent with the present invention;
[0015] [0015]FIG. 4 illustrates an exemplary expanding device in an implementation consistent with the present invention;
[0016] [0016]FIG. 5 illustrates the expanding device of FIG. 4 in an assembled, unexpanded state;
[0017] [0017]FIG. 6 illustrates the expanding device of FIG. 4 in an assembled, expanded state;
[0018] [0018]FIG. 7 illustrates an exemplary configuration of the processing module/frame interface in an alternative implementation consistent with the present invention;
[0019] [0019]FIG. 8 illustrates an exemplary configuration of the dovetail interface in another implementation consistent with the present invention; and
[0020] [0020]FIG. 9 illustrates an exemplary configuration of the processing module/frame interface in a further implementation consistent with the present invention.
DETAILED DESCRIPTION
[0021] The following detailed description of implementations consistent with the present invention refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims and equivalents.
[0022] Implementation s consistent with the present invention provide a dovetail interface for retaining modules within a frame of an underwater device. In an exemplary embodiment, an expanding device is attached to the frame of the underwater device. A dovetail portion of a processing module may be inserted within a receiving portion of the frame. Upon expansion of the expanding device, the dovetail portion is brought into compression with the receiving portion of the frame. Such a configuration enhances the dissipation of heat to the surrounding frame.
Exemplary System Configuration
[0023] [0023]FIG. 1 illustrates an exemplary system 100 in which systems and methods consistent with the present invention may be implemented. As illustrated, system 100 includes two land communication portions that are interconnected via an underwater communication portion. The land portions may include land networks 110 and land terminals 120 . The underwater portion may include line units 130 (sometimes referred to as “repeaters”) and an underwater network 140 . Two land networks 110 , land terminals 120 , and line units 130 are illustrated for simplicity. It will be appreciated that a typical system may include more or fewer devices and networks than are illustrated in FIG. 1.
[0024] The land network 110 may include one or more networks, such as the Internet, an intranet, a wide area network (WAN), a local area network (LAN), or another type of network. Land terminals 120 include devices that convert signals received from the land network 110 into optical signals for transmission to the line unit 130 , and vice versa. The land terminals 120 may connect to the land network 110 via wired, wireless, or optical connections. In an implementation consistent with the present invention, the land terminals 120 connect to the line units 130 via an optical connection.
[0025] The land terminals 120 may include, for example, long reach transmitters/receivers that convert signals into an optical format for long haul transmission and convert underwater optical signals back into a format for transmission to the land network 110 . The land terminals 120 may also include wave division multiplexers and optical conditioning units that multiplex and amplify optical signals prior to transmitting these signals to line units 130 , and line current equipment that provides power to the line units 130 and underwater network 140 .
[0026] The underwater network 140 may include groups of line units and/or other devices capable of routing optical signals in an underwater environment. The line units 130 include devices capable of receiving optical signals and transmitting these signals to other line units 130 via the underwater network 140 or to land terminals 120 .
[0027] [0027]FIG. 2 illustrates an exemplary configuration of the line unit 130 of FIG. 1. As illustrated, the line unit 130 may include an outer case 210 , an insulating layer 220 , a frame 230 , groups of processing modules 240 - 246 , and expanding devices 250 . It will be appreciated that a typical line unit 130 may include other devices (not shown) that aid in the reception, processing, or transmission of optical signals.
[0028] The outer case 210 holds the electronic circuits needed for receiving and transmitting optical signals to other line units 130 and land terminals 120 . The outer case 210 provides the electronic circuits with a pressure or watertight environment. As illustrated, the outer case 210 may be of a hollow cylindrical shape. Alternative configurations are also possible.
[0029] The outer case 210 may be fabricated of a high strength material, such as beryllium copper, aluminum, steel, or the like. In an underwater or undersea environment, such a material should be chosen that provides good heat transfer characteristics for dissipating heat from inside the line unit 130 to the surrounding water.
[0030] The insulation layer 220 electrically isolates the electronic circuits and circuit mountings within the line unit 130 from the outer case 210 . The insulator 220 may be applied uniformly to the inside of the outer case 210 to a thickness to withstand expected high voltage within the line unit 130 , but limited from any excessive thickness to maximize heat transfer through the insulator 220 .
[0031] The frame (or chassis) 230 holds the processing modules 240 - 246 in place within the line unit 130 . The frame 230 may also act as a heat sink for the processing modules 240 - 246 and as a heat conduit for the layer of insulation 220 . The frame 230 may be constructed from a high conductivity material, such as aluminum.
[0032] The processing modules 240 - 246 may include electronic circuits for receiving, processing, and transmitting optical signals. The processing modules 240 - 246 may be positioned so that free space exists between adjacent ones of them, allowing them to be free of stress when the line unit 130 is in a high pressure location (e.g., at sea bottom). As will be described in more detail below, one end of each of the processing modules 240 - 246 may have a dovetail configuration that allows the processing module 240 - 246 to be slid into place within the frame 230 in which it is installed.
[0033] The expanding devices 250 lock the processing modules 240 - 246 in place within the frame 230 . With the expanding devices 250 in a relaxed (i.e., non-expanded) state, the processing modules 240 - 246 may slide freely into position within the frame 230 . This allows for a loose fit and generous tolerances in the designs of both the processing modules 240 - 246 and the frame 230 . As the expanding devices 250 are expanded, the interface between the processing modules 240 - 246 and the frame 230 is closed and put into compression. Keeping the processing modules 240 - 246 in intimate contact with the frame 230 assures good thermal conductivity. FIG. 3 illustrates this connection in greater detail.
[0034] As illustrated, a dovetail interface exists between the processing module (e.g., processing module 240 ) and the frame 230 . The optimum angle of the dovetail may depend upon the mass of the processing module 240 , the distance of the center of mass from the base of the sliding dovetail, the direction of any external loads, such as gravity, shock impulses, vibration, centripetal forces, and the like, the width of the sliding dovetail, the desired compression at the interface of the processing module 240 with the frame 230 , and the load producing capability of the expanding device 250 . In an implementation consistent with the present invention, the dovetail angles may be between 30 and 75 degrees. Generally, steeper dovetail angles allow for a wider interface between the processing module 240 and the frame 230 , and the shallower the angle, the greater the compression force generated at the dovetail interface by the expanding device 250 .
[0035] [0035]FIG. 4 illustrates an exemplary expanding device 400 in an implementation consistent with the present invention. It will be appreciated that other expanding devices may alternatively be used. As illustrated, the expanding device 400 includes a rail 410 , a group of wedge lock segments 420 - 428 , washers 440 , and a fastener 450 .
[0036] The rail 410 allows for mounting of the wedge lock segments 420 - 428 . The length and composition of the rail 410 may be selected so as to ensure that the expanding device 400 is capable of locking a processing module 240 - 246 into position within the frame 230 . In one implementation consistent with the present invention, the length of the rail 410 may be approximately equal to the length of the line unit 130 . The rail 410 may be configured to have a “T” bar-like cross-section along its length. Such a configuration allows the rail 410 to retain the wedge lock segments 420 - 428 once the wedge lock segments 420 - 428 are in place. Other configurations may alternatively be used. The rail 410 may be securely mounted to the frame 230 via screws, adhesives, rivets, or the like.
[0037] The wedge lock segments 420 - 428 may be of such a configuration as to allow the wedge lock segments 420 - 428 to slide onto and mate with the rail 410 in such a way that precludes the wedge segments 420 - 428 from becoming easily misaligned. In other words, the wedge segments 420 - 428 should not be able to rotate about the rail 410 , or be removed from the rail 410 except by sliding them off an end of the rail 410 . The wedge lock segments 420 - 428 may include ramped ends that allow the overall height of the expanding device 400 to be adjusted once the segments 420 - 428 are positioned on the rail 410 . The number of wedge segments, and the length of each wedge segment, may be varied in accordance with the type or size of expanding device desired. The wedge lock segments 420 - 428 may be composed of aluminum or other similar types of heat conductive materials.
[0038] The washers 440 may include any conventional type of washers. The fastener 450 may be a screw or another type of fastening device capable of applying pressure to the wedge lock segments 420 - 428 in order to compress the various wedge segments 420 - 428 together and expand the expanding device 400 to the desired height.
[0039] The expanding device 400 may be assembled in the following manner. The rail 410 may be attached to the frame 230 or another appropriate surface, such as the processing module 240 . As illustrated, the rail 410 may include a group of attachment holes 415 that allow the rail 410 to be mounted to the frame 230 via screws, rivets, and the like. Alternatively, the rail 410 may be mounted to the frame 230 through the use of adhesives.
[0040] The end wedge segment 420 may be attached to the rail 410 via an attachment pin 430 or other similar type of mechanism. The end wedge segment 420 serves to retain the other wedge segments 422 - 428 on the rail 410 . The end wedge segment 420 may be attached to the rail 410 prior to or after the rail 410 has been mounted to the frame 230 .
[0041] Once the end wedge segment 420 has been attached to the rail 410 , the other wedge segments 422 - 426 and end wedge segment 428 may be slid onto the rail 410 . As illustrated, the end wedge segment 428 may be configured with an unramped front end that allows the fastener 450 to apply pressure equally through the washers 440 to the wedge lock segments 420 - 428 . The washers 440 and fastener 450 should be locked in place so as to prohibit loosening during use. This may be accomplished, for example, through the use of a mechanical locking device or a thread-locking adhesive.
[0042] Once the wedge segments 420 - 428 have been slid onto the rail 410 , the fastener 450 may connect to the rail 410 via the wedge lock attachment opening 460 in a well-known manner. FIG. 5 illustrates the expanding device 400 of FIG. 4 in an assembled, unexpanded state. As illustrated, when the expanding device 400 is in an unexpanded state, a gap may exist between the expanding device 400 and the processing module 240 . By tightening the fastener 450 , the expanding device 400 expands to fill the gap, as illustrated in FIG. 6. In such a position, the expanding device 400 causes the dovetail interface of the processing module 240 to come in contact with the frame 230 thereby improving thermal dissipation.
[0043] [0043]FIG. 7 illustrates an exemplary configuration of the processing module/frame interface 700 in an alternative implementation consistent with the present invention. As illustrated, gap-filling thermal material 710 is positioned between the dovetail end of the processing module 240 and the frame 230 . The thermal material 710 may include any type of material (e.g., a mica-filled epoxy) that facilitates heat transfer from the processing module 240 to the frame 230 . The thermal material 710 may be applied uniformly to the frame 230 at a thickness to maximize heat transfer through the thermal material 710 to the frame 230 . While shown to fill only part of the gap between the processing module 240 and frame 230 , the thermal material 710 may fill a larger or smaller part of the gap. With the thermal material 710 in place, the transfer of heat from the processing module 240 to the frame 230 is improved.
[0044] [0044]FIG. 8 illustrates an exemplary configuration of the dovetail interface 800 in another implementation consistent with the present invention. Depending upon the length of the processing modules 240 - 246 , two or more expanding devices may be used to lock the processing modules 240 - 246 in place within the frame 230 . For simplicity, two expanding devices 810 and 820 are illustrated in FIG. 8.
[0045] The expanding devices 810 and 820 may be configured in a manner similar to the expanding device described above with respect to FIGS. 4 - 6 . For ease of access, expanding devices 810 and 820 may be accessible via different ends of the processing module 240 . For smaller processing modules, two or more expanding devices may be desirable to increase the compressive load, thereby supporting greater loads and enhancing thermal performance.
[0046] [0046]FIG. 9 illustrates an exemplary configuration of the processing module/frame interface 900 in a further implementation consistent with the present invention. As illustrated, the processing module 240 may include dissimilar dovetail interfaces 910 and 920 . Dovetail angles may be selected so as to optimize thermal and/or structural performance. As described above, an optimum dovetail angle may be selected based on a variety of factors, such as the mass of the processing module 240 , the distance of the center of mass from the base of the sliding dovetail, the direction of any external loads, such as gravity, shock impulses, vibration, centripetal forces, and the like, the width of the sliding dovetail, the desired compression at the interface of the processing module 240 with the frame 230 , and the load producing capability of the expanding device 250 .
Conclusion
[0047] Systems and methods, consistent with the present invention, improve retention of and heat dissipation from processing modules in an underwater device. A dovetail portion of a processing modules is forced into compression with a receiving portion of a frame through the use of an expanding device. As a result, heat transfer to the frame is enhanced.
[0048] The foregoing description of exemplary embodiments of the present invention provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. For example, while the above description focused on an underwater environment, implementations consistent with the present invention are not so limited. For example, the dovetail interface could alternatively be implemented in other environments, such as ground-based, space, or aerospace environments.
[0049] No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one” or similar language is used.
[0050] The scope of the invention is defined by the claims and their equivalents. | A retainer includes a device having at least one dovetail-shaped portion, a frame configured to receive the dovetail-shaped portion, and at least one expanding device. The expanding device is configured to compress the dovetail-shaped portion against the frame, thereby securing the device against the frame. | 5 |
This is a division of application Ser. No. 08/231,396 filed Apr. 22, 1994, now pending, which is a continuation-in-part of application Ser. No. 08/171,654 filed on Dec. 22, 1993, now pending which is a division of application Ser. No. 07/902,693 filed Jun. 23, 1992, now U.S. Pat. No. 5,279,657 which is a continuation of application Ser. No. 07/719,166 filed on Jun. 21, 1991, now. U.S. Pat. No. 5,171,363 which is a continuation of application Ser. No. 07/251,034 filed Sep. 26, 1988, now U.S. Pat. No. 5,059,245 which is a continuation of application Ser. No. 06/812,814 filed on Dec. 23, 1985, now abandoned which is a continuation-in-part of application Ser. No. 06/567,638 filed Jan. 3, 1984, now abandoned which is a continuation of application Ser. No. 06/314,695 filed Oct. 26, 1981, now U.S. Pat. No. 4,434,010 which is a division of application Ser. No. 06/108,004 filed Dec. 28, 1979, now abandoned.
This invention relates to a high chroma durable paint and multilayer interference platelets for use therein.
Paints are used extensively in many different applications for different purposes. Paints are often used to provide protection to the surfaces painted. In addition, they are utilized to provide color or other appearance enhancing features to structures, articles, vehicles and many other items which are in use at the present time. There is a continuing long-felt need for paints which are durable and which have other distinguishing desirable characteristics, as for example high chroma.
SUMMARY OF THE INVENTION
In general, it is an object of the present invention to provide a high chroma durable paint and multilayer interference platelets having high chroma for use therein.
Another object of the invention is to provide platelets of the above character which are optically variable.
Another object of the invention is to provide platelets of the above character which are of a single color.
Another object of the invention is to provide platelets of the above character which are opaque.
Another object of the invention is to provide platelets of the above character which are symmetrical.
Another object of the invention is to provide platelets of the above character which are very durable.
Another object of the invention is to provide platelets of the above character which can be readily incorporated into a liquid vehicle to provide a paint in which the vehicle will solidify to provide a solidified paint.
Another object of the invention is to provide a paint of the above character which can be readily applied.
Additional objects and features of the invention will appear from the following description in which the preferred embodiments are set forth in detail.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view, an automobile with a high chroma durable paint incorporating the present invention on the outer surfaces thereof.
FIG. 2 is a cross-sectional view of a paint incorporating the present invention.
FIG. 3 is a cross-sectional view of another embodiment of a paint incorporating the present invention.
FIG. 4 is a cross-sectional view of an automobile paint incorporating the present invention.
FIG. 5 is a cross-sectional view of a platelet for use in a paint incorporating the present invention utilizing a metal-dielectric multilayer thin film interference stack providing optically variable characteristics.
FIG. 6 is another cross-sectional view of a platelet for use in a paint incorporating the present invention of a metal-dielectric multilayer thin film interference stack providing a solid color.
FIG. 7 is a cross-sectional view of a platelet for use in a paint incorporating the present invention of an all dielectric thin film interference stack providing optically variable characteristics.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In general, the collection of thin film plates of the present invention which are adapted to be added to a liquid medium for producing a predetermined optical response through radiation incident on a surface of a solidified version of the medium. The collection of flakes is produced by forming a symmetrical mutilayer thin film structure on a flexible web of material and separating the thin film structure from the web to provide a collection of platelets. The platelets are characterized by being comprised of a symmetrical multilayer thin film interference structure in which the layers lie in parallel planes and in that they have an aspect ratio of at least 2:1, preferably 5:1, respectively, for the longest planar dimension of the surfaces parallel to the planes of the layers and surfaces perpendicular to the planes of the layers or in other words, the thickness of the platelet. The flakes also have a maximum dimension on any surface ranging from approximately 2 to 200 microns.
More in particular, in FIG. 1, there is shown a motorized vehicle 11 of a conventional type which is provided with a high chroma durable paint 12 incorporating the present invention which is provided on the exterior surface of the car body 13 which can be formed of a suitable conventional material such as steel or fiberglass. Although the high chroma durable paint 12 of the present invention has been shown being provided on the paint for the entire body of the vehicle 11, it should be appreciated that if desired, the paint 12 of the present invention can also be provided on interior and exterior molding provided on the vehicle. Also alternatively it can be utilized to provide a pin stripe on the exterior of the vehicle.
A cross-sectional view of an optically variable paint incorporating the present invention is shown in FIG. 2. The substrate 21 can be formed of a suitable metal such as steel, plastic, fiberglass, wood or any other material which is to be painted. The substrate is provided with a surface 22 to which is to be applied a high chroma durable paint of the present invention. Thus, by way of example, a primer or prime coat 23 of a suitable type can be applied to the surface 22 to ensure that the high chroma paint layer 26 will adhere to the substrate 21. The high chroma durable paint 26 of the present invention is comprised of a polymeric paint vehicle 27 which consists typically of polyesters, acrylics, epoxies, alkyds, polyurethane or latex-type formulations. Interference platelets 28 of the type hereinafter described are disposed in the polymeric paint vehicle 27. The prime coat 23 and the paint vehicle 27 with the interference platelets 28 therein can be applied to a substrate in various manners, such as brushing, spraying, flow coating, rolling or dipping. The paint can then be dried by allowing the liquid medium to evaporate, either at ambient temperature or by force drying by infrared heating.
Another embodiment of a painted substrate painted with high chroma durable paint is shown in FIG. 3. The substrate 31 can be of the same type of substrate as the substrate 21 having a surface 32 to be painted. As shown in FIG. 3, this paint structure on the surface also consists of a prime coat 33 followed by a base coat 36 which contains a liquid vehicle 37 in the form of a lacquer with not only interference platelets 38, but additional non-interference pigments 37 that can be used to modify the color or control the brightness. Such noninterference materials can include aluminum flake, carbon black, titanium dioxide, transparent and non-transparent dyes, transparent pigments, including iron oxides and phthalocyanines. Also, interference based mica pigments can be used. Additional additives can also be included, such as viscosity controllers, antioxidant leveling agents and the like. In order to impart an additional durability to the paint being applied, an additional clear lacquer pigment 40 can be provided on the surface of the base coat 36. In the clear lacquer top coat 41, additional subtractive colorants may be added to achieve still different colors.
A cross-sectional view of a portion of the body 13 of the vehicle is shown in FIG. 4 in which the body 13 is represented as a substrate 41 which can be formed of a suitable material such as steel, plastic or fiberglass. The substrate is provided with a surface 42 to which is to be applied a high chroma durable paint of the present invention. Thus, by way of example, a pre-coat 43 is first applied to the substrate 41. This pre-coat 43 is deposited using a cathodic electro-painted process using zinc phosphate coatings well known to those skilled in the art. On top of the zinc phosphate coating 43, a prime coat 44 is deposited based on epoxy/amine resins carried out by cathodic electro-coating. This resin may also contain carbon black, TiO 2 and other extender type pigments. These two layers 43 and 44 are deposited on to the substrate 41 for corrosion protection of the metal base substrate. A sealer coat 46 is then applied to the prime coat 44. This sealer may contain pigments, including prime pigments such as TiO 2 and carbon, plus extender pigments such as barium sulphate, china clay, Winnofil or talc. This sealer layer provides key properties such as mechanical resistance, i.e., stone chip resistance, flexibility, resistance to moisture and a good even surface to maximize a smooth surface to the following coats. This sealer layer or coat 46 also removes the imperfections of the metal layer.
The next layer 47 which is the base coat layer generally consists of polyester resins in which has been added optically variable pigment platelets 48 plus other color control pigments, such as TiO 2 , carbon black, mica, aluminum flake, etc. The base coat layer 47 is followed by a clear coat layer 49 which can be a clear coat acrylic with UV blocking and light stabilizers. It functions as a scratch resistant coating and protects the underlying layers of pigment containing polymers. Alternatively, a thermosetting or a thermoplastic acrylic can be substituted for the top two layers 48 and 49. Pigments in the surface sealer coat 46 may or may not be present depending on the concentration of the optically variable pigment platelets present in the base coat 47. Generally, the base coat 47 and clear coat 49 in the form of therma setting, thermoplastic acrylics are spray coated on to the sealer coat 46. Each layer may be cured before the following layer is added by subjecting the paint structure to elevated temperatures for a period of time, i.e., the layers may be applied in the spray booth and then dried using infrared heat.
The interference platelets 28 and 38 can be of the type described in the earlier filed application, Ser. No. 08/171,654 filed on Dec. 22, 1993 now pending, of which this is a continuation-in-part. Thus, as therein described and as herein depicted in FIG. 5 there is shown a representative embodiment of a metal-dielectric design utilizing optically variable characteristics. As described in the co-pending application the platelets can be formed by utilizing a flexible web 51 in a roll coater and having a surface 52 upon which materials are deposited to provide a multilayer thin film interference coating which is broken up to form the interference platelets 48 utilized in the high chroma durable paint 12 of the present invention.
Thus, there is provided a release coat or a layer 53 of a suitable type on the surface 52 which allows the thin film coating to be removed as thin film platelets. For example, the release coat may be an organic solvent soluble or a water soluble coating such as acrylic resins, cellulosic propionates, (polyvinyl pyrrolidine) polyvinyl alcohol or acetate. Thereafter, the first layer of the multilayer thin film interference coating can be deposited in the form of a semi-opaque layer 54 of a suitable material as for example, a metal such as chromium (Cr) to a suitable thickness ranging from 50-150 Å and preferably a thickness of approximately 70 Å. Thereafter, a dielectric layer 56 is deposited at an appropriate optical thickness, as for example two-quarter wave thickness at a design wavelength of 400 nanometers to a six-quarter wavelength thickness at a design wavelength of 700 nanometers, depending upon the color desired. One material found to be particularly satisfactory is magnesium fluoride (MgF 2 ) having an index or refraction of 1.38 which was formed to a thickness of four quarter wavelengths at a design wavelength of 550 nanometers. This is followed by an opaque reflecting metal layer 57 of a suitable material, such as aluminum. However, it should be appreciated that if desired, a semi-opaque metal layer can be provided. Typically such a metal layer becomes opaque at approximately 350-400 Å. Thus, where semi-opaqueness is desired a thickness less than 500 Å can be provided, where 100 Å can be utilized effectively. It should be appreciated that there are a number of other reflecting materials which can be utilized in the place of aluminum such as silver, copper or gold and the like depending upon the color effects desired.
After the aluminum layer 57 has been deposited, this is followed by a dielectric layer 58 which is formed of the same material and is of the same thickness as the dielectric layer 56 as hereinbefore described. For instance, it can be formed of four quarter waves of magnesium fluoride at a design wavelength of 550 nanometers. This is followed by a semi-opaque layer 59 of the same type and thickness as the semi-opaque layer 54 and as hereinbefore described can be formed of chromium having a thickness of approximately 70 Å.
In addition to pigments described above which are symmetrical, the optically variable pigment platelets could be produced where the two sides have asymmetry with respect to the dielectric layer thickness. For example, on one side there could be a four quarter wave thickness of MgF 2 at a design wavelength of 550 nanometers and on the other side there could be a six quarter wave of MgF 2 at a design wavelength of 550 nanometers. Thus, the pigment would have two different colors on both sides of the pigment and the resulting mix of platelets would show a new color which is the combination of the two colors. The resulting color would be based on additive color theory of the two colors coming from the two sides of the platelets. In a multiplicity of flakes, the resulting color would be the additive sum of the two colors resulting from the random distribution of flakes having different sides oriented toward the observer.
With the construction hereinbefore described in conjunction with FIG. 5 it can be seen that a symmetrical multilayer thin film interference structure has been provided on opposite sides of the metal reflecting layer 56 to achieve the maximum optical effects from platelets formed from such a construction. It should be appreciated that if desired, platelets can be formed which are non-symmetrical, in other words, in which the dielectric layer and the metal layer on one side of the reflector layer can be omitted, or may have different dielectric thicknesses on either side of the reflector layer.
Optically variable platelets can also be combined with non-shifting high chroma platelets to produce unique color effects. In addition, the optically variable pigment platelets can be combined with highly reflective platelets such as MgF 2 /aluminum/MgF 2 platelets to produce additional color effects.
After a coating of the type shown in FIG. 5 has been formed on the web 51, a multilayer thin film interference coating can be stripped from the web 51 in a manner hereinbefore described in the application Ser. No. 08/171,654, filed Dec. 22, 1993, now pending, by use of a solvent to form flakes or platelets which are in sizes ranging from 2-200 microns also described in said application Ser. No. 08/171,654, filed Dec. 22, 1993 now pending. The platelets can be further reduced in size as desired. The flakes can be subjected to an air grind to reduce their size to a size ranging from 2-5 microns without destroying their desirable color characteristics. The flakes or platelets are produced to have an aspect ratio of at least 2:1 and preferably 5 to 10 to 1 with a narrow particle size distribution. The aspect ratio is ascertained by taking the ratio of the largest dimension of a surface of the flake parallel to the planes of the layers forming the thin film to the thickness dimension of the platelet.
In order to impart additional durability to the interference platelets 28, it has been found that it is desirable to anneal or heat treat the platelets at a temperature ranging from 200°-300° C. and preferably from 250°-275° C. for a period of time ranging from 10 minutes to 24 hours, and preferably a time of approximately 15-30 minutes.
After the platelets have been sized, they can be blended with other flakes to achieve the color required by adding flakes in different hues, chrome and brightness to achieve a desired result. The interference platelets can then be introduced into the paint vehicle being utilized in a conventional manner. At the same time, additives of the type hereinbefore described such as the carbon aluminum flake, titanium dioxide, mica and/or other conventional pigments can be mixed into the pigment vehicle to achieve the final desired effects. After this has been accomplished, the high chroma durable paint is ready for use.
By using a metal-dielectric design such as shown in FIG. 5, high chroma durable paint can be achieved in which variable color effects are noticeable to the human eye. By way of example the vehicle 11 when viewed in different angles will change color depending upon the viewing angle. The color of the automobile also varies depending on the angle of the car body relative to the viewing eye. Other color shifts can be achieved by a variation in viewing angle. By way of example, colors which can be achieved utilizing such interference platelets can have color shifts such as the gold-to-green, green-to-magenta, magenta-to-green, green-to-blue, silver-to-green, gold-to-silver, blue-to-red, etc.
When it is desired to achieve a single color, as for example a non-shifting pigment utilizing a metal-dielectric design, as shown in FIG. 6, the substrate 61 is provided with a surface 62 on which there is deposited a release coat 63. Thereafter metal and dielectric layers 64 and 66 are deposited with the metal layer being formed of chromium having a thickness of 70 Å. The dielectric layers 66 and 68 can be comprised of a high refractive index material of ≧2.0 where the thickness of the layers are between two quarter waves at 400 nanometers and six quarter waves at 700 nanometers. For example, the dielectric layers may be comprised of TiO 2 or ZnS. This is followed by a reflecting metal layer 67 formed of aluminum to a thickness of at least 500 Å so that it is opaque followed by a dielectric layer 68 similar to the dielectric layer 66 and followed by a metal layer 69 of the same type as a metal layer 64. Highly reflective colored interference pigments can also be made wherein dielectric layers 66 and 68 are of different thicknesses.
This thin film interference coating can be separated from the web 61 in the manner hereinbefore described in FIG. 5 and can be formed in interference platelets of the desired size and can be treated at an elevated temperature for a period of time as hereinbefore described to improve durability. These interference platelets can be utilized in the pigment vehicles hereinbefore described to provide a pigment with a high chroma of a single non-shifting color which is also durable.
In applications where it may be desirable to utilize an all-dielectric multilayer interference thin film, construction such as that shown in FIG. 7 can be utilized such as described in U.S. Pat. No. 4,705,256. Thus, as shown in FIG. 7, a web 71 is provided having a surface 72 with a release coat 73 thereon upon which there is deposited a symmetrical dielectric stack 74 comprised of nine layers forming, alternatively, low/high index pairs. However, such a stack can range from 5-11 layers. The stack 74 is of the form ##EQU1## where "α" and "β" are units of quarter wave optical thicknesses of the low (L) and high (H) index materials respectively and "x" is the number of periods in the stack. Such symmetrical periods of the form previously described may involve multiple periods of that design. The low index material has an index of refraction where n ≦2.0 and the high index material has an index of refraction where n≧2.0.
Such all dielectric symmetrical multilayer thin film interference films can be removed by separating the coating shown in FIG. 7 from the web in the manner hereinbefore described to form thin film interference platelets. Following the removal of the platelets from the web, the platelets can be sized and annealed in the manner described herein to provide a high durable high chroma interference platelet which can be utilized as paint 12 of the present invention to provide the desired optical characteristics very similar to the optically variable characteristics which can be achieved with the metal-dielectric construction shown in FIG. 5. By first depositing a black paint onto the surface of interest followed by the all dielectric optically variable dielectric paint, one can achieve similar high durable, high chroma color effects. The black paint layer underneath the optically variable all dielectric paint serves the function of removing transmitted light that passes through the dielectric optically variable paint.
Thus, it can be seen that the interference platelets of the present invention can be achieved utilizing either metal-dielectric designs or all-dielectric designs to achieve optically variable characteristics or non-shifting single color characteristics all of high chroma and high durability which particularly suit them for use in many applications where paints of high chroma and durability are desired. The color characteristics of the present invention are achieved by utilizing a collection of durable thin film platelets of high chroma which produce predetermined optical responses to radiation incident on the surface of the platelets.
From the foregoing it can be seen that the unique features of the optically variable pigment flakes for use in paints is that by using the same three materials, aluminum, MgF 2 and chromium or, alternatively, aluminum, a high index dieletric and chromium, various colors can be achieved by changing the optical design. By contrast, at the present time, different colored pigments require completely different materials. Thus, by using three materials in unique designs, thin film optical designs having various colors can be achieved, all exhibiting the same durability. In other words, if a new color is to be developed, it is not necessary for a full durability program to be carried out with the new color.
Also in connection with the present invention it can be seen that optically variable pigment platelets of different colors can be mixed with themselves. Such platelets can also be mixed with non-shifting high chroma optical pigment platelets of the type hereinbefore described as well as with other lamellar pigments, such as aluminum flakes, graphite and mica flakes, as well as with non-lamellar pigments such as aluminum powder, carbon black and other inorganic and organic pigments.
It should be appreciated that in addition to being utilized on automobiles for painting the entire body, trim and moldings can be painted. Such paints can have many other applications where the color impressions given are of importance. For example, in addition to be utilized on vehicles of various types, the paints where desired can be utilized on household appliances, architectural structures, flooring, fabrics, electronic packaging/housing, toys and the like. | A color-shifting paint comprising a polymeric paint medium and a plurality of colored interference thin film platelets dispersed in the paint medium. Each platelet being characterized in that platelets has first and second generally planar outer surfaces and an edge thickness perpendicular to the first and second generally planar outer surfaces. Each platelet is comprised of a metal reflecting layer having first and second surfaces. A multilayer interference structure is disposed on each of the first and second surfaces of the metal reflecting layer to provide a symmetrical platelet. The multilayer interference thin film structure comprises a pair of layer consisting of a dielectric layer formed of a dielectric material and a semi-opaque layer. with the dielectric layer directly adjacent to the metal reflecting layer. The thickness of the dielectric layer determines the color and the dielectric material determines the degree of color shift. The platelets have an aspect ratio of at least 2:1 for the longest planar dimension of the first and second outer surfaces in comparison to the edge thickness of the platelets, and have a maximum dimension on any of said surfaces ranging from 2-200 microns. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of the Aug. 26, 1999 filing date of copending provisional application serial No. 60/150,779, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Many techniques have been described by others to extract energy from moving vehicles. See, for example, UK Patent No. 1,332,202 and U.S. Pat. Nos. 4,130,064, 4,238,687, 4,614,875, 4,980,572, and 5,355,674. The methods disclosed by these references involve a vehicle riding over and depressing a treadle or ramp or similar lever because of the weight and momentum of the vehicle. The forced movement of the treadle is then converted into electrical energy by either mechanical linkages or gears coupled to flywheels and/or electrical generators or by pistons or other fluid pumps that drive fluid through a hydraulic motor. The hydraulic motor may be used to rotate an electrical generator or drive some mechanical actuator.
These methods typically impart a significant vertical component of force to the vehicle wheels. Those methods that make no effort to limit this vertical force cause, at least, a bumpy ride or, at worst, an accident due to the dynamic interaction of the vehicle with the vertical forces exerted by the treadle. Many of these inventions incorrectly state or imply that the energy extracted from the moving vehicle is, in some way, a conversion of otherwise unused or wasted energy. All of the methods that extract energy from the moving vehicle must introduce a force that retards the vehicle. Those inventions that recognize this suggest that the invention only be used in locations where the vehicle would otherwise have to apply brakes. Thus some of the retarding energy is utilized instead of being wasted.
One method, which is disclosed in U.S. Pat. No. 4,700,540 (“the '540 patent”), is designed for railroad applications and creates a fluid pumping action by having the flanges of the wheels successively compress a collapsible tube (roller pump) in a closed-loop hydraulic system. The '540 patent states that the tube walls and a fluid accumulator should be designed to exert a safe limit of vertical reaction force. The '540 patent, however, does not provide the magnitude of this limit. The collapsible tube may be compressed by a train coming from either direction because the proposed system includes a bi-directional valve, which must be operated by an approaching train closing one of two switches (one for each direction) so that the system can operate properly. The '540 patent proposes that such changes as increasing the wheel flange heights by one or two inches would improve performance. However, such a change would have a major economic impact on railroads because of the cost of changing the many wheel sets that are currently in use. For example, in the United States there are about eight million railroad wheels that would have to be replaced.
Known methods proposed by others require a means, such as a spring that is compressed by the action of the vehicle on the treadle (or tube wall) or a weight that is lifted by that action, to provide a restoring force to reset the treadle (or tube wall) to its initial operating position. These methods all store a portion of the energy removed from the vehicle in the form of potential energy and then use that portion of stored energy to reset the device. These means for resetting the device using stored energy require the use of components that complicate the design and increase the likelihood of system failure.
PURPOSES AND SUMMARY OF THE INVENTION
A purpose of this invention is to reduce the vertical dynamic reaction force exerted by an energy converter on railroad vehicles while extracting energy from passing trains. Reduction of this vertical reaction force reduces the probability of an accidental derailment.
Another purpose of this invention is to eliminate the need to store some of the extracted energy for resetting the energy converter system after the passage of each wheel. According to an aspect of this invention, passage of a vehicle wheel is utilized to perform the resetting of the energy conversion system.
It is a further purpose of this invention to provide railroads with a system for extracting energy from a moving train that does not require substantial modification to existing railroad equipment.
An energy extractor in accordance with the principles of the invention may include a pivoting member composed of two elements that are contacted by a railroad wheel as the wheel passes. The pivoting member will be moved from its initial position to a second position as the railroad wheel contacts the first element and then is returned to its initial position as the wheel contacts the second element and passes beyond it. This pivoting motion, which is forced by the passing wheel, may be converted into useful electrical or mechanical energy by any one or more of the many possible means that are well known.
The pivoting member may be disposed to rotate in a horizontal plane, a vertical plane, or in any other plane of rotation that is found to be desirable. Preferably, the pivoting member is disposed in a horizontal plane. In such a configuration, the contact elements preferably reduce the vertical reaction force on each wheel by permitting each contact element to rotate about a horizontal axis. In this way, vertical motion of the rim of the wheel merely rotates the contact member while the wheel exerts a lateral force to push aside the contact member.
Depending upon the desired amount of energy to be extracted from the moving train, a multiplicity of pivoting members may be utilized by placing the pivoting members sequentially along the track. The extraction of energy from the train causes a retarding force to be exerted against each wheel as it is in contact with a pivoting member. For safety considerations, it is preferable to use the same number of pivoting members and associated energy conversion means on each of the two rails. In this way, both wheels of each axle will contact the pivoting members at substantially the same time, thereby minimizing any unbalance of forces that would otherwise tend to skew the axle.
There are regions of railroad track that do not have access to electrical power because they are far from electrical utility lines. Such regions are called “dark territory” in railroad parlance. Motorists at road crossings at grade in dark territory are alerted to the presence of railroad tracks by a static sign, usually in the form of an X (crossbuck), that says “Railroad Crossing.” Such signs have been found to be virtually ineffective in preventing accidents. A study by the Federal Railroad Administration, “Safety of Highway-Railroad Grade Crossings, Vol. II. January, 1996, DOT-VNTSC-FRA-95-12.2,” found that the crossbuck sign is approximately only one-one hundredth as effective as a flashing warning light in reducing the potential of a grade crossing accident. Gates are more than one thousand times more effective than a crossbuck sign. This report found that the crossbuck sign is barely more effective than nothing at all. If energy extracted from a passing train were used to operate some sort of active warning devices, such as flashing lights, then there may be a significant reduction in the probability of accidents at grade crossings in dark territory.
Additional features and advantages of the invention will be apparent upon reviewing the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a system for extracting energy from a passing railcar wheel in accordance with certain inventive principles.
FIG. 2 depicts a plurality of energy extracting devices positioned in close proximity to railroad rails.
FIG. 3 is a detailed view of a contact element for contacting a passing railcar wheel in accordance with certain inventive principles.
FIG. 4 depicts a system for extracting energy from a passing railcar wheel in accordance with certain inventive principles.
FIG. 5 depicts a system for converting extracted energy into electrical energy.
FIG. 6 depicts preferred dimensions of a contacting element relative to the width of a railcar wheel flange.
FIG. 7 depicts various preferred contact element shapes in accordance with certain inventive principles.
FIG. 8 depicts a pivoting member in accordance with certain inventive principles.
DETAILED DESCRIPTION OF THE INVENTION
Various inventive aspects will be described in connection with FIGS. 1-8 in which like parts are depicted with like reference numbers.
A preferred embodiment of the invention is depicted in FIG. 1, which shows railroad wheel 1 riding on the head of rail 2 . Wheel 1 has encountered an energy extraction device in accordance with certain inventive principles. The energy extraction device includes a pivoting member, comprising arms 3 and 4 , contact elements 5 and 6 , and shaft 7 . Referring to FIG. 8, pivoting member 27 is depicted in accordance with certain inventive principles. Longitudinal axes 28 and 29 define a plane in which contact elements 5 and 6 on arms 3 and 4 , respectively, may rotate about shaft 7 . Arms 3 and 4 may have any convenient shape such that the arms 3 and 4 allow the contact elements 5 and 6 to alternately contact the side of the head of the rail. Longitudinal axis 30 of shaft 7 is preferably substantially perpendicular to the plane of rotation defined by axes 28 and 29 . Referring again to FIG. 1, the energy extraction device is depicted therein connected to conversion device 8 . Conversion device 8 may be used to convert the pivoting motion of pivoting member 27 into a useable form of energy as described in more detail below.
As depicted in FIG. 1, contact elements 5 and 6 are mounted on the ends of arms 3 and 4 of the pivoting member. Shaft 7 of the pivoting member connects the pivoting member to conversion device 8 such that shaft 7 is substantially perpendicular to the plane in which contact elements 5 and 6 of the pivoting member rotate, also referred to as the plane of rotation of the pivoting member. Shaft 7 , therefore, rotates first in one direction, for instance, counter-clockwise with reference to FIG. 1, and then in the other direction, for instance, clockwise with reference to FIG. 1, as a result of the passage of railroad wheel 1 from left to right in FIG. 1 . Shaft 7 may serve as a drive shaft for any desired energy conversion performed by energy converter 8 .
If it is desirable to extract more energy from a train than can be accomplished using one pair of energy extractors (one on each rail),additional pairs of extractors can be placed along the track, as depicted in FIG. 2 .
Contact elements 5 and 6 are mounted on arms 3 and 4 in such a way that each contact element may turn or rotate freely around the end of the arm to which it is attached. As shown in FIG. 3, bearing 9 , which may be a journal bearing, may be used to mount contact element 5 to arm 3 so that substantially no significant vertical component of force can be transmitted from the arm 3 to wheel flange 11 . As will be apparent, contact element 6 may be mounted to arm 4 in a similar manner. The vertical component of motion of wheel flange 11 , therefore, results in rotation of contact elements 5 and 6 about arms 3 and 4 , respectively. In FIG. 3, collars 10 prevent contact element 5 from falling off of arm 3 . As will be apparent, contact elements 5 and 6 may be constrained from falling off their respective supporting arms by any other suitable means.
According to certain inventive principles depicted in FIG. 1, if wheel 1 , approaches from left to right, as wheel flange 11 encounters contact element 5 , wheel flange 11 pushes aside contact element 5 thereby rotating the pivoting member in a counter-clockwise direction with reference to FIG. 1 . Arms 3 and 4 of pivoting member 27 are long enough so that wheel flange 11 can touch only one of contact elements 5 and 6 at any particular time. As wheel flange 11 leaves contact with first contact element 5 and encounters second contact element 6 , pivoting member 27 is rotated back to its original position as wheel flange 11 pushes aside, in a direction away from rail 2 , second contact element 6 . If the next train approaches from right to left, then the first wheel to encounter the energy extractor will reset pivoting member 27 and each subsequent wheel will cause pivoting member 27 to rotate in both directions. No special switches are required to prepare the energy extractor for a train coming from either direction.
The shape of contact elements 5 and 6 may be selected so that wheel flange 11 will push a respective contact element and arm of pivoting member 27 aside, in a direction away from rail 2 , rather than in any other direction. Contact elements 5 and 6 are preferably of circular cross section perpendicular to bearing 9 and the longitudinal axis through the end of arm 3 . FIG. 6 shows contact element 20 in contact with gage face 21 of the railhead. Contact element 20 is a figure of rotation about centerline 22 . In FIG. 6, wheel flange 11 is shown approaching contact element 20 from the left toward the right. The distance 23 between collar 10 at the end of contact element 20 and gage face 21 of the rail is preferably greater than the thickness 24 of wheel flange 11 . Guide rails, the use of which is well known in the art, may also be used to assure that wheel flange 11 is in proper alignment with gage face 21 and contact element 20 .
The shape of the surface of the contact elements may be varied but, in general, the radius of a contact element preferably starts small at the ends and grows larger toward the center of the contact element. For example, as shown in FIG. 7, the shape may be oval, 24 , linear (conical) from end to center, 25 , or s-shaped from end to center, 26 , or may be other shapes with similar characteristics such that the wheel flange can push the pivoting member aside in a direction away from the rail. Each shape is shown in FIG. 7 as a figure of rotation about a centerline 22 .
Another aspect of the invention is shown in FIG. 4 . Wheel 1 rides on rail head 2 . Rail web 12 and rail base 13 are also shown. In FIG. 4, pivoting member 27 is mounted such that arms 3 and 4 rotate in a vertical plane. Contact elements 5 and 6 and arms 3 and 4 are pushed down rather than aside, thus requiring less lateral space for the energy extraction device. The same two-directional pivoting action occurs as was previously described above. In this manner, a useful form of energy may be extracted from the train. An energy extractor configured as shown in FIG. 4 results in a vertical reaction force being exerted on wheel 1 . For safety, this vertical reaction force should be maintained low enough so that derailment potential is minimal. The vertical reaction force on flange 11 results in a reduction of the vertical force at the wheel tread. A commonly used indicator of derailment potential is the ratio of the lateral force on the wheel to the vertical force on the wheel at the wheel—rail interface. This ratio is commonly called the L/V ratio. An increase in L/V ratio of no more than 0.1 for the lightest car in a train is preferably considered a safe limit on the increase of L/V.
For example, if an empty freight car weighs 50,000 lb., then one wheel will exert a vertical force of 6,250 lb. because there usually are eight wheels on a freight car. If V 1 =vertical force at the wheel tread when the wheel is not in contact with the energy extractor and V 2 =vertical force at the wheel tread when in contact with the energy extractor, and L is the lateral force at the tread, then (L/V 2 )/(L/V 1 )=1.1 may be considered the limit of the ratio. This equation reduces to V 2 =0.9 V 1 . The reduction in vertical force at the tread is then V 1 -V 2 =0.1 V 1 or 625 lb. The value of 625 lb. may be considered to be the upper limit on the value of the vertical reaction force that the energy extractor may safely exert against the wheel flange. This method of calculating the limit on the vertical reaction force also can be used if a railroad prefers a different limit on the allowable increase of the L/V ratio.
One means for converting the pivoting motion into electrical energy may be understood with reference to FIG. 5 . In FIG. 5, the pivoting member, with its associated arms 3 and 4 , contact elements 5 and 6 , and shaft 7 , is coupled to a conversion device 8 that converts the pivoting motion to useful energy through a unidirectional coupling, such as a ratchet. Conversion device 8 may include a hydraulic pump. The hydraulic pump may drive a combined hydraulic motor/electrical dynamo 14 by pumping hydraulic fluid to the hydraulic motor and receiving the flow from the outlet port of the motor by means of a closed hydraulic loop 15 . The electrical output of the dynamo may be connected by a pair of wires 16 to a power conditioning circuit 17 .
Power conditioning circuit 17 preferably provides smoothened and stable power to an electrical load (the end use of the extracted energy) that may be coupled to output lines 19 . Power conditioning circuits are well known. They generally consist of such components as rectifiers, energy storage elements such as capacitors, current smoothing elements such as inductors, and voltage regulating circuits. In general, the function of the power conditioning circuit is to accept the pulsatile electrical energy from the passage of each wheel and provide as an output the average of the individual energy pulses.
Associated with power conditioning circuit 17 is storage battery 18 . Storage battery 18 may also function to help smooth and stabilize the output voltage of the power conditioner and to provide energy when no trains are passing through the energy extractor system. Whenever more energy is extracted from the train than is needed by the electrical load, the excess energy may be stored in storage battery 18 .
Various modifications may occur to others upon reading and understanding the foregoing detailed description. For example, energy extraction could also be accomplished by contacting the wheel tread on the field side (outside of the track) rather than by the flange. Under these circumstances, the contact elements could be positioned above the head of the rail. Because the wheel tread is wider than the rail head, the wheel will project beyond the railhead and can be used to deflect the contact elements in either a vertical, horizontal, or other desirable plane. The invention includes all modifications that may occur to others to the extent that they come within the scope of the appended claims or their equivalents. | A system for extracting energy from the passing wheels of a railcar, converting the energy to into rotation of a shaft in first and second directions, converting the rotation of the shaft into electrical energy, and storing any excess generated electricity. A pivoting member includes a shaft, first and second arms extending from the shaft, and contact elements at the ends of the arms. The vertical reaction force imparted to the wheels of a passing railcar may be minimized by, among other techniques, orienting the pivoting member so that the contact elements move in a horizontal plane and by coupling the contact elements to the ends of the pivoting member arms via respective journal bearings. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a continuation of U.S. patent application Ser. No. 13/228,420, filed Sep. 8, 2012, which claims priority to each of U.S. Provisional Patent Application No. 61/381,040, filed Sep. 8, 2010, and U.S. Provisional Patent Application No. 61/391,461, filed Oct. 8, 2010, and U.S. Provisional Patent Application No. 61/425,024, filed Dec. 20, 2010, and U.S. Provisional Patent Application No. 61/437,515, filed Jan. 28, 2011. Each of the above-identified patent applications is incorporated herein by reference in its entirety.
This patent application is also related to PCT Patent Application No. PCT/US2011/050876, entitled IMPROVED 2XXX ALUMINUM ALLOYS, AND METHODS FOR PRODUCING THE SAME, filed Sep. 8, 2011, and PCT Patent Application No. PCT/US2011/050868, entitled IMPROVED 7XXX ALUMINUM ALLOYS, AND METHODS FOR PRODUCING THE SAME, filed Sep. 8, 2011, and PCT Patent Application No. PCT/US2011/050884, entitled IMPROVED ALUMINUM LITHIUM ALLOYS, AND METHODS FOR PRODUCING THE SAME, filed Sep. 8, 2011.
BACKGROUND
Aluminum alloys are useful in a variety of applications. However, improving one property of an aluminum alloy without degrading another property is elusive. For example, it is difficult to increase the strength of an alloy without decreasing the toughness of an alloy. Other properties of interest for aluminum alloys include corrosion resistance and fatigue crack growth rate resistance, to name two.
SUMMARY OF THE DISCLOSURE
Broadly, the present patent application relates to improved wrought, heat treatable aluminum alloys, and methods for producing the same. Specifically, the present patent application relates to improved wrought, 6xxx aluminum alloy products, and methods for producing the same. Generally, the 6xxx aluminum alloy products achieve an improved combination of properties due to, for example, the post-solutionizing cold work and post-cold-working thermal treatments, as described in further detail below.
6xxx aluminum alloys are aluminum alloys containing silicon and magnesium, where at least one of the silicon and the magnesium is the predominate alloying element of the aluminum alloy body other than aluminum. For purposes of the present application, 6xxx aluminum alloys are aluminum alloys having 0.1-2.0 wt. % silicon and 0.1-3.0 wt. % magnesium, where at least one of the silicon and the magnesium is the predominate alloying element of the aluminum alloy body other than aluminum.
One conventional process for producing 6xxx aluminum alloy products in rolled form is illustrated in FIG. 1 . In the conventional process, a 6xxx aluminum alloy body is cast ( 10 ), after which it is homogenized ( 11 ) and then hot rolled to an intermediate gauge ( 12 ). Next, the 6xxx aluminum alloy body is cold rolled ( 13 ) to final gauge, after which it is solution heat treated and quenched ( 14 ). “Solution heat treating and quenching” and the like, generally referred to herein as “solutionizing”, means heating an aluminum alloy body to a suitable temperature, generally above the solvus temperature, holding at that temperature long enough to allow soluble elements to enter into solid solution, and cooling rapidly enough to hold the elements in solid solution. The solid solution formed at high temperature may be retained in a supersaturated state by cooling with sufficient rapidity to restrict the precipitation of the solute atoms as coarse, incoherent particles. After solutionizing ( 14 ), the 6xxx aluminum alloy body may be optionally stretched a small amount (e.g., 1-5%) for flatness ( 15 ), thermally treated ( 16 ) and optionally subjected to final treatment practices ( 17 ). FIG. 1 is consistent with a process path for producing aluminum alloys in a T6 temper (the T6 temper is defined later in this patent application).
One embodiment of a new process for producing new 6xxx aluminum alloy products is illustrated in FIG. 2 . In this new process, a 6xxx aluminum alloy body is prepared for post-solutionizing cold work ( 100 ), after which it is cold worked ( 200 ), and then thermally treated ( 300 ). The new process may also include optional final treatment(s) ( 400 ), as described in further detail below. “Post-solutionizing cold work” and the like means cold working of an aluminum alloy body after solutionizing. The amount of post-solutionizing cold work applied to the 6xxx aluminum alloy body is generally at least 25%, such as more than 50% cold work. By first solutionizing, and then cold working by at least 25%, and then appropriately thermally treating the 6xxx aluminum alloy body, the 6xxx aluminum alloy body may realize improved properties, as described in further detail below. For example, strength increases of 5-25%, or more, may be realized relative to conventional aluminum alloy products in the T6 temper, and in a fraction of the time required to process those conventional aluminum alloy products to the T6 temper (e.g., 10%-90% faster than T6 temper processed alloys). The new 6xxx aluminum alloy body may also realize good ductility, generally realizing an elongation of more than 4%, such as elongations of 6-15%, or higher. Other properties may also be maintained and/or improved (e.g., fracture toughness, corrosion resistance, fatigue crack growth resistance, appearance).
A. Preparing for Post-Solutionizing Cold Work
As illustrated in FIG. 2 , the new process includes preparing an aluminum alloy body for post-solutionizing cold work ( 100 ). The aluminum alloy body may be prepared for post-solutionizing cold work ( 100 ) in a variety of manners, including the use of conventional semi-continuous casting methods (e.g., direct chill casting of ingot) and continuous casting methods (e.g., twin-roll casting). As illustrated in FIG. 3 , the preparing step ( 100 ) generally comprises placing the aluminum alloy body in a form suitable for the cold working ( 120 ) and solutionizing the aluminum alloy body ( 140 ). The placing step ( 120 ) and solutionizing step ( 140 ) may occur sequentially or concomitant to one another. Some non-limiting examples of various preparing steps ( 100 ) are illustrated in FIGS. 4-8 , which are described in further detail below. Other methods of preparing an aluminum alloy body for post-solutionizing cold work ( 100 ) are known to those skilled in the art, and these other methods are also within the scope of the preparing step ( 100 ) present invention, even though not explicitly described herein.
In one approach, the preparing step ( 100 ) comprises a semi-continuous casting method. In one embodiment, and with reference now to FIG. 4 , the placing step ( 120 ) includes casting the aluminum alloy body ( 122 ) (e.g., in the form of an ingot or billet), homogenizing the aluminum alloy body ( 124 ), hot working the aluminum alloy body ( 126 ), and optionally cold working the aluminum alloy body ( 128 ). After the placing step ( 120 ), the solutionizing step ( 140 ) is completed. Similar steps may be completed using continuous casting operations, although the aluminum alloy body would not be in the form of an ingot/billet after casting ( 120 ).
In another embodiment, and with reference now to FIG. 5 , a preparing step ( 100 ) includes casting the aluminum alloy body ( 122 ), homogenizing the aluminum alloy body ( 124 ) and hot working the aluminum alloy body ( 126 ). In this embodiment, the hot working step ( 126 ) may be completed to place soluble elements in solid solution, after which the aluminum alloy body is quenched (not illustrated), thereby resulting in the solutionizing step ( 140 ). This is one example of the placing step ( 120 ) and solutionizing step ( 140 ) being completed concomitant to one another. This embodiment may be applicable to press-quenched products (e.g., extrusions) and hot rolled products that are quenched after hot rolling, among others.
In another approach, the preparing step ( 100 ) comprises a continuous casting method, such as belt casting, rod casting, twin roll casting, twin belt casting (e.g., Hazelett casting), drag casting, and block casting, among others. One embodiment of a preparing step ( 100 ) employing a continuous casting methodology is illustrated in FIG. 6 . In this embodiment, the aluminum alloy body is cast and solutionized at about the same time ( 142 ), i.e., concomitant to one another. The casting places the aluminum alloy body in a form sufficient to cold work. When the solidification rate during casting is sufficiently rapid, the aluminum alloy body is also solutionized. In this embodiment, the casting/solutionizing step ( 142 ) may include quenching of the aluminum alloy body after casting (not illustrated). This embodiment may be applicable to twin-roll casting processes, among other casting processes. Some twin-roll casting processes capable of completing the process of FIG. 6 are described in U.S. Pat. No. 7,182,825 and U.S. Pat. No. 6,672,368.
In another embodiment, and with reference now to FIG. 7 , a preparing step ( 100 ) includes casting the aluminum alloy body ( 122 ) and, after the casting step ( 122 ), then solutionizing the aluminum alloy body ( 140 ). In this embodiment, the placing step ( 120 ) comprises the casting ( 122 ). This embodiment is applicable to twin-roll casting processes, among other casting processes.
In another embodiment, and with reference now to FIG. 8 , a preparing step ( 100 ) includes casting the aluminum alloy body ( 122 ), hot working the aluminum alloy body ( 126 ), and optionally cold working the aluminum alloy body ( 128 ). In this embodiment, the placing step ( 120 ) includes the casting ( 122 ), the hot working ( 126 ), and optional cold working ( 128 ) steps. After the placing step ( 120 ), the solutionizing step ( 140 ) is completed. This embodiment may be applicable to continuous casting processes.
Many of the steps illustrated in FIGS. 2-8 can be completed in batch or continuous modes. In one example, the cold working ( 200 ) and thermal treatment step ( 300 ) are completed continuously. In this example, a solutionized aluminum alloy body may enter the cold working operation at ambient conditions. Given the relatively short thermal treatment times achievable with the new processes described herein, the cold worked aluminum alloy body could be immediately thermally treated ( 300 ) after cold working (e.g., in-line). Conceivably, such thermal treatments could occur proximal the outlet of the cold working apparatus, or in a separate heating apparatus connected to the cold working apparatus. This could increase productivity.
As described above, the preparing step ( 100 ) generally comprises solutionizing of the aluminum alloy body. As noted above, “solutionizing” includes quenching (not illustrated) of the aluminum alloy body, which quenching may be accomplished via a liquid (e.g., via an aqueous or organic solution), a gas (e.g., air cooling), or even a solid (e.g., cooled solids on one or more sides of the aluminum alloy body). In one embodiment, the quenching step includes contacting the aluminum alloy body with a liquid or a gas. In some of these embodiments, the quenching occurs in the absence of hot working and/or cold working of the aluminum alloy body. For example, the quenching may occur by immersion, spraying and/or jet drying, among other techniques, and in the absence of deformation of the aluminum alloy body.
Those skilled in the art recognize that other preparing steps ( 100 ) can be used to prepare an aluminum alloy body for post-solutionizing cold work (e.g., powder metallurgy methods), and that such other preparing steps fall within the scope of the preparing step ( 100 ) so long as they place the aluminum alloy body in a form suitable for cold working ( 120 ) and solutionize the aluminum alloy body ( 140 ), and irrespective of whether these placing ( 120 ) and solutionizing ( 140 ) steps occur concomitantly (e.g., contemporaneously) or sequentially, and irrespective of whether the placing step ( 120 ) occurs before the solutionizing step ( 140 ), or vice-versa.
B. Cold Working
Referring back to FIG. 2 , and as noted above, the new process includes cold working ( 200 ) the aluminum alloy body a high amount. “Cold working” and the like means deforming an aluminum alloy body in at least one direction and at temperatures below hot working temperatures (e.g., not greater than 400° F.). Cold working may be imparted by one or more of rolling, extruding, forging, drawing, ironing, spinning, flow-forming, and combinations thereof, among other types of cold working methods. These cold working methods may at least partially assist in producing various 6xxx aluminum alloy products (see, Product Applications, below).
i. Cold Rolling
In one embodiment, and with reference now to FIG. 9 , the cold working step ( 200 ) comprises cold rolling ( 220 ) (and in some instances consists of cold rolling ( 220 ), with optional stretching or straightening for flatness ( 240 )). In this embodiment, and as described above, the cold rolling step ( 220 ) is completed after the solutionizing step ( 140 ). Cold rolling ( 220 ) is a fabrication technique where an aluminum alloy body is decreased in thickness, generally via pressure applied by rollers, and where the aluminum alloy body enters the rolling equipment at a temperature below that used for hot rolling ( 124 ) (e.g., not greater than 400° F.). In one embodiment, the aluminum alloy body enters the rolling equipment at ambient conditions, i.e., the cold rolling step ( 220 ) is initiated at ambient conditions in this embodiment.
The cold rolling step ( 220 ) reduces the thickness of a 6xxx aluminum alloy body by at least 25%. The cold rolling step ( 220 ) may be completed in one or more rolling passes. In one embodiment, the cold rolling step ( 220 ) rolls the aluminum alloy body from an intermediate gauge to a final gauge. The cold rolling step ( 220 ) may produce a sheet, plate, or foil product. A foil product is a rolled product having a thickness of less than 0.006 inch. A sheet product is a rolled product having a thickness of from 0.006 inch to 0.249 inch. A plate product is a rolled product having a thickness of 0.250 inch or greater.
“Cold rolled XX %” and the like means XX CR %, where XX CR % is the amount of thickness reduction achieved when the aluminum alloy body is reduced from a first thickness of T 1 to a second thickness of T 2 by cold rolling, where T 1 is the thickness prior to the cold rolling step ( 200 ) (e.g., after solutionizing) and T 2 is the thickness after the cold rolling step ( 200 ). In other words, XX CR % is equal to:
XX CR %=(1 −T 2 /T 1 )*100%
For example, when an aluminum alloy body is cold rolled from a first thickness (T 1 ) of 15.0 mm to a second thickness of 3.0 mm (T 2 ), XX CR % is 80%. Phrases such as “cold rolling 80%” and “cold rolled 80%” are equivalent to the expression XX CR %=80%.
In one embodiment, the aluminum alloy body is cold rolled ( 220 ) at least 30% (XX CR %≧30%), i.e., is reduced in thickness by at least 30%. In other embodiments, the aluminum alloy body is cold rolled ( 220 ) at least 35% (XX CR %≧35%), or at least 40% (XX CR %≧40%), or at least 45% (XX CR %≧45%), or at least 50% (XX CR %≧50%), or at least 55% (XX CR %≧55%), or at least 60% (XX CR %≧60%), or at least 65% (XX CR %≧65%), or at least 70% (XX CR %≧70%), or at least 75% (XX CR %≧75%), or at least 80% (XX CR %≧80%), or at least 85% (XX CR %≧85%), or at least 90% (XX CR %≧90%), or more.
In some embodiments, it may be impractical or non-ideal to cold roll ( 220 ) by more than 90% (XX CR %≦90%). In these embodiments, the aluminum alloy body may be cold rolled ( 220 ) by not greater than 87% (XX CR %≦87%), such as cold rolled ( 220 ) not more than 85% (XX CR %≦85%), or not greater than 83% (XX CR %≦83%), or not greater than 80% (XX CR %≦80%).
In one embodiment, the aluminum alloy body is cold rolled in the range of from more than 50% to not greater than 85% (50%<XX CR %≦85%). This amount of cold rolling may produce an aluminum alloy body having preferred properties. In a related embodiment, the aluminum alloy body may be cold rolled in the range of from 55% to 85% (55%≦XX CR %≦85%). In yet another embodiment, the aluminum alloy body may be cold rolled in the range of from 60% to 85% (60%≦XX CR %≦85%). In yet another embodiment, the aluminum alloy body may be cold rolled in the range of from 65% to 85% (65%≦XX CR %≦85%). In yet another embodiment, the aluminum alloy body may be cold rolled in the range of from 70% to 80% (70%≦XX CR %≦80%).
Still referring to FIG. 9 , in this embodiment of the process, optional pre-cold rolling ( 128 ) may be completed. This pre-cold rolling step ( 128 ) may further reduce the intermediate gauge of the aluminum alloy body (due to the hot rolling 126 ) to a secondary intermediate gauge before solutionizing ( 140 ). As an example, the optional cold rolling step ( 128 ) may be used to produce a secondary intermediate gauge that facilitates production of a final cold rolled gauge during the cold rolling step ( 220 ).
ii. Other Cold Working Techniques
Aside from cold rolling, and referring back to FIG. 2 , cold working may be imparted by one or more of extruding, forging, drawing, ironing, spinning, flow-forming, and combinations thereof, among other types of cold working methods, alone or in combination with cold rolling. As noted above, the aluminum alloy body is generally cold worked by at least 25% after solutionizing. In one embodiment, the cold working works the aluminum alloy body to its substantially final form (i.e., no additional hot working and/or cold working steps are required to achieve the final product form).
“Cold working by XX %” (“XX CW %”) and the like means cold working the aluminum alloy body an amount sufficient to achieve an equivalent plastic strain (described below) that is at least as large as the amount of equivalent plastic strain that would have been achieved if the aluminum alloy body had been cold rolled XX % (XX CR %). For example, the phrase “cold working 68.2%” means cold working the aluminum alloy body an amount sufficient to achieve an equivalent plastic strain that is at least as large as the amount of equivalent plastic strain that would have been achieved if the aluminum alloy body had been cold rolled 68.2%. Since XX CW % and XX CR % both refer to the amount of equivalent plastic strain induced in an aluminum alloy body as if the aluminum alloy body was cold rolled XX % (or actually is cold rolled XX % in the case of actual cold rolling), those terms are used interchangeably herein to refer to this amount of equivalent plastic strain.
Equivalent plastic strain is related to true strain. For example, cold rolling XX %, i.e., XX CR %, may be represented by true strain values, where true strain (ε true ) is given by the formula:
ε true =−ln(1−%CR/100) (1)
Where % CR is XX CR %, true strain values may be converted to equivalent plastic strain values. In the case where biaxial strain is achieved during cold rolling, the estimated equivalent plastic strain will be 1.155 times greater than the true strain value (2 divided by the √3 equals 1.155). Biaxial strain is representative of the type of plastic strain imparted during cold rolling operations. A table correlating cold rolling XX % to true strain vales and equivalent plastic strain values is provided in Table 1, below.
TABLE 1 Cold Rolling Thickness Reduction Cold Rolling Estimated Equivalent (XX CR %) True Strain Value Plastic Strain 25% 0.2877 0.3322 30% 0.3567 0.4119 35% 0.4308 0.4974 40% 0.5108 0.5899 45% 0.5978 0.6903 50% 0.6931 0.8004 55% 0.7985 0.9220 60% 0.9163 1.0583 65% 1.0498 1.2120 70% 1.2040 1.3902 75% 1.3863 1.6008 80% 1.6094 1.8584 85% 1.8971 2.1906 90% 2.3026 2.6588
These equivalent plastic strain values assume:
A. no elastic strain;
B. the true plastic strains preserve volume constancy; and
C. the loading is proportional.
For proportional loading, the above and/or other principles may be used to determine an equivalent plastic strain for various cold working operations. For non-proportional loading, the equivalent plastic strain due to cold working may be determined using the formula:
d ɛ p = 2 3 [ ( d ɛ 1 p - d ɛ 2 p ) 2 + ( d ɛ 1 p - d ɛ 3 p ) 2 + ( d ɛ 3 p - d ɛ 2 p ) 2 ] ( 2 )
where de p is the equivalent plastic strain increment and dε i p (i=1, 2, 3) represent the increment in the principal plastic strain components. See, Plasticity, A. Mendelson, Krieger Pub Co; 2nd edition (August 1983), ISBN-10: 0898745829.
Those skilled in the art appreciate that the cold working step ( 200 ) may include deforming the aluminum alloy body in a first manner (e.g., compressing) and then deforming the aluminum alloy body in a second manner (e.g., stretching), and that the equivalent plastic strain described herein refers to the accumulated strain due to all deformation operations completed as a part of the cold working step ( 200 ). Furthermore, those skilled in the art appreciate that the cold working step ( 200 ) will result in inducement of strain, but not necessarily a change in the final dimensions of the aluminum alloy body. For example, an aluminum alloy body may be cold deformed in a first manner (e.g., compressing) after which it is cold deformed in a second manner (e.g., stretching), the accumulated results of which provide an aluminum alloy body having about the same final dimensions as the aluminum alloy body before the cold working step ( 200 ), but with an increased strain due to the various cold deformation operations of the cold working step ( 200 ). Similarly, high accumulated strains can be achieved through sequential bending and reverse bending operations.
The accumulated equivalent plastic strain, and thus XX CR %, may be determined for any given cold working operation, or series of cold working operations, by computing the equivalent plastic strain imparted by those cold working operations and then determining its corresponding XX CR % value, via the methodologies shown above, and other methodologies known to those skilled in the art. For example, an aluminum alloy body may be cold drawn, and those skilled in the art may compute the amount of equivalent plastic strain imparted to the aluminum alloy body based on the operation parameters of the cold drawing. If the cold drawing induced, for example, an equivalent plastic strain of about 0.9552, then this cold drawing operation would be equivalent to an XX CR % of about 56.3% (0.9552/1.155 equals a true strain value of 0.8270 (ε true ); in turn, the corresponding XX CR % is 56.3% using equation (1), above). Thus, in this example, XX CR %=56.3, even though the cold working was cold drawing and not cold rolling. Furthermore, since “cold working by XX %” (“XX CW %”) is defined (above) as cold working the aluminum alloy body an amount sufficient to achieve an equivalent plastic strain that is at least as large as the amount of equivalent plastic strain that would be achieved if the aluminum alloy body had been reduced in thickness XX % solely by cold rolling (“XX CR %”), then XX CW is also 56.3%. Similar calculations may be completed when a series of cold working operations are employed, and in those situations the accumulated equivalent plastic strain due to the series of cold working operations would be used to determine the XX CR %.
As described earlier, the cold working ( 200 ) is accomplished such that the aluminum alloy body realizes an XX CW % or XX CR %≧25%, i.e., ≧0.3322 equivalent plastic strain. “Cold working XX %” and the like means XX CW %. Phrases such as “cold working 80%” and “cold worked 80%” are equivalent to the expression XX CW %=80. For tailored non-uniform cold working operations, the amount of equivalent plastic strain, and thus the amount of XX CW or XX CR , is determined on the portion(s) of the aluminum alloy body receiving the cold work ( 200 ).
In one embodiment, the aluminum alloy body is cold worked ( 200 ) sufficiently to achieve, and realizes, an equivalent plastic strain (“EPS”) of at least 0.4119 (i.e., XX CW %≧30%). In other embodiments, the aluminum alloy body is cold worked ( 200 ) sufficiently to achieve, and realizes, an EPS of at least 0.4974 (XX CW %≧35%), or at least 0.5899 (XX CW %≧40%), or at least 0.6903 (XX CW %≧45%), or at least 0.8004, (XX CW %≧50%), or at least 0.9220 (XX CW %≧55%), or at least 1.0583 (XX CW %≧60%), or at least 1.2120 (XX CW %≧65%), or at least 1.3902 (XX CW %≧70%), or at least 1.6008 (XX CW %≧75%), or at least 1.8584 (XX CW %≧80%), or at least 2.1906 (XX CW %≧85%), or at least 2.6588 (XX CW %≧90%), or more.
In some embodiments, it may be impractical or non-ideal to cold work ( 200 ) by more than 90% (XX CW %≦90% and EPS≦2.6588). In these embodiments, the aluminum alloy body may be cold worked ( 200 ) not more than 87% (XX CW %≦87% and EPS≦2.3564), such as cold worked ( 200 ) not more than 85% (XX CW %≦85% and EPS≦2.1906), or not more than 83% (XX CW %≦83% and EPS≦2.0466), or not more than 80% (XX CW %≦80% and EPS≦1.8584).
In one embodiment, the aluminum alloy body is cold worked ( 200 ) in the range of from more than 50% to not greater than 85% (50%≦XX CW %≦85%). This amount of cold working ( 200 ) may produce an aluminum alloy body having preferred properties. In a related embodiment, the aluminum alloy body is cold worked ( 200 ) in the range of from 55% to 85% (55%≦XX CW %≦85%). In yet another embodiment, the aluminum alloy body is cold worked ( 200 ) in the range of from 60% to 85% (60%≦XX CW %≦85%). In yet another embodiment, the aluminum alloy body is cold worked ( 200 ) in the range of from 65% to 85% (65%≦XX CW %≦85%). In yet another embodiment, the aluminum alloy body is cold worked ( 200 ) in the range of from 70% to 80% (70%≦XX CW %≦80%).
iii. Gradients
The cold working step ( 200 ) may be tailored to deform the aluminum alloy body in a generally uniform manner, such as via rolling, described above, or conventional extruding processes, among others. In other embodiments, the cold working step may be tailored to deform the aluminum alloy body in a generally non-uniform manner. Thus, in some embodiments, the process may produce an aluminum alloy body having tailored cold working gradients, i.e., a first portion of the aluminum alloy body receives a first tailored amount of cold work and a second portion of the aluminum alloy body receives a second tailored amount of cold work, where the first tailored amount is different than the second tailored amount. Examples of cold working operations ( 200 ) that may be completed, alone or in combination, to achieve tailored non-uniform cold work include forging, burnishing, shot peening, flow forming, and spin-forming, among others. Such cold working operations may also be utilized in combination with generally uniform cold working operations, such as cold rolling and/or extruding, among others. As mentioned above, for tailored non-uniform cold working operations, the amount of equivalent plastic strain is determined on the portion(s) of the aluminum alloy body receiving the cold work ( 200 ).
iv. Cold Working Temperature
The cold working step ( 200 ) may be initiated at temperatures below hot working temperatures (e.g., not greater than 400° F.). In one approach, the cold working step ( 200 ) is initiated when the aluminum alloy body reaches a sufficiently low temperature after solutionizing ( 140 ). In one embodiment, the cold working step ( 200 ) may be initiated when the temperature of the aluminum alloy body is not greater than 250° F. In other embodiments, the cold working step ( 200 ) may be initiated when the temperature of the aluminum alloy body is not greater than 200° F., or not greater than 175° F., or not greater than 150° F., or not greater than 125° F., or less. In one embodiment, a cold working step ( 200 ) may be initiated when the temperature of the aluminum alloy body is around ambient. In other embodiments, a cold working step ( 200 ) may be initiated at higher temperatures, such as when the temperature of the aluminum alloy body is in the range of from 250° F. to less than hot working temperatures (e.g., less than 400° F.).
In one embodiment, the cold working step ( 200 ) is initiated and/or completed in the absence of any purposeful/meaningful heating (e.g., purposeful heating that produces a material change in the microstructure and/or properties of the aluminum alloy body). Those skilled in the art appreciate that an aluminum alloy body may realize an increase in temperature due to the cold working step ( 200 ), but that such cold working steps ( 200 ) are still considered cold working ( 200 ) because the working operation began at temperatures below those considered to be hot working temperatures. When a plurality of cold working operations are used to complete the cold working step ( 200 ), each one of these operations may employ any of the above-described temperature(s), which may be the same as or different from the temperatures employed by a prior or later cold working operation.
As noted above, the cold working ( 200 ) is generally initiated when the aluminum alloy body reaches a sufficiently low temperature after solutionizing ( 140 ). Generally, no purposeful/meaningful thermal treatments are applied to the aluminum alloy body between the end of the solutionizing step ( 140 ) and the beginning of the cold working step ( 200 ), i.e., the process may be absent of thermal treatments between the completion of the solutionizing step ( 140 ) and the initiation of the cold working step ( 200 ). In some instances, the cold working step ( 200 ) is initiated soon after the end of the solutionizing step ( 140 ) (e.g., to facilitate cold working). In one embodiment, the cold working step ( 200 ) is initiated not more than 72 hours after the completion of the solutionizing step ( 140 ). In other embodiments, the cold working step ( 200 ) is initiated in not greater than 60 hours, or not greater than 48 hours, or not greater than 36 hours, or not greater than 24 hours, or not greater than 20 hours, or not greater than 16 hours, or not greater than 12 hours, or less, after the completion of the solutionizing step ( 140 ). In one embodiment, the cold working step ( 200 ) is initiated within a few minutes, or less, of completion of the solutionizing step ( 140 ) (e.g., for continuous casting processes). In another embodiment, the cold working step ( 200 ) is initiated concomitant to completion of the solutionizing step ( 140 ) (e.g., for continuous casting processes).
In other instances, it may be sufficient to begin the cold working ( 200 ) after a longer elapse of time relative to the completion of the solutionizing step ( 140 ). In these instances, the cold working step ( 200 ) may be completed one or more weeks or months after the completion of the solutionizing step ( 140 ).
C. Thermally Treating
Referring still to FIG. 2 , a thermally treating step ( 300 ) is completed after the cold working step ( 200 ). “Thermally treating” and the like means purposeful heating of an aluminum alloy body such that the aluminum alloy body reaches an elevated temperature. The thermal treatment step ( 300 ) may include heating the aluminum alloy body for a time and at a temperature sufficient to achieve a condition or property (e.g., a selected strength, a selected ductility, among others).
After solutionizing, most heat treatable alloys, such as 6xxx aluminum alloys, exhibit property changes at room temperature. This is called “natural aging” and may start immediately after solutionizing, or after an incubation period. The rate of property changes during natural aging varies from one alloy to another over a wide range, so that the approach to a stable condition may require only a few days or several years. Since natural aging occurs in the absence of purposeful heating, natural aging is not a thermal treatment step ( 300 ). However, natural aging may occur before and/or after the thermal treatment step ( 300 ). Natural aging may occur for a predetermined period of time prior to the thermal treatment step ( 300 ) (e.g., from a few minutes or hours to a few weeks, or more). Natural aging may occur between or after any of the solutionizing ( 140 ), the cold working ( 200 ) and the thermal treatment steps ( 300 ).
The thermally treating step ( 300 ) heats the aluminum alloy body to a temperature within a selected temperature range. For the purposes of the thermally treating step ( 300 ), this temperature refers to the average temperature of the aluminum alloy body during the thermally treating step ( 300 ). The thermally treating step ( 300 ) may include a plurality of treatment steps, such as treating at a first temperature for a first period of time, and treating at a second temperature for a second period of time. The first temperature may be higher or lower than the second temperature, and the first period of time may be shorter or longer than the second period of time.
The thermally treating step ( 300 ) is generally completed such that the aluminum alloy body achieves/maintains a predominately unrecrystallized microstructure, as defined below. As described in further detail below, a predominately unrecrystallized microstructure may achieve improved properties. In this regard, the thermally treating step ( 300 ) generally comprises heating the aluminum alloy body to an elevated temperature, but below the recrystallization temperature of the aluminum alloy body, i.e., the temperature at which the aluminum alloy body would not achieve a predominately unrecrystallized microstructure. For example, the thermally treating step ( 300 ) may comprise heating the 6xxx aluminum alloy body to a temperature in the range of from 150° F. to 425° F. (or higher), but below the recrystallization temperature of the aluminum alloy body.
The thermally treating step ( 300 ) may be completed in any suitable manner that maintains the aluminum alloy body at one or more selected temperature(s) for one or more selected period(s) of time (e.g., in order to achieve a desired/selected property or combination of properties). In one embodiment, the thermally treating step ( 300 ) is completed in an aging furnace, or the like. In another embodiment, the thermally treating step ( 300 ) is completed during a paint-bake cycle. Paint-bake cycles are used in the automotive and other industries to cure an applied paint by baking it for a short period of time (e.g., 5-30 minutes). Given the ability for the presently described processes to produce aluminum alloy bodies having high strength within a short period of time, as described below, paint-bake cycles, and the like, may be used to complete the thermally treating step ( 300 ), thereby obviating the need for separate thermal treatment and paint-bake steps. Similarly, in another embodiment, the thermally treating step ( 300 ) may be completed during a coating cure step, or the like.
D. Cold Working and Thermally-Treating Combination
The combination of the cold working step ( 200 ) and the thermally treating step ( 300 ) are capable of producing aluminum alloy bodies having improved properties. It is believed that the combination of the high deformation of the cold working step ( 200 ) in combination with the appropriate thermally treatment conditions ( 300 ) produce a unique microstructure (see, Microstructure, below) capable of achieving combinations of strength and ductility that have been heretofore unrealized. The cold working step ( 200 ) facilitates production of a severely deformed microstructure while the thermally treating step ( 300 ) facilitates precipitation hardening. When the cold working ( 200 ) is at least 25%, and preferably more than 50%, and when an appropriate thermal treatment step ( 300 ) is applied, improved properties may be realized.
In one approach, the cold working ( 200 ) and thermally treating ( 300 ) steps are accomplished such that the aluminum alloy body achieves an increase in strength (e.g., tensile yield strength (R 0.2 ) or ultimate tensile strength (R m )). The strength increase may be realized in one or more of the L, LT or ST directions.
In one embodiment, the cold working ( 200 ) and thermally treating ( 300 ) steps are accomplished such that the aluminum alloy body achieves an increase in strength as compared to a reference-version of the aluminum alloy body in the “as-cold worked condition”. In another embodiment, the cold working ( 200 ) and thermally treating ( 300 ) steps are accomplished such that the aluminum alloy body achieves an increase in strength as compared to a reference-version of the aluminum alloy body in the T6 temper. In another embodiment, the cold working ( 200 ) and thermally treating ( 300 ) steps are accomplished such that the aluminum alloy body achieves an increase a higher R-value as compared to a reference-version of the aluminum alloy body in the T4 temper. These and other properties are described in the Properties section, below.
The “as-cold worked condition” (ACWC) means: (i) the aluminum alloy body is prepared for post-solutionizing cold work, (ii) the aluminum alloy body is cold worked, (iii) not greater than 4 hours elapse between the completion of the solutionizing step ( 140 ) and the initiation of the cold working step ( 200 ), and (iv) the aluminum alloy body is not thermally treated. The mechanical properties of the aluminum alloy body in the as-cold worked condition should be measured within 4-14 days of completion of the cold working step ( 200 ). To produce a reference-version of the aluminum alloy body in the “as-cold worked condition”, one would generally prepare an aluminum alloy body for post-solutionizing cold work ( 100 ), and then cold work the aluminum alloy body ( 200 ) according to the practices described herein, after which a portion of the aluminum alloy body is removed to determine its properties in the as-cold worked condition per the requirements described above. Another portion of the aluminum alloy body would be processed in accordance with the new processes described herein, after which its properties would be measured, thus facilitating a comparison between the properties of the reference-version of the aluminum alloy body in the as-cold worked condition and the properties of an aluminum alloy body processed in accordance with the new processes described herein (e.g., to compare strength, ductility, fracture toughness). Since the reference-version of the aluminum alloy body is produced from a portion of the aluminum alloy body, it would have the same composition as the aluminum alloy body.
The “T6 temper” and the like means an aluminum alloy body that has been solutionized and then thermally treated to a maximum strength condition (within 1 ksi of peak strength); applies to bodies that are not cold worked after solutionizing, or in which the effect of cold work in flattening or straightening may not be recognized in mechanical property limits. As described in further detail below, aluminum alloy bodies produced in accordance with the new processes described herein may achieve superior as compared to the aluminum alloy body in a T6 temper. To produce a reference-version of the aluminum alloy body in a T6 temper, one would prepare an aluminum alloy body for post-solutionizing cold work ( 100 ), after which a portion of the aluminum alloy body would be processed to a T6 temper (i.e., a referenced aluminum alloy body in the T6 temper). Another portion of the aluminum alloy body would be processed in accordance with the new processes described herein, thus facilitating a comparison between the properties of the reference-version of the aluminum alloy body in the T6 temper and the properties of an aluminum alloy body processed in accordance with the new processes described herein (e.g., to compare strength, ductility, fracture toughness). Since the reference-version of the aluminum alloy body is produced from a portion of the aluminum alloy body, it would have the same composition as the aluminum alloy body. The reference-version of the aluminum alloy body may require work (hot and/or cold) before the solutionizing step ( 140 ) to place the reference-version of the aluminum alloy body in a comparable product form to the new aluminum alloy body (e.g., to achieve the same final thickness for rolled products).
The “T4 temper” and the like means an aluminum alloy body that has been solutionized and then naturally aged to a substantially stable condition; applies to bodies that are not cold worked after solutionizing, or in which the effect of cold work in flattening or straightening may not be recognized in mechanical property limits. To produce a reference-version of the aluminum alloy body in a T4 temper, one would prepare an aluminum alloy body for post-solutionizing cold work ( 100 ), after which a portion of the aluminum alloy body would be allowed to naturally age to a T4 temper (i.e., a referenced aluminum alloy body in the T4 temper). Another portion of the aluminum alloy body would be processed in accordance with the new processes described herein, thus facilitating a comparison between the properties of the reference-version of the aluminum alloy body in the T4 temper and the properties of an aluminum alloy body processed in accordance with the new processes described herein (e.g., to compare strength, ductility, fracture toughness). Since the reference-version of the aluminum alloy body is produced from a portion of the aluminum alloy body, it would have the same composition as the aluminum alloy body. The reference-version of the aluminum alloy body may require work (hot and/or cold) before the solutionizing step ( 140 ) to place the reference-version of the aluminum alloy body in a comparable product form to the new aluminum alloy body (e.g., to achieve the same thickness for rolled products).
E. Microstructure
i. Recrystallization
The cold working ( 200 ) and thermally treating ( 300 ) steps may be accomplished such that the aluminum alloy body achieves/maintains a predominately unrecrystallized microstructure. A predominately unrecrystallized microstructure means that the aluminum alloy body contains less than 50% of first type grains (by volume fraction), as defined below.
An aluminum alloy body has a crystalline microstructure. A “crystalline microstructure” is the structure of a polycrystalline material. A crystalline microstructure has crystals, referred to herein as grains. “Grains” are crystals of a polycrystalline material.
“First type grains” means those grains of a crystalline microstructure that meet the “first grain criteria”, defined below, and as measured using the OIM (Orientation Imaging Microscopy) sampling procedure, described below. Due to the unique microstructure of the aluminum alloy body, the present application is not using the traditional terms “recrystallized grains” or “unrecrystallized grains”, which can be ambiguous and the subject of debate, in certain circumstances. Instead, the terms “first type grains” and “second type grains” are being used where the amount of these types of grains is accurately and precisely determined by the use of computerized methods detailed in the OIM sampling procedure. Thus, the term “first type grains” includes any grains that meet the first grain criteria, and irrespective of whether those skilled in the art would consider such grains to be unrecrystallized or recrystallized.
The OIM analysis is to be completed from the T/4 (quarter-plane) location to surface of the L-ST plane. The size of the sample to be analyzed will generally vary by gauge. Prior to measurement, the OIM samples are prepared by standard metallographic sample preparation methods. For example, the OIM samples are generally polished with Buehler Si—C paper by hand for 3 minutes, followed by polishing by hand with a Buehler diamond liquid polish having an average particle size of about 3 microns. The samples are anodized in an aqueous fluoric-boric solution for 30-45 seconds. The samples are then stripped using an aqueous phosphoric acid solution containing chromium trioxide, and then rinsed and dried.
The “OIM sample procedure” is as follows:
The software used is TexSEM Lab OIM Data Collection Software version 5.31 (EDAX Inc., New Jersey, U.S.A.), which is connected via FIREWIRE (Apple, Inc., California, U.S.A.) to a DigiView 1612 CCD camera (TSL/EDAX, Utah, U.S.A.). The SEM is a JEOL JSM6510 (JEOL Ltd. Tokyo, Japan). OIM run conditions are 70° tilt with a 18 mm working distance and an accelerating voltage of 20 kV with dynamic focusing and spot size of 1 times 10 −7 amp. The mode of collection is a square grid. A selection is made such that orientations are collected in the analysis (i.e., Hough peaks information is not collected). The area size per scan (i.e., the frame) is 2.0 mm by 0.5 mm for 2 mm gauge samples and 2.0 mm by 1.2 mm for 5 mm gauge samples at 3 micron steps at 80×. Different frame sizes can be used depending upon gauge. The collected data is output in an *.osc file. This data may be used to calculate the volume fraction of first type grains, as described below.
Calculation of Volume Fraction of First Type Grains:
The volume fraction of first type grains is calculated using the data of the *.osc file and the TexSEM Lab OIM Analysis Software version 5.31. Prior to calculation, data cleanup may be performed with a 15° tolerance angle, a minimum grain size=3 data points, and a single iteration cleanup. Then, the amount of first type grains is calculated by the software using the first grain criteria (below).
First Grain Criteria: Calculated via grain orientation spread (GOS) with a grain tolerance angle of 5°, minimum grain size is three (3) data points, and confidence index is zero (0). All of “apply partition before calculation”, “include edge grains”, and “ignore twin boundary definitions” should be required, and the calculation should be completed using “grain average orientation”. Any grain whose GOS is ≦3° is a first type grain. If multiple frames are used, the GOS data are averaged.
“First grain volume” (FGV) means the volume fraction of first type grains of the crystalline material.
“Percent Unrecrystallized” and the like is determined via the formula:
U RX %=(1−FGV)*100%
As mentioned above, the aluminum alloy body generally comprises a predominately unrecrystallized microstructure, i.e., FGV<0.50 and U RX %≧50%. In one embodiment, the aluminum alloy body contains (by volume fraction) not greater than 0.45 first type grains (i.e., the aluminum alloy body is at least 55% unrecrystallized (U RX %≧55%), per the definitions provided above). In other embodiments, the aluminum alloy body may contain (by volume fraction) not greater than 0.40 first type grains (U RX %≧60%), or not greater than 0.35 first type grains (U RX %≧65%), or not greater than 0.30 first type grains (U RX %≧70%), or not greater than 0.25 first type grains (U RX %≧75%), or not greater than 0.20 first type grains (U RX %≧80%), or not greater than 0.15 first type grains (U RX %≧85%), or not greater than 0.10 first type grains (U RX %≧90%), or less.
ii. Texture
The aluminum alloy body may achieve a unique microstructure. This unique microstructure may be illustrated by the R-values of the aluminum alloy body derived from crystallographic texture data. The microstructure of an aluminum alloy body relates to its properties (e.g., strength, ductility, toughness, corrosion resistance, among others).
For purposes of the present application, R-values are generated according to the R-value generation procedure, described below.
R-Value Generation Procedure:
Instrument:
An x-ray generator with a computer-controlled pole figure unit (e.g., Rigaku Ultima III diffractometer (Rigaku USA, The Woodlands, Tex.) and data collection software and ODF software for processing pole figure data (e.g., Rigaku software included with the Rigaku diffractometer) is used. The reflection pole figures are captured in accordance with “Elements of X-ray Diffraction” by B. D. Cullity, 2 nd edition 1978 (Addison-Wesley Series in Metallurgy and Materials) and the Rigaku User Manual for the Ultima III Diffractometer and Multipurpose Attachment (or other suitable manual of other comparable diffractometer equipment).
Sample Preparation:
The pole figures are to be measured from the T/4 location to surface. Thus, the sample used for R-value generation is (preferably) ⅞ inch (LT) by 1¼ inches (L). Sample size may vary based on measurement equipment. Prior to measurement of the R-value, the sample may be prepared by:
1. machine the rolling plane from one side to 0.01″ thicker than the T/4 plane (if thickness justifies); and
2. chemically etching to the T/4 location.
X-Ray Measurement of Pole Figures:
Reflection of Pole Figure (Based on Schulz Reflection Method)
1. Mount a sample on the sample ring holder with an indication of the rolling direction of the sample 2. Insert the sample holder unit into the pole figure unit 3. Orient the direction of the sample to the same horizontal plane of the pole figure unit (β=0°) 4. Use a normal divergence slit (DS), standard pole figure receiving slit (RS) with Ni K β filter, and standard scatter slit (SS) (slit determination will depend on radiation used, the 2θ of the peaks, and the breadth of the peaks). The Rigaku Ultima III diffractometer uses ⅔ deg DS, 5 mm RS, and 6 mm SS. 5. Set the power to recommended operating voltage and current (default 40 KV 44 mA for Cu radiation with Ni filter on the Ultima III) 6. Measure the background intensity from α=15°, β=0° to α=90°, β=355° of the Al (111) , Al (200) , and Al (220) peaks at 5° steps and counting for 1 second at each step (three pole figures are usually sufficient for an accurate ODF) 7. Measure the peak intensity from α=15°, β=0° to α=90°, β=355° of Al (111) , Al (200) , Al (220) , and Al (311) peaks at 5° steps and counting for 1 second at each step 8. During measurements, the sample should be oscillated 2 cm per second to achieve a larger sampling area for improved sampling statistics 9. Subtract the background intensity from the peak intensity (this is usually done by the user-specific software) 10. Correct for absorption (usually done by the user-specific software)
The output data are usually converted to a format for input into ODF software. The ODF software normalizes the data, calculates the ODF, and recalculates normalized pole figures. From this information, R-values are calculated using the Taylor-Bishop-Hill model (see, Kuroda, M. et al., Texture optimization of rolled aluminum alloy sheets using a genetic algorithm , Materials Science and Engineering A 385 (2004) 235-244 and Man, Chi-Sing, On the r - value of textured sheet metals , International Journal of Plasticity 18 (2002) 1683-1706).
Aluminum alloy bodies produced in accordance with the presently described methods may achieve high normalized R-values as compared to conventionally produced materials. “Normalized R-value” and the like means the R-value as normalized by the R-value of the RV-control sample at an angle of 0° relative to the rolling direction. For example, if the RV-control sample achieves an R-value of 0.300 at an angle of 0° relative to the rolling direction, this and all other R-values would be normalized by dividing by 0.300.
“RV-control sample” and the like means a control sample taken from a reference-version aluminum alloy body in a T4 temper (defined above).
“Rolling direction” and the like means the L-direction for rolled products (see, FIG. 13 ). For non-rolled products, and in the context of R-values “rolling direction” and the like means the principle direction of extension (e.g., the extrusion direction). For purposes of the present application, the various R-values of a material are calculated from an angle of 0° to an angle of 90° relative to the rolling direction, and in increments of 5°. For purposes of simplicity, “orientation angle” is sometimes used to refer to the phrase “angle relative to the rolling direction”.
“Maximum normalized R-value” and the like means the maximum normalized R-value achieved at any angle relative to the rolling direction.
“Max RV angle” and the like means the angle at which the maximum normalized R-value is achieved.
As a non-limiting example, a chart containing R-values (both non-normalized and normalized) of an RV-control sample and an aluminum alloy body processed in accordance with the new processes described herein is provided in Table 2, below.
TABLE 2
Normalized
R-value
Normalized R-value
Rolling
R-value
R-value
(New Process)
(New Process)
Angle
(Control)
(Control)
(85% CW)
(85% CW)
0
0.5009
1.000
0.7780
1.553
5
0.5157
1.030
0.7449
1.487
10
0.5065
1.011
0.7241
1.446
15
0.4948
0.988
0.7802
1.558
20
0.4650
0.928
0.9111
1.819
25
0.4372
0.873
1.0866
2.169
30
0.4145
0.827
1.3999
2.795
35
0.3858
0.770
1.7234
3.441
40
0.3717
0.742
2.1556
4.304
45
0.3495
0.698
2.4868
4.965
50
0.3631
0.725
2.6023
5.196
55
0.3755
0.750
2.3778
4.747
60
0.3861
0.771
2.1577
4.308
65
0.4159
0.830
1.7318
3.458
70
0.4392
0.877
1.4117
2.818
75
0.4592
0.917
1.2048
2.406
80
0.4789
0.956
1.1133
2.223
85
0.4753
0.949
1.0214
2.039
90
0.4714
0.941
1.0508
2.098
The normalized R-values for the Control and the 85% Cold Work samples are plotted as function of orientation angle in FIG. 10 . FIG. 10 also contains the normalized R-values for aluminum alloy bodies with 11%, 35% and 60% cold work.
As illustrated in FIG. 10 , the high cold worked aluminum alloy bodies achieve higher R-values than the RV-control sample, especially between orientation angles of 20° and 70° relative to the rolling direction. For the 85% cold worked body, a maximum normalized R-value of 5.196 is achieved at a max RV angle of 50°. The RV-control sample achieves a maximum normalized R-value of 1.030 at a max RV angle of 5°. These R-values may be indicative of the texture (and hence microstructure) of the new aluminum alloy bodies as compared to conventionally produced aluminum alloy bodies.
In one approach, an aluminum alloy body processed in accordance with the new methods described herein may achieve a maximum normalized R-value of at least 2.0. In one embodiment, the new aluminum alloy body may achieve a maximum normalized R-value of at least 2.5. In other embodiments, the new aluminum alloy body may achieve a maximum normalized R-value of at least 3.0, or at least 3.5, or at least 4.0, or at least 4.5, or at least 5.0, or higher. The maximum normalized R-value may be achieved at an orientation angle of from 20° to 70°. In some embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 30° to 70°. In other embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 35° to 65°. In yet other embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 40° to 65°. In yet other embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 45° to 60°. In other embodiments, the maximum normalized R-value may be achieved at an orientation angle of from 45° to 55°.
In another approach, an aluminum alloy body processed in accordance with the new methods described herein may achieve a maximum normalized R-value that is at least 200% higher than the RV-control sample at the max RV angle of the new aluminum alloy body. In this approach, the normalized R-value of the new aluminum alloy body is compared to the normalized R-value of the RV-control sample at the angle where the max RV angle of the new aluminum alloy body occurs. For example, as shown in FIG. 10 and Table 2, above, the 85% cold worked aluminum alloy body realizes a 717% increase in normalized R-value at its max RV angle of 50° as compared to the normalized R-value of the RV-control sample at the same angle of 50° (5.196/0.725*100%=717%). In one embodiment, an aluminum alloy body may achieve a maximum normalized R-value that is at least 250% higher than the RV-control sample at the max RV angle of the new aluminum alloy body. In other embodiments, the aluminum alloy body may achieve a maximum normalized R-value that is at least 300% higher, or at least 350% higher, or at least 400% higher, or at least 450% higher, or at least 500% higher, or at least 550% higher, or at least 600% higher, or at least 650% higher, or at least 700% higher, or more, than the RV-control sample at the max RV angle of the aluminum alloy body.
In another approach, an aluminum alloy body processed in accordance with the new methods described herein may achieve a maximum normalized R-value that is at least 200% higher than the maximum normalized R-value of the RV-control sample. In this approach, the maximum normalized R-value of the new aluminum alloy body is compared to the maximum normalized R-value of the RV-control sample, irrespective of the angle at which the maximum normalized R-values occur. For example, as shown in FIG. 10 and Table 2, above, the 85% cold worked aluminum alloy body alloy realizes a maximum normalized R-value of 5.196 at an orientation angle of 50°. The maximum normalized R-value of the RV-control sample is 1.030 at an orientation angle of 5°. Thus, the 85% cold worked aluminum alloy body realizes a 505% increase in maximum normalized R-value over the RV-control sample (5.196/1.030*100%=505%). In one embodiment, an aluminum alloy body may achieve a maximum normalized R-value that is at least 250% higher than the maximum normalized R-value of the RV-control sample. In other embodiments, the aluminum alloy body may achieve a maximum normalized R-value that is at least 300% higher, or at least 350% higher, or at least 400% higher, or at least 450% higher, or at least 500% higher, or more, than the maximum normalized R-value of the RV-control sample.
iii. Micrographs
Optical micrographs of some 6xxx aluminum alloys bodies produced in accordance with the new processes described herein are illustrated in FIGS. 11 b - 11 e . FIG. 11 a is a microstructure of a reference-version of the aluminum alloy body in the T6 temper. FIGS. 11 b - 11 e are microstructures of new aluminum alloy bodies having 11%, 35%, 60% and 85% cold work, respectively. These micrographs illustrate some aspects of the unique microstructures that may be attained using the new processes described herein. As illustrated, the grains of the new aluminum alloy bodies appear to be non-equiaxed (elongated) grains. For the 60% and 85% cold-worked bodies, the grain structure appears fibrous/rope-like, and with a plurality of shear bands. These unique microstructures may contribute to the improved properties of the new aluminum alloy bodies.
F. Optional Post-Thermal Treatments
After the thermal treatment step ( 300 ), the 6xxx aluminum alloy body may be subjected to various optional final treatment(s) ( 400 ). For example, concomitant to or after the thermal treatments step ( 300 ), the 6xxx aluminum alloy body may be subjected to various additional working or finishing operations (e.g., forming operations, flattening or straightening operations that do not substantially affect mechanical properties, such as stretching, and/or other operations, such as machining, anodizing, painting, polishing, buffing). The optional final treatment(s) step ( 400 ) may be absent of any purposeful/meaningful thermal treatment(s) that would materially affect the microstructure of the aluminum alloy body (e.g., absent of any anneal steps). Thus, the microstructure achieved by the combination of the cold working ( 200 ) and thermally treating ( 300 ) steps may be retained.
In one approach, one or more of the optional final treatment(s) ( 400 ) may be completed concomitant to the thermal treatment step ( 300 ). In one embodiment, the optional final treatment(s) step ( 400 ) may include forming, and this forming step may be completed concomitant to (e.g., contemporaneous to) the thermal treatment step ( 300 ). In one embodiment, the aluminum alloy body may be in a substantially final form due to concomitant forming and thermal treatment operations (e.g., forming automotive door outer and/or inner panels during the thermal treatment step).
G. Composition
As noted above, the 6xxx aluminum alloy body is made from a 6xxx aluminum alloy. 6xxx aluminum alloys are aluminum alloys containing both silicon and magnesium, with at least one of silicon and magnesium being the predominate alloying ingredient. For purposes of the present application, 6xxx aluminum alloys are aluminum alloys having 0.1-2.0 wt. % silicon and 0.1-3.0 wt. % magnesium, where at least one of the silicon and the magnesium is the predominate alloying element of the aluminum alloy body other than aluminum. In one embodiment, the 6xxx aluminum alloy includes at least 0.25 wt. % Mg. In one embodiment, the 6xxx aluminum alloy includes not greater than 2.0 wt. % Mg. In one embodiment, the 6xxx aluminum alloy includes at least about 0.25 wt. % Si. In one embodiment, the 6xxx aluminum alloy includes not greater than about 1.5 wt. % Si. The 6xxx aluminum alloy may also include secondary elements, tertiary elements and/or other elements, as defined below.
The 6xxx aluminum alloy may include secondary elements. The secondary elements are selected from the group consisting of copper, zinc and combinations thereof. In one embodiment, the 6xxx aluminum alloy includes copper. In another embodiment, the 6xxx aluminum alloy includes zinc. In yet another embodiment, the 6xxx aluminum alloy includes both copper and zinc. When present in sufficient amounts, these secondary elements, in combination with the primary elements of silicon and magnesium, may promote one or both of a strain hardening response and a precipitation hardening response. Thus, when used in combination with the new processes described herein, the 6xxx aluminum alloy may realize an improved combination of properties, such as improved strength (e.g., as compared to the 6xxx aluminum alloy body in the T6 temper).
When copper is used, the 6xxx aluminum alloy generally includes at least 0.35 wt. % Cu. In one embodiment, the 6xxx aluminum alloy includes at least 0.5 wt. % Cu. The 6xxx aluminum alloy generally includes not greater than 2.0 wt. % Cu, such as not greater than 1.5 wt. % Cu. In other embodiments, copper may be present at low levels, and in these embodiments is present at levels of from 0.01 wt. % to 0.34 wt. %. In other embodiments, copper is included in the alloy as an impurity, and in these embodiments is present at levels of less than 0.01 wt. % Cu.
When zinc is used, the 6xxx aluminum alloy generally includes at least 0.35 wt. % Zn. In one embodiment, the 6xxx aluminum alloy includes at least 0.5 wt. % Zn. The 6xxx aluminum alloy generally includes not greater than 2.5 wt. % Zn. In one embodiment, the 6xxx aluminum alloy includes not greater than 2.0 wt. % Zn. In another embodiment, the 6xxx aluminum alloy includes not greater than 1.5 wt. % Zn. In other embodiments, zinc may be present at low levels, and in these embodiments is present at levels of from 0.05 wt. % to 0.34 wt. % Zn. In other embodiments, zinc is included in the alloy as an impurity, and in these embodiments is present at levels of 0.04 wt. % Zn, or less.
The 6xxx aluminum alloy may include a variety of tertiary elements for various purposes, such as to enhance mechanical, physical or corrosion properties (i.e. strength, toughness, fatigue resistance, corrosion resistance), to enhance properties at elevated temperatures, to facilitate casting, to control cast or wrought grain structure, and/or to enhance machinability, among other purposes. When present, these tertiary elements may include one or more of: (i) up to 3.0 wt. % Ag, (ii) up to 2.0 wt. % each of one or more of Li, Mn, Sn, Bi, and Pb, (iii) up to 1.0 wt. % each of one or more of Fe, Sr, Sb, and Cr and (iv) up to 0.5 wt. % each of one or more of Ni, V, Zr, Sc, Ti, Hf, Mo, Co, and rare earth elements. When present, a tertiary element is usually contained in the alloy by an amount of at least 0.01 wt. %.
The 6xxx aluminum alloy may include iron as a tertiary element or as an impurity. When iron is are not included in the alloy as a tertiary element, iron may be included in the 6xxx aluminum alloy as an impurity. In these embodiments, the 6xxx aluminum alloy generally includes not greater than 0.50 wt. % iron. In one embodiment, the 6xxx aluminum alloy includes not greater than 0.25 wt. % iron. In another embodiment, the 6xxx aluminum alloy includes not greater than 0.15 wt. % iron. In yet another embodiment, the 6xxx aluminum alloy includes not greater than 0.10 wt. % iron. In another embodiment, the 6xxx aluminum alloy includes not greater than 0.05 wt. % iron.
The 6xxx aluminum alloy generally contains low amounts of “other elements” (e.g., casting aids and non-Fe impurities). Other elements means any other element of the periodic table that may be included in the 6xxx aluminum alloy, except for the aluminum, the magnesium, the silicon, the secondary elements (when included), the tertiary elements (when included), and iron (when included). When any element of the secondary and/or tertiary elements is contained within the alloy only as an impurity, such elements fall within the scope of “other elements”, except for iron. For example, if a 6xxx alloy includes copper as an impurity (i.e., below 0.01 wt. % Cu for purposes of this patent application), and not as an alloying addition, the copper would fall within the scope of “other elements”. Likewise, if a 6xxx alloy includes zinc as an impurity (i.e., at or below 0.04 wt. % Zn for purposes of this patent application), and not as an alloying addition, the zinc would fall within the scope of “other elements”. As another example, if Mn, Ag, and Zr are included in the 6xxx alloy as alloying additions, those tertiary elements would not fall within the scope of “other elements”, but the other tertiary elements would be included within the scope of other elements since they would be included in the alloy only as an impurity. However, if iron is contained in the 6xxx alloy as an impurity, it would not fall within the scope of “other elements” since it has its own defined impurity limits, as described above.
Generally, the aluminum alloy body contains not more than 0.25 wt. % each of any element of the other elements, with the total combined amount of these other elements not exceeding 0.50 wt. %. In one embodiment, each one of these other elements, individually, does not exceed 0.10 wt. % in the 6xxx aluminum alloy, and the total combined amount of these other elements does not exceed 0.35 wt. %, in the 6xxx aluminum alloy. In another embodiment, each one of these other elements, individually, does not exceed 0.05 wt. % in the 6xxx aluminum alloy, and the total combined amount of these other elements does not exceed 0.15 wt. % in the 6xxx aluminum alloy. In another embodiment, each one of these other elements, individually, does not exceed 0.03 wt. % in the 6xxx aluminum alloy, and the total combined amount of these other elements does not exceed 0.1 wt. % in the 6xxx aluminum alloy.
In one approach, a 6xxx aluminum alloy includes:
0.1-2.0 wt. % silicon;
0.1-3.0 wt. magnesium;
wherein at least one of the silicon and the magnesium is the predominate alloying element of the aluminum alloy body other than aluminum;
optionally one or more of the secondary elements of:
0.35 to 2.0 wt. % Cu, 0.35 to 2.5 wt. % Zn,
optionally with one or more of the tertiary elements of:
(i) up to 3.0 wt. % Ag, (ii) up to 2.0 wt. % each of one or more of Li, Mn, Sn, Bi, and Pb; (iii) up to 1.0 wt. % each of one or more of Fe, Sr, Sb and Cr; and (iv) up to 0.5 wt. % each of one or more of Ni, V, Zr, Sc, Ti, Hf, Mo, Co, and rare earth elements,
if not included in the 6xxx aluminum alloy as a tertiary element:
up to 0.5 wt. % Fe as an impurity;
the balance being aluminum and other elements, wherein the other elements are limited to not more than 0.25 wt. % each, and not more than 0.5 wt. % in total.
The total amount of the primary, secondary, and tertiary alloying elements should be chosen so that the aluminum alloy body can be appropriately solutionized (e.g., to promote hardening while restricting the amount of constituent particles).
In one approach, the 6xxx aluminum alloy contains sufficient solute to promote at least one of a strain hardening response and a precipitation hardening response to achieve a long-transverse tensile yield strength of at least 60 ksi. In some of these embodiments, copper and/or zinc is used to at least partially promote the strain hardening response and/or precipitation hardening response, and thus may be included in the alloy in the amounts described above.
In another approach, the 6xxx aluminum alloy contains sufficient magnesium to promote a hardening response. In this approach, the 6xxx aluminum alloy generally contains at least 1.1 wt. % Mg, such as at least 1.2 wt. % Mg, or at least 1.3 wt. % Mg, or at least 1.4 wt. % Mg, or more. In some of these embodiments, the 6xxx aluminum alloy also contains at least one of 0.35-2.0 wt. % copper and/or 0.35-2.5 wt. % zinc to at least partially promote the strain hardening response and/or precipitation hardening response. In others of these embodiments, the 6xxx aluminum alloy includes low-levels and/or impurity levels of copper and/or zinc, as defined above. In some of these embodiments, the 6xxx aluminum alloy achieves a high tensile yield strength, such as any of the strength levels described below. In a particular embodiment, the 6xxx contains at least 1.1 wt. % Mg, less than 0.35 wt. % Cu, less than 0.35 wt. % Zn, and achieves a tensile yield strength of at least about 35 ksi, such as at least about 45 ksi, or even at least about 55 ksi.
In one embodiment, the 6xxx aluminum alloy is one of the following wrought 6xxx aluminum alloys, as defined by the Aluminum Association: 6101, 6101A, 6101B, 6201, 6201A, 6401, 6501, 6002, 6003, 6103, 6005, 6005A, 6005B, 6005C, 6105, 6205, 6006, 6106, 6206, 6306, 6008, 6009, 6010, 6110, 6110A, 6011, 6111, 6012, 6012A, 6013, 6113, 6014, 6015, 6016, 6016A, 6116, 6018, 6019, 6020, 6021, 6022, 6023, 6024, 6025, 6026, 6028, 6033, 6040, 6041, 6042, 6043, 6151, 6351, 6351A, 6451, 6951, 6053, 6056, 6156, 6060, 6160, 6260, 6360, 6460, 6560, 6061, 6061A, 6261, 6162, 6262, 6262A, 6063, 6063A, 6463, 6463A, 6763, 6963, 6064, 6064A, 6065, 6066, 6069, 6070, 6081, 6181, 6181A, 6082, 6182, 6082A, 6091, and 6092, or as modified to contain sufficient solute to promote at least one of a strain-hardening and precipitation hardening response, as described above.
In one embodiment, the 6xxx aluminum alloy includes an amount of alloying elements that leaves the 6xxx aluminum alloy free of, or substantially free of, soluble constituent particles after solutionizing. In one embodiment, the 6xxx aluminum alloy includes an amount of alloying elements that leaves the aluminum alloy with low amounts of (e.g., restricted/minimized) insoluble constituent particles after solutionizing. In other embodiments, the 6xxx aluminum alloy may benefit from controlled amounts of insoluble constituent particles.
H. Properties
The new 6xxx aluminum alloy bodies produced by the new processes described herein may achieve (realize) an improved combination of properties.
i. Strength
As mentioned above, the cold working ( 200 ) and the thermally treating ( 300 ) steps may be accomplished to achieve an increase in strength as compared to a reference-version of the aluminum alloy body in the as cold-worked condition and/or the T6 temper (as defined above). Strength properties are generally measured in accordance with ASTM E8 and B557.
In one approach, the aluminum alloy body achieves at least a 5% increase in strength (TYS and/or UTS) relative to a reference-version of the aluminum alloy body in the T6 condition. In one embodiment, the aluminum alloy body achieves at least a 6% increase in tensile yield strength relative to a reference-version of the aluminum alloy body in the T6 condition. In other embodiments, the aluminum alloy body achieves at least a 7% increase in tensile yield strength, or at least a 8% increase in tensile yield strength, or at least a 9% increase in tensile yield strength, or at least a 10% increase in tensile yield strength, or at least a 11% increase in tensile yield strength, or at least a 12% increase in tensile yield strength, or at least a 13% increase in tensile yield strength, or at least a 14% increase in tensile yield strength, or at least a 15% increase in tensile yield strength, or at least a 16% increase in tensile yield strength, or at least a 17% increase in tensile yield strength, or at least an 18% increase in tensile yield strength, or at least a 19% increase in tensile yield strength, or at least a 20% increase in tensile yield strength, or at least a 21% increase in tensile yield strength, or at least a 22% increase in tensile yield strength, or at least a 23% increase in tensile yield strength, or at least a 24% increase in tensile yield strength, or at least a 25% increase in tensile yield strength, or at least a 26% increase in tensile yield strength, or more, relative to a reference-version of the aluminum alloy body in the T6 condition. These increases may be realized in the L and/or LT directions.
In a related embodiment, the aluminum alloy body may achieve at least a 6% increase in ultimate tensile strength relative to the aluminum alloy body in the T6 condition. In other embodiments, the aluminum alloy body may achieve at least a 7% increase in ultimate tensile strength, or at least an 8% increase in ultimate tensile strength, or at least a 9% increase in ultimate tensile strength, or at least a 10% increase in ultimate tensile strength, or at least an 11% increase in ultimate tensile strength, or at least a 12% increase in ultimate tensile strength, or at least a 13% increase in ultimate tensile strength, or at least a 14% increase in ultimate tensile strength, or at least a 15% increase in ultimate tensile strength, or at least a 16% increase in ultimate tensile strength, or at least a 17% increase in ultimate tensile strength, or at least an 18% increase in ultimate tensile strength, or at least a 19% increase in ultimate tensile strength, or at least a 20% increase in ultimate tensile strength, or at least a 21% increase in ultimate tensile strength, or at least a 22% increase in ultimate tensile strength, or at least a 23% increase in ultimate tensile strength, or at least a 24% increase in ultimate tensile strength, or at least a 25% increase in ultimate tensile strength, or more, relative to a reference-version of the aluminum alloy body in the T6 condition. These increases may be realized in the L and/or LT directions.
In one approach, the aluminum alloy body achieves at least equivalent tensile yield strength as compared to a reference-version of the aluminum alloy body in the as-cold worked condition. In one embodiment, the aluminum alloy body achieves at least a 2% increase in tensile yield strength as compared to a reference-version of the aluminum alloy body in the as-cold worked condition. In other embodiments, the aluminum alloy body achieves at least a 4% increase in tensile yield strength, or at least a 6% increase in tensile yield strength, or at least a 8% increase in tensile yield strength, or at least a 10% increase in tensile yield strength, or at least a 12% increase in tensile yield strength, or at least a 14% increase in tensile yield strength, or at least an 16% increase in tensile yield strength, or more, as compared to a reference-version of the aluminum alloy body in the as-cold worked condition. Similar results may be obtained relative to ultimate tensile strength. These increases may be realized in the L or LT directions.
In one embodiment, a new 6xxx aluminum alloy body realizes a typical tensile yield strength in the LT direction of at least 35 ksi. In other embodiments, a new 6xxx aluminum alloy body realizes a typical tensile yield strength in the LT direction of at least 40 ksi, or at least 45 ksi, or at least 50 ksi, or at least 51 ksi, or at least 52 ksi, or at least 53 ksi, or at least 54 ksi, or at least 55 ksi, or at least 56 ksi, or at least 57 ksi, or at least 58 ksi, or at least 59 ksi, or at least 60 ksi, or at least 61 ksi, or at least 62 ksi, or at least 63 ksi, or at least 64 ksi, or at least 65 ksi, or at least 66 ksi, or at least 67 ksi, or at least 68 ksi, or at least 69 ksi, or at least 70 ksi, or at least 71 ksi, or at least 72 ksi, or at least 73 ksi, or at least 74 ksi, or at least 75 ksi, or more. Similar results may be achieved in the longitudinal (L) direction.
In a related embodiment, a new 6xxx aluminum alloy body realizes a typical ultimate tensile strength in the LT direction of at least 40 ksi. In other embodiments, a new 6xxx aluminum alloy body realizes a typical ultimate tensile strength in the LT direction of at least 45 ksi, or at least 50 ksi, 51 ksi, or at least 52 ksi, or at least 53 ksi, or at least 54 ksi, or at least 55 ksi, or at least 56 ksi, or at least 57 ksi, or at least 58 ksi, or at least 59 ksi, or at least 60 ksi, or at least 61 ksi, or at least 62 ksi, or at least 63 ksi, or at least 64 ksi, or at least 65 ksi, or at least 66 ksi, or at least 67 ksi, or at least 68 ksi, or at least 69 ksi, or at least 70 ksi, or at least 71 ksi, or at least 72 ksi, or at least 73 ksi, or at least 74 ksi, or at least 75 ksi, or more. Similar results may be achieved in the longitudinal (L) direction. Similar results may be achieved in the longitudinal (L) direction.
The new 6xxx aluminum alloy bodies may achieve a high strength and in a short time period relative to a reference-version of the 6xxx aluminum alloy body in the T6 temper. In one embodiment, a new 6xxx aluminum alloy body realizes its peak strength at least 10% faster than a reference-version of the aluminum alloy body in the T6 temper. As an example of 10% faster processing, if the T6-version of the 6xxx aluminum alloy body realizes its peak strength in 35 hours of processing, the new 6xxx aluminum alloy body would realize its peak strength in 31.5 hours or less. In other embodiments, the new 6xxx aluminum alloy body realizes it peak strength at least 20% faster, or at least 25% faster, or at least 30% faster, or at least 35% faster, or at least 40% faster, or at least 45% faster, or at least 50% faster, or at least 55% faster, or at least 60% faster, or at least 65% faster, or at least 70% faster, or at least 75% faster, or at least 80% faster, or at least 85% faster, or at least 90% faster, or more, as compared to a reference-version of the aluminum 6xxx aluminum alloy body in the T6 temper.
In one embodiment, a new 6xxx aluminum alloy body realizes its peak strength in less than 10 hours of thermal treatment time. In other embodiments, a new 6xxx aluminum alloy body realizes its peak strength in less than 9 hours, or less than 8 hours, or less than 7 hours, or less than 6 hours, or less than 5 hours, or less than 4 hours, or less than 3 hours, or less than 2 hours, or less than 1 hour, or less than 50 minutes, or less than 40 minutes, or less than 30 minutes, or less than 20 minutes, or less than 15 minutes, or less than 10 minutes of thermal treatment time, or less. Due to the short thermal treatment times, it is possible that paint baking cycles or coating cures could be used to thermally treat the new 6xxx aluminum alloy bodies.
ii. Ductility
The aluminum alloy body may realize good ductility and in combination with the above-described strengths. In one approach, the aluminum alloy body achieves an elongation (L and/or LT) of more than 4%. In one embodiment, the aluminum alloy body achieves an elongation (L and/or LT) of at least 5%. In other embodiments, the aluminum alloy body may achieve an elongation (L and/or LT) of at least 6%, or at least 7%, or at least 8%, or at least 9%, or at least 10%, or at least 11%, or at least 12%, or at least 13%, or at least 14%, or at least 15%, or at least 16%, or more.
iii. Fracture Toughness
The new 6xxx aluminum alloy bodies may realize good fracture toughness properties. Toughness properties are generally measured in accordance with ASTM E399 and ASTM B645 for plane-strain fracture toughness (e.g., K IC and K Q ) and in accordance with ASTM E561 and B646 for plane-stress fracture toughness (e.g., K app and K R25 ).
In one embodiment, the new 6xxx aluminum alloy body realizes a toughness decrease of not greater than 10% relative to a reference-version of the aluminum alloy body in the T6 temper. In other embodiments, the new 6xxx aluminum alloy body realizes a toughness decrease of not greater than 9%, or not greater than 8%, or not greater than 7%, or not greater than 6%, or not greater than 5%, or not greater than 4%, or not greater than 3%, or not greater than 2%, or not greater than 1% relative to a reference-version of the 6xxx aluminum alloy body in the T6 temper. In one embodiment, the new 6xxx aluminum alloy body realizes a toughness at least equivalent to that of a reference-version of the 6xxx aluminum alloy body in the T6 temper.
iv. Stress Corrosion Cracking
The new 6xxx aluminum alloy bodies may realize good stress corrosion cracking resistance. Stress corrosion cracking (SCC) resistance is generally measured in accordance with ASTM G47. For example, a new 6xxx aluminum alloy body may achieve a good strength and/or toughness, and with good SCC corrosion resistance. In one embodiment, a new 6xxx aluminum alloy body realizes a Level 1 corrosion resistance. In another embodiment, a new 6xxx aluminum alloy body realizes a Level 2 corrosion resistance. In yet another embodiment, a new 6xxx aluminum alloy body realizes a Level 3 corrosion resistance. In yet another embodiment, a new 6xxx aluminum alloy body realizes a Level 4 corrosion resistance.
Corrosion
Short-transverse stress (ksi)
Resistance Level
for 20 days (minimum) without failure
1
≧15
2
≧25
3
≧35
4
≧45
v. Exfoliation Resistance
The new 6xxx aluminum alloy bodies may be exfoliation resistant. Exfoliation resistance is generally measured in accordance with ASTM G34. In one embodiment, an aluminum alloy body realizes an EXCO rating of EB or better. In another embodiment, an aluminum alloy body realizes an EXCO rating of EA or better. In yet another embodiment, an aluminum alloy body realizes an EXCO rating of P, or better.
vi. Appearance
Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize improved appearance. The below appearance standards may be measured with a Hunterlab Dorigon II (Hunter Associates Laboratory INC, Reston, Va.), or comparable instrument.
Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize at least 5% higher specular reflectance as compared to the referenced aluminum alloy body in the T6 temper. In one embodiment, the new aluminum alloy bodies realize at least 6% higher specular reflectance as compared to the referenced aluminum alloy body in the T6 temper. In other embodiments, the new aluminum alloy bodies realize at least 7% higher specular reflectance, or at least 8% higher specular reflectance, or at least 9% higher specular reflectance, or at least 10% higher specular reflectance, or at least 11% higher specular reflectance, or at least 12% higher specular reflectance, or at least 13% higher specular reflectance, or more, as compared to the referenced aluminum alloy body in the T6 temper.
Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize at least 10% higher 2 degree diffuseness as compared to the referenced aluminum alloy body in the T6 temper. In one embodiment, the new aluminum alloy bodies realize at least 12% higher 2 degree diffuseness as compared to the referenced aluminum alloy body in the T6 temper. In other embodiments, the new aluminum alloy bodies realize at least 14% higher 2 degree diffuseness, or at least 16% higher 2 degree diffuseness, or at least 18% higher 2 degree diffuseness, or at least 20% higher 2 degree diffuseness, or at least 22% higher 2 degree diffuseness, or more, as compared to the referenced aluminum alloy body in the T6 temper.
Aluminum alloy bodies processed in accordance with the new processes disclosed herein may realize at least 15% higher 2 image clarity as compared to the referenced aluminum alloy body in the T6 temper. In one embodiment, the new aluminum alloy bodies realize at least 18% higher 2 image clarity as compared to the referenced aluminum alloy body in the T6 temper. In other embodiments, the new aluminum alloy bodies realize at least 21% higher 2 image clarity, or at least 24% higher 2 image clarity, or at least 27% higher 2 image clarity, or at least 30% higher 2 image clarity, or more, as compared to the referenced aluminum alloy body in the T6 temper.
I. Product Applications
The new processes described herein may have applicability in a variety of product applications. In one embodiment, a product made by the new processes described herein is used in an aerospace application, such as wing skins (upper and lower) or stringers/stiffeners, fuselage skin or stringers, ribs, frames, spars, seat tracks, bulkheads, circumferential frames, empennage (such as horizontal and vertical stabilizers), floor beams, seat tracks, doors, and control surface components (e.g., rudders, ailerons) among others. Many potential benefits could be realized in such components through use of the products including higher strength, superior corrosion resistance, improved resistance to the initiation and growth of fatigue cracks, and enhanced toughness to name a few. Improved combinations of such properties can result in weight savings or reduced inspection intervals or both.
In another embodiment, a product made by the new processes described herein is used in a munitions/ballistics/military application, such as in ammunition cartridges and armor, among others. Ammunition cartridges may include those used in small arms and cannons or for artillery or tank rounds. Other possible ammunition components would include sabots and fins. Artillery, fuse components are another possible application as are fins and control surfaces for precision guided bombs and missiles. Armor components could include armor plates or structural components for military vehicles. In such applications, the products could offer weight savings or improved reliability or accuracy.
In another embodiment, a product made by the new processes described herein is used in a fastener application, such as bolts, rivets, screws, studs, inserts, nuts, and lock-bolts, which may be used in the industrial engineering and/or aerospace industries, among others. In these applications, the products could be used in place of other heavier materials, like titanium alloys or steels, for weight reduction. In other cases, the products could provide superior durability.
In another embodiment, a product made by the new processes described herein is used in an automotive application, such as closure panels (e.g., hoods, fenders, doors, roofs, and trunk lids, among others), wheels, and critical strength applications, such as in body-in-white (e.g., pillars, reinforcements) applications, among others. In some of these applications the products may allow down-gauging of the components and weight savings.
In another embodiment, a product made by the new processes described herein is used in a marine application, such as for ships and boats (e.g., hulls, decks, masts, and superstructures, among others). In some of these applications the products could be used to enable down-gauging and weight reductions. In some other cases, the products could be used to replace products with inferior corrosion resistance resulting in enhanced reliability and lifetimes.
In another embodiment, a product made by the new processes described herein is used in a rail application, such as for hopper tank and box cars, among others. In the case of hopper or tank cars, the products could be used for the hoppers and tanks themselves or for the supporting structures. In these cases, the products could provide weight reductions (through down-gauging) or enhanced compatibility with the products being transported.
In another embodiment, a product made by the new processes described herein is used in a ground transportation application, such as for truck tractors, box trailers, flatbed trailers, buses, package vans, recreational vehicles (RVs), all-terrain vehicles (ATVs), and the like. For truck tractors, buses, package vans and RV's, the products could be used for closure panels or frames, bumpers or fuel tanks allowing down-gauging and reduced weight. Correspondingly, the bodies could also be used in wheels to provided enhanced durability or weight savings or improved appearance.
In another embodiment, a product made by the new processes described herein is used in an oil and gas application, such as for risers, auxiliary lines, drill pipe, choke-and-kill lines, production piping, and fall pipe, among others. In these applications the product could allow reduced wall thicknesses and lower weight. Other uses could include replacing alternate materials to improve corrosion performance or replacing alternate materials to improve compatibility with drilling or production fluids. The products could also be used for auxiliary equipment employed in exploration like habitation modules and helipads, among others.
In another embodiment, a product made by the new processes described herein is used in a packaging application, such as for lids and tabs, food cans, bottles, trays, and caps, among others. In these applications, benefits could include the opportunity for down-gauging and reduced package weight or cost. In other cases, the product would have enhanced compatibility with the package contents or improved corrosion resistance.
In another embodiment, a product made by the new processes described herein is used in a reflector, such as for lighting, mirrors, and concentrated solar power, among others. In these applications the products could provide better reflective qualities in the bare, coated or anodized condition at a given strength level.
In another embodiment, a product made by the new processes described herein is used in an architecture application, such as for building panels/facades, entrances, framing systems, and curtain wall systems, among others. In such applications, the product could provide superior appearance or durability or reduced weight associated with down-gauging.
In another embodiment, a product made by the new processes described herein is used in an electrical application, such as for connectors, terminals, cables, bus bars, and wires, among others. In some cases the product could offer reduced tendency for sag for a given current carrying capability. Connectors made from the product could have enhanced capability to maintain high integrity connections over time. In other wires or cables, the product could provide improved fatigue performance at a given level of current carrying capability.
In another embodiment, a product made by the new processes described herein is used in a fiber metal laminate application, such as for producing high-strength sheet products used in the laminate, among others which could result in down-gauging and weight reduction.
In another embodiment, a product made by the new processes described herein is used in an industrial engineering application, such as for tread-plate, tool boxes, bolting decks, bridge decks, and ramps, among others where enhanced properties could allow down-gauging and reduced weight or material usage.
In another embodiment, a product made by the new processes described herein is used in a fluid container (tank), such as for rings, domes, and barrels, among others. In some cases the tanks could be used for static storage. In others, the tanks could be parts of launch vehicles or aircraft. Benefits in these applications could include down-gauging or enhanced compatibility with the products to be contained.
In another embodiment, a product made by the new processes described herein is used in consumer product applications, such as laptops, cell phones, cameras, mobile music players, handheld devices, computers, televisions, microwaves, cookware, washer/dryer, refrigerators, sporting goods, or any other consumer electronic products requiring durability or desirable appearance. In another embodiment, a product made by the new processes described herein is used in a medical device, security systems, and office supplies, among others.
In another embodiment, the new process is applied to a cold hole expansion process, such as for treating holes to improve fatigue resistance, among others, which may result in a cold work gradient and tailored properties, as described above. This cold hole expansion process may be applicable to forged wheels and aircraft structures, among others.
In another embodiment, the new process is applied to cold indirect extrusion processes, such as for producing cans, bottles, aerosol cans, and gas cylinders, among others. In these cases the product could provide higher strength which could provide reduced material usage. In other cases, improved compatibility with the contents could result in greater shelf life.
In another embodiment, a product made by the new processes described herein is used in a heat-exchanger application, such as for tubing and fins, among others where higher strength can be translated into reduced material usage. Improved durability and longer life could also be realized.
In another embodiment, the new process is applied to a conforming processes, such as for producing heat-exchanger components, e.g., tubing where higher strength can be translated into reduced material usage. Improved durability and longer life could also be realized.
The new 6xxx aluminum alloy products may find use in multi-layer applications. For example it is possible that a multi-layer product may be formed using a 6xxx aluminum alloy body as a first layer and any of the 1xxx-8xxx alloys being used as a second layer. FIG. 12 illustrates one embodiment of a method for producing multi-layered products. In the illustrated embodiment, a multi-layered product may be produced ( 107 ), after which it is homogenized ( 122 ), hot rolled ( 126 ), solutionized ( 140 ) and then cold rolled ( 220 ), as described above relative to FIG. 9 . The multi-layered products may be produced via multi-alloy casting, roll bonding, and metallurgical bonding, among others. Multi-alloy casting techniques include those described in U.S. Patent Application Publication No. 20030079856 to Kilmer et al., U.S. Patent Application No. 20050011630 to Anderson et al., U.S. Patent Application No. 20080182122 to Chu et al., and WO2007/098583 to Novelis (the so-called FUSION™ casting process).
These and other aspects, advantages, and novel features of this new technology are set forth in part in the description that follows and will become apparent to those skilled in the art upon examination of the description and figures, or may be learned by practicing one or more embodiments of the technology provided for by the patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart illustrating a conventional process for producing aluminum alloy products.
FIG. 2 is a flow chart illustrating a new process for producing aluminum alloy products.
FIGS. 3-8 are flow charts illustrating various embodiments of preparing an aluminum alloy body for post-solutionizing cold work.
FIG. 9 is a flow chart illustrating one embodiment of a method for producing a rolled aluminum alloy body.
FIG. 10 is a graph illustrating R-values as a function of orientation angle for various aluminum alloy bodies.
FIGS. 11 a - 11 e are optical micrographs illustrating aluminum alloy body microstructures; the optical micrographs were obtained by anodizing the samples and viewing them in polarized light.
FIG. 12 is a flow chart illustrating one method of producing multi-layered aluminum alloy products.
FIG. 13 is a schematic view illustrating the L, LT and ST directions of a rolled product.
FIGS. 14-22 are graphs illustrating the thermal treatment response of various 6xxx aluminum alloy bodies.
FIG. 23 is a graph illustrating the ductility of various 6xxx aluminum alloy bodies as a function of time when thermally treated at 350° F.
FIG. 24 is a graph illustrating the fatigue response of various 6xxx aluminum alloy bodies.
FIG. 25 is a graph illustrating trendlines of the fatigue response of various 6xxx aluminum alloy bodies based on the data of FIG. 24 .
FIG. 26 is a graph illustrating the strength and fracture toughness properties of various 6xxx aluminum alloy bodies.
FIGS. 27-35 are graphs illustrating various properties of various 6013 alloy bodies, both conventionally processed and as processed in accordance with the new processes described herein.
FIG. 36 is a graph illustrating various properties of various 6061 alloy bodies, both conventionally processed and as processed in accordance with the new processes described herein.
FIG. 37 is a graph illustrating various properties of various 6022 alloy bodies, both conventionally processed and as processed in accordance with the new processes described herein.
FIGS. 38-39 are graphs illustrating R-values as a function of orientation angle for various 6022 and 6061 aluminum alloy bodies.
FIGS. 40-51 are graphs illustrating various properties of high magnesium 6xxx aluminum alloy bodies, both conventionally processed and as processed in accordance with the new processes described herein.
DETAILED DESCRIPTION
Example 1
Testing of 6xxx Aluminum Alloy Having Copper and Zinc
A 6xxx aluminum alloy having both copper and zinc (the “6xxx+Cu+Zn alloy”) is direct chill cast as an ingot. This alloy is similar to that disclosed in U.S. Pat. No. 6,537,392. The 6xxx+Cu+Zn alloy has the composition provided for in Table 3, below.
TABLE 3 Composition of 6xxx + Cu + Zn aluminum alloy (all values in wt. %) Others Others Si Fe Mn Cu Mg Zn Cr Ti each Total Bal. 0.86 0.12 0.01 0.73 0.89 0.69 0.22 0.02 ≦0.05 ≦0.15 Al
After casting, the ingot is homogenized and then hot rolled to an intermediate gauge of 2.0 inches. The 2.0 inch body is split into five sections, bodies A-E.
Body A is conventionally processed into sheet by hot rolling the 2.0 inch plate to a second intermediate gauge of 0.505 inch, then cold rolling into sheet having a final gauge of 0.194 inch, after which it is solutionized (Sheet A), stretched about 1% for flatness.
Bodies B-E are processed into sheet using the new process by hot rolling to second intermediate gauges of 1.270 inches (Body E), 0.499 inch (Body D), 0.315 inch (Body C), and 0.225 inch (Body B), and then solutionizing, and then cold rolling these bodies to a final sheet gauge of about 0.200 inch. Sheet B receives about 11% CW, Sheet C receives about 35% CW, Sheet D receives 60% CW and Sheet E receives about 85% CW.
Test 1 Samples
A sample of Sheet A is thermally treated at 350° F. Since Sheet A was solutionized and then thermally treated, i.e., no cold work was applied between the solutionizing and thermal treatment step, Sheet A is considered to be treated to a T6 temper. The mechanical properties of the sample from Sheet A are measured as a function of time at various intervals.
Various samples from Sheets B-E are thermally treated. A first set is thermally treated at 300° F., a second set is thermally treated at 325° F., a third set is thermally treated at 350° F., a fourth set is thermally treated at 375° F., and a fifth set is thermally treated at 400° F. The mechanical properties of each the samples from of Sheets B-E are measured as a function of time at various intervals.
FIGS. 14-23 illustrate the thermal treatment response of Sheets A-E. The sheets made by the new process (Sheets B-E) achieve higher strength and in a shorter period of time relative to the conventional sheet product (Sheet A). Table 4, below illustrates some of the tensile properties using the 350° F. thermal treatment condition, all values in ksi and in the LT (long transverse) direction.
TABLE 4
Strength of the 6xxx + Cu + Zn alloy at various thermal treatment times 350° F.)
Sheet E
Sheet D
Sheet C
Sheet B
Sheet A
85% CW
60% CW
35% CW
11% CW
Time
(T6) (old)
(new)
(new)
(new)
(new)
(hr)
TYS
UTS
TYS
UTS
TYS
UTS
TYS
UTS
TYS
UTS
2
41.7
53.7
70.9
72.9
65.6
68.9
59.3
63.4
52.2
57.9
4
49.7
56.9
67.8
70.2
65.0
68.1
60.6
64.0
54.8
59.3
8
54.2
58.5
64.9
66.8
63.0
65.3
60.0
63.2
55.6
59.1
16
55.3
58.5
61.2
63.1
60.6
62.7
58.7
61.4
54.4
57.7
24
54.8
58.3
60.3
62.1
59.5
61.5
57.5
60.0
53.9
56.9
As illustrated in Table 4, above, and FIG. 16 , Sheets C-E made by the new process and having at least 25% cold work realize an increase in strength over Sheet A. Indeed, Sheet E with 85% CW and thermally treated at 350° F. realizes about a strength of 70.9 ksi and with only 2 hours of thermal treatment (its peak strength may be higher since it achieved high strength so quickly). The conventionally processed sheet (Sheet A) in the T6 temper reaches its measured highest strength around 16 hours of thermal treatment, and then only realizes a strength of about 55.3 ksi. In other words, new Sheet E achieves about a 28% increase in tensile yield strength over the strength of the conventionally prepared material, and with only 2 hours of thermal treatment (i.e., 87.5% faster, (1−2/16)*100%=87.5%). Stated differently, new Sheet E achieves about a 28% increase in strength over conventional Sheet A and in about 1/10 th of the time required for Sheet A to its peak strength of 55.3 ksi.
Sheets C, D and E with more than 25% cold work realize tensile yield strengths in excess of 60 ksi. Sheets D and E with 60% and 85% cold work, respectively, realize tensile yield strengths in excess of 65 ksi, indicating that more than 35% cold work, such as more than 50% cold work, may be required to regularly achieve tensile yield strengths in excess of 60 ksi for this particular alloy.
FIGS. 19-21 illustrate the yield strengths for Sheets B-E at various thermal treatment temperatures. As illustrated, at higher thermal treatment temperatures the time required to attain a given yield strength gets progressively shorter. Due to this short thermal treatment time, it is possible that paint baking cycles or coating cures could be used to thermally treat new 6xxx aluminum alloy bodies, making them particularly useful for automotive applications and rigid container packaging applications, among others.
Given these significant strength increases, a significant drop in ductility would be expected for Sheets B-E. However, as shown in Table 5, below and FIG. 23 , the 6xxx+Cu+Zn aluminum alloy bodies realize good elongation values. All elongation values are in percent. Similar elongation values are measured for the samples thermally treated at 300° F., 325° F., 375° F., and 400° F.
TABLE 5
Elongation (%) of the 6xxx + Cu + Zn alloy at various
thermal treatment times (350° F.)
Sheet E
Sheet D
Sheet C
Sheet B
Sheet A
85% CW
60% CW
35% CW
11% CW
Time
(T6) (old)
(new)
(new)
(new)
(new)
2
24
12.0
12.0
10.0
14.0
4
18.5
12.0
11.0
10.0
11.0
8
14
11.0
11.0
8.0
10.0
16
13
12.0
10.0
8.0
10.0
24
12
11.0
12.0
7.5
6.0
Test 2 Samples—Mechanical Properties
Samples from Sheets A-E are thermally treated, the conditions of which are provided in Table 6, below (“the test 2 samples”). Mechanical properties are measured, the averages of which are also provided in Table 6. Sheets C-E of the new process and having more than 25% cold work achieve higher strengths than the Sheet A product of the old process, and in all directions, while Sheet B with less than 25% cold work realizes similar properties to that of Sheet A.
TABLE 6
Mechanical Properties of the 6xxx + Cu + Zn alloy
Product
(thermal treatment
Test
temp, duration)
Direction
TYS (ksi)
UTS (ksi)
El (%)
Sheet E
L*
71.3
73.6
10.5
85% CW
LT
74.0
78.1
13.3
(300° F., 8 hours)
45°
66.7
70.2
12.0
Sheet D
L
67.9
70.1
9.5
60% CW
LT
66.0
69.3
11.5
(300° F., 24 hours)
45°
63.7
67.4
10.3
Sheet C
L
62.8
65.2
12.0
35% CW
LT
58.5
63.4
10.5
(300° F., 24 hours)
45°
58.3
63.3
11.3
Sheet B
L
56.0
59.3
14.0
11% CW
LT
55.1
60.0
11.0
(300° F., 48 hours)
45°
54.2
59.3
12.5
Sheet A
L
56.8
58.7
14.0
(T6)
LT
54.1
57.9
11.5
(350° F., 12 hours)
45°
53.4
57.1
11.5
*= single specimen - not average values
Test 2 Samples—Fatigue
The test 2 samples from Sheets A-E are also subjected to strain fatigue testing in accordance with ASTM E606, the results of which are illustrated in FIGS. 24-25 . As shown, the sheets made by the new process and with more than 25% cold work realize high cycle fatigue performance over the conventionally processed material, i.e., Sheet A in the T6 temper. In the low cycle (high strain) regime, these sheets are similar or better than Sheet A.
Test 2 Samples—Fracture Toughness
The test 2 samples from Sheets A-E are subjected to fracture toughness testing in accordance with ASTM E561 and B646. The fracture toughness is measured using M(T) specimens with a width of about 6.3 inches and a thickness of about 0.2 inch, with an initial crack length of from about 1.5 to about 1.6 inches (2a o ). The measured K app values from the fracture toughness test are provided in Table 7, below. The above-noted strength values are also reproduced for convenience.
TABLE 7
K app values for Sheets A-E ((M)T, T-L, W = 6.3 inches)
Sheet B
Sheet C
Sheet D
Sheet E
Material
Sheet A
11% CW
35% CW
60% CW
85% CW
(ID)
(T6) (old)
(new)
(new)
(new)
(new)
K app
62.9
59.7
57.1
56.9
61.9
(ksi √in)
Percent
—
5.1%
9.2%
9.5%
1.6%
decrease
over Alloy A
TYS (LT)
54.1
55.1
58.5
66.0
74.0
Percent
—
1.8%
8.1%
22%
37%
increase
over alloy A
Ratio
—
0.35
0.88
2.32
23.13
of TYS
increase:FT
decrease
Sheets D-E realize only slightly lower fracture toughness than Sheet A, even though Sheets D-E have much higher strength. All of the results are within a relatively narrow range of ˜57 to 63 ksi√in. R-curve data (not shown) indicates that, despite the range in strength of the material, all of Sheets A-E have similar R-curves. FIG. 26 illustrates the strength and fracture toughness values using the K app values of Table 7 and the LT strength values of Table 6. Generally, the new alloy bodies produced by the new process and having more than 25% cold work realize a similar or better combination of strength and fracture toughness relative to the conventionally produce T6 product. For example, Sheet E of the new process with 85% CW realizes about a 37% increase in strength, with only about a 1.6% decrease in fracture toughness over Sheet A in the T6 temper.
Test 2 Samples—Corrosion Resistance
The test 2 samples from Sheets A-E are tested for corrosion resistance in accordance with ASTM G110. The test results are summarized in Table 8, below. The average and maximum depth-of-attack (from 10 readings) for each of Sheets A-E are provided.
TABLE 8
Corrosion Properties of the 6xxx + Cu + Zn alloy
Ave Depth
Min. Depth
Max. Depth
Sheet
CW %
(μm)
(μm)
(μm)
Sheet A
N/A -
64
5
130
T6
Sheet B
11
97
67
152
Sheet C
35
92
43
154
Sheet D
60
56
3
87
Sheet E
85
39
33
51
Overall, the results indicate that the new processing methodology does not significantly affect the corrosion performance of the alloy. In fact, increasing cold work appears to decrease the average and max depth of attack.
The 6xxx+Cu+Zn alloy bodies are also tested for grain structure as per the OIM procedure, described above. The results are provided in Table 9, below.
TABLE 9
Microstructure (OIM) Properties of the 6xxx + Cu + Zn alloy
Measurement
First Type Grains
Percent
Sample
Location
per OIM (%)
Unrecrystallized
Control
T/4 to surface
98%
2%
11% CW
T/4 to surface
95%
5%
35% CW
T/4 to surface
12%
88%
60% CW
T/4 to surface
8%
92%
85% CW
T/4 to surface
5%
95%
The new 6xxx+Cu+Zn alloy bodies with more than 25% cold work have a predominately unrecrystallized microstructure, having a volume faction of not greater than 0.12 first type grains (i.e., 88% unrecrystallized) in all instances. Conversely, the control body is nearly fully recrystallized having a volume fraction of 0.98 first type grains (i.e., 2% unrecrystallized).
The R-values of the 6xxx+Cu+Zn alloy bodies are also tested as per the R-value generation procedure, described above. The results are illustrated in FIG. 10 and Table 2, described above. The new 6xxx+Cu+Zn alloy bodies with 60% and 85% cold work have high normalized R-values, both achieving a maximum R-value of more than 3.0, and achieving this maximum normalized R-value at an orientation angle of 50°. These high R-values may be indicative of the unique texture, and thus microstructure, of the new 6xxx+Cu+Zn alloy bodies described herein. The new 6xxx+Cu+Zn alloy bodies with 60% and 85% cold work also realize about 369% to 717% higher maximum R-values as compared to the R-value of the control body (for the purpose of measuring R-values, the control is in the T4 temper, not the T6 temper).
Example 2
Multi-Layered Product Testing in the Form of can Body Stock
Several multi-layered products comprising AA3104 as the cladding and AA6013 as the core is produced similar to the methodology of FIG. 12 , described above, and in the H temper. The multi-layered product is produced in both the 2-layer (3014-6013) and the 3-layer (3104-6013-3104) form. The mechanical properties of the multi-layered products are tested in both the H1x temper and after curing of the coating. The results are provided in Table 10, below.
TABLE 10
Mechanical Properties of multi-layered products
AS COLD
AFTER COATING
Finish
ROLLED
CURE (400° F./
Thick-
Cold
H1x TEMPER
20 minutes)
ness
Work
TYS
UTS
Elong
TYS
UTS
Elong
Material
Lot
(inch)
(%)
(ksi)
(Ksi)
(%)
(ksi)
(ksi)
(%)
3104
A
0.014
86%
41.1
45.0
6.0
37.9
41.9
5.0
(conv.)
3-Layer
B
0.028
72%
55.2
60.4
8.0
55.1
58.5
7.0
C
0.023
77%
56.6
61.3
8.0
56.0
59.2
6.5
D
0.018
82%
56.8
61.2
7.5
55.6
58.9
6.0
E
0.013
87%
58.7
63.1
7.0
56.1
59.1
4.5
2-Layer
F
0.028
72%
67.6
72.2
9.5
67.8
69.4
5.5
G
0.023
77%
64.9
69.2
8.0
64.0
66.1
5.5
H
0.016
84%
69.8
73.5
7.0
65.8
67.4
5.0
I
0.014
86%
69.3
72.6
7.0
65.6
67.1
4.5
All multi-layered products realize an improved combination of strength and ductility over the standard 3104 alloy product, realizing an increase in TYS (after cure) of from about 17 ksi to 30 ksi, and with similar or better ductility. The clad layer of 3104 may be used to restrict pick-up of aluminum and oxides on the ironing dies during can making. The core layer of 6013 may be thermally treated during the coating cure, which may increase its strength.
Example 3
Testing of Alloy 6013
Aluminum Association alloy 6013 is produced in manner similar to that of Example 1, and its mechanical properties are measured. Alloy 6013 is a zinc-free, copper-containing 6xxx alloy. The composition of the tested 6013 alloy is provided in Table 11, below. The mechanical properties are illustrated in FIG. 27-35 .
TABLE 11
Composition of 6013 alloy (all values in wt. %)
Others
Others
Si
Fe
Mn
Cu
Mg
Cr
each
Total
Bal.
0.70
0.25
0.32
0.89
0.94
0.03
≦0.05
≦0.15
Al
Alloy 6013 achieves a peak LT tensile yield strength of about 64-65 ksi with 75% cold work and 60-61 ksi with 55% cold work, which is several 8-13 ksi higher than the peak strength of the control alloy (T6). The 75% and 55% cold worked alloys realize these strengths faster than the control (T6) alloy.
The optical properties of the control, 55% cold work and 75% cold work 6013 sheets is evaluated using a Hunterlab Dorigon II (Hunter Associates Laboratory INC, Reston, Va.). The sheets are first mechanical polished to a mirror finish, cleaned, chemically polished, anodized to 0.3 mil oxide thickness and sealed. The specular reflectance, image clarity and 2 degree diffuseness are measured to quantify the appearance of the anodized surface. Higher specular reflectance and image clarity values are indicative of brighter and more uniform appearance. Lower 2 degree diffuseness indicates a reduced level of haze in the reflected image. High specular reflectance and image clarity and low 2 degree diffuseness are valued for applications where the product is used as a reflector (as in lighting applications) and in other consumer electronics applications where a bright, uniform surface may be desired. Having aluminum alloy products with bright surfaces and high strength may be advantageous in these (and other) applications.
The measured optical properties of these 6013 sheets are provided shown in Table 15. As shown in the table, the optical properties for the 55% and 75% cold work 6013 sheets are improved over the control. The 55% and 75% cold work 6013 sheets also have improved strength, as shown above.
TABLE 15
Optical Properties of 6013 alloy
Sheet (old)
Sheet (new)
Sheet (new)
Optical Properties
Control
55% CW
75% CW
Specular Reflectance
15.2
16.4
17.3
2 Degree Diffuseness
7.66
6.52
5.86
Image Clarity
29.3
35.0
38.4
Specular Reflectance %
NA
7.9
13.8
improvement
2 Degree Diffuseness %
NA
14.9
23.5
improvement
Image Clarity % improvement
NA
19.5
31.
Example 4
Testing of Alloys 6022 and 6061
Aluminum Association alloys 6022 and 6061 are produced in manner similar to that of Example 1, and their mechanical properties are measured. Alloy 6022 is a low copper, zinc-free alloy, having 0.05 wt. % Cu. Alloy 6061 is another low-copper, zinc-free alloy, having 0.25 wt. % Cu. The compositions of the tested 6022 and 6061 alloys are provided in Tables 12 and 13, below. The mechanical properties are illustrated in FIG. 36-37 .
TABLE 12
Composition of 6022 alloy (all values in wt. %)
Others
Others
Si
Fe
Mn
Cu
Mg
Cr
each
Total
Bal.
0.86
0.16
0.07
0.05
0.61
0.02
≦0.05
≦0.15
Al
TABLE 13
Composition of 6061 alloy (all values in wt. %)
Others
Others
Si
Fe
Mn
Cu
Mg
Cr
each
Total
Bal.
0.65
0.46
0.06
0.25
0.95
0.19
≦0.05
≦0.15
Al
Neither alloy 6022 nor 6061 is able to achieve an LT tensile yield strength of more than 60 ksi. The results of Examples 1-4 indicate that the strengthening response of an alloy relative to the new process disclosed herein may be dependent upon the type and amount of alloying elements used. It is believed that alloying elements that promote strain hardening and/or precipitation hardening may provide improved properties. It is also believed that the alloys may require sufficient solute to achieve improved properties. It is believed that the 6xxx+Cu+Zn alloy and the 6013 alloy are able to achieve the more than 60 ksi strengths because they contain sufficient solute (e.g. additional copper and/or zinc) to facilitate a high degree of hardening response (strain and/or precipitation). It is believed that alloys 6061 and 6022 do not achieve the 60 ksi strength level because they do not appear to have sufficient solute to facilitate a high degree of hardening response when high cold working and an appropriate thermal treatment are applied.
The R-values of the 6061 and 6022 alloys are also tested as per the R-value generation procedure, described above, the results of which are illustrated in FIGS. 38-39 . The results indicate that these alloys have a different microstructure than the higher solute 6xxx+Cu+Zn and 6013 alloys. The 6022 alloy ( FIG. 38 ) does not have a maximum R-value in the orientation angle range of from 20° to 70°, as was realized by the 6xxx+Cu+Zn alloy. Indeed, the shape of the R-curve nearly mirrors the control specimen, realizing its maximum R-value at an orientation angle of 90°. As shown in FIG. 39 , the 6061 alloy attains a maximum R-value at an orientation angle of 45°, but achieves an R-value of less than 3.0.
Example 5
Testing of High-Mg 6xxx Alloy
A 6xxx alloy with high magnesium (6xxx-high-Mg alloy) is produced in sheet and plate form in a manner similar to that of Example 1. The final thickness of the sheet is 0.08 inch and the final thickness of the plate is 0.375 inch. The composition of the 6xxx-high-Mg alloy is provided in Table 14, below. The 6xxx-high-Mg alloy has low copper at 0.14 wt. % and is zinc-free (i.e., contains zinc only as an impurity). The mechanical properties of the 6xxx-high-Mg alloy are illustrated in FIGS. 40-51 .
TABLE 14
Composition of 6xxx-high-Mg alloy (all values in wt. %)
Others
Others
Si
Fe
Mn
Cu
Mg
Cr
each
Total
Bal.
0.81
0.28
0.61
0.14
1.45
0.14
≦0.05
≦0.15
Al
The 6xxx-high-Mg alloy in sheet form achieves an LT tensile yield strength of more than 60 ksi when cold worked and with good elongation. The results of Examples 4 and 5 show that such high-Mg 6xxx alloys may achieve at least 60 ksi LT yield strength, with low levels of copper and without zinc (i.e., zinc as an impurity only). The high magnesium may promote a strain hardening response and/or precipitation hardening response. Other high-magnesium alloy bodies may realize a strength level of less than 60 ksi, but may still find utility in various product applications.
While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present disclosure. | New 6xxx aluminum alloy bodies and methods of producing the same are disclosed. The new 6xxx aluminum alloy bodies may be produced by preparing the aluminum alloy body for post-solutionizing cold work, cold working by at least 25%, and then thermally treating. The new 6xxx aluminum alloy bodies may realize improved strength and other properties. | 2 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/030,403, filed Jul. 29, 2014, which is hereby incorporated by reference in its entirety.
BACKGROUND AND SUMMARY
[0002] This disclosure relates generally to CT scanners; in particular, this disclosure relates to a proton-computed tomography device.
[0003] Existing treatment planning systems at proton therapy centers use x-ray CT as the primary imaging modality for treatment planning to calculate doses to tumor and healthy tissues. One limitation of x-ray CT is in the conversion of x-ray attenuation coefficients to relative (proton) stopping powers, or RSP. This results in more proton range uncertainty, larger target volumes and therefore, more dosage to healthy tissues. Therefore, there exists a need for a novel device for imaging and reconstructing more accurate RSP values.
[0004] According to one aspect, this disclosure provides a high performance computer system for three dimensional proton computed tomography. The system includes a proton computed tomography (pCT) detector assembly with an arrangement of fibers attached to silicon photo multipliers (SiPMs), the SiPMs generating signals representative of proton energy detected by the arrangement of fibers. An electronic circuit is provided that is in electrical communication with the SiPMs of the pCT detector system. In some embodiments, the electronic circuit includes an amplifier, a digitizer, a network communication device and a processor. The amplifier is configured to amplify the signals of the SiPMs. The digitizer is configured to digitize the signals of the SiPMs. The network communication device transmits messages over a network. The processor controls amplifying and digitizing of the signals of the SiPMs and is configured to send packetized messages with data of the SiPMs using the network communication device. In some embodiments, the system includes a data acquisition system in electronic communication with the electronic circuit for storing data received from the electronic circuit.
[0005] According to another aspect, this disclosure provides a method of imaging an object. The method includes the step of providing a proton computed tomography (pCT) detector assembly including an arrangement of fibers attached to silicon photo multipliers (SiPMs). Each of the SiPMs generate a signal representative of proton energy detected by one or more of the fibers. The signals of a plurality of SiPMs are amplified and digitized with an electronic circuit and sent in packetized messages via a network for image reconstruction.
[0006] Additional features and advantages of the disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrated embodiment exemplifying the best mode of carrying out the invention as presently perceived. It is intended that all such additional features and advantages be included within this description and be within the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present disclosure will be described hereafter with reference to the attached drawings which are given as non-limiting examples only, in which:
[0008] FIG. 1 is a diagrammical view of a proton CT imaging system according to an embodiment of this disclosure.
[0009] FIG. 2 is a side view of an example of fiber configuration according to an embodiment of this disclosure.
[0010] FIG. 3A shows an example of an (X,Y) fiber tracker station according to an embodiment of this disclosure.
[0011] FIG. 3B shows an example of an arrangement of fibers attached to silicon photo multipliers (SiPMs) according to an embodiment of this disclosure.
[0012] FIG. 4A is a graph showing an example of pedestal and single photoelectron noise signal peaks for a single calorimeter tile.
[0013] FIG. 4B is a graph showing an example of ADC distribution as a function of file number for 200 MeV protons.
[0014] FIG. 4C is a graph showing an example of photo-electron count per fiber tracker bundle for 200 MeV protons.
[0015] FIG. 5 is a diagrammatic view of an example of front end electronics that could be used for amplifying, digitizing and storing data before sending to the data acquisition system according to an embodiment of this disclosure.
[0016] FIG. 6 is a diagrammatic view of an example of a data acquisition system according to an embodiment of this disclosure.
[0017] FIG. 7 is a photograph of an example of a proton CT scanner according to an embodiment of this disclosure.
[0018] Corresponding reference characters indicate corresponding parts throughout the several views. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principals of the disclosure. The exemplification set out herein illustrates embodiments of the disclosure, and such exemplification is not to be construed as limiting the scope of the disclosure in any manner.
DETAILED DESCRIPTION
[0019] While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific exemplary embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.
[0020] This disclosure relates to a proton CT scanner for applications in proton treatment planning. In proton therapy, the current treatment planning systems are based on X-ray CT images that have intrinsic limitations in terms of dose accuracy to tumor volumes and nearby critical structures. Proton CT aims to overcome these limitations by determining more accurate relative proton stopping powers directly as a result of imaging with protons. At present, the proton RSPs for various tissues, as derived from X-ray CT, produce range uncertainties (Schneider, 1994) of about 3 to 4%. This disclosure attempts to reduce this to approximately 1% of the total range using proton CT. In addition, three to five times lower doses than X-ray CT are possible and absence of artifacts from high density dental or other implants will add to higher quality images. The proton CT imaging requires reconstruction of the individual proton tracks and their energy losses in the scanned volume. The number of protons to acquire for the head-size volume scan is of order one billion. To finish scan in a time acceptable for the patients the track collection rate should be of order 2 MHz, that requires fast tracker and energy detectors. To date two proton CT scanners are under development in the United States. The system that uses silicon strip technology for the tracker planes and five plastic scintillators for the range measurements was built in the Santa Cruz Institute of Particle Physics and is undergoing testing at Loma Linda University Medical Center (Sadrozinski, 2013).
[0021] A proton CT scanner based on fiber tracker and scintillator stack range detector that has been developed at Northern Illinois University in conjunction with FNAL in Batavia, Ill. For example, U.S. Pat. No. 8,766,180 for a High Performance Computing For Three Dimensional Proton Computed Tomography (HPC-PCT), which is hereby incorporated by reference, describes example device. FIG. 1 shows a schematic of a proton CT scanner 100 . In the illustrative example shown, the system 100 includes eight planes of tracking detectors 102 ; two X and two Y coordinate measurements both before and after the patient 104 . This provides the information for finding the trajectory through the head 104 to correct, as much as possible, for multiple coulomb scattering in the patient 104 . A “most likely path” formalism (Erdelyi, 2009) is used to find which voxels, of order 1 mm 3 are crossed by every track. In addition, a calorimeter 106 having a stack of thin scintillator tiles is used to determine the water equivalent path length (WEPL) of each track through the head 104 . The X-Y coordinates and WEPL are required input for image reconstruction software to find RSP values of each voxel in the head 104 and generate corresponding 3D image.
[0022] 1. Design Specification
[0023] In addition to a high data rate of 2 MHz, large enough area should be covered to image an adult human head so that table motion is not required or that splice data from multiple scans are not required to make an image long enough along the body axis. For head scans, in one embodiment, a maximum head size of 23 cm diameter and a length along the body axis of 20 cm were chosen. This will allow imaging of the head 104 down to the jaw bone in one 360° gantry rotation. A fixed incident proton beam energy of 200 MeV with a range of 26 cm in water can be used for head size imaging. This proton CT detector is compatible with the geometric constraints of most proton treatment nozzles and patient positioners. Beam spreading from an effective source in the nozzle sets the detector sizes required for cone beam geometry. Multiple coulomb scattering in the tracking detectors requires a reduction of the mass of the detectors as much as possible. For this reason, each tracking plane has a water equivalent thickness less than 1 mm.
[0024] 2. Detector Design and Construction
[0025] In order to have low mass detectors, with high proton rates, and continuous area coverage over a large area, the tracker was constructed from 0.5 mm diameter polystyrene scintillating fibers by Kuraray (KurarayCo.). In one embodiment, fibers were initially cut to 50 cm length, then laid flat, and doubled layered (see, e.g., FIG. 2 ) on a low density, 0.03 g/cm3, 2 mm thick rohocell substrate with machined grooves and glued to hold the fibers in place with close spacing to avoid gaps in detecting passing protons. The entire assembly is supported on carbon fiber frames. A photograph of one tracker plane, 20×24 cm, is shown in FIG. 3A for purposes of example.
[0026] In the illustrative embodiment shown, fibers are grouped in triplets, called bundles, according to FIG. 2 , which give a pitch between bundles of 0.94 mm. Each bundle is readout into silicon photo multipliers (SiPMs), produced by CPTA (CPTA Ltd.) which are mounted on Techtron blocks that connect each of them to a fiber triplet. The SiPMs chosen have the best chromatic (or wavelength) match to the Kuraray scintillators. One end of each fiber is polished and mirrored. The other end is polished and mechanically pressed to a SiPM on a block shown in FIG. 3B . The rms spatial resolution of each tracker plane is given by the pitch divided by √{square root over (12)}, or 0.27 mm. The integrated water equivalent thickness (WET) of each tracker along the beam direction is less than 1 mm. With four planes of 20×24 cm 2 in area and four planes with 24×30 cm 2 in area, there are about 2100 channels of readout for the entire tracker.
[0027] In one illustrative embodiment, the calorimeter 106 chosen for this design is a proton range detector which includes a stack of 96, 3.2 mm thick, polyvinyltoluene (PVT) scintillating tiles, with 0.006 mm aluminized mylar between adjacent tiles. Each tile, 27×36 cm 2 in area, is machine grooved to embed a 1.2 mm diameter wavelength shifting (WLS) fiber that weaves four times across the tile for improved light collection efficiency. Both ends of the WLS fiber are read out through SiPMs. This requires 192 channels of readout for the calorimeter. Each SiPM signal is amplified and digitized for later analysis for fitting to the shape of a Bragg peak to determine the proton range in the calorimeter. Water equivalent blocks can be used to calibrate range measured in calorimeter (Hurley, 2012).
[0028] An intrinsic limitation in any proton calorimeter is the combined range (or energy) straggling due to the mass represented by the patient plus calorimeter. In near water equivalent materials such as brain tissue and PVT scintillator, the sum of energy straggling in the human head and calorimeter is almost constant and approximately equal to ±3.6 mm (Janni, 1982). Therefore, there is little incentive to produce tiles less than 3 mm thickness.
[0029] The 96 tile calorimeter was built and underwent first tests with 200 MeV proton beam at Central DuPage Hospital in Warrenville, Ill. Examples of pedestal distribution and a single photoelectron distribution from a calorimeter tile are shown in FIG. 4A . FIG. 4B shows the Bragg peak from a sample of 200 MeV protons. To measure signal to noise ratio of the fiber bundles a fiber tracker plane prototype was also exposed to a 200 MeV proton beam. The results are shown in FIG. 4C , with 15 to 20 photo-electrons per proton per channel in the beam spot area.
[0030] 3. Electronics
[0031] In the embodiment shown in FIG. 5 , the electronics that read out the SiPMs 502 include a custom circuit board 500 with preamplifiers 504 , digitizers 506 , and ethernet readout 508 . In one illustrative embodiment, this custom board uses commercial off-the-shelf (COTS) components to provide readout for up to 32 channels of SiPM in a 220 mm×100 mm format that fits into a standard 3 U sub-rack. The same board 500 is used for readout of the trackers 102 and the calorimeter 106 . The digitization of the signals from SiPMs, after appropriate amplification and shaping, is illustratively 12 bits per channel at 75 MSPS. The board 500 is completely self-contained and generates the bias 510 for the SiPMs (one bulk voltage but with a 3 V adjustment range for each SiPM). It also contains an FPGA 512 for processing all of the data generated by the SiPMs, memory 514 for buffering up to 128 MB of data and a gigabit ethernet interface 508 for pushing data directly to the data acquisition (DAQ) system 516 . Other support circuitry includes temperature sensors for the SiPMs, clock management 518 and a high speed USB port 520 for debugging. Parameters such as the board's ethernet address or the correct bias voltage for the SiPMs are stored in a small flash memory 522 on the board. The board 500 is illustratively powered by a single 5 V power supply and has a power consumption of up to 15 W for 32 SiPM electronics channels. Each board locks to the clock provided by one board in each of the 9 sub-racks. Each of these boards in turn locks to a “master” board which has a free running crystal clock. Run control is accomplished by communicating with this “master” over ethernet.
[0032] The scanner is “self triggered” in the sense that any channel with a signal above threshold will be time stamped and stored in a local buffer for readout. A synchronous signal allows all boards to provide a timestamp that is used by the DAQ system to associate the data from different parts of the detector for a single proton history. Data from signals in the detector is highly compressed (only fiber address and timestamp from the trackers, compressed amplitude and time stamp from the calorimeter) and sent to the DAQ as soon as it is available. A synchronization signal which circulates across all boards approximately once per millisecond initiates a packet or “frame” of data readout from memory 512 to DAQ memory via 1 Gbit/s ethernet with only slight dead time penalty. A “footer” with error messages can be sent with each packet as well. Organizing the data into these one millisecond “time frames” allows for a relatively small timestamp (16 bits of 75 MHz clock cycles) and allows the DAQ 516 to monitor the integrity of the data.
[0033] 4. Data Acquisition System
[0034] FIG. 6 shows an illustrative embodiment with a detector 100 in electronic communication with front end boards 500 , which sends data to DAQ 516 via a plurality of aggregating switches 600 over Ethernet. The front end electronics 500 will illustratively send data to the DAQ 516 via 1 Gbit/s ethernet lines using UDP protocol. Each proton event contains data for 8 tracker planes and the 96 tile scintillator stack. Each event is calculated to generate about 25 bytes from the 8 hits on the 8 planes and about 75 bytes from the 96 tiles. For a 10 minute scan with 90 projection angles at a data rate of 2 million protons per second, we expect 200 MB/s written to RAM by 24 data collectors running on six interconnected Linux workstations. At the end of the scan, the back end DAQ 516 will write data to disk 602 and subsequently, through post processing of the data 604 , obtain proton histories in the format for image reconstruction, i.e., 4 X and 4 Y coordinates, WEPL, and beam (or phantom) rotation angle.
[0035] 5. Summary
[0036] The NIU Phase II proton CT scanner is fully assembled and installed for tests in a 200 MeV proton beam in Warrenville, Ill., USA. FIG. 7 illustratively shows the scanner mounted on a cart in a treatment room. After system commissioning, a CIRS head phantom (Computerized Imaging Reference Systems, Inc.) will be inserted between tracker planes to collect data for image reconstruction on a CPU/GPU compute cluster (Duffin, 2012). This compute cluster has been tested with data acquired with an earlier prototype scanner (Coutrakon, 2011 and Sadrozinski, 2012) and has demonstrated high quality 3D image reconstruction of a 14 cm spherical Lucy phantom from Standard Imaging, Inc. (www.standardimaging.com). The first 3D head scan images are expected to be obtained in summer of 2014. The detailed project documentation can be found at (http://www.nicadd.niu.edu/research/medical).
PUBLICATIONS
[0037] Publications cited in this application are herein incorporated by reference to the extent they relate materials or methods disclosed herein,
Computerized Imaging Reference Systems, Inc., www.cirsinc.com, Norfolk, Va. Coutrakon, G. et al., “Design and Construction of the 1st Proton CT Scanner”, AIP Conference Proceedings, No. 1525, Application of Accelerators in Research and Industry, Ft. Worth, Tex., August 2012, p. 327-331. CPTA Ltd., www.cpta-apd.ru, Moscow, Russia. Duffin, K. et al., “An analysis of a distributed GPU implementation of proton computed tomographic reconstruction”, Proceedings of the 2012 SC Companion: HPC, networking, storage and analysis, p. 166-175, ISBN no. 978-0-7695-4956-9, November 2012, Seattle, Wash. Erdelyi, B., “A comprehensive study of the most likely path formalism for proton computed tomography”, Physics in Medicine and Biology 54, p. 6095 (2009). Hurley, R. F. et al., “Water equivalent path length calibration of a prototype CT scanner”, Med. Phys. 39 (5), p. 2438 (2012). Janni, J., “Proton range-energy tables, 1 keV-10 GeV,” Atomic Data and Nuclear Data Tables 27(2-5), p. 147-429 (1982). KurarayCo., Ltd, Japan, http://kuraraypsf.jp/psf/index.html Sadrozinski, H. F. W. et al., “Development of a head scanner for proton CT”, Nucl. Instrum. Meth. A699, 205-210 (2013). Sadrozinski, H. F. W. et al., IEEE NSS-MIC Conference, 4457-4461, (2011). Schneider, U., “Proton Radiography as a tool for quality control in proton Therapy”, Med. Phys. 22, p. 353 (1994). Uzunyan, S. et al., “Development of a proton Computed Tomography (pCT) scanner at NIU”, Proceedings of the New Trends in High-Energy Physics, p. 152-157, Alushta, Crimea, Ukraine, September 2013, arXiv:1312.3977 (2013). http://www.nicadd.niu.edu/recearch/medical http://www.standardimagingcom, see Lucy 3D QA phantom, Middleton, Wis. 53562. | A high performance computer system for three dimensional proton computed tomography and method of imaging an object are disclosed. The system includes a proton computed tomography (pCT) detector assembly with an arrangement of fibers attached to silicon photo multipliers (SiPMs). An electronic circuit amplifies and digitizes signals received from the SiPMs and communicates the digitized data over a network for image reconstruction. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Pursuant to 35 U.S.C. § 120, this application is a divisional application of U.S. application Ser. No. 10/204,585, filed on Aug. 22, 2002, which is the U.S. National Phase application of WIPO Application No. PCT/DE00/00498, filed on Feb. 23, 2000. The contents of the prior applications are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a photoluminescent composition (e.g., a layer) as well as related articles, methods, and devices.
BACKGROUND
[0003] A more or less effective luminescence conversion has already been used for some time in various fields, for example in radiation detector technology. In general, functional units that are used for luminescence conversion are based on absorption/emission processes. Utilized is the fact that there is a shift of luminescence to longer wavelengths compared to absorption in most cases, for energetic reasons. This phenomenon can be used, for example, for spectral matching of detector sensitivity to a radiation source.
[0004] Furthermore, the property of luminescence radiation no longer to be bound to the direction of the incident radiation is of interest, since concentration of radiation in a medium can be realized by total reflection at the interfaces.
[0005] A recent example is the production of “white” light by way of partial conversion of the radiation from a blue luminescent diode. The LUCOLED (P. Schlotter, R. Schmidt, J. Schneider, Appl. Phys. A 64, 417 (1997)) utilizes this principle. A portion of the high-energy blue luminescent radiation is absorbed by a suitable layer in the beam direction and is emitted again shifted toward lower energies, so that a white color impression is produced by additive mixing. DE 196 25 622 A1 describes such a light-radiating semiconductor component with a semiconductor body emitting radiation and with a luminescence conversion element. The semiconductor body has a sequence of semiconductor layers that emits electromagnetic radiation with a wavelength λ of ≦520 nm, and the semiconductor conversion element converts radiation of a first spectral subregion of the radiation emitted by the semiconductor body from radiation originating from a first wavelength region into radiation of a second wavelength region, so that the semiconductor component emits radiation from a second spectral subregion of the first wavelength region and radiation of the second wavelength region. Thus, for example, radiation emitted by the semiconductor body is absorbed with spectral selectivity by the luminescence conversion element and is emitted in the longer-wavelength region (in the second wavelength region). In this method, organic dye molecules are imbedded in an organic matrix.
[0006] DE 196 38 667 A1 also discloses a semiconductor component with a semiconductor body emitting radiation and a luminescence conversion element that emits mixed-color light, with the luminescence conversion element having a luminous inorganic substance, in particular a phosphor.
[0007] Besides spectral suitability with regard to the corresponding application, such a layer has two principal requirements: The photoluminescence quantum yield must be high, usually clearly greater than 50%, and its stability must permit long service lives, usually more than 10,000 hours.
[0008] The basic concept for realizing such a layer with organic dyes consists of separating and immobilizing molecules in a matrix so that they behave like monomers with optical properties similar to a liquid solution, particularly with high quantum yield. Polymers and sol-gel layers are known as matrices.
[0009] Mixed layers that were produced from the organic dye 3,4,9,10-perylenetetracarboxylic acid dianhydride (PTCDA) and SiO 2 by co-vaporization onto quartz substrates under high vacuum are described in H. Fröb, K. Kurpiers, K. Leo, CLEO '98, San Francisco/CA, May 1998, 210; 1998 OSA Technical Digest Series Vol. 6, published by Optical Society of America (“The Fröb publication”). The concentration range studied was 0.65-100 vol. %. It was observed that the absorption and emission spectra for decreasing concentrations gradually approach those in a liquid solution, and for the lowest concentration a photoluminescence quantum yield of about 50% is achieved at room temperature ( FIG. 6 , corresponding to FIG. 2 of the Fröb publication).
[0010] A device used for this purpose is described by M. A. Herman, H. Sitter, Molecular Beam Epitaxy, Ch. 2 (Sources of Atomic and Molecular Beams), Springer 1989, pp. 29-59. A dye vaporizer and a metal oxide vaporizer are provided in a vacuum chamber, whose vapor beam is aimed at a substrate, with the dye vaporizer being cup-shaped and consisting, viewed from the inside toward the outside, of a quartz cuvette, a graphite block, a heater, a shield, and a jacket, with a thermocouple being placed between the quartz cuvette and the graphite block in the bottom center of the cup.
[0011] FIG. 7 shows the normalized absorption and emission of 30-nm thick layers for a pure and a diluted dye layer. It is important that the spectra of the diluted layers can be fitted to those of monomers with their typical vibrational progression. It is found that the line width remains constant for all low concentrations; its enlargement compared to that observed in liquid solution is not surprising, considering the inhomogeneous conditions of the surroundings of the molecule.
[0012] The authors hold a weakening Förster transfer because of the increasing mean molecular separation responsible for the increase of quantum yields toward lower concentrations, and they expect a maximum at about 0.1 vol. %, but of course without experimental confirmation of this. No predictions are made about the lifetime, with regard to which all organic conversion layers so far have foundered.
SUMMARY OF THE INVENTION
[0013] The invention relates to a photoluminescent composition (e.g., a layer) as well as related articles, methods, and devices.
[0014] It is important for the solution of the problem that organic dye molecules are imbedded in an inorganic, amorphous or nanocrystalline matrix. The use of a silicon or metal suboxide in the vaporization is especially crucial for the optical stability of the photoluminescent layer. During the deposition of the silicon or metal suboxide in mixed vaporization of the components under high vacuum on the substrate, the suboxide reacts with residual gaseous oxygen of the high vacuum, with a slightly sub-stoichiometric oxygen content being reached by the matrix material under suitable vapor deposition conditions (characterized by the ratio of oxygen partial pressure to rate of vapor deposition). It is characteristic of the sub-stoichiometric oxygen content that with a matrix material of SiO x or TiO x x is between 1.95 and 2. A precise adjustment of the dye vapor deposition rate is necessary. For a low dye concentration, a definite adjustment to a low dye deposition rate (down to <10 −5 nm/s) is critically important. In certain embodiments, a temperature-regulated dye vaporizer is used for this purpose.
[0015] The vaporizer pursuant to the invention differs from the dye vaporizers known from the state of the art in the fact that the cover in the cup-shaped opening of the dye vaporizer constricted to a cut-out hole is connected to the quartz cuvette and is displaced toward the dye, so that the cut-out hole in the cover has a temperature like that of the heated quartz cuvette.
[0016] In some embodiments, the configuration of the photoluminescent layer makes it possible by extremely low dye surface densities, for example, to provide luminescence standards with almost ideal point sources of light for appropriately equipped microscopes (for example optical near-field microscopes, confocal luminescence microscopes) for the determination of resolving power and optical transmission functions or tests for the determination of the optical properties of individual molecules.
[0017] The benefits produced by the invention in particular, lie in the fact that a material is available that satisfies practical requirements with regard to optical stability with an average number of excitation/de-excitation cycles per molecule greater than 10 11 , that can be applied to very diverse substrates by dry technology (mixed vaporization of the components under high vacuum), and that at the same time has the highest known concentration of dyes in solutions without having photoluminescence quantum yields limited by aggregation or by Förster transfer.
[0018] Embodiments advantageously provide high optical stability for a photoluminescent layer based on a solid solution of organic dyes, as measured by the numerical midpoint of the excitation/deexcitation cycles per molecule before a fixed value of the decline of photoluminescence of the overall system.
DESCRIPTION OF DRAWINGS
[0019] The invention is explained in detail below with reference to examples of embodiment. The drawings show:
[0020] FIG. 1 an illustration of the photoluminescence quantum yield of 30-nm thick layers with various dye concentrations
[0021] FIG. 2 an illustration of the change of photoluminescence with high-intensity irradiation
[0022] FIG. 3 an illustration of the luminescence of SiO x layers with equal amounts of the dye MPP with different dye concentration
[0023] FIG. 4 a dye vaporizer pursuant to the invention in cross section
[0024] FIG. 5 an Arrhenius plot for calibrating the dye vaporizer
[0025] FIG. 6 an illustration of the photoluminescence quantum yield of PTCDA-SiO 2 mixed layers at room temperature
[0026] FIG. 7 normalized absorption and emission of 30-nm thick layers for pure and diluted PTCDA layers
DETAILED DESCRIPTION
[0027] A photoluminescent layer is described. The layer is photoluminescent in the optical and adjoining spectral regions. The layer is typically a solid solution of organic dye molecules within a silicon oxide or metal oxide. The layer can be applied (e.g., vapor deposited) on a substrate.
[0028] Applications of the layer include using the layer to provide white light, using the layer to input or output light to or from a waveguide, using the layer as a radiation detector, or using the layer as a point source for testing near-field microscopes or the like. In general, the layer is applied on a substrate for particular applications.
Example 1
[0029] In Example 1, 3,4,9,10-perylenetetracarboxylic acid dianhydride (PTCDA) was incorporated in an SiO x matrix, where 1.95<x<2. The layer is produced by thermal vaporization at operating pressures of about 10 −4 Pa produced by a turbomolecular pump, with SiO having been vapor-deposited at a deposition rate of 10 −2 nm/s for the production of the matrix, which reacts on the substrate with residual gaseous oxygen to give SiO x . The quartz resonators used in this multiple-source vapor deposition for the independent control of deposition rate and layer thickness are shielded from the other sources. To be able to measure even very small deposition rates, the measuring head for PTCDA is at a small distance from the vaporizer; this is possible with no problems because of the comparatively low vaporization temperature (typically 300-400° C.). For extremely small rates of vapor deposition, a temperature-regulated dye vaporizer was developed that permits stable rates down to <10 −5 nm/s for a period of at least one hour.
[0030] Radiationless energy transmission to nonradiating traps is the limiting factor for luminescence quantum yield. To reach a quantum yield similar to that in liquid solution, volume concentrations of about 0.1% are necessary in the present system ( FIG. 1 ). Compared to the data given in H. Fröb, M. Kurpiers, K. Leo, CLEO '98, San Francisco/CA, May 1998, 210, 1998 OSA Technical Digest Series Vol. 6, published by Optical Society of America, both a lower concentration was achieved and the quantum yields were determined and corrected with greater accuracy.
[0031] Results of studies of the optical stability of the layer are shown in FIG. 2 . To achieve adequately high excitation densities, a confocal microscope was used (excitation wavelength 532 nm); the luminescence was detected. After an initially severe non-exponential decline, a state is reached that can be described by a lifetime with about 10 11 excitation cycles per molecule, a value that is about 2 orders of magnitude above the best known in such systems.
[0032] One possible application is found as a photoluminescent layer in a system similar to the LUCOLED (P. Schlotter, R. Schmidt, J. Schneider, Appl. Phys. A 64, 417 (1997)). Applied to luminous densities occurring in luminescent diodes, service lives of the order of magnitude of 10 5 hours would be expected, based on the data in FIG. 2 .
Example 2
[0033] Production is analogous to that in Example 1, using N,N-dimethylperylene-3,4,9,10-bisdicarboximide (MPP), and the same effects are observed relative to the context of the invention: Increase of the photoluminescence quantum yield with decreasing concentration ( FIG. 3 ) and optical stability in the aforementioned sense of about 10 11 excitation cycles per molecule. The fact that the quantum yield becomes maximum at comparatively higher concentrations is due to the smaller absorption strength of MPP compared to that of PTCDA.
Example 3
[0034] Production is analogous to that in Example 1, with the difference that (a) the vapor deposition rate of PTCDA is extremely low, typically <10 −5 nm/s, and (b) the PTCDA vapor jet to the substrate is released by suitable diaphragms for only a very short time. Assuming that the procedure is performed extremely cleanly and exactly, dye molecules in this way can be placed enclosed by matrix material, with an average lateral molecular spacing of more than 100 nm being achievable. An optical near-field microscope at this time can achieve a resolving power of better than 50 nm; with a cover layer of 5 nm SiO x over the dye layer there is thus a test that permits determining the point transmission function by a direct path, or with which optical properties of individual molecules can be determined.
[0035] FIG. 4 shows a dye vaporizer that is placed in a vacuum chamber with a metal oxide vaporizer to carry out the procedure. The vapor jet of each vaporizer is aimed at a substrate. Diaphragms can be placed between vaporizers and substrate to interrupt the vapor deposition. The dye vaporizer shown in FIG. 4 , viewed from the inside to the outside, consists of a quartz cuvette 1 , a graphite block 2 , a heater 3 , a shield 4 , and a water-cooled copper jacket 5 . There is a thermocouple 7 in the bottom center of the cup between the quartz cuvette 1 and the graphite block 2 . There is a cover constricted to a cut-out hole in the cup-shaped opening of the dye vaporizer which is connected to the quartz cuvette 1 and is displaced toward the dye 6 , so that the cut-out hole in the cover has a temperature like that of the heated quartz cuvette 1 .
[0036] This dye vaporizer provides the capability of definitely setting an extremely low dye vapor deposition rate of <10 −5 nm/s, since such rates are not accessible to direct measurement. Such low rates of deposition are achieved by using the temperature-regulated dye vaporizer with high temperature distribution homogeneity in the quartz cuvette 1 , with a small heated cut-out hole in the cover of the quartz cuvette 1 , and extrapolation based on calibration with an Arrhenius plot ( FIG. 5 ). | This invention relates to a photoluminescent layer in the optical and adjoining spectral regions based on a solid solution of organic dyes. The photoluminescent layer includes organic dye molecules with a low dye concentration and a matrix material of metal oxides, with the matrix material having a slightly sub-stoichiometric oxygen content. A method and a device for producing the photoluminescent layer are described. | 2 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to a washer inlet attaching structure for attaching a washer inlet of a washer tank of a motor vehicle to a vehicle structural body.
[0003] 2. Description of the Related Art
[0004] A washer tank of a motor vehicle is a tank for storing a windshield washer fluid which is used by a windshield wiper system of the vehicle. The washer tank is disposed within an engine compartment of the vehicle, for example. Other component elements are also disposed within the engine compartment, and the washer tank is disposed in such a manner as to avoid accommodation spaces for those component elements. This sometimes causes a case where a washer tank cannot be disposed as an upper portion of the engine compartment, and as this occurs, a washer tank is used which has a configuration in which a washer inlet (a pouring pipe) is provided on a tank main body.
[0005] In attaching a washer tank having the configuration described above to a vehicle body, not only is the washer tank fixed to a vehicle structural body, but also the washer inlet is fixed to the vehicle structural body. This prevents the looseness or unsteadiness of the washer inlet.
[0006] In recent years, there are more and more vehicles which employ reins for their structural bodies. As a washer inlet attaching structure for fixing the washer inlet to such a vehicle structural body of resin, there is known a structure like one shown in FIGS. 9A and 9B . In this washer inlet attaching structure, a bracket 310 is attached to a washer inlet 301 , and the bracket 310 is then fixed to a vehicle structural body 321 with a fixing tool 316 such as a clip.
[0007] Specifically, the bracket 310 has a washer inlet gripping portion 311 , an attaching let portion 312 , and an attaching surface portion 313 . The washer inlet gripping portion 311 is such that a strip-like member is formed into an arc-like shape. The attaching leg portion 312 has a plate-like shape, and the washer inlet gripping portion 311 is connected to one end portion side of the attaching leg portion 312 . The attaching surface portion 313 , which is molded into a planar shape, is provided on the other end portion side of the attaching leg portion 312 . A projecting portion 315 and a through hole 314 are provided on the attaching surface portion 313 . An attached surface portion 322 , which is molded into a planar shape, is provided on the vehicle structural body 321 . The attached surface portion 322 is adapted to be brought into surface contact with the attaching surface 313 of the bracket 310 . A fixing hole 323 and a positioning hole 324 are provided in the attached surface portion 322 .
[0008] When the washer inlet 301 is attached to the vehicle structural body 321 by the bracket 310 , firstly, the washer inlet gripping portion 311 of the bracket 310 is fixed to the washer inlet 301 . Following this, the projecting portion 315 of the bracket 310 is inserted into the positioning hole 324 in the vehicle structural body 321 , so that the attaching surface portion 313 of the bracket 310 and the attached surface portion 322 of the vehicle structural body 321 are brought into surface contact with each other. In this state, the bracket 310 is fixed to the vehicle structural body 321 with the fixing tool 316 . This allows the washer inlet 301 to be attached to the vehicle structural body 321 via the bracket 310 .
[0009] A washer tank attaching structure described in JP-A-7-329733 is raised as another approach. In this washer tank attaching structure, by making use of a bracket in which a locking portion having a connection hole opened therein is provided on a holder portion which is formed into an arc-like shape, an inlet portion (a washer inlet) is attached to a vehicle body structure (a vehicle structural body).
[0010] In the washer inlet attaching structure described first above, however, the operations of positioning the bracket 310 , bringing the attaching surface portion 313 into surface contact with the attached surface portion 322 and fixing the bracket 310 with the fixing tool 316 needed to be performed, and these operations were complex and troublesome. In addition, places where to dispose the washer tank differs from model line to model line and hence, washer inlets of different shapes need to be attached to different attaching places. Because of this, different brackets need to be prepared to match corresponding model lines, and this reduces the versatility and calls for an increase in manufacturing costs. Further, since a washer tube (not shown) also needs to be fixed to the bracket 310 with a clip or the like, the number of parts is increased.
[0011] As with the washer inlet attaching structure that has just been described above, also in the washer tank attaching structure described in JP-A-7-329733, washer inlets of different shapes need to be prepared for different model lines. Because of this, brackets of different shapes need to be prepared for different model lines, and this reduces the versatility and calls for an increase in manufacturing costs.
SUMMARY
[0012] According to an aspect of the invention, there is provided a washer inlet attaching structure, configured to attach a washer inlet to a vehicle structural body made of resin, the washer inlet communicating with a tank main body adapted to store a windshield washer fluid and guiding the windshield washer fluid into the tank main body, the washer inlet attaching structure including a washer inlet holding portion, configured to hold the washer inlet, the washer inlet holding portion being molded integrally with the vehicle structural body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawing which is given by way of illustration only, and thus is not limitative of the present invention and wherein:
[0014] FIG. 1 is a perspective view of a washer inlet attaching structure according to a first embodiment of the invention;
[0015] FIG. 2 is a side view of a vehicle showing where to dispose a washer tank in the vehicle;
[0016] FIGS. 3A and 3B are explanatory diagrams of the washer inlet attaching structure according to the first embodiment of the invention, of which FIG. 3A shows a state resulting before a washer inlet is attached and 3 B shows a state resulting after the washer inlet is attached;
[0017] FIG. 4 is a perspective view of a washer inlet attaching structure according to a second embodiment of the invention;
[0018] FIG. 5 is a perspective view of the waster inlet attaching structure according to the second embodiment of the invention;
[0019] FIG. 6 is a bottom view of the washer inlet attaching structure according to the second embodiment of the invention;
[0020] FIGS. 7A and 7B are explanatory diagrams of the washer inlet attaching structure according to the second embodiment of the invention, of which FIG. 7A shows a state resulting before a washer inlet is attached and 7 B shows a state resulting after the washer inlet is attached;
[0021] FIGS. 8A and 8B are explanatory diagrams of a cap's open-state holding tool included in the washer inlet attaching structure according to the second embodiment of the invention, of which FIG. 8A shows a state in which an opening in the washer inlet is closed by a cap and FIG. 8B shows a state in the opening in the washer inlet is opened; and
[0022] FIGS. 9A and 9B are explanatory diagrams of a related-art washer inlet attaching structure, of which FIG. 9A shows a state resulting before a washer inlet is attached and FIG. 9B shows a state resulting after the washer inlet is attached.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A best mode for carrying out a washer inlet attaching structure according to the invention will be described specifically based on embodiments thereof.
[0024] A washer inlet attaching structure according to a first embodiment of the invention will be described by reference to FIGS. 1 , 2 , 3 A and 3 B.
[0025] FIG. 1 is a perspective view of a washer inlet attaching structure according to a first embodiment of the invention, FIG. 2 is a side view of a vehicle showing where to dispose a washer tank in the vehicle, FIGS. 3A and 3B are explanatory diagrams of the washer inlet attaching structure according to the first embodiment of the invention, of which FIG. 3A shows a state resulting before a washer inlet is attached and 3 B shows a state resulting after the washer inlet is attached. In FIGS. 1 , 2 , 3 A and 3 B, a line with an arrow FR denotes a direction of the front of the vehicle, and a line with an arrow UP denotes a direction of the rear of the vehicle. In FIGS. 1 , 3 A and 3 B, a line with an arrow ER denotes a direction of an interior of an engine compartment.
[0026] In this embodiment, as is shown in FIG. 2 , a washer tank 10 is disposed in an interior of an engine compartment E of a vehicle 20 . The washer tank 10 includes a tank main body 11 and a washer inlet 12 (a pouring pipe) which is provided in such a manner as to communicate with the tank main body 11 . The tank main body 11 is attached to a vehicle structural body (not shown). The washer inlet 12 is attached to an upper frame inner (a vehicle structural body) 21 which extends in a vehicle front-rear or longitudinal direction on a side portion of the vehicle and in the vicinity of an upper portion of the engine compartment E (refer to FIGS. 1 , 3 A and 3 B). A windshield washer fluid of the vehicle is stored in the tank main body 11 . The washer inlet 12 guides the windshield washer fluid into an interior of the tank main body 11 .
[0027] As is shown in FIGS. 1 , 3 A and 3 B, the washer inlet attaching structure according to the first embodiment has a washer inlet holder 100 (a washer inlet holding portion) which is formed integrally with the upper frame inner 21 . The upper frame inner 21 and the washer inlet holder 100 are molded of a resin.
[0028] The washer inlet holder 100 has a washer inlet gripping portion 111 , a first intermediate portion 120 , a second intermediate portion 130 and a tube holding portion 140 .
[0029] The washer inlet gripping portion 111 is molded as looking like a strip-like member extends into an arc-like shape. Specifically, the washer inlet gripping portion 111 is molded into a shape in which an inner wall portion 111 f thereof contacts a circumferential wall portion 12 a of the washer inlet 12 in a circumferential direction thereof. Both end portions 111 c, 111 d of the washer inlet gripping portion 111 are spaced apart on a side which faces the rear of the vehicle. Namely, the washer inlet gripping portion 111 is molded into a shape in which the washer inlet gripping portion 111 is opened on the side facing the rear of the vehicle. Further, in positions in the vicinity of the end portions 111 c, 111 d thereof, the washer inlet gripping portion 111 is formed into a shape in which the washer inlet gripping portion 111 extends outwards while being bent in that direction. By this configuration, when the washer inlet 12 is attached to the washer inlet gripping portion 111 , by the washer inlet 12 being brought into contact with both the end portions 111 c, 111 d of the washer inlet gripping portion 111 , the washer inlet 12 is restrained from being caught at the entrance to the washer inlet gripping portion 111 . As a result, the washer inlet 12 can be guided smoothly into the washer inlet gripping portion 111 from a rear side of the vehicle so that the washer inlet 12 can easily be attached therein.
[0030] The first intermediate portion 120 is such as to be interposed between the washer inlet gripping portion 111 and the upper frame inner 21 . The first intermediate portion 120 is molded into a plate-like shape and is made up of two members such as an intermediate member 121 and a reinforcement member 123 . A boundary portion 161 between one end portion side of the intermediate member 121 and a side wall portion 21 a of the upper frame inner 21 is formed rectilinearly. The other end portion side of the intermediate member 121 is connected to an outer wall portion 1113 w of the washer inlet gripping portion 111 . The reinforcement member 123 is connected to a lower portion of the intermediate member 121 , a lower wall portion 21 b of the upper frame inner 21 and a lower portion 111 b of the washer inlet gripping portion 111 and is such as to function as a reinforcement material of the intermediate member 121 . A boundary portion 163 between one end portion side of the reinforcement member 123 and the lower wall portion 21 b of the upper frame inner 21 is formed rectilinearly. By the boundary portions 161 , 163 being formed rectilinearly in the way described above, the rigidity at the boundary portions can be ensured.
[0031] An upper wall portion 122 of the intermediate member 121 extends from one end portion side (a side facing the upper frame inner 21 ) to the other end portion side (a side facing the washer inlet gripping portion 111 ) while extending downwards of the vehicle and has a first arc portion 122 a which is formed into an arc-like shape which projects upwards of the vehicle. Further, the upper wall portion 122 of the intermediate member 121 continues to the first arc portion 122 a, extends from the one end portion side (the side acing the upper frame inner 21 ) to the other end portion side (the side facing the washer inlet gripping portion 111 ) while extending upwards of the vehicle, and has a second arc portion 122 b which is formed into an arc portion which projects downwards of the vehicle. In addition, the second arc portion 122 b constitutes a tube supporting portion for supporting a washer tube, which will be described in detail later.
[0032] As with the first intermediate portion 120 , the second intermediate portion 130 is such as to be interposed between the washer inlet gripping portion 111 and the upper frame inner 21 . The second intermediate portion 130 is molded into a plate-like shape, is molded in a position lying further rearwards than the first intermediate portion 120 in the vehicle longitudinal direction, and is made up of two members such as an intermediate member 131 and a reinforcement member 133 . A boundary portion 162 between one end portion side of the intermediate member 131 and the side wall portion 21 a of the upper frame inner 21 is formed rectilinearly. The other end portion side of the intermediate member 131 is connected to the outer wall portion 111 e of the washer inlet gripping portion 111 . The reinforcement member 131 is connected to a lower portion of the intermediate member 131 , the lower wall portion 21 b of the upper frame inner 21 and the lower portion 111 b of the washer inlet gripping portion 111 and is such as to function as a reinforcement material of the intermediate member 131 . A boundary portion (not shown) between one end portion side of the reinforcement member 133 and the lower wall portion 21 b of the upper frame inner 21 is also formed rectilinearly. By the boundary portion 162 and the boundary portion just described above being formed rectilinearly, the rigidity at the boundary portion 162 and the boundary portion, not shown, can be ensured.
[0033] An upper wall portion 132 of the intermediate member 131 has a first arc portion 132 a which is formed into an arc-like shape which extends from one end portion side (a side facing the upper frame inner 21 ) to the other end portion side (a side facing the washer inlet gripping portion 111 ) while extending downwards of the vehicle so as to project upwards of the vehicle. Further, the upper wall portion 132 of the intermediate member 131 has a second arc portion 132 b which is formed into an arc-like portion which continues to the first arc portion 132 a and extends from the one end portion side (the side facing the upper frame inner 21 ) to the other end portion side (the side facing the washer inlet gripping portion 111 ) while extending upwards of the vehicle so as to project downwards of the vehicle. In addition, the second arc portion 132 b constitutes a tube supporting portion for supporting the washer tube which will be described in detail later.
[0034] A tube holding portion 140 is molded in such a manner as to connect to the outer wall portion 111 e of the washer inlet gripping portion 111 . Specifically, the tube holding portion 140 is molded in such a manner as to connect to the outer wall portion 111 e of the washer inlet gripping portion 111 between a connecting portion with the first intermediate portion 120 and a connecting portion with the second intermediate portion 130 and in the vicinity of an upper end portion 111 a of the washer inlet gripping portion. The tube holding portion 140 has a horizontal portion 141 which connects to the outer wall portion 111 e of the washer inlet gripping portion 111 at a proximal end portion side and extends in a substantially horizontal direction and a bent portion 142 which continues to a distal end of the horizontal portion 141 and extends downwards while being bent in that direction. By the tube holding portion 140 which is shaped in the way described above being molded integrally with the washer inlet gripping portion 111 , the necessity of a holder for holding a washer tube 16 is obviated, thereby making it possible to reduce the number of parts. Further, the washer tube 16 can be held by the tube holding portion 140 without using the holder, whereby the attaching work becomes simple, and the working properties are increased.
[0035] Here, attaching work of the washer inlet 12 to the upper frame inner 21 , which constitutes the vehicle structural body, by the use of the washer inlet attaching structure which is configured as has been described heretofore will be describe by reference FIGS. 3A and 3B . Note that reference numeral 13 denotes a cap, reference numeral 14 denotes a hinge, and reference numeral 15 denotes a cap fixing portion. The cap 13 is connected with the cap fixing portion 15 via the hinge 14 .
[0036] Firstly, as is shown in FIG. 3A , the washer inlet 12 is positioned at the side of the washer inlet gripping portion 111 which faces the rear of the vehicle. Following this, as is shown in FIG. 3B , the washer inlet 12 is attached to the washer inlet gripping portion 111 . In addition, the washer tube 16 is positioned below the horizontal portion 141 of the tube holding portion 140 and is positioned above the second arc portion 132 b of the second intermediate portion 130 .
[0037] Consequently, the washer inlet 12 is held in the washer inlet gripping portion 111 , and the washer tube 16 is supported by the tube holding portion 140 and the second arc portions 122 b, 132 b. In other words, the washer inlet 12 and the washer tube 16 are fixed to the upper frame inner 21 by the washer inlet holder 100 .
[0038] Consequently, according to the washer inlet attaching structure according to this embodiment, the washer inlet holder 100 is molded integrally with the upper frame inner 21 , which provides the relatively simple structure and increases the assembling accuracy. Positioning work of positioning the washer inlet holder 100 relative to the upper frame inner 21 does not have to be performed, and the washer inlet 12 can easily be attached to the washer inlet holder 100 , which increases the attaching properties. In addition, compared with the washer inlet attaching structure in which the bracket is attached with the clip, the number of parts involved can be reduced.
[0039] By the boundary portions 161 , 162 being formed in the two locations, the strength of the washer inlet holder 100 itself can be increased.
[0040] By the washer inlet holder 100 being made up of the first and second intermediate portions 120 , 130 , and the washer inlet gripping portion 111 having the shape in which the strip-like member extends into the arc shape, the washer inlet 12 can be attached to the upper frame inner 21 only by inserting the washer inlet 12 into the washer inlet gripping portion 111 , and compared with the washer inlet attaching structure in which the bracket is attached with the clip, the attaching properties are increased. Further, the number of parts can be reduced.
[0041] By the second arc portions 122 b, 132 b being provided on the first and second intermediate portions 120 , 130 , respectively, when the washer tube 16 is attached to the tube holding portion 140 , the washer tube 16 can be supported from therebelow, whereby the washer tube 16 can be attached to the washer inlet holder 100 in an ensured fashion.
[0042] A washer inlet attaching structure according to a second embodiment of the invention will be described by reference to FIGS. 4 , 5 , 6 , 7 A and 7 B, and 8 A and 8 B.
[0043] FIGS. 4 and 5 are perspective views of a washer inlet attaching structure according to a second embodiment of the invention, FIG. 6 is a bottom view of the washer inlet attaching structure according to the second embodiment of the invention, FIGS. 7A and 7B are explanatory diagrams of the washer inlet attaching structure according to the second embodiment of the invention, of which FIG. 7A shows a state resulting before a washer inlet is attached and 7 B shows a state resulting after the washer inlet is attached, and FIGS. 8A and 8B are explanatory diagrams of a cap's open-state holding tool included in the washer inlet attaching structure according to the second embodiment of the invention, of which FIG. 8A shows a state in which an opening in the washer inlet is closed by a cap and FIG. 8B shows a state in the opening in the washer inlet is opened. In FIGS. 4 , 5 , 6 , 7 A and 7 B, and 8 A and 8 B, a line with an arrow FR denotes a direction of the front of the vehicle, and a line with an arrow ER denotes a direction of an interior of an engine compartment. In FIGS. 4 , 5 , 7 A and 7 B, and 8 A and 8 B, a line with an arrow UP denotes a direction oriented upwards of the vehicle.
[0044] This second embodiment differs from the first embodiment in that the opening location of the washer inlet gripping portion included in the washer inlet attaching structure of the latter is changed, the shapes of the first and second connecting portion in the same attaching structure are changed and a cap's open-state holder is additionally provided to the attaching structure and has the same component elements (including the tube holding portion) other than those changed and added.
[0045] In the second embodiment, like reference numerals will be given to like constituent elements to those of the washer inlet attaching structure according to the first embodiment that has been described above, and the description thereof will be omitted.
[0046] As is shown in FIGS. 4 and 5 , a washer inlet attaching structure of this embodiment has a washer inlet attachment 200 which is formed integrally with an upper frame inner 21 . The upper frame inner 21 and the washer inlet attachment 200 are molded of a resin.
[0047] The washer inlet attachment 200 has a washer inlet gripping portion 211 , a first intermediate portion 220 , a second intermediate portion 230 , a tube holding portion 140 , and a cap's open-state holder 250 .
[0048] The washer inlet gripping portion 211 is molded as looking like a strip-like member extends into an arc-like shape. Specifically, the washer inlet gripping portion 211 is molded into a shape in which an inner wall portion 211 thereof contacts a circumferential wall portion 12 a of a washer inlet 12 (refer to FIGS. 7A and 7B , and FIGS. 8A and 8B ) in a circumferential direction thereof. Both end portions 211 c, 211 d of the washer inlet gripping portion 211 are spaced apart at a side which faces the front of the vehicle. Namely, the washer inlet gripping portion 211 is molded into a shape in which the washer inlet gripping portion is opened at the side which faces the front of the vehicle. Further, the washer inlet gripping portion 211 is molded into a shape in which the washer inlet gripping portion 211 extends outwards while being bent in that direction in the vicinity of the one end portion 211 d. By this configuration, when the washer inlet 12 is attached to the washer inlet gripping portion 211 , the washer inlet 12 is restrained from being caught at the one end portion 211 d as a result of being brought into contact therewith. As a result, the washer inlet 12 can be smoothly guided into the washer inlet gripping portion 211 from a front side of the vehicle so that the washer inlet 12 can easily be attached to the washer inlet gripping portion 211 .
[0049] The washer inlet gripping portion 211 connects to the upper frame inner 21 via the first intermediate portion 220 and the second intermediate portion 230 . A distal end portion of the tube holding portion 140 connects to an outer wall portion 211 e of the washer inlet gripping portion 211 . The cap's open-state holder 250 is molded integrally with the washer inlet gripping portion 211 in a position on the outer wall portion 211 e of the washer inlet gripping portion 21 which lies to confront the tube holding portion 140 .
[0050] The first intermediate portion 220 is such as to be interposed between the washer inlet gripping portion 211 and the upper frame inner 21 . The first intermediate portion 220 is molded into a plate-like shape and is made up of two members such as an intermediate member 221 and a reinforcement member 223 . A boundary portion 261 between one end portion side of the intermediate member 221 and a side wall portion 21 a of the upper frame inner 21 is formed rectilinearly. The other end portion side of the intermediate member 221 connects to the outer wall portion 211 e of the washer inlet gripping portion 211 . The reinforcement member 223 connects to a lower portion of the intermediate member 221 , a lower wall portion 21 b of the upper frame inner 21 , and a lower portion 211 b of the washer inlet gripping portion 221 and is such as to function as a reinforcement member of the intermediate member 221 . A boundary portion 263 between the one end portion side of the reinforcement member 223 and the lower wall portion 21 b of the upper frame inner 21 is formed rectilinearly. By the boundary portions 261 , 263 being formed rectilinearly in the way described above, the rigidity at the boundary portions 261 , 263 can be ensured.
[0051] An upper wall portion 222 of the intermediate member 221 has an inclined portion 222 a which is formed to extend from one end portion side (a side facing the upper frame inner 21 ) to the other end portion side (a side facing the washer inlet gripping portion 211 ) while extending obliquely downwards of the vehicle. Further, the upper wall portion 222 of the intermediate member 221 has an arc portion 222 b which is formed into an arc-like shape which continues to the inclined portion 222 a and extends from the one end portion side (the side facing the upper frame inner 21 ) to the other end portion side (the side facing the washer inlet gripping portion 211 ) so as to project downwards of the vehicle. In addition, the arc portion 222 b constitutes a tube supporting portion for supporting a washer tube, which will be described in detail later.
[0052] As with the first intermediate portion 220 , the second intermediate portion 230 is such as to be interposed between the washer inlet gripping portion 211 and the upper frame inner 21 . The second intermediate portion 230 is molded into a plate-like shape, is molded in a position lying further rearwards than the first intermediate portion 220 in the vehicle longitudinal direction, and is made up of two members such as an intermediate member 231 and a reinforcement member 233 . A boundary portion 262 between one end portion side of the intermediate member 231 and the side wall portion 21 a of the upper frame inner 21 is formed rectilinearly. The other end portion side of the intermediate member 231 connects to the outer wall portion 211 e of the washer inlet gripping portion 211 . The reinforcement member 233 connects to a lower portion of the intermediate member 231 , the lower wall portion 21 b of the upper frame inner 21 and the lower portion 211 b of the washer inlet gripping portion 211 and is such as to function as a reinforcement material of the intermediate member 231 . A boundary portion 264 between one end portion side of the reinforcement member 233 and the lower wall portion 21 b of the upper frame inner 21 is also formed rectilinearly. By the boundary portions 262 , 264 being formed rectilinearly, the rigidity at the boundary portions 262 , 264 can be ensured.
[0053] An upper wall portion 232 of the intermediate member 231 has an inclined portion 232 a which is formed to extend from one end portion side (a side facing the upper frame inner 21 ) to the other end portion side (a side facing the washer inlet gripping portion 211 ) while extending obliquely downwards of the vehicle. Further, the upper wall portion 232 of the intermediate member 221 has an arc portion 232 b which is formed into an arc-like shape which continues to the inclined portion 232 a and extends from the one end portion side (the side facing the upper frame inner 21 ) to the other end portion side (the side facing the washer inlet gripping portion 211 ) so as to project downwards of the vehicle. In addition, the second arc portion 232 b constitutes a tube supporting portion for supporting the washer tube, which will be described in detail later.
[0054] A distance L 1 between the boundary portions 261 and the boundary portion 262 that have been described above is, as is shown in FIG. 6 , becomes almost the same as a diameter D 1 of the washer inlet 12 . In other words, the two boundary portions 261 , 262 are separated by the distance almost equal to the diameter D 1 of the washer inlet 12 . By this configuration, the holding rigidity of the washer inlet attachment 200 is increased.
[0055] Here, work of attaching the washer inlet 12 to the upper frame inner 21 by the use of the washer inlet attaching structure which is configured as has been described heretofore will be described by reference to FIGS. 7A and 7B .
[0056] Firstly, as is shown in FIG. 7A , the washer inlet 12 is positioned at the vehicle front side of the washer inlet gripping portion 211 . Following this, as is shown in FIG. 7B , the washer inlet 12 is attached to the washer inlet gripping portion 211 . In addition, the washer tube 16 is positioned below the horizontal portion 141 of the tube holding portion 140 and is positioned above the arc portion 222 b of the first intermediate portion 220 and above the arc portion 232 b of the second intermediate portion 230 .
[0057] Thus, the washer inlet 12 is held in the washer inlet gripping portion 211 , and the washer tube 16 is supported by the tube holding portion 140 and the arc portions 222 b, 232 b. In other words, the washer inlet 12 and the washer tube 16 are fixed to the upper frame inner 21 by the washer inlet attachment 200 .
[0058] As is shown in FIGS. 4 , 5 , 6 , the cap's open-state holder 250 is formed substantially into a box shape which is opened upwards. The cap's open-state holder 250 has a hinge accommodation portion 251 which accommodates the hinge 14 in a cap closed state. Further, the cap's open-state holder 250 has projecting portions 255 , 256 which locks and supports the hinge 14 in a cap open state. The hinge accommodation portion 251 is surrounded by side wall portions 252 , 253 , a supporting portion 254 and the projecting portions 255 , 256 . The side wall portions 252 are molded in such a manner as to connect to the outer wall portion 211 e of the washer inlet gripping portion 211 . The side wall portion 252 and the side wall portion 253 are molded in such a manner as to confront each other. The side wall portions 252 , 253 are formed into plate-like shapes, in which a proximal end portion side (a side facing the washer inlet gripping portion 211 ) is made higher than a distal end portion side. The supporting portion 254 is molded in such a manner as to connect to the side wall portions 252 , 253 between the proximal end portion side and the distal end portion side of the side wall portions 252 , 253 . The projecting portions 255 , 256 are molded in such a manner as to connect to the side wall portions 252 , 253 , respectively. The projecting portion 255 and the projecting portion 256 are molded in such a manner as to confront each other and are molded in such a manner that distal ends thereof are spaced apart from each other. The side wall portion 252 and the side wall portion 253 connect to the side wall portion 257 at distal ends thereof. A bottom wall portion 258 is connected to lower portions at the proximal end portion side (the side facing the washer inlet gripping portion 211 ) of the side wall portion 252 and the side wall portion 253 .
[0059] By the cap's open-state holder 250 that is configured as has been described above being molded in such a manner as to connect to the washer inlet gripping portion 211 , as is shown in FIG. 8A , with the opening at the upper end of the washer inlet 12 closed by the cap 13 , the hinge 14 is accommodated in the hinge accommodating portion 251 . In addition, as is shown in FIG. 8B , when the opening 12 b at the upper end of the washer inlet 12 is opened, the cap 13 is removed from the opening 12 b of the washer inlet 12 , and the hinge 14 is inclined at an angle larger than about 90 degrees, whereby the hinge 14 is locked and held by the projecting portions 255 , 256 , whereby the state is maintained in which the opening 12 b at the upper end of the washer inlet 12 is opened. This allows a windshield washer fluid to be poured into the washer tank main body through the washer inlet 12 .
[0060] Consequently, according to the washer inlet attaching structure according to the embodiment, as with the washer inlet attaching structure according to the first embodiment, the washer inlet attaching structure becomes a relatively simple structure, and the assembling accuracy is increased. The washer inlet holder 200 does not have to be positioned relative to the upper frame inner 21 , and hence, the washer 12 can easily be attached to the washer inlet holder 200 , this increasing the attaching properties. In addition, compared with the washer inlet attaching structure in which the bracket is attached by the clip, the number of component elements can be reduced.
[0061] Further, with the cap's open-state holder 250 provided, when pouring the windshield washer fluid into the washer tank, the cap 13 can be held opened, whereby pouring work of the windshield washer fluid can be performed with good efficiency, thereby making it possible to increase the working properties.
[0062] While the invention has been described using the washer inlet attaching structure in which the washer inlet 12 is attached to the upper frame inner 21 , the invention can also be applied to a washer inlet attaching structure in which the washer inlet is attached to other vehicle structural bodies than the upper frame. While the invention has been described using the washer inlet attaching structure having the intermediate portions 120 , 130 , 220 , 230 which are made up of the intermediate members 121 , 131 , 221 , 222 and the reinforcement members 123 , 133 , 223 , 233 , the invention can also be applied to a washer inlet attaching structure having intermediate portions made up of intermediate members. Even with these washer inlet attaching structures, the same functions and advantages as those of the washer inlet attaching structures according to the first and second embodiments can be provided.
[0063] Since the washer inlet attaching structure according to the invention increases the attaching properties by the relatively simple structures, the invention can extremely usefully be made use of in the automotive industry. | A washer inlet attaching structure, configured to attach a washer inlet to a vehicle structural body made of resin, the washer inlet communicating with a tank main body adapted to store a windshield washer fluid and guiding the windshield washer fluid into the tank main body, the washer inlet attaching structure includes a washer inlet holding portion, configured to hold the washer inlet, the washer inlet holding portion being molded integrally with the vehicle structural body. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. Ser. No. 13/739,561 filed Jan. 11, 2013 having priority to European Patent Office application No. 12150741.2 EP filed Jan. 11, 2012. Each of the applications is incorporated by reference herein in their entirety.
FIELD OF INVENTION
The application describes an armature assembly apparatus for assembling an armature of an electrical machine; an armature holding apparatus; a ring segment conveyance; and a method of assembling an armature of an electrical machine.
BACKGROUND OF INVENTION
A conventional wind turbine generally comprises a gearbox to increase the rotational speed of its generator relative to its rotor shaft and to increase the pole change frequency. A gearbox comprises many components that are subject to wear and must be maintained or replaced at intervals. Complex and expensive bearing arrangements are also required to bear the extreme loads and torque acting on the rotor shaft and the gearbox. A direct-drive wind turbine has several features over such a conventional wind turbine, whereby a major feature is that a direct-drive turbine does not require such a gearbox. A direct-drive wind turbine requires fewer parts, is less complex, and more reliable. For these reasons, demand for direct drive wind turbines is increasing.
A direct-drive generator has a relatively large diameter and many magnets of altering polarity arranged along a circumference of a field magnet arrangement—usually an outside rotor—to allow for a sufficiently high pole-change frequency. The physical dimensions and weight of such a large generator pose problems during its assembly. Handling of the heavy, unwieldy and vulnerable components is complex and time-consuming, and is also hazardous, so that strict safety measures must be adhered to. This adds considerably to the overall time and cost required for the assembly of a direct-drive generator.
For example, stator ring segments must be handled with care, but each ring segment can weigh hundreds of kilos, making it difficult to manoeuvre into position ready for mounting to a stator bedframe, which usually comprises a frontplate and a backplate mounted to a hollow stator shaft. A stator ring segment generally comprises several coil sections with windings wrapped in isolating material, and end-sections shaped to be connected to end-sections of neighbouring ring segments. Usually, a stator ring segment is transported to the partially assembled stator using a hoisting or crane, and is connected to this by cables or chains. The ring segment must be suspended in place until it is mounted to the stator bedframe. Extreme care must be taken when the ring segment is suspended during transport so that the vulnerable parts such as insulation or connectors are not damaged or bent, and so that the isolating material is not damaged. Furthermore, care must be taken to avoid damage or distortion of bedframe connecting device that are necessary for connecting the ring segment to the stator bedframe, otherwise an exact mounting is not possible. Damage to any of these elements results in expensive repair work and holds up production.
SUMMARY OF INVENTION
It is an object of the application to provide a more economical and reliable way of assembling an armature for a generator of a direct-drive wind turbine.
This object is achieved by the armature assembly of the claims; by the armature holding apparatus of the claims; by the ring segment conveyance of the claims; and by the method of the claims of assembling an armature of an electrical machine.
According to the application, the armature assembly apparatus for assembling an armature of an electrical machine comprises an armature holding apparatus realized to hold a partially assembled armature such that a rotation axis of the armature is horizontal; a rotating device for rotating the partially assembled armature about a rotation axis; and a ring segment conveyance for conveying an armature ring segment to a mounting position relative to a free ring segment portion of the partially assembled armature.
The armature holding apparatus or “assembly station” can be a frame realized to bear the weight of an assembled armature, and can also be realized to move from one point of an assembly line to another. The armature holding apparatus may also be referred to as an armature frame or armature transport frame in the following. In the armature assembly apparatus according to the application, the rotation axis of the armature is horizontal or parallel to the ground. This is in contrast to prior art assembly arrangements that involve a vertical orientation of the armature, as described in the introduction, and allows the armature to be retained in that orientation for most or all of the assembly stages of the generator. In other words, various assembly stages can be carried out to the armature as it is held in the horizontal orientation, so that lifting equipment such as cranes and hoists are not required, and the armature or armature ring segments are held securely and cannot be dropped and cannot swing against other components. A ring segment does not have to be manually hoisted or lifted into place and held while it is being secured to the armature, but can simply be brought into a mounting position relative to the free ring segment portion using the ring segment conveyance. A feature of the armature holding apparatus according to the application is that the sensitive and expensive components are effectively protected from damage, and an elastic deformation of the ring segment is avoided. Furthermore, the armature holding apparatus according to the application effectively protects an armature, primarily designed to bear the weight of the ring segments in a horizontal position, from any distortion.
According to the application, the armature holding apparatus, for use in the assembly of an armature of an electrical machine, comprises a connecting device for detachably connecting a partially assembled armature to the armature holding apparatus such that a rotation axis of the armature is horizontal; and a rotating device for rotating the partially assembled armature about a rotation axis.
According to the application, the ring segment conveyance for use in the assembly of an armature of an electrical machine comprises a support for supporting an armature ring segment; and a positioning device for bringing the armature ring segment into a mounting position relative to a free ring segment portion of a partially assembled armature.
While such a ring segment conveyance could be realized to bring an armature ring segment into position at an angle relative to the armature, for example from the side or from above, the ring segment conveyance according to the application is realized to bring a ring segment into position from below the partially assembled armature. In other words, the ring segment conveyance holds the armature ring segment in position underneath the partially assembled armature. In this way, there is no risk of the ring segment slipping or being dropped before it can be mounted to the armature.
According to the application, the method of assembling an armature of an electrical machine comprises the steps of
(A) connecting a partially assembled armature to an armature holding apparatus such that a rotation axis of the armature is horizontal; (B) actuating a rotating device to rotate the partially assembled armature about a rotation axis of the rotating device to bring a free ring segment portion into position; (C) conveying an armature ring segment to the partially assembled armature; (D) controlling an adjusting device of the armature assembly apparatus to bring the armature ring segment into a mounting position on the free ring segment portion of the partially assembled armature; (E) mounting the armature ring segment to the free ring segment portion of the partially assembled armature; and repeating steps to until a desired number of armature ring segments have been mounted onto the armature. Of course, the sequence or order in which these steps are carried out is not limited to the order in which they are listed here.
The feature of the method according to the application is that it allows the armature to be assembled without the hazardous or time-consuming handling steps known from the prior art. A number of armature ring segments can be “lined up” ready for mounting, and as soon as one ring segment is mounted to the partially assembled armature, this can be rotated by a suitable amount so that the next ring segment can be mounted, and so on.
Embodiments and features of the application are given by the dependent claims, as revealed in the following description. Features of different claim categories may be combined as appropriate to give further embodiments not described herein.
While the windings could be mounted on a rotating component of the generator, in a direct-drive wind turbine the windings are generally arranged on a stationary stator, which is usually arranged inside the rotor, i.e. the rotor comprises an outside rotor. In the following, without restricting the application in any way, it may be assumed that the armature is a stator, and the terms “armature” and “stator” may be used interchangeably in the following. Also, without restricting the application in any way, it may be assumed that the generator is for a wind turbine. During assembly of the armature, it may be assumed that the ring segments are mounted to the exterior of the armature. It may also be assumed that an armature ring segment is a radial ring segment, i.e. the armature ring segment occupies a radial fraction of an exterior circumferential curved plane of the armature.
The expression “rotation axis of the armature” is to be understood as the axis about which a rotating part of the assembled generator will rotate. Usually, the generator exhibits rotational symmetry about its axis of rotation. The rotating part can be the armature itself, in which case the field magnet arrangement of the generator can be stationary. Alternatively, the armature itself does not rotate, as would be the case for a generator comprising a stationary armature and a rotating field magnet arrangement.
The ring segment conveyance can be any suitable conveyance for bringing a ring segment to the partially assembled stator for mounting. For example, the ring segment conveyance can be realized as a type of conveyor belt. However, an embodiment of the application, the ring segment conveyance comprises a trolley or wagon arranged on wheels or rollers so that it is freely moveable relative to the stator frame. In the following, without restricting the application in any way, the ring segment conveyance may be referred to simply as a “trolley” or “ring segment trolley”.
The rotating device of the armature assembly apparatus can be realized to rotate the partially assembled armature in any suitable manner. For example it may be realized to allow the partially assembled armature to “roll” along a predefined path, so that the rotational axis of the armature is displaced in a horizontal direction parallel to the ground. However, in an embodiment of the application, the rotating device is realized to rotate the partially assembled armature about the rotation axis of the armature. In other words, the armature is not displaced laterally and is only rotated about its own axis of rotation.
The partially assembled armature could simply be suspended in place such that it can engage with the rotating device during assembly of the armature. However, an embodiment of the application, the armature holding apparatus comprises a connecting device for detachably connecting the partially assembled armature to the rotating device, so that the partially assembled armature is at all times securely fastened to the transport frame.
The rotating device can comprise any suitable apparatus or device that is realized to turn the relatively heavy armature. The rotating device comprises a meshed gear arrangement. For example such enmeshed in your arrangement can comprise one large gear wheel realized to engage with a smaller driving you really substantially larger gear wheel is arranged to accommodate a shaft of the stator. In an alternative arrangement, the meshed gear arrangement can comprise a set of helical gears, a worm and wheel arrangement, or a rack and pinion arrangement.
Such a rotating device is realized to be driven by a suitable actuating device, for example a motor such as an electric motor. The actuating device is realized to actuate the rotating device to rotate the partially assembled armature about its rotation axis. In an embodiment of the application, the rotating device is realized to rotate the partially assembled armature by a radial amount corresponding to a radial width of an armature ring segment. For example, if twelve ring segments are to be mounted to the stator bedframe, the actuating device can be realized to rotate the partially assembled stator by 30°, so that the next free ring segment portion can be brought into position ready for the next assembly step.
The armature assembly apparatus according to the application comprises some kind of adjusting device for bringing the armature ring segment into a mounting position on the free ring segment portion of the partially assembled armature. For example, the armature frame can be realized to be adjustable in the several degrees of freedom so that the partially assembled armature itself is moved relative to a stationary ring segment held on the conveyance or trolley. However, the large dimensions and considerable weight of the partially assembled armature can make this relatively difficult to achieve. In an embodiment of the application, such an adjusting device is realized as part of the trolley. In such a realisation, the armature frame can remain stationary relative to the trolley.
In a further embodiment of the application, the adjusting device or aligning device is realized to adjust the position of the armature ring segment relative to the free ring segment portion of the partially assembled armature. To this end, the adjusting device can be connected in some suitable way to a control interface or control module which can be used by a controller, human or automated, to control the adjusting device. For example, such a control module can be a handheld module connected to the adjusting device of the trolley by a cabled connection or a wireless connection. Such a control module can also be realized to issue control signals to the driving device of the trolley, so that it can be used, for example, to control the motion of the trolley over a factory floor.
The ring segment trolley comprises a supporting device or carrying bed, realized to bear the armature ring segment in an horizontal orientation underneath the armature assembly. To ensure that the ring segment is transported in a safe and secure manner, such a supporting device or carrying bed is shaped in a concave manner in keeping with the curved form of a stator ring segment. Since the stator ring segment is transported in an horizontal position, i.e. in a “lying” position, the adjusting device is realized to raise or lower the ring segment relative to the free ring segment portion of the armature assembly. In other words, an adjusting device is realized to have an vertical direction of travel.
The adjusting device can comprise any suitable moving parts that can be controlled to alter a vertical or horizontal orientation of the ring segment that is carried by the ring segments trolley. In an embodiment of the application, the adjusting device comprises a plurality of individually moveable adjusting points. The adjusting device comprises three individually moveable adjusting points, since three such individually movable adjusting points are sufficient to obtain any desired orientation of the ring segment relative to the stator bedframe. An adjusting point comprises a linear actuator such as a hydraulic cylinder and piston arrangement that can be actuated to extend or contract along its direction of travel. In one realisation, the adjusting points can be controlled simultaneously, so that the ring segment is raised or lowered evenly without altering its orientation. However, sometimes a slight adjustment may need to be made to one side or corner of the ring segment. In addition to or as an alternative to the preceding embodiment, each adjusting point can be controlled or actuated independently of the others. With such an arrangement of individually controllable adjusting points, the adjusting device can be realized to raise the armature ring segment in an upward vertical direction towards the free ring segment portion of the partially assembled armature, and can “fine tune” the position of the ring segment relative to the free ring segment portion of the stator bedframe.
The step of bringing the ring segment into position relative to the stator bedframe, so that these can be connected, can be assisted by one or more sensors. For example, a laser or sonic measurement device can be used to determine a distance between a point on the ring segment and a corresponding “target” point on the stator bedframe. Such a signal can be used by the control module or control interface and can be used as the basis for control signals sent to the adjusting points of the trolley.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present application will become apparent from the following detailed descriptions considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for the purposes of illustration and not as a definition of the limits of the application.
FIG. 1 shows a perspective view of an armature assembly apparatus according to an embodiment of the application;
FIG. 2 shows a side view of the armature assembly apparatus of FIG. 1 with a partially assembled armature;
FIG. 3 shows a frontal view of the armature assembly apparatus of FIG. 1 with the partially assembled armature in a first stage of assembly;
FIG. 4 shows a frontal view of the armature assembly apparatus of FIG. 1 with the partially assembled armature in a second stage of assembly;
FIG. 5 shows a frontal view of the armature assembly apparatus of FIG. 1 with the partially assembled armature in a third stage of assembly.
DETAILED DESCRIPTION OF INVENTION
In the diagrams, like numbers refer to like objects throughout. Objects in the diagrams are not necessarily drawn to scale.
FIG. 1 shows a perspective view of an armature assembly apparatus 1 according to an embodiment of the application. The armature assembly apparatus 1 comprises a large robust stator transport frame 2 , and in this example also comprises four rollers 23 or wheels 23 , one at each corner, so that the transport frame 2 can be moved from one location to another, for example in an assembly line. The transport frame 2 also comprises a turning device 20 , 21 , 22 , in this case a set of meshed gears, wherein a large gear 20 can be moved by driving a smaller gear 21 . To this end, a motor 22 or other driving device 22 , indicated schematically here, can be connected to the smaller driving gear 21 . The motor 22 can be mounted to the stator frame, or can be arranged elsewhere, as appropriate. Such a motor can comprise a shaft or other transmission for connecting to the driving gear 21 . The large gear 20 is arranged around a hollow shaft 25 which is realized or shaped to accommodate a shaft of an armature or stator. The diagram also shows a ring segment conveyance 3 or trolley 3 , which is freely movable relative to the stator transport frame 2 . The ring segment trolley 3 comprises a flatbed body 30 connected to four rollers 32 or wheels 32 , and a supporting device 31 shaped to accommodate a curved ring segment. This supporting device 31 is arranged on a number of linear actuators 33 , which, as will be shown later, can be controlled to adjust to the position of the supporting device 31 in a vertical direction. To ensure that the trolley is correctly aligned underneath the stator assembly, it can be guided using, for example, markings on the floor.
FIG. 2 shows a side view of the armature assembly apparatus 1 of FIG. 1 with a partially assembled armature 4 , referred to as the stator 4 in the following, for a generator of a direct-drive wind turbine. A bedframe of the stator 4 comprises a hollow shaft 40 , a backplate 42 and a frontplate 41 . The annular backplate 42 is mounted to the shaft 40 on a tower interface side, i.e. the side of the shaft that will face into the nacelle of the wind turbine. The frontplate 41 will face into the hub of the wind turbine. A cooling system 43 with components such as encasement, fan, heat exchanger, tubing etc. are arranged as indicated here in the space between the backplate 42 and the frontplate 41 . In a generator for a direct-drive wind turbine, the stator bedframe can comprise 5 m or more in diameter, and the distance between the frontplate and backplate can comprise about 1.5 m to 2 m.
The diagram also shows the ring segment trolley 3 with a stator ring segment 5 lying in the supporting device 31 ready for mounting to the stator bedframe 4 . A stator ring segment 5 comprises copper windings 50 arranged on a bedframe interface 51 . The bedframe interface 51 is realized to be mounted to an outer rim of the frontplate 41 and backplate 42 , as will be explained in the following. In the diagram, no stator ring segments have yet been mounted to the stator bedframe 4 .
FIG. 3 shows a frontal view of the armature assembly apparatus of FIG. 1 with the partially assembled stator 4 in a first stage of assembly. Here, one ring segment 5 has already been mounted. A second ring segment 5 is in place on the supporting device 31 of the ring segment trolley 3 . A controller 6 , here indicated schematically, is used to drive the ring segment trolley 3 , for example by sending control signals 62 to a motor or other driving device (not shown here) of the ring segment trolley 3 . One or more sensors 60 , positioned at some suitable position on the ring segment trolley 3 , can send measurement signals 61 to the controller 6 , so that this can react accordingly. The sensor 60 can detect the relative position of the ring segment 5 relative to the stator frontplate 41 and backplate 42 , for example by using guiding device 420 of the stator frontplate 41 and backplate 42 as reference points. The controller 6 can send appropriate adjustment signals 62 to the trolley 3 to adjust the position of the ring segment 5 relative to the stator frontplate 41 and backplate 42 until the position of the stator ring segment 5 is considered satisfactory. Since the ring segment 5 is only elevated while it rests on the cradle of the trolley 3 , an elastic deformation of the ring segment 5 is avoided. Furthermore, this horizontal position is the same position that will be taken by the ring segment 5 during operation of the wind turbine. Since the stator plates 41 , 42 are primarily designed to bear the weight of the ring segments 5 in a horizontal position, these are also effectively protected from any distortion.
FIG. 4 shows a frontal view of the armature assembly apparatus of FIG. 1 with the partially assembled stator 4 in a second stage of assembly. This diagram shows a next stage in the mounting process. The controller 6 can send adjustment signals 63 to the linear actuators 33 of the ring segment trolley 3 so that the supporting device 31 can be raised to the required height in a vertical direction D as indicated in the diagram. Again, a sensor 60 can deliver measurement signals 61 to the controller 6 so that this can respond by issuing appropriate control signals 63 . A bedframe interface 51 of the stator ring segment 5 is designed so that, once it has been brought into a mounting position relative to the frontplate 41 and backplate 42 , it can be slotted into place. This can be achieved by appropriate control signals 62 , 63 issued by the controller 6 .
FIG. 5 shows a frontal view of the armature assembly apparatus of FIG. 1 with the partially assembled armature in a third stage of assembly. In this diagram, almost all of the ring segments 5 have mounted onto the stator bedframe 4 , 41 , 42 . The diagram clearly shows another stator ring segment 5 with its windings wrapped, for example, in a fibreglass band to protect the windings, arranged on the trolley 3 ready for mounting. The stator bedframe 4 has been rotated in the direction indicated so that the second-last free ring segment portion 420 is brought into a suitable position for mounting of the next stator ring segment 5 .
Once the stator bedframe 4 , 41 , 42 has been filled with ring segments 5 , the stator transport frame 2 can be moved to a next assembly position by the rollers 24 mounted on the four corners of the transport frame 2 .
Although the present application has been disclosed in the form of embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the application.
For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. The mention of a “unit” or a “module” does not preclude the use of more than one unit or module. | An armature assembly apparatus for assembling an armature of an electrical machine is provided. The armature assembly apparatus has an armature holding apparatus to hold a partially assembled armature such that a rotation axis of the armature is horizontal. The armature assembly apparatus has a rotating device for rotating the partially assembled armature about a rotation axis. The armature assembly apparatus also has a ring segment conveyance for conveying an armature ring segment to a mounting position relative to a free ring segment portion of the partially assembled armature. | 8 |
FIELD OF THE INVENTION
The present invention relates to a riser tensioner safety system for use in conducting floating drilling operations. More particularly, the invention pertains to a safety system which is triggered by a loss of tension in the tensioner cables thereby preventing damage to the floating drilling equipment.
BACKGROUND OF THE INVENTION
In recent years the search for oil and gas has moved offshore. Early offshore oil wells were drilled from fixed, bottom-founded structures. Subsequently, methods and apparatus were developed for conducting floating drilling operations. Today, most offshore exploration wells are drilled from floating drill ships. Additionally, deep water production wells are likely to be drilled from floating vessels or structures.
In floating drilling operations a marine riser is used to guide the drill string into the well and to provide a path for conducting the drilling fluid back to the vessel. The riser is connected at its lower end to the blowout preventer located at the subsea wellhead and at its upper end to the drilling vessel. Since the drilling vessel is subject to vertical movement due to the action of waves and tides, a vertically extensible slip joint is placed in the upper end of the riser string to accommodate the vessel's vertical motion. As the drilling vessel heaves, the slip joint telescopes to compensate for the vessel movement.
The riser can buckle under the influence of its own weight and the weight of the drilling fluid contained therein if adequate vertical tension is not maintained at its top. Typically, this is provided by using tensioning devices loctated on the drilling vessel to apply axial tension to the upper end of the riser. The tensioning devices are connected to the lower portion of the slip joint. In this manner the vessel is allowed to freely move up and down while maintaining a relatively constant tension in the riser.
Marine risers have been tensioned in various manners including the use of counterweight systems and pneumatic spring systems. The counterweight was the first technique utilized to apply tension to the top of the marine riser. The weight was hung from a wire rope which was reeved up over wire rope sheaves and down to the top of the riser pipe. The tension was equal to the counterweight and therefore was practical only for shallow water drilling where the amount of tension required is low. A second disadvantage of counterweight systems was that large inertial loads were developed when the vessel's movement was large. The pneumatic spring tensioner systems replaced the counterweight systems as deeper and rougher water drilling evolved. The pneumatic spring tensioning devices use a large volume of compressed air to apply nearly constant tension to the top of the riser through wire ropes. See, Harris, L. P., Design for Reliability in Deepwater Floating Drilling Operations, Chapter 14, "Marine Riser Tensioning System", pages 188-194, The Petroleum Publishing Company, Tulsa, Okla., 1979.
Nearly, all floating drilling vessels are now equipped with pneumatic/hydraulic tensioning systems. A large air supply keeps a nearly constant pressure above oil in an air-oil accumulator cylinder. The oil then provides pressure to the face of the piston. As the vessel heaves, the piston moves up and down against a relatively constant force and the tension lines maintain a relatively constant pull on the riser. A series of sheaves are provided on the tensioner and the reeving typically used will give a piston stroke of about 1/4 of the vessel heave.
The tensioner lines are normally run over fixed sheaves supported from the drilling vessel substructure and attached to a tension ring near the top of the outer barrel of the riser slip joint. An even number of tensioners are generally employed and the lines are equally loaded with opposing pairs on opposite sides of the outer barrel. The angles between the tensioner lines and the riser are minimized by locating the turndown sheaves as close to the axis of the riser as possible so that the maximum vertical tension can be applied to the riser.
One disadvantage of present tensioner systems is that the tensioning lines occasionally fail under high tension. Failure is generally attributed to fatigue caused by continuously bending the wire cable back and forth over the sheaves. When the wire cable fails the unrestrained tensioner piston tends to extend rapidly. Since the force behind the piston is generally very high, this unrestrained movement is likely to cause damage to the tensioning device and potentially to the vessel itself. Past efforts to prevent damage from a broken cable event have included the use of flow limiting valves in the tensioner's hydraulic fluid supply line and orifice plates in the exhaust line to limit the final velocity of the piston. Unfortunately, use of these devices also tends to reduce the efficiency of the tensioning system during periods of normal operation.
A second disadvantage of present tensioner systems occurs in the event of an emergency disconnect of the riser. The drilling vessel may move off station due to the action of wind, waves and currents. Alternatively, the automatic positioning system of a dynamically positioned vessel may fail causing the vessel to move laterally. This lateral movement may cause one or more damaging events. For example, the slip joint may contact the vessel's moonpool or may over extend. Also, the riser's lower ball joint may hit its stop. Typically, risers are equipped with a system which allows rapid uncoupling of the riser from the blowout preventer. This uncoupling sharply reduces the tension in the tensioning lines. In such an emergency situation there is not always time to relieve the pressure in the tensioning system. If the riser is disconnected while the tensioning system is still pressurized, the unrestrained riser will be accelerated rapidly upwardly by the tensioning system causing damage to the drilling rig and the vessel. Flow limiting valves and orifice plates partially solve this problem, however, these devices do not completely arrest the riser's upward motion. Also, as noted above, such devices adversely effect the operating efficiency of the tensioning system during normal operation.
Thus, it is apparent that a need exists for a riser tensioner safety system which will prevent damage during a broken cable event or an emergency disconnect of the riser while permitting maximum operating efficiency during periods of normal operation.
SUMMARY OF THE INVENTION
The present invention solves the problems outlined above by providing a riser tensioner safety system which is triggered by a reduction of tension in the tensioner cables below a predetermined level.
The system uses standard pneumatic/hydraulic tensioners to apply force to the tensioner cable. Alternatively, pneumatic spring tensioners, well known in the art, could be used. One end of the tensioner cable is attached to a tension ring located near the top of the outer barrel of the riser slip joint. The other end of the cable is attached to a full opening valve located at the stationary anchor point of the system. The valve is mounted in the hydraulic fluid supply line to the tensioner cylinder and is held open by the tension in the cable. During normal operation the valve stays fully open allowing maximum tensioner operating efficiency. If tension in the cable is lost due to a broken cable event, or sharply reduced due to an emergency disconnect of the riser, the valve closes rapidly stopping the piston.
During normal start up operations, the safety valve is closed preventing fluid flow from reaching the tensioner cylinder. A manually operated valve in a hydraulic line which by-passes the safety valve is used to supply hydraulic fluid to the piston during start up. When the tensioner cable has been tensioned to the point where it will hold the safety valve open, the manually operated valve is closed and all hydraulic fluid supplied to the tensioner must pass through the safety valve.
Any of several different types of valves may be used as a safety valve. It is only important that the valve be capable of being held open by tension in the riser tensioner cable and closed rapidly when tension is lost. The valve may be closed by a mechanical spring, by compressed air or by other known means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a floating drilling vessel which uses the riser tensioner safety system of the present invention.
FIG. 2 is an enlarged side view in partial cross section of one embodiment of the safety valve apparatus of the present invention.
FIG. 3 is a flow diagram of the riser tensioner safety system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown drilling vessel 10 floating in body of water 12 and engaged in drilling a subsea well 14. The vessel has mounted on its deck a substructure 16 which supports a derrick 18 which includes a drawworks (not shown) and other usual apparatus for conducting floating drilling operations. Extending between the vessel and the wellbore is a marine riser generally indicated at 20 which is connected at its upper end to the substructure 16 and at its lower end to the wellhead through the usual blowout preventer apparatus 22. An emergency disconnect system 36, well known in the art, is installed between the riser 20 and the blowout preventer 22. Typically, the disconnect system would be hydraulically operated. See for example, the disconnect system described at column 6, lines 6-35 of U.S. Pat. No. 3,426,843 to Visser (1969). The marine riser 20 includes a slip joint 24 near its upper end. The slip joint 24 includes an upper cylindrical portion 26 generally referred to as the "inner barrel", which is mounted from and is movable with the vessel 10 and a lower cylindrical portion 28 generally referred to as the "outer barrel", which is attached to the riser 20. The inner barrel 26 telescopes into and out of the outer barrel 28 as the vessel moves vertically relative to the wellbore.
A drill string generally indicated at 30 is supported from a swivel 32 within the derrick. The swivel 32 is suspended from a traveling block 34 which in turn is connected by cables to the crown block (not shown) at the top of the derrick. The drill string extends downwardly through the marine riser 20 into the wellbore 14.
The riser 20 must be supported to prevent it from buckling under the influence of its own weight and the weight of the drilling fluid contained therein. Typically, this is accomplished by using large, pneumatic/hydraulic tensioning devices, well known in the applicable art, to apply an upward axial tension to the top of the riser. See, for example, the discussion of riser tensioning systems in The Technology of Offshore Drilling, Completion and Production, Chapter 6, pp. 187-204, Compiled by ETA Offshore Seminars, Inc., The Petroleum Publishing Company, Tulsa, Okla., 1976.
Referring again to FIG. 1, a plurality of tensioning devices 38 are attached to the drilling vessel 10. Tensioning devices 38 may be either pneumatic/hudraulic tensioners or pneumatic spring tensioners. For the remainder of this discussion, it will be assumed that tensioning devices 38 are pneumatic/hydraulic tensioners. Each tensioning device has a movable wire cable sheave 40 attached to the outer end of its piston rod or ram and a stationary wire cable sheave 42 attached to the end of the cylinder body. Additionally, each tensioning device has associated therewith a turndown sheave 44 which is attached to the drilling vessel 10 as close to the horizontal centerline of the riser as possible. A tension ring 46 is mounted near the top of outer barrel 28 of riser slip joint 24. A wire cable or other flexible tensioning line 48 for transmitting tension from the tensioning device 38 to the riser 20 is attached by suitable means to tension ring 46. The cable is then reeved over turndown sheave 44, around stationary sheave 42 and movable sheave 40, and attached by suitable means to valve actuator 50, as will be more fully described below. For clarity, FIG. 1 shows cable 48 reeved once around sheaves 40 and 42. However, in actual practice it is likely that the cable would be reeved a second time around sheaves 40 and 42 prior to being attached to valve actuator 50 so that the necessary piston stroke is only about 1/4 of the vessel heave.
As noted above, one end of cable 48 is attached to valve actuator 50. As best shown in FIG. 2, valve actuator 50 is a lever pivotally mounted in a suitable bracket 52. The free end of valve actuator 50 is pivotally attached to the upper end of valve stem 54 which is part of safety valve 56. Tension in cable 48 exerts an upward force on valve actuator 50 which, in turn, exerts an upward force on valve stem 54 thereby holding safety valve 56 open. Other methods of actuating safety valve 56 will be readily apparent to those skilled in the art.
The safety valve depicted in FIG. 2 is a modified globe valve. Other types of valves such as gate valves, needle valves and ball valves could also be used as a safety valve in accordance with the present invention. It is only important that the valve be capable of being held fully open by tension in cable 48 and rapidly closed if tension drops below a predetermined level. The safety valve is installed in the hydraulic fluid supply line (or air pressure supply line if tensioning device 38 is a pneumatic spring tensioner) to tensioning device 38, as will be more fully explained below. The modified globe valve shown in FIG. 2 consists essentially of valve stem 54, housing 58, compression spring 60 and a plurality of O-rings 62 of various sizes which serve to seal the various chambers of the valve. Housing 58 is divided into two separate chambers, upper chamber 64 and lower chamber 66. When the valve is open (as shown in FIG. 2), hydraulic fluid may flow from downstream pipe 68, through lower chamber 66 and into upstream pipe 70. Upstream pipe 70 leads directly to the inlet port of tensioning device 38. Alternatively, the direction of flow may be reversed so that hydraulic fluid will flow from tensioning device 38, through upstream pipe 70 and lower chamber 66, and into downstream pipe 68. Downstream pipe 68 leads directly to the oil portion of air-oil accumulator 72 (shown diagrammatrically in FIG. 3). The direction of flow is dependent on whether tensioning device 38 is extending or retracting to maintain the tension in cable 48.
Valve stem 54 has a reduced diameter shank 74 formed on its upper end which extends through the top of housing 58 and connects to valve actuator 50. A compression spring 60 located in upper chamber 64 surrounds shank 74. Tension in cable 48 pulls upwardly on valve actuator 50 which, in turn, pulls upwardly on shank 74 thereby compressing spring 60. If tension in cable 48 drops below the force in preloaded spring 60, the spring extends rapidly forcing valve stem 54 downwardly until the face 76 of valve stem 54 contacts valve seat 78 thereby shutting off flow in both directions. When this happens the piston of tensioning device 38 may extend slightly since it is unrestrained by tension in cable 48. However, due to the incompressibility of the hydraulic fluid further motion of the piston will be prevented.
In an alternate embodiment air pressure is used to close safety valve 56. Spring 60 is eliminated and upper chamber 64 is connected to an air pressure source. When tension in cable 48 drops below a predetermined level, the air pressure forces valve stem 54 downwardly closing the valve.
FIG. 3 diagrammatically illustrates one embodiment of the riser tensioner safety system of the present invention. The tensioning device 38 contains piston 90 which is attached to piston rod 92. Movable sheave 40 is attached to the top of piston rod 92. Stationary sheave 42 is attached to the bottom of tensioning device 38. The tension cable 48 extends from tension ring 46 which is mounted on outer barrel 28 of the riser 20 over turndown sheave 44, around sheaves 42 and 40, and attaches to valve actuator 50. Pressurized hydraulic fluid is supplied to the bottom of piston 90 by air-oil accumulator 72. The chamber 94 above piston 90 may be filled with a low pressure oil in which case the exhaust 98 would be connected to a low pressure oil reservoir (not shown). Alternatively, chamber 94 may be filled with air. As the vessel heaves upwardly, tension in cable 48 forces piston 90 downwardly which, in turn, forces the high pressure hydraulic fluid out of lower chamber 96 of tensioning device 38 and into the air-oil accumulator 72. Conversely, if the vessel heaves downwardly, air-oil accumulator 72 forces additional hydraulic fluid into lower chamber 96 thereby forcing piston 90 upwardly to maintain tension in cable 48.
An air compressor 80 is used to maintain a preselected pressure in air pressure vessel 82 which may include additional pressure regulation equipment (not shown). The pressure may be as high as 2400 psi. Pressure vessel 82 maintains the air pressure in air-oil accumulator 72. A floating piston 84 is used to separate the pressurized air from the pressurized hydraulic fluid. The hydraulic fluid flows from air-oil accumulator 72, through downstream pipe 68, safety valve 56 and upstream pipe 70, and into tensioning device 38. Alternatively, the hydraulic flow may be reversed. The direction of flow is dependent on whether vessel 10 is heaving up or down.
During start up operations safety valve 56 is closed since there is no tension in cable 48. A by-pass pipeline 88 containing a manually operated valve 86 is used to supply hydraulic fluid to tensioning device 38 during start up. When cable 48 has been tensioned sufficiently to hold safety valve 56 open, manually operated valve 86 is closed. Thereafter all fluid flow to and from tensioning device 38 must pass through safety valve 56.
Due to the high tension in cable 48 it may be advisable to include a mechanical stop (not shown) in the actuator mechanism (see FIG. 2) to prevent valve actuator 50 from damaging safety valve 56. Use of such a device is well known in the art.
The apparatus of the present invention and the best mode contemplated for practicing the invention have been described. It should be understood that the invention is not to be unduly limited to the foregoing which has been set forth for illustrative purposes. Various modifications and alterations of the invention will be apparent to those skilled in the art without departing from the true scope of the invention defined in the following claims. For example, other types of tensioners and other types of valves could be employed. A pneumatic spring tensioner could be used in place of the pneumatic/hydraulic tensioner described above. The valve stem could be directly connected to the tension cable without use of an actuator mechanism. Alternatively, the valve could be remote from the triggering mechanism which, for example, could be an electrical, hydraulic or pneumatic switch which is closed by a reduction of tension in the tensioner cable. Chains could be used in place of wire cables. Further, the tensioner safety system described above would be applicable to the tensioning of other equipment extending from the surface of a body of water to a subsea wallhead such as, for example, a guideline. | A riser tensioner safety system for preventing damage to a floating drilling vessel in a broken cable event or an emergency disconnect of the riser is disclosed. The system uses standard pneumatic/hydraulic tensioning devices together with a safety valve which is installed in the hydraulic fluid supply line to the tensioning device. The valve is held open by tension in the riser tensioner lines. If tension drops below a predetermined level due to a broken cable event or an emergency disconnect of the riser, the valve closes rapidly preventing acceleration of the tensioner piston. | 4 |
RELATED APPLICATION
This application is a continuation-in-part of U.S. Pat. application Ser. No. 656,330 filed Oct. 1, 1984 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to a system for rolling and unrolling a web for uncovering and covering a surface on which the web rests. More particularly, the web is in the form of a large, one-piece storable artificial material suitable for covering a playing field, but which may be removed when necessary.
Large sized artifical materials are utilized as surface coverings for base surfaces such as playing surfaces for football and baseball and other applications, and require apparatus for handling such material in laying it down and rolling it up on a spindle or core. Normally, carriers are provided for laying and removing the cover, with or without a vehicle, such that the carriers support the bulky and extremely heavy rolled material as they traverse the playing field during coering and uncovering. It can be seen that the cost of providing and powering the necessary equipment to carry out the rolling and unrolling operations for artificial turf material, can be extremely high, and the operations time-consuming and labor intensive.
Moreover, prior techniques employed in rolling and unrolling such a cover are beset with problems in bulging of the web during web rolling and unrolling which increases the likelihood of web damage due to pinching or creasing and results in uneven covering of the playing field.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a system for rolling and unrolling the web of material directly across the surface to be covered without the need for carrier apparatus of any type, and in a manner whereby the web is tightly rolled and unrolled to reduce the likelihood of bulging and to assure that the web is flatly and evenly laid on its surface.
The system according to the invention for tightly rolling up the web includes either a gear motor coupled to the core about which the web is rolled for rolling it up, or a plurality of spaced straps wrapped about the outer periphery of the roll in the same direction of roll-up. Or, both the gear motor and the straps may be used together in rolling up the web. Means are provided for tightening the roll turns about one another during roll-up, such means comprising a closed-ended tube of flexible and unstretchable material partially filled with a fluid. The tube has a length substantially the same as the web width and underlies the roll for supporting it above the web which covers the surface. The tube lies initially beneath the roll such that its central axis is spaced from the central axis of the roll in the direction of roll-up, the tube normally lying beneath the roll such that the central axes lie in a common plane perpendicular to the web covering surface. In such manner, the tube shifts during web roll-up by rolling on itself from its initial to its normal position for causing the roll to slip to thereby tighten the web, whereafter the tube rolls on itself and moves in the same direction parallel to the web core so as to maintain a tight web.
The web unrolling system of the invention includes a plurality of leather straps disposed between individual turns of the wound web in the same direction of web winding such that an unwinding of the straps effects an unrolling of the web. The gear motor operatively coupled with the core is unpowered and unlocked so as to retard rotation of the core against unrolling to thereby effect a tightening of the web during unrolling.
A further feature of the invention includes the provision of guide arms journaled at both ends of the core and engaging grooves in the surface to be covered for guiding the web roll therealong during rolling and unrolling.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is schematic illustration in plan view of a playing field to be covered and uncovered in accordance with the invention;
FIG. 2 is a sectional view of the playing field of FIG. 1, taken substantially along the line 2--2 thereof, showing the fully rolled up web located in a storage pit;
FIG. 3 is a view similar to FIG. 2 showing the web fully unrolled over the playing surface, with the empty roll stored in a storage pit at the other end of the field;
FIG. 4 is a view similar to FIG. 2 showing the full roll raised out of its pit prior to unrolling;
FIG. 5 is a view similar to FIG. 3 showing the web in the process of being unrolled over the playing surface;
FIGS. 6 and 7 are plan views of unrolling and rolling winch assemblies, respectively;
FIG. 8 is a perspective view if a portion of the web roll showing the rolling and unrolling straps;
FIG. 9 is a side elevational view, at an enlarged scale, of the full roll after having been raised out of its pit;
FIG. 10 is a view taken substantially along the line 10-10 of FIG. 9;
FIG. 11 is an enlarged side view of the web roll in the process of being rolled up; and
FIG. 12 is a top view of the gear motor operatively coupled to the web core, taken substantial along the line 12--12 of FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings wherein like reference characters refer to like and corresponding parts throughout the several views, a playing field, e.g. a football field, is schematically illustrated in FIG. 1 with its surface covered by a web 10 of artificial turf material substantially throughout the length 1 and width w thereof in a lengthwise direction of the field employing the system according to the invention. A pair of winch assemblies generally designated 11 are mounted in their respective pits 12 located at one end of the playing field for unrolling the web. And, corresponding winches generally designated 13 are located at the opposite end of the field mounted on a wall 14 (FIG. 4). Playing surface 15 to be covered is typically a hard surface such as concrete shown in FIG. 2 although, of course, may be of any other suitable hard surfaces such as asphalt.
Each of the winch assemblies 11, shown in FIG. 6, includes a drive motor 16, which may comprise a gear motor or the like, having an output shaft 17 supporting a rotatably mounted strap storage reel 18 for rotation through a suitable clutch 19 of any known type. The output drive shaft of the motor likewise supports a cable reel 21 for rotation through a suitable clutch 22.
At the other end of the field, each winch assembly 13 (FIG. 7) includes a cable reel 23 mounted on a shaft 24, and a strap storage reel 25 likewise mounted on the shaft, the reels being engaged and disengaged from the shaft for rotation therewith via a clutch 26. And, an idler pulley 27 is suitably mounted for rotation coaxial with reels 23 and 25. A right angle gear drive 28 is operatively connected with shaft 24, and is driven by a removable handle (not shown).
Referring to FIGS. 4 to 7, a web of artificial turf material 10, having a width approximately equal to width w of the playing surface to be covered, is illustrated in a rolled up condition on a drum or core 29 (FIG. 4). The fully rolled up web is initially stored in an elongated pit 31 on an elevator platform 32. The platform has internally threaded openings at its four corners in threaded engagement with externally threaded elevator rods 33. Sprockets 34 are mounted on the rods beneath the platform, and a continuous sprocket chain 35 is trained about all four sprockets. A drive motor 36 is operatively coupled with one of the elevator rods for rotation which causes all the rods to rotate simultaneously in the same direction to thereby elevate platform 32. As the platform is elevated, the web roll 37 bears against the underside of a hatch cover 38 hinged at 39 to pit 31 for opening the hatch cover from its FIG. 2 to its FIG. 4 positions resting against wall 14. The top of the elevator platform is now coplanar with playing surface 15.
An end 41 of web 10 is anchored as at 42 to the elevator platform, and the web roll may be cradled within a shallow trough (not shown) provided in the surface of platform 32 for stablizing the roll against inadvertant movement at its storage position.
Straps are employed for unrolling the web roll from its fully rolled up position and for rolling it back up. A fabric strap 43 of each winch assembly 13, is shown in FIG. 7 as reeled on its storage reel 25 and wrapped about the outer periphery of the rolled up web (FIGS. 4 and 8). Each strap 43 underlies the web roll and is tacked at its free end beneath free end 41 of the web. And, a strap 44 lies between individual turns of the wound web roll after having been rolled up together therewith in the same direction of winding as will become more apparent hereinafter when describing the web rolling operation. Strap 44, associated with each of the winch assemblies 11, is clearly illustrated in FIG. 8.
A cable 45 is reeled up on its storage reel 21 (FIG. 6), and has a hooked free end. When the rolled web is to be unrolled from its FIG. 4 position across the length of the playing surface, clutch 22 is disengaged, and the free end of cable 45 is carried across the length of the field unrolling from its free wheeling cable reel 21. The cable is attached to the free end of fabric strap 44 as at 46. Clutch 22 is then engaged while clutch 26 is disengaged to permit free wheeling of strap reel 25. Motor 16 is then operated for driving reel 21 which reels up cable 45 to thereby unwind strap 43 causing the web roll to rotate in the direction of the curved arrow of FIG. 4, and to move toward the center of the field. As the web unrolls by pulling on each strap 43, the web is tensioned as it is laid across surface 15 and the weight of the web roll, as it continually moves along the layed web, squeezes out any air pockets which could otherwise occur during the laying operation. Moreover, as the web unrolls, strap 43 continues to surround the web roll as it decreases in diameter and underlies the laid web while the strap is unreeled from its free wheeling reel 25.
As the web is unrolled to mid-field, strap 43, which has a length substantially equal to length 1 of the surface to be covered, has fully unrolled from its strap reel 25, so that its trailing end simply falls onto the upper surface of the web with nearly half its length now lying on top of the unrolled web. Strap 43 is releasably attached in any normal manner to its reel 25 to facilitate release without resistance. And, the free end of strap 44, at the mid-field position, has traveled the full length of the field. Strap 44 is then detached from the end of cable 45, cable 45 is stored on its reel 21, and the full end of strap 44 is attached to strap reel 18 in any normal manner.
To continue the web unrolling operation, clutch 22 is disengaged and clutch 19 is engaged. The motor is operated for driving reel 18 so as to reel in strap 44 which facilitates a continued unrolling of the web, shown in the process of unrolling in FIG. 5 to its fully unrolled position of FIG. 3. As the web is being unrolled, strap 43 continues to be laid under the web by the progressively unrolling web roll. At the fully unrolled position, strap 44 will be fully rolled up on its storage reel 18, and strap 43 will be fully unrolled under the web.
For rolling the web back onto its drum or core 29 to uncover the playing surface, clutches 19 and 22 are disengaged. The free end of cable 45 is then carried across the field from its free wheeling reel 21, looped around free running sheave 27 and carried back across the field and attached to the free end of strap 43. Clutch 22 is then reengaged.
Motor 16 is then operated for driving reel 21 which reels in cable 45 so as to pull the connected end of strap 43 in a direction toward the other end of the field. The reel is therefore caused to roll up on its drum 50, while strap 44 rolls up together with the web between individual web turns as strap 45 unreels from its free wheeling reel 18. At mid-field, the free end of strap 43 will have reached winch assembly 13. And, since the length of strap 44 is substantially equal to length 1 of the playing surface to be covered, and being releasably attached to its reel 18 in some suitable manner, it will release therefrom at the mid-field position and simply fall onto surface 15, while the remaining one-half length of this strap has been rolled up with the web as aforedescribed. At such mid-field position, cable 45 is removed from sheave 27 and is disconnected from strap 43, and strap 43 is releasably connected to its strap reel 25. Cable 45 is then connected to the free end of a cable 47 stored on its storage roll 23, and clutch 26 is engaged to couple reels 23 and 25 together for rotation with common shaft 24.
Motor 16 is then operated to complete the rolling operation as cable 45 is reeled in and pulls the end of cable 47 to travel the full length of the field. During this process, strap 43 is reeled up on its reel 25. Cable 45 is then disconnected from cable 47, and clutch 26 is disengaged. The removable hand crank may then be utilized to reel cable 47 back onto its cable reel 23.
During a rolling up of the web roll, the outermost turn of the web may bulge so as to form a loop 48 (FIG. 11) which, if not tightened, could cause the web to crease or wrinkle during roll up which could not only damage the web but would manifestly persist during an unrolling of the web thereby causing an uneven web surface. According to the present invention, a means for tightening the web turns during roll up is provided in the form of an elongated tube 49 of flexible and unstretchable material, such as a fabric, partially filled with a fluid, such as air. The tube has a length substantially of the same as the entire width of the web, and underlies the roll for supporting the roll above web 10 which overlies surface 15. As shown in solid outline in FIG. 11, the tube lies in an initial position beneath the roll such that the central axis of the tube is spaced in the direction of roll movement (roll arrow) from the central axis of the roll. And, the tube shifts from this initial position to its phantom outline position in which its central axis lies in the same plane as the central axis of the tube which plane is perpendicular to surface 15 and web 10 which covers it. In such manner, during a rolling up of the web, the tube shifts by simply rolling on itself from its solid outline to its phantom outline positions for causing the roll to slip as it rotates about its central axis without moving in its forward direction. Loop 48 is thus taken up and tightened against the roll as shown in phantom outline in FIG. 11, whereafter the tube moves together with the roll in the direction of the arrows shown in FIG. 11 during the continued roll up operation.
Web core 29 includes an axle 51 extending outwardly of opposite ends thereof (only one shown in FIG. 12), and pairs of guide arms 52, 53 being journaled to the axle at both ends of the core, the inner ends of the guide arms being mounted on a sleeve 54 on the axle, collars 55, 56, or the like on opposite ends of the sleeve being fixed to the axle for locating the sleeve thereon at an appropriate distance from the core such that centerline 57 of the guide arm pair coincides with the centerline of a guide track 58 (FIG. 10), while an edge 59 at the outer face of the core coincides with the edge of the artificial material. A gear motor 61 is mounted on sleeve 54 by means of a clamp 62 (FIG. 9), output shaft 63 of the motor having a drive sprocket 64 thereon, and axle 51 having a sprocket 65 thereon. Sprockets 64, 65 are slightly spaced apart out of meshing engagement, and an endless drive chain 66 surrounds both sprockets.
The outer ends of arms 52, 53 have idler rollers 67 thereon for rolling along track 58 (FIGS. 9 and 10). And, a coil spring 68 interconnects arms 52, 53 for resiliently biasing the arms together and insuring that the rollers are maintained within the guide track as the included angle between the arms changes as the web roll diameter changes during the web rolling and unrolling operations.
The aforedescribed drive motor and guide arms are located at both ends of the web core, and the motors are powered via power supplies 69 at opposite sides of the field shown schematically in FIG. 1.
A pit 71 extends along the width of the field opposite pit 31, pit 71 being deeper and wider than each pit 12 but being in open communication therewith. And, tracks 58 continue along opposite ends of the pit 71. Thus, when the web is fully unrolled as shown in FIG. 3, the web roll diameter is at its minimum, and the included angle between guide arms 52, 53 is at its maximum with the coil spring therebetween fully stretched as rollers 67 continue to roll along guide track 58.
During the unrolling operation from the fully rolled up position of FIG. 4, winch assemblies 11 are operated for reeling in straps 44 as in the manner aforedescribed. However, in order to continually tighten the web turns about one another during web unrolling so as to assure an even carpet lay down without bulging or creasing, the power from power supplies 69 is turned off such that motors 61 at opposite ends of the web core are turned off but are unlocked. Thus, the gear rotation of the motors coupled with the rotating web core via sprockets 64, 65, acts as a brake so as to retard rotation of the web core (counterclockwise as shown in FIG. 9), such that the web turns are tightened about one another during unrolling. And, the guide arms at opposite ends of the web core accurately guide the web along tracks 58 and maintain edges 59 of the web spaced from the guide track. When the web is fully unrolled as shown in FIG. 3, the web core and its guide arm pairs 52, 53 at opposite ends are lowered into pit 71 which may be subsequently covered with a hatch (not shown) during field play.
When the web is being rolled up, each winch assembly 13 is activated for reeling in strap 43 as in the manner aforedescribed. In addition to the use of these roll-up straps 43, or in lieu thereof, motors 61 are activated as their supplies 69 are turned on rotating the core in a clockwise direction (viewed in FIGS. 9, 11). At some convenient stage during the process of rolling up the web, tube 49 is disposed beneath the roll in its initial position shown in FIG. 11 for allowing the roll to slip to thereby tighten the outer roll turn to take up any bulging such as 48 shown in this Figure. The bag then shifts to its position shown in phantom outline, and progresses in the direction of the arrows shown in FIG. 11 together with the core during rolling up.
Obviously, many modifications and variations of the present invention are made possible in the light of the above teachings. It it therefore to be understood within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | A system for tightly rolling and unrolling a web employed as a ground cover includes the use of unrolling tapes for unrolling the web, and an unpowered gear motor which serves to retard unrolling, rollup tapes and/or the gear motor being employed for rolling up the web together with an elongated flexible and unstretchable tube partially filled with fluid which supports the web and causes it to slip on itself for tightening any web bulges while being rolled up. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to PCT Application No. PCT/CN2015/073185, filed on Feb. 16, 2015, which claims priority to Chinese Patent Application No. 201410061030.3, filed on Feb. 24, 2014, Chinese Patent Application No. 201410061051.5, filed on Feb. 24, 2014, Chinese Patent Application No. 201420092359.1, filed on Mar. 3, 2014, and Chinese Patent Application No. 201510010023.5, filed on Jan. 8, 2015, the entire content of all of which is incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure generally relates to the field of adhesive film and encapsulation assembly and, more particularly, relates to a polyolefin film and preparation method, and related encapsulation method and encapsulation assembly.
BACKGROUND
[0003] Encapsulation technology has been widely used in semiconductor devices, crystalline silicon solar cells, light emitting diodes (LEDs), organic light-emitting diodes (OLEDs), display screens, etc. Moreover, encapsulation films are used to adhere to the interior photovoltaic cell and to other layers in laminate structures and to protect the interior photovoltaic cell. Encapsulation films are usually made by polyolefin including ethylene-vinyl acetate (EVA) or polyolefin elastomer, which has been widely used for encapsulation.
[0004] EVA resin can be used as the sole material, plastic sheeting and hot melt adhesive. When used as a hot melt adhesive, the EVA resin that contains high weight percentage of VA (vinyl acetate) may be used, which may also has a low melting point, generally lower than 90° C. Before being used, the hot melt adhesive film, the EVA resin is made into a stick or an adhesive film that is convenient for users to process as needed. When the EVA resin contains VA having a weight percentage between 20 and 35 wt %, the EVA resin may possess excellent transparency greater than 90%, and may have desirable flexibility. Such EVA resin is ideally suited as a laminated film within double glaze or an encapsulation film for a solar module, which can buffer for the glass from being attacked or protect the very brittle solar cell chips behind the glass in the solar module. However, the EVA resin prepared to contain VA having a weight percentage between 20 and 35 wt % has a melting point between 60-80° C., lower than room temperature. It is hard for such EVA resin to maintain its dimensional stability and physical strength at room temperature for a long term. Such EVA resin has to be used after being crosslinked. In order to crosslink, thermo-crosslinking agent must be added to form an EVA resin film, which usually includes an organic peroxide, such as dicumyl peroxide (DCP), peroxy-2-ethylhexyl carbonate t-butyl ester (TBEC), etc. The EVA resin film with added thermo-crosslinking agent may be placed between the glasses in double glaze, or placed on both side of the solar cells behind the glass of solar module, vacuumed while being heated to be greater than 135° C. to melt the EVA resin to fill the gaps between the EVA resin film and the glass or between the EVA resin film and the solar cell. At the same time, EVA resin undergoes a crosslinking reaction by organic peroxide decomposition. In this stage, the crosslinking degree of EVA resin can reach 75-95%. The crosslinked EVA film is a thermoset material with elasticity without being melted and may permanently maintain the shape and strength. Usually the EVA film has not been crosslinked before used, the dimensional stability is poor, and it overflows from glass's edge after being heated, which may contaminate the equipment being used. When laying the colored and transparent EVA films up and down simultaneously, due to poor dimensional stability, the boundary of the colored and the transparent films may be unclear and interpenetrating.
[0005] A polyolefin elastomer (POE) resin refers to copolymer(s) of ethylene and butene, pentene, hexene or octane. It was first invented by Dow, which was copolymerized by octene and ethylene elastomer that possess relatively narrow molecular weight distribution and uniform short-branched chain distribution, using metallocene as catalyst. The elastomer crystalline region from ethylene chain in polyolefin elastomer is used as a physical crosslinking point, and butane, pentene, hexane, octene with long chain form amorphous rubber phase. As a result, the polyolefin elastomer has dual characteristics of rubber elasticity and thermoplasticity. The polyolefin elastomer is widely used in processing modified polyolefin such as modified polypropylene used in auto accessories, because it is well compatible with polyolefin especially polyethylene and polypropylene, and has excellent properties of weather resistance and no unsaturated bond simultaneously. The melting temperature of the polyolefin elastomer is low, usually between 50° C.-70° C., there are almost no reports that polyolefin elastomer may be used by itself or polyolefin elastomer may be used as the main material. The polyolefin elastomer film made from the mixture of polyolefin elastomer and polyethylene compound by Dow, is served as a substitute of conventional EVA film in solar PV modules. The main component, polyolefin elastomer made from the mixture of polyethylene with high melt point and polyolefin elastomer compound with low melt point may have a melting point above 100° C. In a Chinese patent application CN103289582A, the polyolefin elastomer film can be prepared from the polyolefin elastomer by a reactive extrusion grafting step utilizing a graftable alkoxysilane-containing compound and a step adding organic peroxide. The polyolefin elastomer film may be crosslinked by organic peroxide decomposition by heating, providing heat-resistance. Due to very low melting point of the polyolefin elastomer, under the circumstance of adding polyethylene with high melting point or crosslinking agent, the melting point of the polyolefin elastomer is still very low. That the elastomer melt quickly during heating leads to inconvenience, meanwhile, low melting point causes high requirements for transportation and storage, which limits the use of the polyolefin elastomer.
[0006] Both POE film and EVA film have low melting points. The heating temperature for solar PV module's lamination is usually between 135° C. to 150° C., which is much higher than both melting points. Gradually the film melts in the lamination, and it is impossible to maintain moldability and stability, great changes may occur in the film's size and shape after lamination. For example: the two-layer film, whose size is smaller than glass, may overflow after lamination. In another example, when one of the two films is in color, after lamination the boundary is unclear and interpenetrating. The above problems have affected the final quality of the assembly or the production process.
[0007] It is important to improve the heat-resistant property of the EVA film or POE film and other polyolefin encapsulation film as hot-melt adhesive in the manufacturing process of encapsulation assembly to allow a clear interface of encapsulation.
[0008] Radiation crosslinking is a technique that uses crosslinking reaction between long chain polymers triggered by radiation. Radiation has two categories: one is ionizing radiation, which means that a (alpha), β (beta), γ (gamma), X and neutron rays, that can make a direct or indirect ionization (i.e., atoms or molecules gain or lose electrons and become ions); the other is non-ionizing radiation, such as visible light, ultraviolet light, sound radiation, heat radiation and low-energy electromagnetic radiation and so on. There is lack of binding force between molecular chains of the polymer, making it prone to deformation or damage when subjected to an external force and the ambient temperature, thus restricting its application. Crosslinking reaction forms binding sites such as chemical bonds between the polymer long chains so that the physical and chemical properties of the polymer are improved which is very effective means for polymer modification. During radiation crosslinking, there is no physical contact between the polymer and radiation generator, the shape of the polymer does not change before and after the reaction, but there is internal crosslinking reaction inside the polymer. Polymer product can be directly placed in the radiation for the crosslinking reaction. Further, crosslinking agent may be added into the polymer to promote efficiency of radiation crosslinking. However, non-ionizing radiation such as ultraviolet light has bad penetrability and limited cure depth, and moreover light initiator must be used for ultraviolet light curing. Therefore, it's difficult or impossible for partial crosslinking operation for polymer. However, radiation energy that can directly trigger polymer crosslinking reactions, such as β-rays, γ-rays, X-rays and etc. Use of radiation energy becomes more convenient, and achieves better results for partial crosslinking, since light initiator is not needed.
[0009] Radiation crosslinking is widely used in producing heat-shrinkable tube, and the plastics may have a shape memory capacity due to the crosslinking after radiation. Thus the plastic tube will return to the original shape. At room temperature the radiation-crosslinked plastic tube may be expanded, and then shrunk to its original shape while being heated. Another area in which it is commonly used is the production of automotive wire, radiation crosslinking can increase usage temperature of the automotive wire that has to be operated at a high temperature for vehicle engines.
BRIEF SUMMARY OF THE DISCLOSURE
[0010] To overcome the defects of EVA film, POE film and other polyolefin encapsulation films in the encapsulation process of encapsulation assembly, which is widely used in semiconductor devices, crystalline silicon solar cells, LEDs, OLEDs, display screens etc., the present invention provides a method for producing a radiation pre-crosslinked polyolefin film for encapsulation. The method may include: preparing a film by mixing polyolefin raw (based) materials together; using the radiation energy to irradiate the film, the radiation energy can directly stimulate the polyolefin raw(based) materials to undergo a crosslinking reaction; adjusting the irradiation dose of the radiation energy, to make the crosslinking degree of the film reach 3% to 95%; adjusting the energy of radiation, to make the film's thickness of crosslinked portion reach 5% to 100%, where 100% indicates an all crosslinked film.
[0011] In one embodiment, the method for producing a radiation pre-crosslinked polyolefin film for encapsulation includes the following steps: preparing a film after mixing polyolefin raw materials together; using the radiation energy to irradiate the film to directly stimulate the polyolefin raw materials to undergo a crosslinking reaction; adjusting the irradiation dosage of the radiation energy, to make the crosslinking degree of the film reach about 3% to about 95%; adjusting the radiation energy, to make the film thickness of crosslinked portion reach about 5% to about 100% of the film. The 100% in thickness indicates that the film is all crosslinked.
[0012] In one embodiment, the pre-crosslinked portion in the film forms at least one layer of the film surface.
[0013] In one embodiment, the radiation energy includes one of β rays, γ rays, X rays, α rays, and neutron rays.
[0014] The disclosed methods for preparing the film after mixing polyolefin raw materials together may include, but are not limited to, using a T-shaped flat mold for extruding film, or using two casting rollers for rolling into a film. For example, the film formation temperature is 70 to 200° C., and/or the mold temperature is 70 to 200° C.
[0015] The radiation energy can be adjusted to irradiate a laminated polyolefin film or an expanded polyolefin film.
[0016] In one embodiment, the polyolefin film includes an ethylene-vinyl acetate resin film. The ethylene-vinyl acetate (EVA) resin film may include, by weight, an EVA resin of about 51 parts to about 99.58 parts; an organic peroxide crosslinking agents of about 0.3 part to about 2 parts; assistant crosslinking agents of about 0.01 part to about 5 parts; antioxidants of about 0.1 part to about 2 parts; silane coupling agents of about 0.01 part to about 2 parts; pigments of about 0 to about 40 parts; and polyolefin elastomer of 0 to about 40 parts.
[0017] In one embodiment, the irradiation dosage is about 0.2 KGY to about 100 KGY. A pre-crosslinking degree of the ethylene-vinyl acetate resin film is about 5% to about 74% when 100% thickness of the film is radiation pre-crosslinked.
[0018] The radiation pre-crosslinked ethylene-vinyl acetate resin film has a single-layer, double layers, or multiple layers that are co-extruded.
[0019] The thickness of the radiation pre-crosslinked ethylene-vinyl acetate resin film is about 0.01 mm to about 2 mm. For example, the thickness is about 0.3 mm to about 0.7 mm.
[0020] The EVA resin may contain VA of about 20% to about 35% by weight, for example, the weight percentage may be about 25% to about 33% by weight.
[0021] The organic peroxide as crosslinking agents include, but are not limited to: one or more of the dialkyl peroxides, alkyl aryl peroxides, diaryl peroxides, hydrogen peroxides, diacyl peroxides, peroxy esters, ketone peroxide, peroxycarbonate, and peroxy ketals.
[0022] The assistant crosslinking agents include, but are not limited to: one or more of acrylics, methacrylics, acrylamides, allyls, and epoxy compounds.
[0023] The antioxidants include, but are not limited to: one or more of the light stabilizers, UV absorbers, and thermal oxidative aging decomposers.
[0024] The silane coupling agent is an organic silicon compound which contains two chemical groups with different chemical properties.
[0025] The pigments are additives that can change the color of the EVA film, and include, but are not limited to: one or more of carbon blacks, lithopone, zinc sulfide, titanium dioxide, ultra-fine barium sulfate, and glass beads.
[0026] The polyolefin elastomer is carbon-carbon chain resin that can be mixed with EVA, and can include one or more of the low-density polyethylene, copolymer of ethylene and butene/octene.
[0027] The polyolefin film may be a polyolefin elastomer film. The polyolefin elastomer film may include, by a weight, a polyolefin elastomer of about 69 to about 99.8 parts, assistant crosslinking agents of about 0.01 to about 5 parts, antioxidants of about 0.01 to about 2 parts, silane coupling agents of 0 to about 2 parts, organic peroxide crosslinking agents of 0 to about 2 parts, and pigments of 0 to about 20 parts. The irradiation dosage is about 10 to about 200 KGY. The pre-crosslinking degree of the polyolefin elastomer film is about 3% to about 70% when the film is radiation pre-crosslinked with entire thickness.
[0028] The thickness of radiation pre-crosslinked polyolefin elastomer film is about 0.2 mm to about 1 mm. More preferably, the thickness is about 0.3 to about 0.7 mm.
[0029] The polyolefin elastomer is one or more of the copolymers of ethylene with one or more of butene, pentene, hexene and octene.
[0030] The polyolefin elastomer may or may not be grafted by a polar group. When forming the film, the polar group is added as a small molecule additive. For example, the polar group is a silane coupling agent. For example, a silane coupling agent in elastomer may be grafted onto the elastomer molecular chain before forming the film, whose grafting ratio is less than about 3%. In one embodiment, a grafted vinyltrimethoxysilane ethylene-hexene copolymer may be formed having a grafting rate nearly about 0.6%.
[0031] The assistant crosslinking agent is a monomer with multi-functional groups, including, but not limited to: one or more of triallyl isocyanurate, cyanuric acid triallyl, trimethylol propane triacrylate, and trimethylol propane trimethacrylate.
[0032] The antioxidant refers to decomposition heat aging and UV absorbers, including, but not limited to: phenolic antioxidants, hindered amine antioxidants, phosphorous acids, benzophenone, benzotriazoles including, for example: four [β-(3,5-di-t-butyl-4-hydroxyphenylyl) propionic acid] pentaerythritol ester, sebacate (2,2,6,6-tetramethyl-4-piperidyl) ester and N,N′-di-sec-butyl-p-phenylenediamine.
[0033] The silane coupling agents are organic silicon compounds containing two chemical groups with different chemical properties, preferably KH550.
[0034] The organic peroxide crosslinking agents are thermal crosslinking organic peroxide crosslinking agents, usually used for plastics, including, but not limited to: one or more of dicumyl peroxide, peroxy-2-ethylhexyl carbonate t-butyl, and 2, 5-dimethyl-2, 5-bis (t-butylperoxy) hexyl.
[0035] The pigments are additives that can change the color of EVA film that include, but are not limited to: one or more of carbon blacks, lithopone, zinc sulfide, titanium dioxide, and glass beads.
[0036] Crosslinking part of the polyolefin film after the irradiation of radiation energy may include about 5% to 100% thickness of the polyolefin film. The 100% indicates that the film is all crosslinked in thickness. A crosslinking degree of the crosslinking part is about 3% to about 95%.
[0037] The disclosed radiation pre-crosslinked encapsulation polyolefin film may include a crosslinked portion in the film as a surface layer of the film. In one embodiment, the polyolefin film includes an ethylene-vinyl acetate resin film. The ethylene-vinyl acetate (EVA) resin film may include, by weight, an EVA resin of about 51 parts to about 99.58 parts; an organic peroxide crosslinking agents of about 0.3 part to about 2 parts; assistant crosslinking agents of about 0.01 part to about 5 parts; antioxidants of about 0.1 part to about 2 parts; silane coupling agents of about 0.01 part to about 2 parts; pigments of about 0 to about 40 parts; and polyolefin elastomer of 0 to about 40 parts.
[0038] The pre-crosslinking degree of the radiation pre-crosslinked ethylene-vinyl acetate resin film is about 5% to about 74% when the film is pre-crosslinked along an entire thickness.
[0039] The radiation pre-crosslinked ethylene-vinyl acetate resin film may include a single layer, double layers, or multiple layers that are co-extruded.
[0040] The thickness of the radiation pre-crosslinked ethylene-vinyl acetate resin film is about 0.01 mm to about 2 mm; more preferably, the thickness is about 0.3 mm to about 0.7 mm.
[0041] The ethylene-vinyl acetate resin film may contain VA having a weight percentage of about 20 to about 35% by weight, and more preferably, the weight percentage is about 25 wt % to 33 wt %.
[0042] The organic peroxide as crosslinking agents including, but are not limited to: one or more of dialkyl peroxides, alkyl aryl peroxides, diaryl peroxides, hydrogen peroxides, diacyl peroxides, peroxy esters, ketone peroxides, peroxycarbonates, and peroxy ketals.
[0043] The assistant crosslinking agents include, but are not limited to: one or more of acrylics, methacrylics, acrylamides, allyls, and epoxy compounds.
[0044] The antioxidants include, but are not limited to: one or more of light stabilizers, UV absorbers, and thermal oxidative aging decomposers.
[0045] The silane coupling agent includes organic silicon compounds and contains two chemical groups with different chemical properties.
[0046] The pigments are additives that can change the color of EVA film, and include, but are not limited to: one or more of carbon blacks, lithopone, zinc sulfide, titanium dioxide, and glass beads.
[0047] The polyolefin elastomer may be carbon-carbon chain resin that can be mixed with EVA, and include one or more of the low-density polyethylene, copolymer of ethylene and butene or octene. The polyolefin film may be polyolefin elastomer film.
[0048] The polyolefin film may be a polyolefin elastomer film. The polyolefin elastomer film may include, by a weight, a polyolefin elastomer of about 69 to about 99.8 parts, assistant crosslinking agents of about 0.01 to about 5 parts, antioxidants of about 0.01 to about 2 parts, silane coupling agents of 0 to about 2 parts, organic peroxide crosslinking agents of 0 to about 2 parts, and pigments of 0 to about 20 parts.
[0049] The pre-crosslinking degree of the polyolefin elastomer film may be about 3% to about 70% when the film is radiation pre-crosslinked in the entire thickness.
[0050] The thickness of radiation pre-crosslinked polyolefin elastomer film is about 0.2 mm to about 1 mm; and more preferably, the thickness is about 0.3 mm to about 0.7 mm.
[0051] In the disclosed radiation pre-crosslinked polyolefin film, the polyolefin elastomer includes one or more of the copolymers of ethylene and butane, pentene, hexane or octene.
[0052] The polyolefin elastomer may or may not be grafted by a polar group. When forming the film, the polar group is added as a small molecule additive. For example, the polar group is a silane coupling agent. For example, a silane coupling agent in elastomer may be grafted onto the elastomer molecular chain before forming the film, whose grafting ratio is less than about 3%. In one embodiment, a grafted vinyltrimethoxysilane ethylene-hexene copolymer may be formed having a grafting rate nearly about 0.6%.
[0053] The assistant crosslinking agent may be a monomer with multi-functional groups, that include but are not limited to: one or more of triallyl isocyanurate, cyanuric acid triallyl, trimethylol propane triacrylate, and trimethylol propane trimethacrylate.
[0054] The antioxidants refer to decomposition heating aging and UV absorbers, and include, but are not limited to: phenolic antioxidants, hindered amine antioxidants, phosphorous acids, benzophenone, benzotriazoles including, for example, four [β-(3,5-di-tert-butyl-4-hydroxyphenyl) propionic acid] pentaerythritol ester, sebacate (2,2,6,6-tetramethyl-4-piperidyl) ester, and N,N′-di-sec-butyl-p-phenylenediamine.
[0055] The silane coupling agents are organic silicon compounds containing two chemical groups with different chemical properties, preferably KH550.
[0056] The organic peroxide crosslinking agents are thermal crosslinking organic peroxide crosslinking agents, usually used for plastics, which include but are not limited to: one or more of dicumyl peroxide, peroxy-2-ethylhexyl carbonate t-butyl, and 2, 5-dimethyl-2, 5-bis (t-butylperoxy) hexyl.
[0057] The pigments are additives that can change the color of EVA film, and include, but are not limited to: one or more of carbon blacks, lithopone, zinc sulfide, titanium dioxide, and glass beads.
[0058] An encapsulation method using the radiation pre-crosslinked polyolefin film may include the following steps: preparing a film after mixing polyolefin raw material together; using the radiation energy to irradiate the film, the radiation energy directly stimulating the polyolefin raw materials to undergo a crosslinking reaction; adjusting the irradiation dosage of the radiation energy, to make the crosslinking degree of the film of about 5% to about 95%; adjusting the radiation energy, to make the film thickness of crosslinked portion from about 5% to about 100% of the film, 100% indicating that the film is all crosslinked in thickness; placing the film between a front protective layer and an encapsulation substrate, and constructing encapsulation assembly with an encapsulated body, the pre-crosslinked portion of the film being in contact with the encapsulated body; and heating the encapsulation assembly, to further crosslink the film and to complete the process of the encapsulation.
[0059] The pre-crosslinked portion in the film forms a layer of the film surface.
[0060] The radiation energy is the one of β rays, γ rays, X rays, α-rays, and neutron rays.
[0061] The methods for preparing the film after mixing polyolefin raw materials together include, but are not limited to: using a T-shaped flat mold for extruding film, or using two casting rollers for rolling to form the film.
[0062] The film formation temperature is about 70 to about 200° C., and the mold temperature is about 70 to about 200° C.
[0063] In the disclosed encapsulation method using radiation pre-crosslinked polyolefin film, the radiation may irradiate the laminated polyolefin film or the expanded polyolefin film.
[0064] In one embodiment, the polyolefin film includes an ethylene-vinyl acetate resin film. The ethylene-vinyl acetate (EVA) resin film may include, by weight, an EVA resin of about 51 parts to about 99.58 parts; an organic peroxide crosslinking agents of about 0.3 part to about 2 parts; assistant crosslinking agents of about 0.01 part to about 5 parts; antioxidants of about 0.1 part to about 2 parts; silane coupling agents of about 0.01 part to about 2 parts; pigments of about 0 to about 40 parts; and polyolefin elastomer of 0 to about 40 parts.
[0065] The irradiation dosage is about 0.2 KGY to about 100 KGY.
[0066] The pre-crosslinking degree of the ethylene-vinyl acetate resin film is about 5% to about 74% when the film is pre-crosslinked through the entire thickness.
[0067] The radiation pre-crosslinked ethylene-vinyl acetate resin film includes a single-layer, double layers, or multiple layers that are co-extruded.
[0068] The thickness of the radiation pre-crosslinked ethylene-vinyl acetate resin film is about 0.01 mm to about 2 mm; and more preferably, the thickness is about 0.3 mm to about 0.7 mm.
[0069] The polyolefin film is a polyolefin elastomer film.
[0070] The polyolefin film may be a polyolefin elastomer film. The polyolefin elastomer film may include, by a weight, a polyolefin elastomer of about 69 to about 99.8 parts, assistant crosslinking agents of about 0.01 to about 5 parts, antioxidants of about 0.01 to about 2 parts, silane coupling agents of 0 to about 2 parts, organic peroxide crosslinking agents of 0 to about 2 parts, and pigments of 0 to about 20 parts. The irradiation dosage is about 10 to about 200 KGY. The pre-crosslinking degree of the polyolefin elastomer film is about 3% to about 70% when the film is radiation pre-crosslinked with entire thickness.
[0071] The thickness of radiation pre-crosslinked polyolefin elastomer film is about 0.2 mm to about 1 mm; and more preferably, the thickness is about 0.3 to about 0.7 mm.
[0072] The polyolefin elastomer may be one or more of the copolymers of ethylene and butene, pentene, hexene or octene.
[0073] When heating the encapsulation assembly, the encapsulation assembly may be pressured or vacuumed for the encapsulation.
[0074] The encapsulated body may include, but be not limited to: crystalline silicon solar cells, LEDs, OLEDs, display devices, etc.
[0075] The encapsulation method using radiation pre-crosslinked polyolefin film may include: placing a film including two layers between the front protective layer and the encapsulation substrate, and at least one of the two films is the pre-crosslinked film, and placing the encapsulated body between the two layers of the film.
[0076] The front protective layer may be a transparent protective layer, in particular is a transparent glass, a transparent ceramic or a transparent plastic.
[0077] The film may include a layer of EVA (ethylene-vinyl acetate resin) film and a layer of pre-crosslinking EVA film, and the EVA film is placed on or adjacent to the front protective layer.
[0078] In one embodiment, both of the two layers of film are pre-crosslinking POE (polyolefin elastomer) films.
[0079] The radiation pre-crosslinked polyolefin film is placed between a front protective layer and encapsulation substrate, the encapsulation assembly is constructed with the encapsulated body, and the pre-crosslinked portion of the film is in contact with the encapsulated body.
[0080] The encapsulated body includes, but is not limited to: crystalline silicon solar cells, LEDs, OLEDs, display devices, etc.
[0081] In an exemplary encapsulation assembly, a film including two layers is placed between the front protective layer and the encapsulation substrate, at least one of the two films is the pre-crosslinked film. The encapsulated body is placed between the two layers of the film.
[0082] The front protective layer is a transparent protective layer, in particular, a transparent glass, a transparent ceramic, or a transparent plastic.
[0083] In one embodiment, the film include a layer of EVA (ethylene-vinyl acetate resin) film and a layer of pre-crosslinked EVA film, and the EVA film is placed on or adjacent to the front protective layer.
[0084] Both of the two layers of film are pre-crosslinking POE (polyolefin elastomer) films. The encapsulation substrate includes glass, ceramic, plastic, etc.
[0085] The present disclosure provides following advantages and beneficial effects.
[0086] The present disclosure provides a pre-crosslinked polyolefin film by high-energy rays. Since the polyolefin film is formed by a crosslinking reaction, the dimensional stability and heat-resistance of the film are greatly improved, as compared with the non-crosslinked film.
[0087] Other aspects or embodiments of the present disclosure can be understood by those skilled in the art in light of the description, the claims, and the drawings of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0088] The following drawings are merely examples for illustrative purposes according to various disclosed embodiments and are not intended to limit the scope of the present disclosure.
[0089] FIG. 1 illustrates an exemplary encapsulation assembly using radiation pre-crosslinked polyolefin film in accordance with various embodiments in the present disclosure;
[0090] FIG. 2 illustrates another exemplary encapsulation assembly using radiation pre-crosslinked polyolefin film in accordance with various embodiments in the present disclosure; and
[0091] FIG. 3 illustrates another exemplary encapsulation assembly using radiation pre-crosslinked polyolefin film in accordance with various embodiments in the present disclosure.
DETAILED DESCRIPTION
[0092] Reference will now be made in detail to exemplary embodiments of the disclosure, which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Embodiment 1
[0093]
[0000]
Weight
Ingredient
percentage
Ethylene - buten copolymer
99
3-aminopropyltriethyloxy silane (KH550)
0.4
triallyl isocyanurate (TAIC)
0.5
4 [β-(3,5-di-t-butyl-4-hydroxyphenyl) propionate]
0.1
pentaerythritol (anti-oxide agent 1010)
[0094] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 110° C., and the temperature of the mold is 110° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.3 mm, the length is 100 m for a single reel. A 3-inch paper core is used to reel the uncrosslinked film up.
[0095] A reel or multiple reels of the uncrosslinked film are expanded and placed under an X-ray generator. The radiation dosage of irradiation is 200 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 100% of the total thickness of the film. The degree of crosslinking of the film is measured to be in the range of 60%-70%. The pre-crosslinked film is cut into pieces according to the size of the double-glazing and placed between the double-glazing, vacuumed and pressurized, and then heated to 200° C. for 10 minutes. The resulting degree of crosslinking can reach to more than 95%. The adhesive force between the pre-crosslinked film and glass is more than 75 N/cm. This pre-crosslinked film overflows out of the edge of the double-glazing for less than 5 mm.
[0096] Five pieces of A4-sized pre-crosslinked films and five pieces of A4-sized uncrosslinked films are respectively folded and placed in an oven at 35° C. Weights of 1000 g are placed on the films. After 24 hours, the pre-crosslinked films and uncrosslinked films are taken out to compare the adhesions there-between. As the result, the adhesion between the radiation pre-crosslinked films is remarkably less than that of the un-crosslinked films.
[0097] Five pieces of stripe-shaped pre-crosslinked films (1 cm×15 cm) and five pieces of stripe-shaped uncrosslinked films (1 cm×15 cm) are compared in tensile-strength. As the result, the tensile-strength of radiation crosslinked films is higher than that of the un-crosslinked films.
Embodiment 2
[0098]
[0000]
Weight
Ingredient
percentage
Ethylene-hexene copolymer grafted by vinyl-
58
trimethoxy-silican(A-171), grafting 0.6%
Titanium dioxide
40
TMPTMA
1
Butylperoxy-2-ethylhexyl carbonate tert-butyl (TBEC)
0.8
Sebacate (2,2,6,6-tetramethyl-4-piperidyl) ester
0.2
(Anti-oxide agent 770)
[0099] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 90° C., and the temperature of the mold is 90° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.6 mm, the length is 100 m for a single reel. A 3-inch paper core is used to reel the uncrosslinked film up.
[0100] A reel or multiple reels of the uncrosslinked film are expanded and placed under a β-ray generator having electronic accelerator energy of 10 MeV, and having a radiation dosage of 100 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 100% of the total thickness of the film. The degree of crosslinking of the film is measured to be in the range of 50%-70%. The pre-crosslinked film is cut into pieces according to the size of the double-glazing and placed between the double-glazing, vacuumed and pressurized, and then heated to 200° C. for 10 minutes. The resulting degree of crosslinking can reach to more than 95%. The adhesive force between the pre-crosslinked film and glass is more than 75 N/cm.
[0101] Five pieces of A4-sized pre-crosslinked films and five pieces of A4-sized uncrosslinked films are respectively folded and placed in an oven at 35° C. Weights of 1000 g are placed on the films. After 24 hours, the pre-crosslinked films and uncrosslinked films are taken out to compare the adhesions there-between. As the result, the adhesion between the radiation pre-crosslinked films is remarkably less than that of the un-crosslinked films.
[0102] Five pieces of stripe-shaped pre-crosslinked films (1 cm×15 cm) and five pieces of stripe-shaped uncrosslinked films (1 cm×15 cm) are compared in tensile-strength. As the result, the tensile-strength of radiation crosslinked films is higher than that of the un-crosslinked films.
Embodiment 3
[0103]
[0000]
Weight
Ingredient
percentage
Ethylene-octene copolymer
40
Ethylene- hexene copolymer
40
zinc sulfide
16.5
Triallyl isocyanurate (TAIC)
1
3-aminopropyl triethoxysilane (KH550)
1
Dicumyl peroxide (DCP)
1
N,N′-disuccinic sec-butyl-p-
0.5
phenylenediamine (anti-oxide agent 4720)
[0104] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 90° C., and the temperature of the mold is 90° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.7 mm, the length is 20 m for a single reel. A 3-inch paper core is used to reel the uncrosslinked film up.
[0105] A reel or multiple reels of the uncrosslinked film are expanded and placed under a β-ray generator having electronic accelerator energy of 5 MeV, and having a radiation dosage of 10 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 100% of the total thickness of the film. The degree of crosslinking of the film is measured to be in the range of 3%-9%. The pre-crosslinked film is cut into pieces according to the size of the double-glazing and placed between the double-glazing, vacuumed and pressurized, and then heated to 200° C. for 10 minutes. The resulting degree of crosslinking can reach to more than 95%. The adhesive force between the pre-crosslinked film and glass is more than 90 N/cm.
[0106] Five pieces of A4-sized pre-crosslinked films and five pieces of A4-sized uncrosslinked films are respectively folded and placed in an oven at 35° C. Weights of 1000 g are placed on the films. After 24 hours, the pre-crosslinked films and uncrosslinked films are taken out to compare the adhesions there-between. As the result, the adhesion between the radiation pre-crosslinked films is remarkably less than that of the un-crosslinked films.
[0107] Five pieces of stripe-shaped pre-crosslinked films (1 cm×15 cm) and five pieces of stripe-shaped uncrosslinked films (1 cm×15 cm) are compared in tensile-strength. As the result, the tensile-strength of radiation crosslinked films is higher than that of the un-crosslinked films.
Embodiment 4
[0108]
[0000]
Weight
Ingredient
percentage
Ethylene-hexene copolymer
94
3-aminopropyl triethoxysilane (KH550)
0.4
Titanium dioxide
5
Triallyl isocyanurate (TAIC)
0.5
4 [β-(3,5-di-t-butyl-4-hydroxyphenyl) propionate]
0.1
pentaerythritol (anti-oxide agent 1010)
[0109] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 110° C., and the temperature of the mold is 110° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.6 mm, the length is 400 m for a single reel. A 3-inch paper core is used to reel the uncrosslinked film up.
[0110] A reel or multiple reels of the uncrosslinked film are expanded and placed under a γ-ray generator, then reeled onto another 3-inch paper core, and then radiated at a radiation dosage of 200 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 100% of the total thickness of the film. The degree of crosslinking of the film is measured to be in the range of 60%-68%. The pre-crosslinked film is placed on a backside of the double glazing solar module cells. The crosslinked surface is placed to the side of the cell, and the uncrosslinked surface is placed under and in contact with the lower layer of the glass. The front of the cell is covered with a normal transparent polyolefin elastomer film. After placing the formed solar module cells with the pre-crosslinked film between two pieces of glass having a same size, together the entire workpiece is then placed into a laminating machine used to produce the solar photovoltaic modules, vacuumed for 6 minutes, meanwhile heated to 200° C., and pressurized for 15 minutes, until the resulting degree of cross-linking can reach more than 95%. In the laminated layer, the pulling force between the pre-crosslinked film and glass is greater than 50 N/cm. The interface between the pre-cross-linked film and the transparent polyolefin elastomer film that is on the cell is clear. The lower film of the pre-crosslinked film does not migrate to the top surface of the cell of the solar module cell.
Embodiment 5
[0111] The formula of EVA film is shown in the table below.
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 25%
51.5
Ethylene - butene copolymer polyolefin elastomer
40
Titanium dioxide
5
Trimethylol propane trimethacrylate (TMPTA)
1
Dicumyl peroxide
1
4 [β-(3,5-di-t-butyl-4-hydroxyphenyl) propionate]
1
pentaerythritol (anti-oxide agent 1010)
Vinyltrimethoxysilane (Silane coupling agent A-171)
0.5
[0112] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 110° C., and the temperature of the mold is 110° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked EVA film's thickness is 0.1 mm, and the length is 100 m for a single reel. A 3-inch paper core is used to reel the uncrosslinked EVA film up.
[0113] The reeled EVA film is expanded and placed under a β-ray generator, then reeled onto another 3-inch paper core, and then irradiated by an electron beam having accelerator energy of 100 keV and electron beam radiation dosage of 0.2 KGY. Radiation pre-crosslinked film is obtained after radiation. The thickness of the pre-crosslinked film takes 50% of the total thickness of the film. The pre-crosslinked EVA film is placed on a backside of the double glazing solar module cells. The crosslinked surface is placed to the side of the cell, and the uncrosslinked surface is placed under and in contact with the lower layer of the glass. The front side of the cell is covered with a normal transparent EVA film. After placing the formed solar module cells with the pre-crosslinked EVA film between two pieces of glass having a same size, together the entire workpiece is then placed into a laminating machine used to produce the solar photovoltaic modules, vacuumed for 6 minutes, meanwhile heated to 150° C., and pressurized and laminated for 15 minutes. In the laminated layer, the pulling force between the pre-crosslinked EVA film and glass is greater than 70 N/cm. The interface between the pre-crosslinked EVA film and the transparent EVA film that is on the cell is clear. The lower film of the pre-crosslinked film does not migrate to the top surface of the cell of the solar module cell.
Embodiment 6
[0114] This embodiment includes double-layer-coextruded EVA film having one transparent EVA layer and one black EVA layer. The formula of each of two EVA layers is shown below.
[0000]
Weight
percentage
Transparent EVA layer ingredient
EVA resin, VA content 33%
97
Triallyl isocyanurate (TAIC)
1
2,5-dimethyl-2,5-bis (tert-butylperoxy) hexane
0.5
N,N′-disuccinic sec-butyl-p-phenylenediamine
0.5
(anti-oxide agent 4720)
2-(2H-benzotriazole-2)-4,6-2(1-methyl-1-
0.2
phenylethyl) phenol
Vinyltrimethoxysilane (Silane coupling agent A-171)
0.8
Black EVA layer ingredient
EVA resin, VA content 28%
92.8
Carbon black
5
Triallyl isocyanurate (TAIC)
0.4
2,5-dimethyl-2,5-bis (tert-butylperoxy) hexane
0.5
N,N′-disuccinic sec-butyl-p-phenylenediamine
0.5
(anti-oxide agent 4720)
Vinyltrimethoxysilane (Silane coupling agent A-171)
0.8
[0115] The fully mixed transparent EVA layer component and the fully mixed black EVA layer component are added into two barrels of double layer coextruding extruder set (including two extruders), the temperature of the extrusion is 100° C., the temperature of distributor is 100° C. and the temperature of the mold is 102° C. The mixture is melted by the extruder, entered into the distributor and the T-shaped flat mold to form an EVA film, which is then reeled up.
[0116] The uncrosslinked EVA film is expanded and placed under a β-ray generator. The transparent EVA layer in the EVA film faces the β-ray generator for radiation. After the irradiation, 3-inch paper core is used to reel the EVA film. The radiation pre-crosslinked EVA resin co-extruded film is then obtained. The EVA film has a film thickness of 0.7 mm and a single roll length of 300 m. The accelerator energy is 500 keV and the radiation dosage is 50 KGY. The thickness of the pre-crosslinked portion is 100% of the total thickness of the film. The two layers of the pre-crosslinked EVA film are carefully separated by a knife and the crosslinking degree of the transparent layer is measured and the crosslinking degree reaches between 45%-55%. The EVA film is cut into a size of photovoltaic module. A layered structure of glass/cells/double-layer co-extruded EVA film/back sheet are vacuumed and laminated under 148° C. having a vacuum time of 5 minutes and the laminating time of 12 minutes. After laminating, a photovoltaic module, viewed black from glass side to the bottom side and viewed white from back sheet side to a side, is obtained. The interface between black surface and transparent surface has not turnover or other exterior defects.
Embodiment 7
[0117] The formula of EVA film is shown below.
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 25%
60
Ethylene - butene copolymer polyolefin elastomer
31.5
Titanium dioxide
5
Trimethylol propane trimethacrylate (TMPTA)
1
Dicumyl peroxide
1
4 [β-(3,5-di-t-butyl-4-hydroxyphenyl) propionate]
1
pentaerythritol (anti-oxide agent 1010)
Vinyltrimethoxysilane (Silane coupling agent A-171)
0.5
[0118] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 110° C., and the temperature of the mold is 110° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 2 mm, and a single reel length is 200 m. A 3-inch paper core is used to reel the uncrosslinked EVA film up.
[0119] The uncrosslinked EVA film is expanded and placed under a β-ray generator, and then reeled to another 3-inch paper core. The radiation is electron beam radiation having accelerator energy of 300 keV and an electron beam radiation dosage of 30 KGY. The radiation pre-crosslinked film is obtained after radiation. The film thickness of the pre-crosslinked portion is 30% of the total thickness of the film. The crosslinking degree of the film is measured in a range between 25%-35%. The pre-crosslinked film is cut into pieces having a size of the double-glazing and placed between the double-glazing, vacuumed and pressurized, and then heated to 200° C. for 10 minutes. The adhesive force between the EVA film and glass is larger than 60 N/cm. The EVA film overflows out of the edge of the double-glazing glass is smaller than 5 mm.
Embodiment 8
[0120] The formula of EVA film is shown below.
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 28%
78
Ultrafine barium sulfate
19.5
Cyanuric acid triallyl (TAC)
0.5
Butylperoxy-2-ethylhexyl carbonate tert-butyl
1
(TBEC)
Sebacate (2,2,6,6-tetramethyl-4-piperidyl) ester
0.5
(Anti-oxide agent 770)
3-methacryloxypropyl trimethoxy silane (A-174)
0.5
[0121] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 90° C., and the temperature of the mold is 90° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.1 mm, a single reel length is 20 m. A 3-inch paper core is used to reel the uncrosslinked EVA film up.
[0122] A reel or multiple reels of the uncrosslinked EVA film are expanded and placed under a β-ray generator having electronic accelerator energy of 500 keV, and having a radiation dosage of 100 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 100% of the total thickness of the film. The degree of crosslinking of the film is measured to be in the range of 53%-74%. The pre-crosslinked EVA film is placed on a backside of the double glazing solar module cells. The front side of the cell is covered with a normal transparent EVA film. After placing the formed solar module cells with the pre-crosslinked EVA film between two pieces of glass having a same size, together the entire workpiece is then placed into a laminating machine used to produce the solar photovoltaic modules, vacuumed for 6 minutes, meanwhile heated to 150° C., and pressurized and laminated for 15 minutes. In the laminated layer, the pulling force between the pre-crosslinked EVA film and glass is greater than 70 N/cm. The interface between the pre-crosslinked EVA film and the transparent EVA film that is on the cell is clear. The lower film of the pre-crosslinked film does not migrate to the top surface of the cell of the solar module cell.
Embodiment 9
[0123] The formula of EVA film is shown below.
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 33%
92.5
Carbon black
5
Triallyl isocyanurate (TAIC)
1
2,5-dimethyl-2,5-bis (tert-butylperoxy) hexane
0.5
N,N′-disuccinic sec-butyl-p-phenylenediamine
0.5
(anti-oxide agent 4720)
Vinyltrimethoxysilane (Silane coupling agent A-171)
0.5
[0124] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 100° C., and the temperature of the mold is 102° C. The mixed components are extruded into a film by a T-shaped flat mold and then reeled up. The obtained uncrosslinked EVA film's thickness is 0.7 mm, and a single reel length is 300 m. A 3-inch paper core is used to reel the uncrosslinked EVA film up.
[0125] A reel or multiple reels of the uncrosslinked EVA film are expanded and placed under a α-ray generator, irradiated having a radiation dosage of 100 KGY to form a radiation pre-crosslinked film after radiation. The film thickness of the pre-crosslinked portion is 100% of the total thickness of the film. The crosslinking degree of the EVA film is measured in a range between 35%-55%. The pre-crosslinked EVA film is cut into the size of the double-glazing and placed between the double-glazing, vacuumed, pressurized to laminate, and then heated to 150° C. for 10 minutes, and the crosslinking degree reaches 82%-90%.
[0126] Five pieces of pre-crosslinked films and five pieces of uncrosslinked films are respectively folded and placed in an oven at 35° C. Weights of 1000 g are placed on the two stacks of films. After 40 hours, the pre-crosslinked films and uncrosslinked films are taken out. The five stacked pre-crosslinked films may be easily separated, while the five stacked un-crosslinked films with the same formula as for the crosslinked films is seriously adhered together.
Embodiment 10
[0127] The formula of EVA film is shown below.
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 28%
78
Ultrafine barium sulfate
19.5
Cyanuric acid triallyl (TAC)
0.5
Butylperoxy-2-ethylhexyl carbonate tert-butyl
1
(TBEC)
Sebacate (2,2,6,6-tetramethyl-4-piperidyl) ester
0.5
(Anti-oxide agent 770)
3-methacryloxypropyl trimethoxy silane (A-174)
0.5
[0128] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 90° C., and the temperature of the mold is 90° C. The mixed components are extruded into a film by a T-shaped flat mold and then reeled up. The obtained uncrosslinked EVA film's thickness is 0.1 mm, and a single reel length is 100 m. A 3-inch paper core is used to reel the uncrosslinked EVA film up.
[0129] The reeled EVA film is expanded and placed under the α-ray generator, and then reeled onto another 3-inch paper core. The radiation is α-ray radiation having a radiation dosage of 0.2 KGY. After the radiation, the thickness of the film on the pre-crosslinked portion is 80% of the total thickness of the film. Since the film is too thin and hard to be peeled off. The crosslinking degree of the whole film is measured and the whole crosslinking degree of the EVA film is between 10%-18%. The pre-crosslinked film is cut into a size of the double-glazing and placed between the double-glazing, vacuumed and pressurized to laminate, and then heated to 150° C. for 10 minutes. The adhesive force between EVA film and glass is larger than 80 N/cm. The EVA film overflows out of the edge of the double-glazing for smaller than 2 mm.
Embodiment 11
[0130] The formula of EVA film is shown below.
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 25%
91.5
Titanium dioxide
5
Trimethylol propane trimethacrylate (TMPTA)
1
Dicumyl peroxide (DCP)
1
4 [β-(3,5-di-t-butyl-4-hydroxyphenyl) propionate]
1
pentaerythritol (anti-oxide agent 1010)
Vinyltrimethoxysilane (Silane coupling agent A-171)
0.5
[0131] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 110° C., and the temperature of the mold is 110° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked EVA film's thickness is 0.5 mm, and a single reel length is 20 m. A 3-inch paper core is used to reel the uncrosslinked EVA film up.
[0132] The reeled EVA film is expanded and placed under an x-ray generator, then reeled onto another 3-inch paper core, and then irradiated by x-ray having irradiation dosage of 0.2 KGY. Radiation pre-crosslinked film is obtained after radiation. The thickness of the pre-crosslinked film takes 40% of the total thickness of the film. A top layer of 0.2 mm is used for measuring degree of crosslinking. The degree of crosslinking of the film is measured to be in the range of 11%-18%. The pre-crosslinked EVA film is placed on a backside of the double glazing solar module cells. The crosslinked surface is placed to the side of the cell, and the uncrosslinked surface is placed under and in contact with the lower layer of the glass. The front side of the cell is covered with a normal transparent EVA film. After placing the formed solar module cells with the pre-crosslinked EVA film between two pieces of glass having a same size, together the entire workpiece is then placed into a laminating machine used to produce the solar photovoltaic modules, vacuumed for 6 minutes, meanwhile heated to 150° C., and pressurized and laminated for 15 minutes. In the laminated layer, the pulling force between the pre-crosslinked EVA film and glass is greater than 70 N/cm. The interface between the pre-crosslinked EVA film and the transparent EVA film that is on the cell is clear. The lower film of the pre-crosslinked film does not migrate to the top surface of the cell of the solar module cell.
Embodiment 12
[0133] The formula of EVA film is shown below.
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 25%
91.5
Titanium dioxide
5
Trimethylol propane trimethacrylate (TMPTA)
1
Dicumyl peroxide (DCP)
1
4 [β-(3,5-di-t-butyl-4-hydroxyphenyl) propionate]
1
pentaerythritol (anti-oxide agent 1010)
Vinyltrimethoxysilane (Silane coupling agent A-171)
0.5
[0134] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 110° C., and the temperature of the mold is 110° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.5-mm, and a single reel length is 20 m. A 3-inch paper core is used to reel the uncrosslinked EVA film up.
[0135] The uncrosslinked EVA film is expanded and placed under γ-ray generator, and then reeled to another 3-inch paper core. The radiation is γ-ray radiation having a radiation dosage of 0.2 KGY. The radiation pre-crosslinked film is obtained after radiation. The film thickness of the pre-crosslinked portion is 50% of the total thickness of the film. A top layer of 0.2 mm is used for measuring degree of crosslinking. The degree of crosslinking of the film is measured to be in the range of 15%-22%. The pre-crosslinked EVA film is placed on a backside of the double glazing solar module cells. The crosslinked surface is placed to the side of the cell, and the uncrosslinked surface is placed under and in contact with the lower layer of the glass. The front side of the cell is covered with a normal transparent EVA film. After placing the formed solar module cells with the pre-crosslinked EVA film between two pieces of glass having a same size, together the entire workpiece is then placed into a laminating machine used to produce the solar photovoltaic modules, vacuumed for 6 minutes, meanwhile heated to 150° C., and pressurized and laminated for 15 minutes. In the laminated layer, the pulling force between the pre-crosslinked EVA film and glass is greater than 70 N/cm. The interface between the pre-crosslinked EVA film and the transparent EVA film that is on the cell is clear. The lower film of the pre-crosslinked film does not migrate to the top surface of the cell of the solar module cell.
Embodiment 13
[0136]
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 25%
93
Titanium dioxide
5
Trimethylol propane trimethacrylate (TMPTA)
1
Butylperoxy-2-ethylhexyl carbonate tert-butyl (TBEC)
0.8
Sebacate (2,2,6,6-tetramethyl-4-piperidyl) ester
0.2
(Anti-oxide agent 770)
[0137] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 90° C., and the temperature of the mold is 90° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.2 mm, and a single reel length is 50 m. A 6-inch paper core is used to reel the uncrosslinked film up.
[0138] A reel or multiple reels of the uncrosslinked film are expanded and placed under β-ray generator having electronic accelerator energy of 5 MeV, and having a radiation dosage of 15 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 100% of the total thickness of the film. The degree of crosslinking of the film is measured to be in the range of 12%-29%. The pre-crosslinked film is cut into pieces according to the size of the double-glazing and placed between the double-glazing, vacuumed and pressurized, and then heated to 150° C. for 10 minutes. The resulting degree of crosslinking can reach to more than 95%. The adhesive force between the pre-crosslinked film and glass is more than 75 N/cm.
[0139] Five pieces of A4-sized pre-crosslinked films and five pieces of A4-sized uncrosslinked films are respectively folded and placed in an oven at 35° C. Weights of 1000 g are placed on the films. After 24 hours, the pre-crosslinked films and uncrosslinked films are taken out to compare adhesions between layers. As the result, the pre-crosslinked films are much less adhered with each other compared with un-crosslinked films.
[0140] Five pieces of stripe-shaped pre-crosslinked films (1 cm×15 cm) and five pieces of stripe-shaped uncrosslinked films (1 cm×15 cm) are compared in tensile-strength. As the result, the tensile-strength of radiation crosslinked films is higher than that of the un-crosslinked films.
Embodiment 14
[0141]
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 28%
80
Zinc sulfide
16.5
Triallyl isocyanurate (TAIC)
1
3-aminopropyl triethoxysilane (KH550)
1
Dicumyl peroxide (DCP)
1
N,N′-disuccinic sec-butyl-p-
0.5
phenylenediamine (anti-oxide agent 4720)
[0142] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 90° C., and the temperature of the mold is 90° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.5 mm, and a single reel length is 30 m. A 3-inch paper core is used to reel the uncrosslinked film up.
[0143] A reel or multiple reels of the uncrosslinked film are expanded and placed under β-ray generator having electronic accelerator energy of 10 MeV, and having a radiation dosage of 35 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 100% of the total thickness of the film. The degree of crosslinking of the film is measured to be in the range of 20%-50%. The pre-crosslinked film is cut into pieces according to the size of the double-glazing and placed between the double-glazing, vacuumed and pressurized, and then heated to 150° C. for 10 minutes. The resulting degree of crosslinking can reach to more than 90%.
[0144] Five pieces of A4-sized pre-crosslinked films and five pieces of A4-sized uncrosslinked films are respectively folded and placed in an oven at 35° C. Weights of 1000 g are placed on the films. After 24 hours, the pre-crosslinked films and uncrosslinked films are taken out to compare adhesions between layers. As the result, the pre-crosslinked films are much less adhered with each other compared with un-crosslinked films.
[0145] Five pieces of stripe-shaped pre-crosslinked films (1 cm×15 cm) and five pieces of stripe-shaped uncrosslinked films (1 cm×15 cm) are compared in tensile-strength. As the result, the tensile-strength of radiation crosslinked films is higher than that of the un-crosslinked films.
Embodiment 15
[0146]
[0000]
Weight
Ingredient
percentage
Ethylene-hexene copolymer grafted by vinyl-
98
trimethoxy-silican, grafting 0.6%
TMPTMA
1
Butylperoxy-2-ethylhexyl carbonate tert-butyl (TBEC)
0.8
Sebacate (2,2,6,6-tetramethyl-4-piperidyl) ester
0.2
(Anti-oxide agent 770)
[0147] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 110° C., and the temperature of the mold is 110° C. The mixed components are extruded into a film by a T-shaped flat mold, or are directly rolled into a film using two casting rollers. The film is then reeled up. The obtained uncrosslinked film's thickness is 0.01 mm, and a single reel length is 20 m. A 6-inch paper core is used to reel the uncrosslinked polyolefin elastomer film up.
[0148] The reeled uncrosslinked polyolefin elastomer film are expanded and placed under β-ray generator and then reeled onto another 6-inch paper core. The irradiation includes electron beam having electronic accelerator energy of 100 MeV, and having a radiation dosage of 20 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 100% of the total thickness of the film. The degree of crosslinking of the film is measured to be in the range of 21%-28%. Sequentially stacking an opposite substrates (glass substrate having a thickness of 150 μm)/pre-crosslinked polyolefin elastomer film/organic EL element/substrate (DuPont Teijin Ltd., trade name MelinexS, thickness of 100 μm) to form a laminated body, the crosslinked surface of the pre-crosslinked polyolefin elastomer membrane is placed to the side of organic EL element, the uncrosslinked surface is disposed on the side of opposite substrate in contact with the substrate. The laminated body as a whole is then placed in the vacuum laminating machine that produces the EL display, heated to 100° C., and pressurized to laminate for one hour. In the laminated material, the drawing force between pre-crosslinked polyolefin elastomer film and the glass substrate is greater than 70 N/cm. The polyolefin elastomer film that overflows the edge of the double-layer substrate is less than 2 mm.
Embodiment 16
[0149]
[0000]
Weight
Ingredient
percentage
EVA resin, VA content 25%
60
Ethylene - butene copolymer polyolefin elastomer
31.5
Titanium dioxide
5
Trimethylol propane trimethacrylate (TMPTA)
1
Dicumyl peroxide
1
4 [β-(3,5-di-t-butyl-4-hydroxyphenyl) propionate]
1
pentaerythritol (anti-oxide agent 1010)
Vinyltrimethoxysilane (Silane coupling agent A-171)
0.5
[0150] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 110° C., and the temperature of the mold is 110° C. The mixed components are extruded into a film by a T-shaped flat mold. The film is then reeled up and irradiated to form a pre-crosslinked ethylene-vinyl acetate resin film. The thickness of EVA film is 2 mm, and a single reel length is 200 m. A 3-inch paper core is used to reel the EVA film up.
[0151] A reeled EVA film is expanded and placed under an X-ray generator and then reeled onto another 3-inch paper core. The irradiation includes electron beam having accelerator energy of 200 MeV, and having a radiation dosage of 30 KGY. After the irradiation, the thickness of the pre-crosslinked film takes 20% of the total thickness of the film. A top layer of 0.3 mm of the EVA film is used to measure degree of crosslinking, which is measured to be in the range of 20%-35%.
[0152] Placing the pre-crosslinked EVA film described in Embodiment 1 on the backside of the double-glazing solar module cell, the crosslinked surface is placed on the side of the cells, the uncrosslinked surface is placed on the lower glass and in contact with glass. The front of the cells is covered with the normal transparent EVA film. The solar module cell with the film is placed between two pieces of glasses with the same size, and then all-together is placed into a laminating machine that produces the solar photovoltaic modules, vacuumed for 6 minutes, meanwhile heated to 200° C., and pressurized for 15 minutes. In the laminate, the adhesive force between the EVA film of Embodiment 1 and the glass is greater than 70 N/cm. The interface between EVA film of Embodiment 1 and EVA film on the upper of the cells is optically clear, the lower film does not migrate to the upper of the cells for the EVA film of Embodiment 1.
Embodiment 17
[0153]
[0000]
Weight
Ingredient
Percentage
EVA resin, VA content of 28%
78
Ultra-fine barium sulfate (4000 mesh)
19.5
Cyanuric acid triallyl (TAC)
0.5
Peroxy-2-ethylhexyl carbonate, t-butyl (TBEC)
1
Sebacate (2,2,6,6-tetramethyl-4-piperidyl) ester
0.5
(antioxidant 770)
3-methacryloxy propyl trimethoxysilane (A-174)
0.5
[0154] The above-mentioned components are fully mixed and put into the extruder. The temperature of the extruder is 90° C., and the temperature of the mold is 90° C. The mixed components are extruded into a film by a T-shaped flat mold. The film is then reeled up. The obtained uncrosslinked EVA film's thickness is 0.1 mm, and a single reel length is 100 m. A 3-inch paper core is used to reel the uncrosslinked EVA film up.
[0155] The reeled EVA film is expanded and placed under the electron beam generator, and then reeled onto another 3-inch paper core. The radiation is electron beam radiation having accelerator energy of 50 keV and a radiation dosage of 30 KGY. After the radiation, the thickness of the film on the pre-crosslinked portion is 40% of the total thickness of the film. Since the film is too thin and hard to be peeled off. The crosslinking degree of the whole film is measured and the whole crosslinking degree of the EVA film is between 10%-15%. The pre-crosslinked film is cut into a size of the double-glazing and placed between the double-glazing, vacuumed and pressurized to laminate, and then heated to 150° C. for 10 minutes. The adhesive force between EVA film and glass is larger than 80 N/cm. The EVA film overflows out of the edge of the double-glazing for smaller than 2 mm.
Embodiment 18
[0156] Various embodiments provide encapsulation assembly using pre-crosslinked polyolefin film. The present disclosure is described using solar photovoltaic cell component as one example of the encapsulation assemblies.
[0157] In FIGS. 1 to 3 , the exemplary solar photovoltaic cell assembly includes a rear portion encapsulation layer of the front glass 1 , a two-layer film between the encapsulation layer and the front glass 1 , and at least one layer of the two-layer film is a pre-crosslinked film that is radiated by electron beam, γ-ray, X-ray, an α-ray and/or neutron ray. The pre-crosslinking degree of the pre-crosslinked film is between 3%-74%. The thickness of pre-crosslinked film is consistent with the common film of the photovoltaic cells, and the thickness is from 0.1 mm to 2 mm. Preferably, the thickness is between 0.3 mm and 0.7 mm.
[0158] Compared with non-pre-crosslinked film, the pre-crosslinked film has already formed a certain crosslinked network before using, the heat resistance is greatly improved, the resin of flow is reduced, and a melting temperature increases or disappears. During the lamination process of the component manufacturing, the phenomenon that the film spills around the glass significantly reduces. If a transparent film and a color film are used at the same time, the boundary between the two layers of film is clear.
[0159] The crystalline silicon solar cell 2 or CIGS cells (thin-film solar cells) are provided between the layers of the films.
[0160] The film includes a layer of EVA film and a layer of pre-crosslinked EVA film, and the EVA film is set near the front glass. The two layers of film are pre-crosslinked POE film.
[0161] Rear portion encapsulation layer is backplane or rear glass. Backplane or rear glass, can be thinly conventional photovoltaic modules rear glass or photovoltaic modules backplane, but also can be other material that has the function of support, such as PMMA film (polymethyl methacrylate membrane material, polyamide imide film or sheet, PVC (polyvinyl chloride) profiles, metal sheet and even stone etc.
[0162] As shown in FIG. 1 , the structure of photovoltaic module from front-to-rear includes: front glass 1 , transparent EVA film 3 (not pre-crosslinked, the content of VA is 28%), crystal silicon solar cell 2 , white pre-crosslinked EVA film 5 (pre-crosslinking degree of 74%, reflectivity of 88%), and rear glass 4 . After laminating the structure under 145° C., the degree of crosslinking between transparent EVA film 3 and the white pre-crosslinked EVA film 5 is greater than 80%. The interface between the transparent EVA film 3 and white pre-crosslinked EVA film 5 is clear, the lower white pre-crosslinked EVA film 5 does not penetrate into the transparent EVA film layer 3 , or turn to the crystalline silicon solar cell 2 .
[0163] As shown in FIG. 2 , another structure of photovoltaic module from front-to-rear includes: front glass 1 , transparent pre-crosslinked POE film 6 (pre-crosslinking degree of 3%), crystal silicon solar cell 2 , transparent pre-crosslinked POE film 6 (pre-crosslinking degree of 15%), and rear glass 4 . After laminating the structure under 145° C., the dimensional stability of transparent pre-crosslinked POE film 6 is stable, and the film material spilled from glass around after lamination is rare.
[0164] As shown in FIG. 3 , another structure of photovoltaic module from front-to-rear includes: front glass 1 , transparent EVA film 3 , crystal silicon solar cell 2 , black pre-crosslinked EVA film 7 (pre-crosslinking degree of 35%), and back plate 8 (TPE structure back plate). After laminating the structure under 145° C., the boundary between the transparent EVA film 3 and black pre-crosslinking EVA film 7 is clear, the lower black pre-crosslinked EVA film 7 does not penetrate into the transparent EVA film layer 3 , or turn to the crystalline silicon solar cell 2 .
[0165] The solar photovoltaic modules using the structure, the structure of the photovoltaic modules using the pre-crosslinked film, and its application in solar photovoltaic modules, can achieve the effect of reducing the overflow around the film. If using the transparent film in the upper layer and colored film in the lower layer, at least one of the film is pre-crosslinked film, two layers of the films do not penetrate, which can remain a clear boundary effects.
[0166] While certain embodiments have been described, these embodiments have been presented by preferred Embodiment only, and are not intended to limit the scope of the inventions. The substance of the technical content of the present invention is broadly defined scope of the claims in the application, the accompanying of claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions. | Radiation pre-crosslinked polyolefin film and preparation method, and related encapsulation method and encapsulation assembly are provided. The radiation pre-crosslinked polyolefin film for encapsulation is prepared by preparing a film after mixing polyolefin raw materials together; using a radiation energy source to irradiate the film, wherein the radiation energy source directly stimulate a crosslinking reaction of the polyolefin raw materials; adjusting an irradiation dosage of the radiation energy source, such that a crosslinking degree of a pre-crosslinked portion of the film reaches about 3% to about 95%; and adjusting the irradiation dosage of the radiation energy source, such that the pre-crosslinked portion of the film has a thickness of about 5% to about 100% by a total thickness of the film, wherein: that the pre-crosslinked portion has the thickness of about 100% by the total thickness of the film means the film is all pre-crosslinked. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2005-100131, filed on 30 Mar. 2005, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to a pulse wave measuring apparatus and a method therefor that are used for the purpose of autonomous nervous system measurement, sleep state measurement, health care, and the like.
BACKGROUND OF THE INVENTION
[0003] Heart beats representing various states of a human are used as useful indicators in various fields such as health care, sleep state measurement, and medical treatment. There are mainly two methods for measuring heartbeats. One is a method using an electrocardiogram obtained from an electrode between two points flanking the heart and a reference electrode. The other is a method of capturing pulse waves due to blood flows through blood capillaries or the like synchronizing with the heartbeats.
[0004] It is difficult for ordinary healthy people to use the method using an electrocardiogram in their daily lives.
[0005] The pulse wave measuring method mainly includes a reflection type method and a transmission type method. Both the reflection type method and the transmission type method use a difference of light absorbing characteristics of intravascular substances. In the reflection type method, light-emitting elements and light-receiving elements are arranged side by side on a surface of an organism. Light is irradiated on peripheral blood vessels and an amount of reflected light is captured by the light-receiving elements (see, for example, JP-A-2000-107147 and JP-A-2002-360530). In the transmission type method, light-emitting elements and light-receiving elements are arranged to sandwich an organism to capture an amount of light transmitted through a blood vessel with the light-receiving elements.
[0006] Pulse waves are measured for various purposes such as autonomous nervous system measurement, prevention of life-style related diseases, and sleep state measurement. There is an advantage that pulse waves can be measured easily. However, since a measurement site is a fingertip, an earlobe, a wrist, or the like, the measurement of pulse waves is strongly affected by movement and is susceptible to disturbances such as movement in daily lives.
[0007] Therefore, the invention provides a pulse wave measuring apparatus and a method therefor that copes with a positional deviation of a sensor module and a change in a position of an artery on a real time basis and is robust against disturbances.
BRIEF SUMMARY OF THE INVENTION
[0008] According to an embodiment of the invention, there is provided a measuring apparatus for detecting a pulse wave signal indicating a change in a blood flow in the blood vessel of a patient by using light, comprising: a sensor module including a plurality of light-emitting elements to irradiate the blood vessel, and a plurality of light-receiving elements to receive reflected light as a pulse wave signal from the blood vessel, each element being attached on the surface of the patient; a processor for light emission that causes the plural light-emitting elements to emit light one after another; an autocorrelation value calculating processor that calculates autocorrelation values of respective pulse wave signals corresponding to respective combinations of the light-emitting elements, which have emitted light, and the light-receiving elements, which have received light, respectively; and an optimum position identifying processor that selects a combination of a light-emitting element and a light-receiving element, which has outputted a pulse wave signal with a highest autocorrelation value among the respective autocorrelation values, as an optimum combination.
[0009] According to the embodiment of the invention, it is possible to select a combination of the plural light-receiving elements and the plural light-emitting elements, which are arranged on the surface of the organism of the subject, on a real time basis and always measure stable robust pulse waves.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the accompanying drawings:
[0011] FIG. 1 is a block diagram of a pulse wave measuring apparatus according to a first embodiment of the invention;
[0012] FIG. 2 is a diagram of a first example of arrangement of light-emitting elements and light-receiving elements in a sensor module of the pulse wave measuring apparatus;
[0013] FIG. 3 is a diagram of a second example of the arrangement of light-emitting elements and light-receiving elements in the sensor module of the pulse wave measuring apparatus;
[0014] FIG. 4 is a diagram of a third example of the arrangement of light-emitting elements and light-receiving elements in the sensor module of the pulse wave measuring apparatus;
[0015] FIG. 5 is a perspective view showing an optimum attaching site of the pulse wave measuring apparatus;
[0016] FIG. 6 is a flowchart of the pulse wave measuring apparatus;
[0017] FIG. 7 is a diagram of an optimum combination of a light-emitting element and a light-receiving element in the pulse wave measuring apparatus;
[0018] FIG. 8 is a sectional view showing positions of a sensor module and an artery before a change of an artery position in a second embodiment of the invention;
[0019] FIG. 9 is a diagram of the positions of the sensor module and the artery before the change of the artery position viewed from a surface of an organism in the second embodiment;
[0020] FIG. 10 is a sectional view showing positions of the sensor module and the artery after the change of the artery position in the second embodiment;
[0021] FIG. 11 is a diagram of the positions of the sensor module and the artery after the change of the artery position viewed from the surface of the organism in the second embodiment;
[0022] FIG. 12 is a flowchart of a pulse wave measuring apparatus according to a third embodiment of the invention;
[0023] FIG. 13 is a diagram showing a difference of changes in a pulse wave amplitude in a fourth embodiment of the invention;
[0024] FIG. 14 is a diagram of an attaching position of a sensor module in a fifth embodiment of the invention;
[0025] FIG. 15 is a diagram of an attaching position of a sensor module in a sixth embodiment of the invention; and
[0026] FIG. 16 is a diagram showing a shape of the sensor module in the sixth embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Embodiments of the invention will be explained with reference to the accompanying drawings.
First Embodiment
[0028] A pulse wave measuring apparatus 10 in a first embodiment of the invention will be hereinafter explained with reference to FIGS. 1 to 7 .
[0000] (1) Structure of the Pulse Wave Measuring Apparatus 10
[0029] FIG. 1 is a block diagram showing a structure of the pulse wave measuring apparatus 10 . FIGS. 2, 3 , and 4 are diagrams showing example of arrangement of plural light-emitting elements L and plural light-receiving elements P in a sensor module 11 . As shown in FIG. 1 , the pulse wave measuring apparatus 10 amplifies a pulse wave signal, which is obtained from the sensor module 11 , with amplifiers 12 to 14 and, then, converts the pulse wave signal into a digital signal with an A/D converter 15 . Thereafter, the pulse wave measuring apparatus 10 processes the digital signal with a CPU 15 and displays a result of the processing on a display 17 . Electric power for the pulse wave measuring device 10 is supplied from a battery 18 . Infrared LEDs are used for the light-emitting elements L of the sensor module 11 and photodiodes are used for the light-receiving elements P. Note that a program for realizing a processing method for measurement of a pulse wave described below is stored in the pulse wave measuring device 10 and is processed by the CPU 15 .
[0030] A structure of the sensor module 11 will be explained. The plural light-emitting elements L and the plural light-receiving elements P are provided on an array substrate 9 of the sensor module 11 . The light-emitting elements L and the light-receiving elements P are attached to a wrist or the like.
[0031] FIG. 2 is a diagram of a first example of arrangement of the light-emitting elements L and the light-receiving elements P on the array substrate 9 . This is standard arrangement of the light-emitting elements L and the light-receiving elements P in the sensor module 11 . Light-emitting elements L 1 to L 5 are arranged one after another in a row in the horizontal direction and light-receiving elements P 1 to P 5 are arranged one after another in a row in the horizontal direction in parallel to the light-emitting elements L 1 to L 5 . The light-emitting element L 1 and the light-receiving element P 1 are in a one-to-one relation. The same holds true for the other light-emitting elements L 2 to L 5 and the other light-receiving elements P 2 to P 5 . When the sensor module 11 is attached to a wrist 19 , the plural light-emitting elements L and the plural light-receiving elements P are wound along the periphery of the wrist 19 .
[0032] FIG. 3 is a diagram of a second example of the attachment, in which two light-emitting elements L are associated with one light-receiving element P. The light-emitting elements L 1 to L 5 are arranged one after another in a row in the horizontal direction and the light-receiving elements P 1 to P 5 are arranged one after another in a row in the horizontal direction such that the light-emitting elements L deviate in the horizontal direction with respect to the light-receiving elements P. With the arrangement shown in FIG. 3 , the light emitting elements L and the light-receiving elements P are excellent in detection of a position when the sensor module 11 is attached.
[0033] FIG. 4 is a third example of the arrangement, in which the arrangement in FIG. 3 is further expanded. The light-emitting elements L and the light-receiving elements P are also arranged in the vertical direction to aim at further improvement of detection accuracy. The light-emitting elements L and the light-receiving elements P are arranged alternately in a row in the horizontal direction. The row in the horizontal direction, in which the light-emitting elements L and the light-receiving elements P are arranged in this way, are arranged in plural stages in the vertical direction.
[0000] (2) Processing Method of the Pulse Wave Measuring Apparatus 10
[0034] A processing method of the pulse wave measuring apparatus 10 will be explained using the sensor module 11 shown in FIG. 2 with reference to a flowchart in FIG. 6 .
[0035] First, the sensor module 11 is attached on an artery 20 in a wrist 19 of a patient as shown in FIG. 5 .
[0036] In step 1 , the pulse wave measuring apparatus 10 sets processing to be performed for all combinations of the light-emitting elements L and the light-receiving elements P.
[0037] In step 2 , the pulse wave measuring apparatus 10 causes the light-emitting element L 1 to emit light.
[0038] In step 3 , the pulse wave measuring apparatus 10 receives reflection intensity of the light from the light-emitting element L 1 in the light-receiving elements P 1 to P 5 and stores a pulse wave signal of a light-receiving element with strongest signal intensity. For example, the pulse wave signal is assumed to be a pulse wave signal Y(t) of the light-receiving element P 3 .
[0039] In step 4 , the pulse wave measuring device 10 slices a pulse waveform for one heart beat that is obtained when the pulse wave signal Y(t) is measured for a fixed period. The fixed period is 1.0 to 1.5 seconds.
[0040] In step 5 , the pulse wave measuring apparatus 10 compares a sliced pulse waveform H for one heat beat and the pulse wave signal Y(t), which is continuously inputted, to obtain an autocorrelation S(t). For example, the autocorrelation S(t) is equal to or higher than −1 and equal to or lower than 1. The autocorrelation S(t) is the highest at 1.
[0041] In step 6 , the pulse wave measuring apparatus 10 calculates an autocorrelation value S 0 that is a value obtained by averaging the autocorrelation S(t) in a predetermined time (e.g., five seconds). If a value of the autocorrelation S(t) in a fixed time is constant, the autocorrelation value S 0 is high (e.g., S 0 >0.8). A signal intensity of a pulse wave signal from the light-receiving element is stably high and it can be judged that the pulse wave signal is a pulse wave. If the signal intensity is unstable, it can be judged that the pulse wave signal is noise.
[0042] In step 7 , the calculated autocorrelation value S 0 is an autocorrelation value measured for the first time, the pulse wave measuring apparatus 10 proceeds to step 8 . If the calculated autocorrelation value S 0 is the autocorrelation value S 0 calculated for the second or subsequent time, the pulse wave measuring apparatus 10 proceeds to step 9 . In other words, when combinations of the light-emitting element L 1 and the light-receiving elements P 1 to P 5 are processed first, the autocorrelation value S 0 highest in the combinations is set as the autocorrelation value S 0 at the first time.
[0043] In step 8 , the pulse wave measuring apparatus 10 stores the calculated autocorrelation value S 0 at the first time as an initial value.
[0044] In step 9 , if the calculated autocorrelation value S 0 is high compared with the initial value stored in step 8 in advance or the autocorrelation value S 0 updated in processing in step 9 of the last time, the pulse wave measuring apparatus 10 updates the initial value or the updated autocorrelation value S 0 to the calculated autocorrelation value S 0 and stores the calculated autocorrelation value S 0 . If the calculated autocorrelation value S 0 is low compared with the initial value stored in step 8 in advance or the autocorrelation value S 0 updated in processing in step 9 of the last time, the pulse wave measuring apparatus 10 does not update the initial value or the updated autocorrelation value S 0 .
[0045] In step S 10 , the pulse wave measuring apparatus 10 repeats the processing from step 1 until processing for all combinations of the light-emitting elements L and the light-receiving elements P ends. When the processing for all the combinations ends, the pulse wave measuring apparatus 10 proceeds to step 11 .
[0046] In step 11 , the pulse wave measuring apparatus 10 determines a combination of the light-emitting element L and the light-receiving element P having the highest autocorrelation value. For example, when it is assumed that the combination is a combination of the light-emitting element L 4 and the light-receiving element P 1 , the combination is as shown in FIG. 7 .
[0047] With the processing described above, although the pulse wave measuring apparatus 10 in this embodiment has the plural light-emitting elements L and the plural light-receiving elements P, the pulse wave measuring apparatus 10 can identify an optimum position. Thus, it is possible to realize the wave pulse measuring apparatus that copes with a positional deviation of the sensor module 11 and a change in a position of the artery 20 on a real time basis and is robust against disturbances.
Second Embodiment
[0048] A second embodiment of the invention will be explained with reference to FIGS. 8 to 11 .
[0049] In this embodiment, a method of selecting an optimum combination of the light-emitting element L and the light-receiving element P, which occurs when a position of the blood vessel (the artery) 20 changes in the pulse wave measuring device 10 , will be explained.
[0050] FIGS. 8 and 10 are sectional views showing positions of the sensor module 11 and the artery 20 of the wrist 19 . FIGS. 9 and 11 are schematic diagrams of the sensor module 11 and the artery 20 viewed from a surface of an organism. In FIGS. 9 and 11 , positions of the sensor module 11 and the artery 20 before and after a change of a position of the artery 20 are shown, respectively.
[0051] As a characteristic of the light-emitting elements L used in the sensor module 11 in this embodiment, when light is made incident in an organism and the light is reflected to return to the outside of the organism, a distance between the light-emitting elements L and the light-receiving elements P is proportional to a depth of the light made incident in the organism. As the distance of the light-emitting elements L and the light-receiving elements P are larger, the depth of the light made incident in the organism detected by the light-receiving elements P is larger.
[0052] In FIGS. 8 and 9 , the artery 20 is close to the surface of the organism. Since the artery 20 is close to the surface of the organism, an interval between the light-emitting elements L and the light-receiving elements P is preferably small. A combination of the light-emitting element L 4 and the light-receiving element P 2 shown in FIG. 9 is appropriate.
[0053] In FIGS. 10 and 11 , the artery 20 is far from the surface of the organism. Since the artery 20 is far from the surface of the organism, an interval between the light-emitting elements L and the light-receiving elements P is preferably large. A combination of the light-emitting element L 5 and the light-receiving element P 1 shown in FIG. 11 is appropriate.
Third Embodiment
[0054] A third embodiment of the invention will be explained with reference to FIG. 12 .
[0055] In this embodiment, assuming that an optimum combination of a pair of the light-emitting element L and the light-receiving element P has already been acquired by the method explained in the first embodiment, a method of causing the light-emitting elements P to emit light selectively in selecting an optimum combination again will be explained.
[0056] When a currently selected combination of a pair of the light-emitting element L and the light-receiving element P is as shown in FIG. 2 , if intensity of a pulse wave signal weakens in the combination because of influence of movement, the pulse wave measuring apparatus 10 tries to search for an optimum combination again.
[0057] In this search, the pulse wave measuring apparatus does not cause the light-emitting elements L to emit light in order from the light-emitting element L 1 . Instead, as indicated by steps 20 to 22 in a flowchart in FIG. 12 , the pulse wave measuring apparatus 10 causes the light-emitting elements L to emit light in order from the light-emitting element L near the currently selected light-emitting element L. This makes it possible to select an optimum combination by performing light emission as a small number of times as possible. In that case, as indicated by step 21 , if a pulse wave signal has intensity equal to or higher than a certain threshold value, which allows the pulse wave signal to be used as a pulse wave, the pulse wave measuring apparatus 10 stops the search for an optimum combination at that time. Note that steps 23 to 32 are the same as the processing in steps 2 to 11 .
Fourth Embodiment
[0058] A fourth embodiment of the invention will be explained with reference to FIG. 13 .
[0059] Apart from a combination of the light-emitting element L and the light-receiving element P with a high autocorrelation value calculated according to autocorrelation, intensity of a pulse wave signal may be equal to or lower than a predetermined threshold value.
[0060] In this embodiment, as shown in FIG. 13 , when an amplitude of the pulse wave signal Y(t) falls to be lower than the predetermined threshold value, the pulse wave measuring apparatus 10 detects a combination of the light-emitting element Land the light-receiving element P, which has the pulse wave signal Y(t) with signal intensity equal to or higher than the threshold value, again.
[0061] Consequently, it is possible to realize robust pulse wave measurement.
Fifth Embodiment
[0062] A fifth embodiment of the invention will be explained with reference to FIG. 14 .
[0063] In the first embodiment, the sensor module 11 is attached to a site near a radial artery or an ulnar artery of the wrist 19 . However, in this embodiment, as shown in FIG. 14 , the same effect as the first embodiment is obtained by attaching the sensor module 11 to a carotid artery of a neck 21 .
Sixth Embodiment
[0064] A sixth embodiment of the invention will be explained with reference to FIGS. 15 and 16 .
[0065] In this embodiment, unlike the first and the sixth embodiments, the sensor module 11 is attached to a planta artery near an ankle 22 as shown in FIG. 15 .
[0066] However, since a surface of the skin near the ankle 22 is extremely rough because of a melleolus, a pulse wave is detected by curving the sensor module 11 to stick firmly to the skin as shown in FIG. 16 .
Modifications
[0067] The invention is not limited to the embodiments described above and can be modified in various ways as long as modifications do not depart from the spirit of the invention.
[0068] The invention is suitably applied to measurement of a pulse wave for various purposes such as autonomous nervous system measurement, prevention of life-style related diseases, and sleep state measurement. | A pulse wave measuring apparatus can determine an optimum combination of a pair of light-emitting element and light-receiving element out of plural light-emitting elements and plural light-receiving elements on a real time basis according to a difference of signal intensity of a pulse wave signal from the light-receiving element and always measure an stable pulse wave of a wrist artery robustly. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The present invention generally relates to a film feeding control device which can be used in a camera, a printing apparatus, etc., and particularly relates to a construction of a photo interrupter for detecting perforations of a film to control the feeding thereof and to a structure for mounting the photo interrupter on a frame of the camera, etc.
2. Description of the Related Art
Conventionally, there has been provided a camera with a film feeding control device having a photo reflector for detecting perforations of the film so that the amount of the film fed is detected, as disclosed in Japanese Laid-Open Utility Model Application Nos. 61-114426 and 3-60330.
Meanwhile, there has been proposed a camera with a film feeding control device having a mechanism for detecting perforations of the film so that not only the amount of the film fed is detected, but also a frame of the film is positioned with respect to an aperture of the camera. In order to realize a precise positioning of the frame of the film relative to the aperture of the camera, a precise detection of the perforations of the film is required.
Here, if the photo reflector of the former type of camera is applied to the mechanism of the latter type of camera, it is difficult to detect the perforations of the film precisely to such a degree that the frame of the film can be positioned precisely with respect to the aperture, as explained below.
The photo reflector is so constructed that light emitted from a light emitting part of the photo reflector, is reflected from the film surface towards a light detecting part of the photo reflector, with the light detecting part being disposed on the same side as the light emitting part relative to a film surface. In other words, the precision in detecting the perforations of the film partly depends upon the condition of the film surface such as its flatness and reflectivity, and partly depends upon the relative position of the light emitting part with respect to the light detecting part of the photo reflector.
Because of the foregoing reason, it is difficult for the frames of the film to be positioned precisely relative to the aperture of the camera with the mechanism employing the photo reflector.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a film feeding control device with a mechanism for precisely detecting perforations of the film.
Another object of the present invention is to provide a mounting structure for mounting the mechanism on a frame of a camera, a printing apparatus, etc.
Still another object of the present invention is to provide a method for mounting the mechanism on the frame.
In accomplishing these and other objects of the present invention, there is provided a film feeding control device comprising: a photo interrupter which has a light source for emitting a light, a light detector for detecting the light emitted from the light source and for outputting a detecting signal in accordance with a detection of the light, and a holding member for holding the light source and the light detector; a guiding member for guiding a film between the light source and the light detector; a perforation detector for detecting a perforation of the film based on the detecting signal outputted from the light detector; and a controller for controlling a film feeding operation in accordance with a detection of the perforation by the perforation detector.
With this invention, when a perforation of the film travels between the light source and the light detector of the photo interrupter while the film is being guided by the guiding member, the light emitted from the light source passes through the perforation of the film and reaches the light detector to output the detecting signal, which in turn is detected by the perforation detector. Thus the film feeding operation is controlled in accordance with the detection of the perforation by the controller.
According to this invention, because the detection of the perforation of the film is performed by the photo interrupter, the accuracy of the detection of the perforation of the film is not affected by the condition of the film surface, such as its flatness, nor by the reflection angle of the light on the film. This is in contrast to the effect in the photo reflector of the relative position between the light source and the light detector, which is located on the same side as the light source relative to the film surface. Thus, with the present invention, the detection of the perforation of the film is performed precisely.
In this invention, the controller, for example, controls an amount of the film fed, and/or controls a position of the film relative to an aperture of the film feeding control device.
Specifically, the film feeding control device comprises a frame which has an opening, and a guide surface along which a film is fed; a photo interrupter which is mounted in the opening of the frame, wherein the photo interrupter has a light source for emitting a light, a light detector for detecting the light emitted from the light source, and a holding member for holding the light source and the light detector; and a fixing member for fixing the photo interrupter in the opening of the frame.
In the structure, the photo interrupter can be mounted in the opening of the frame so that a surface, on the side opposite the guide surface, of the photo interrupter is level with a surface, on the same side, of the frame.
According to the structure, because a part of the photo interrupter is inset in an opening in the frame, and is not mounted on a surface of the frame, it is possible to reduce the thickness of the part of the frame at which the photo interrupter is mounted on the thus realizing a compact apparatus such as a compact camera and a compact printing apparatus if the invention is applied thereto.
In this structure, it is preferable to provide a shield member for prevent a light from passing through a chink between an inner peripheral surface, forming the opening of the frame, and an outer peripheral surface of the holding member of the photo interrupter.
With this structure, a careless exposure of the film to the light passing through them is surely prevented.
Specifically, the frame further comprises a first contact surface which is provided around the opening, wherein the photo interrupter further comprises a second contact surface which is provided around a side wall of the holding member and which contacts the first contact surface of the frame when the photo interrupter is mounted in the opening of the frame.
More specifically, for example, the photo interrupter may have a flange-like part on each side of the holding member, wherein the second contact surface is formed on the flange-like part. For example, the second contact surface may be formed on a step-like part provided on the side wall of the holding member of the first contact surface of the frame may be formed tapering in a direction opposite the guide surface thereof, and the second contact surface of the photo interrupter formed tapering so as to be complementary with respect to the first contact surface of the frame.
According to the various structures, because the first contact surface of the frame and the second contact surface of the photo interrupter are so formed that either light does not leak from one side of the frame to the other side thereof through the mounting surface therebetween, or the mounting surface which the light may enter is not constructed straight nor parallel in a direction from one side of the frame to the other side thereof, leaking of the light in a direction of the thickness of the frame is effectively prevented.
In the case where the photo interrupter is of a type in which it has a flange-like part on each side of the holding member, wherein the second contact surface is formed on the flange-like part, or in the case where the photo interrupter is of a type in which the second contact surface is formed on a step-like part provided on the side wall of the holding member, the photo interrupter is so fixed in the opening of the frame that the first and second contact surfaces are substantially parallel to a surface of the film fed, or the flange extends in a plane perpendicular to an optical axis along which the light travels between the light source and the light detector, or the flange extends in a plane parallel to an emitting surface of the light source or to a detecting surface of the light detector.
The flange provided around the holding member may be in a continuous, annular square form, or may be in a discontinuous, annular square form, wherein the flange comprises separate pieces a respective of which corresponds to a respective side of the holding member.
In this structure, it is preferable that the flange has a flat surface, and that the flat surface is perpendicular to an optical axis along which the light travels between the light source and the light detector.
In order to mount the photo interrupter on a frame, there is provided the mounting method, comprising the steps of: providing the frame with an opening; providing the frame with a first contact surface around the opening; providing a holding member of the photo interrupter element with a second contact surface corresponding to the first contact surface of the frame, wherein the holding member holds a light source for emitting a light and a light detector for detecting the light emitted from the light source; and mounting the holding member of the photo interrupter element in the opening of the frame, with the first contact surface of the frame contacting the second contact surface of the holding member.
The mounting method, for mounting the photo interrupter on the frame, contributes towards a manufacture of the film feeding control device in a compact size, thus making it possible to realize any apparatus provided with the control device in a small size.
The method may further comprise the step of fixing the first contact surface of the frame to the second contact surface of the holding member of the photo interrupter element by an adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become clear from the following description taken in conjunction with the preferred embodiments thereof with reference to the accompanying drawings, in which:
FIG. 1 is an explanatory, general view of a camera in which a film feeding control device with a photo interrupter, according to a first embodiment of the present invention, is provided;
FIG. 2 is an enlarged perspective view of a photo interrupter shown in FIG. 1;
FIG. 3 is a partial, enlarged sectional view taken approximately on a line corresponding with 3--3 in FIG. 2;
FIG. 4 is a block diagram of the film feeding control device of FIG. 1;
FIG. 5 is a partial, enlarged sectional view, similar to FIG. 3, showing a photo interrupter and a mounting structure, for mounting the photo interrupter on a camera frame, according to a second embodiment of the present invention;
FIG. 6 is a partly sectional, perspective view of a photo interrupter and a mounting structure, for mounting the photo interrupter on a camera frame, according to a third embodiment of the present invention;
FIG. 7 is a partial, enlarged sectional view, similar to FIG. 3, showing a photo interrupter and a mounting structure, for mounting the photo interrupter on a camera frame, according to a fourth embodiment of the present invention;
FIG. 8 is a perspective view of a photo interrupter according to a fifth embodiment of the present invention;
FIG. 9 is a side elevation view of the photo interrupter shown in FIG. 8;
FIG. 10 is an explanatory, exploded perspective view of a mounting structure for mounting the photo interrupter, shown in FIGS. 8 and 9, on a camera frame;
FIG. 11 is a sectional view, similar to FIG. 3, showing the photo interrupter and its mounting structure of FIG. 10;
FIG. 12 is a perspective view of a photo interrupter, similar to FIG. 8, according to a sixth embodiment of the present invention;
FIG. 13 is a perspective view of a photo interrupter according to a seventh embodiment of the present invention;
FIG. 14 is a sectional view, similar to FIG. 3, showing the photo interrupter of FIG. 13 and a mounting structure for mounting the photo interrupter on a camera frame;
FIG. 15 is a perspective view of a photo interrupter according to an eighth embodiment of the present invention;
FIG. 16 is a sectional view, similar to FIG. 3, showing the photo interrupter of FIG. 15 and a mounting structure for mounting the photo interrupter on a camera frame;
FIG. 17 is a perspective view of a photo interrupter according to a ninth embodiment of the present invention; and
FIG. 18 is a sectional view, similar to FIG. 3, showing the photo interrupter of FIG. 17 and a mounting structure for mounting the photo interrupter on a part of a camera frame.
DETAILED DESCRIPTION OF THE INVENTION
Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals, with different alphabetic letters added after the corresponding numerals for different embodiments except a first embodiment, throughout the accompanying drawings.
Referring to FIGS. 1 through 18, a full description of the present invention is made below on a film feeding control device, with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a first through a ninth embodiment of the present invention.
First, referring to FIGS. 1 through 4, a description is made on a film feeding control device, with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a first embodiment of the present invention.
FIG. 1 is an explanatory general view showing a camera having the film feeding control device in which the photo interrupter and the mounting structure for mounting the photo interrupter on the camera frame are provided. In FIG. 1, a reference numeral 4 points to the camera frame which supports various components and members, 401 to a wall forming a cartridge chamber inside which a film cartridge 2 with its cartridge spool 201 is set, 3 to a film winding spool of the camera, 402 to a spool chamber housing the film winding spool 3, 10 to a length of a film extending between the film cartridge 2 and the film winding spool 3 with a leader of the film 10 being wound around the film winding spool 3, 8 is a railing surface, provided on the frame 4, functioning as a surface for guiding the film 10 which is pulled out of the film cartridge 2 towards the film winding spool 3, 5 to an aperture for exposing the film 10 to light, 7 to a shutter, 12 to a photographing lens, and 1 to the photo interrupter.
With this mechanism, when the shutter 7 is opened, a light from outside the camera passes through the photographing lens 12, the shutter 7, and the aperture 5 to expose the portion of the film 10 adjacent the aperture 5 to light.
The photo interrupter 1 is illustrated as an enlarged perspective view in FIG. 2, and the mounting structure of the photo interrupter 1 is illustrated as an enlarged sectional view in FIG. 3, respectively. The photo interrupter 1 has a light emitting part 50 which is comprised of a LED, for example, and a light detecting part 60 which is comprised of a photo diode. The light emitting part 50 and the light detecting part 60 are held together by two legs 113a and 113b in a U-shape of a supporting member 113 of the photo interrupter 1.
Also, as shown in FIG. 2, the photo interrupter 1 has a pair of first electrodes 115, and a pair of second electrodes 116. When a light-emitting signal is inputted to the first electrodes 115, the light emitting part 50 emits a light.
On the other hand, when the light detecting part 60 detects the light emitted from the light emitting part 50, the light-detecting signal is outputted from the second electrodes 116.
When the film 10 is fed between the film cartridge 2 and the film winding spool 3, the film 10 is so guided on the railing surface 8 of the camera frame 4 that the film 10 passes through a slit 101, which is formed between the two legs 113a and 113b of the supporting member 113 which support the light emitting part 50 and the light detecting part 60.
With this mechanism, if a longitudinal edge part, corresponding to each perforation 102, of the film 10 passes between the light emitting part 50 and the light detecting part 60, the light emitted from the light emitting part 50 passes through the perforation 102 to the light detecting part 60.
On the other hand, if the longitudinal edge part, corresponding to no perforation, of the film 10 passes therebetween, the light emitted from the light emitting part 50 is intercepted by the film 10, so that no light reaches the light detecting part 60.
Accordingly, each time a perforation 102 of the film 10 passes between the light emitting part 50 and the light detecting part 60, a light-detecting signal is outputted from the second electrodes 116 of the light detecting part 60. That is, the passing of a perforation 102 of the film between the light emitting part 50 and the light detecting part 60, is detected and outputted in a form of the electrical signal.
The photo interrupter 1 is mounted on the frame 4 with its mounting structure which is provided in a part of the photo interrupter 1 and in a part of the frame 4, as shown in FIG. 3.
That is, as shown in the figure, the frame 4 has a concave part 6, and leg 113b with the light detecting part 60 of the supporting member 113 of the photo interrupter 1 is embedded in the concave part 6 of the frame 4. In order to prevent the supporting member 113 from dropping off the concave part 6 of the frame 4, a side surface 111 of the supporting member 113 is fixed to a bottom surface of the concave part 6 of the frame 4 by means of an adhesive.
According to the first embodiment, the photo interrupter 1 is fixed to the frame 4 by means of the adhesive, as mentioned above; however, the means to fix both members 1 and 4 to each other is not limited to the use of adhesive. For example, the supporting member 113 may be fixed to the frame 4 by means of a screw which taps the frame 4 on a side of the shutter 7 at a desired position thereof towards the supporting member 113 of the photo interrupter 1.
The film feeding control device is controlled by a control unit, provided in the camera, as shown in a block diagram of FIG. 4. That is, the control unit has a microcomputer 202 which controls the general operation of the camera, to which the shutter 7, the photographing lens 12, the photo interrupter 1, and a film feeding motor 203, which is provided in the film feeding control device are electrically connected.
With this mechanism, the shutter 7 and the photographing lens 12 are controlled by the microcomputer 202, respectively. The microcomputer 202 detects any perforation 102 of the film 10 by detecting the light-detecting signal outputted from the second electrodes 116 of the photo interrupter 1, and in turn energizes the film feeding motor 203 to drive the film feeding control device.
The film winding spool 3 and a fork for driving the cartridge spool 201 are, respectively, interlocked mechanically with the film feeding motor 203, so that the film 10 is fed from the film cartridge 2 towards the film winding spool 3, or the film 10 is fed from the film winding spool 3 back to the film cartridge 2.
In the first embodiment, the control for the amount of the film 10 fed between the film winding spool 3 and the film cartridge 2, and for the positioning of any frame of the film 10 with respect to the aperture 5, is performed by the microcomputer 202 in response to the detection of the perforation 102 of the film 10 by means of the photo interrupter 1, as explained above.
Next, referring to FIG. 5, a description is made of a film feeding control device with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a second embodiment of the present invention.
According to the second embodiment, the frame 4A has a opening 15A which penetrates the frame 4A as shown in FIG. 5, and a part of the supporting member 113A of the photo interrupter 1A is inserted into the opening 15A. In order to prevent the supporting member 113A from dropping out of the opening 15A of the frame 4A, the supporting member 113A is fixed to the frame 4A by means of an adhesive, which is applied to the part of the end surfaces 112A of the supporting member 113A corresponding to an inner peripheral surface of the opening 15A before inserting the supporting member 113A into the opening 15A of the frame 4A.
With the mounting structure of the second embodiment, it is possible to make a side surface 11A, facing the shutter and the photographing lens 12, of the supporting member 113A level or flat with a side surface 41A, facing the shutter 7, of the frame 4A.
Next, referring to FIG. 6, a description is made on a film feeding control device, with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a third embodiment of the present invention.
The third embodiment illustrates a different example of means of fixing a supporting member 113B of the photo interrupter 1B to a camera frame 4B, and employing a pair of fixing members 114B cubic in shape as shown in the figure.
That is, each fixing member 114B is integrated with the camera frame 4B or adhered thereto on a railing surface 8B of the camera frame 4B. A portion of each end surface 112B of the supporting member 113B of the photo interrupter 1B is adhered to the adjacent inner side surface of the fixing members 114B, with the supporting member 113B being inserted in an opening 15B formed in the camera frame 4B.
According to the third embodiment, although the supporting member 113B and the camera frame 4B are mutually fixed by means of the fixing members 114B and the adhesive, the fixing means of both members 113B and 4B are not limited to this example. For instance, the supporting member 113B and the camera frame 4B may be fixed to each other by making a hole through a fixing member 114B and the side 112B and partially through the supporting member 113B, and by fixing them together by driving in a screw from an outer side of the fixing member 114B towards the supporting member 113B.
According to the second and third embodiments, the mounting structure, for mounting the photo interrupter 1A or 1B on the part of the camera frame 4A or 4B, comprises a penetrating hole 15A or 15B, made in a part of the camera frame 4A or 4B, with a peripheral side surface 112A or 112B of the supporting member 113A or 113B of the photo interrupter 1A or 1B being fixed to the inner surface of the penetrating hole 15A or 15B by means of an adhesive. That is, according to the second and third embodiments, there is no need of providing the concave part 6 shown in FIG. 3, for receiving a bottom surface 111, on the side toward the shutter and the photographing lens, of the supporting member 113a of the photo interrupter 1, which is formed with a wall 9 of the frame 4 projecting towards the shutter 7 of the camera. Therefore, with the mounting structure according to the second and third embodiments, it is possible to reduce the thickness of the part of the camera frame, on which the supporting member of the photo interrupter is mounted, thus enabling the design of a compact camera.
Next, referring to FIG. 7, a description is made on a film feeding control device, with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a fourth embodiment of the present invention.
The fourth embodiment illustrates another example in which a supporting member 113C of the photo interrupter 1C is fixed by means of an adhesive to side surfaces of an opening 15C formed in the frame 4C. The adhesive is applied to the portions of the side surfaces of the supporting member 113C, corresponding to an inner peripheral surface of the opening before 15C, before inserting the supporting member 113C is inserted into the opening 15C of the frame 4c.
As shown in FIG. 7, the supporting member 113C is fixed to the part of the camera frame 4C so as to level the surface 111C of the supporting member 113C with the surface 4C, both facing the shutter 7 and the photographing lens 12 of the camera. With this structure, a light-intercepting member 103C, such as an adhesive, opaque tape or cloth, is adhered to both the surface 111C of the supporting member 113C and the surface 41C of the camera frame 4C.
When the opening 15C is formed in the camera frame 4C with a low degree of accuracy, there may exist a slight gap, as designated by 110C in FIG. 7, between the peripheral side surfaces of the supporting member 113C of the photo interrupter 1C and the inner surface of the opening 15C of the camera frame 4C. If such a gap between the supporting member 113C of the photo interrupter 1C and the opening 15C of the camera frame 4C exists, light which enters the inside of the camera through the photographing lens, may pass around the shutter and then through the gap 110C to reach the film and undesirably expose it to the light.
According to the mounting structure of the fourth embodiment, however, the gap 110C between the photo interrupter 1C and the hole 15C of the camera frame 4C is covered by the light-intercepting member 103C; accordingly, the passing of light through the gap 110C is surely prevented. In other words, according to the fourth embodiment, no matter how inaccurately the opening 15C is made in the camera frame 4C, undesirable exposure of the film to light is prevented. As a result, it is possible to reduce the number of steps by which the opening 15C of the frame 4C and the outer side of the supporting member 113C of the photo interrupter 1C are formed.
Next, referring to FIGS. 8, 9, 10 and 11, a description is made on a film feeding control device, with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a fifth embodiment of the present invention.
FIG. 8 illustrates the photo interrupter 1E of the fifth embodiment; FIG. 9 illustrates the photo interrupter 1E as a side elevation view thereof; and FIGS. 10 and 11 illustrate a mounting structure for mounting the photo interrupter, shown in FIGS. 8 and 9, on a part of a camera frame.
As shown in the figures, the photo interrupter 1E is provided with a light emitting part 50E and a light detecting part 60E. The light emitting part 50E, the light detecting part 60E, a pair of the first electrodes 115E electrically connecting to the light emitting part 50E, and a pair of the second electrodes 116E electrically connecting to the light detecting part 60E, are all supported by the supporting member 113E of the photo interrupter 1E. In the figures, 51E designates a light emitting surface of the light emitting part 50E and 61E designates a light detecting surface of the light detecting part 60E.
The supporting member 113E of the photo interrupter 1E has a flange-like projection 70E which surrounds a peripheral side surface 112E of the supporting member 113E. The flange-like projection 70E is formed perpendicular to an optical axis "A" extending between the light emitting part 50E and the light detecting part 60E, or is formed parallel to the light emitting surface 51E or the light detecting surface 61E.
The flange-like projection 70E has a surface, opposite a slit 11E through which the film 10 is passed, which is constructed to be a contacting surface 71E that contacts a contacting surface 20G (explained later) formed around an opening 15G in a camera frame 4G. The contacting surface 71E of the flange-like projection part 70E is also formed perpendicular to the optical axis A extending between the light emitting part 50E and the light detecting part 60E, or is formed parallel to the light emitting surface 51E or the light detecting surface 61E.
The photo interrupter 1E of the fifth embodiment is mounted on a part of the camera frame 4G. The camera frame 4G has an opening 15G in which the supporting member 113E of the photo interrupter 1E is inserted. The opening 15G is designed so as to correspond to the dimension of the part, on the side facing the shutter or the photographing lens, of the supporting member 113E of the photo interrupter 1E.
The part of the camera frame 4G has a contacting surface 20G which is so provided around the opening 15G that the contacting surface 20G is formed step-like nearer the surface on the side facing the shutter with respect to the railing surface 8G. The contacting surface 20G of the camera frame 4G is formed parallel to the railing surface 8G of the camera frame 4G.
With this mounting structure, when an edge part with a surface 111E, on the side facing the shutter, of the supporting member 113E of the photo interrupter 1E is inserted inside the opening 15G, the contacting surface 71E of the flange-like projecting part 70E contacts the contacting surface 20G of the camera frame 4G, with the surface 41G, on the side facing the shutter, of the camera frame 4G being level with the surface 111E, on the same side, of the supporting member 113E of the photo interrupter 1E.
With the contacting surface 20G of the camera frame 4G contacting the contacting surface 71E of the supporting member 113E of the photo interrupter 1E, the supporting member 113E and the camera frame 4G are fixed to each other by means of any fixing means such as an adhesive or screw.
As shown in FIG. 11, when the photo interrupter 1E is mounted on the camera frame 4G, the optical axis "A" of the photo interrupter 1E, the light emitting surface 51E of the light emitting part 50E, and the light detecting surface 61E of the light detecting part 60E, the flange-like projecting part 70E, and the contacting surface 71E are all parallel to the film surface or film 10.
According to the mounting structure of the fifth embodiment, since the thickness of the portion of the frame providing surface 20G around the opening 15G of the camera frame 4G is smaller than the thickness of the other part of the camera frame 4G so that the surface, on the side facing the shutter, of the interrupter 1E is flat with the surface, on the same side, of the camera frame 4G, it is possible to construct a thin mounting part or wall of the camera frame 4G.
In addition, according to the mounting structure of the fifth embodiment, the flange-like projecting part 70E functions as a barrier to prevent the passage of light between the photo interrupter 1E and the surrounding frame 4G. Consequently, a light coming in through the photographing lens and passing around the shutter is prevented from passing between the peripheral surface 112E of the supporting member 113A and the inner surface of the opening 15G of the camera frame 4G towards the film to expose it, even if there exists a gap between the peripheral surface 112E of the supporting member 113A and the inner surface, on the side facing the shutter, of the opening 15G of the camera frame 4G.
As shown in FIGS. 10 and 11, the flange-like projecting part 70E with its contacting surface 71E of the interrupter 1E is provided around the supporting member 113E thereof; therefore, the leaking of light between the peripheral surface 112E of the supporting member 113A and the inner surface of the opening 15G of the camera frame 4G towards the film is effectively prevented.
In the connection, as shown in FIGS. 10 and 11, the first and second electrodes 115E and 116E of the photo interrupter 1E are mounted on the supporting member 113E so that the electrodes 115E and 116E are perpendicular to the optical axis "A" and parallel to both the light emitting surface 51E and the light detecting surface 61E.
Here, the mounting position of the flange-like projecting part 70E with respect to the supporting member 113E of the photo interrupter 1E is not limited to what is shown in the figures. For example, referring to FIGS. 9 and 11, the space or length "h" between the surface 111E, on the side facing the shutter, of the supporting member 113E and the contacting surface 71E of the flange-like projecting part 70E can be voluntarily altered within a range of space or length "H", which substantially corresponds to a thickness of one leg 113Ea, on the side facing the shutter, of the supporting member 113E so that the surface 111E, on the side of the shutter, of the supporting member 113E is level with the surface 41G, on the same side, of the camera frame 41G.
Also, the arrangement of the light emitting part 50E and the light detecting part 60E is not limited to what is illustrated in the figure. For example, as a modification to the fifth embodiment, the light emitting part and the light detecting part may be reversed in position with respect to the supporting member 113E of the photo interrupter 1E.
Also, according to the fifth embodiment, the flange-like projecting part 70E is disposed on the side of the light detecting part 60E; however, the position of the flange-like projecting part is not limited to the illustrated embodiment. For example, the flange-like projecting part may be mounted on the side of the supporting member 113E on the side of the light emitting part 50E.
Next, referring to FIG. 12, a description is made on a film feeding control device, with a photo interrupter, according to a sixth embodiment of the present invention.
FIG. 12 shows the photo interrupter 1F of the sixth embodiment. As shown in the figure, a supporting member 113F does not have a flange-like projecting part annular in shape like the one of the fifth embodiment. Instead, the supporting member 113F has separate, flange-like projecting parts 70aF, 70bF, 70cF and 70dF, each of which is fixed to and is contensive with its corresponding side 112aF, 112bF, 112cF and 112dF of the supporting member 113F, so that the flange-like projecting part has generally square shaped notches 700F at each corner thereof.
With the mounting structure of the sixth embodiment, the leaking of light passing between the supporting member 113F of the photo interrupter 1F and the inner surface of the opening of the camera frame inside which the supporting member 113F is inserted, is also fully prevented.
Also, with the mounting structure of the sixth embodiment, there is no need of any additional light intercepting member to be mounted on the camera frame, so that it is possible to reduce the number of assembling members for the mounting structure, which in turn reduces the assembling steps for the structure.
Next, referring to FIGS. 13 and 14, a description is made of a film feeding control device, with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a seventh embodiment of the present invention.
FIG. 13 illustrates the photo interrupter 1H as a perspective view, and FIG. 14 illustrates the mounting structure as a fragmentary sectional view. As shown in the figures, a supporting member 113H of the photo interrupter 1H is provided with a flange-like projecting part 70H around a peripheral side surface 112H of the supporting member 113H so that a surface, on the side facing the shutter, of the supporting member 113H, is level with a surface, on the same side, of the camera frame 4H.
In the seventh embodiment, a contacting surface 71H, of the supporting member 113H, contacting a contacting surface 20H of the camera frame 4H, is located on a side remote from the shutter or the photographing lens, as shown in FIG. 14. As apparent from the figure, after the supporting member 113H is inserted into the opening 15H of the camera frame 4H from the side facing the shutter, both the supporting member 113H of the photo interrupter 1H and the camera frame 4H are fixed to each other by any fixing means as mentioned above.
Next, referring to FIGS. 15 and 16, a description is made on a film feeding control device with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a eighth embodiment of the present invention.
FIG. 15 illustrates the photo interrupter 1J as a perspective view, and FIG. 16 illustrates its mounting structure as a fragmentary sectional view.
As shown in the figures, the supporting member 113J of the photo interrupter 1J has no flange-like projecting part. Instead, the side of the supporting member 113J facing of the shutter is formed as a step-like part 80J with a contacting surface 71J.
In order to mount the photo interrupter 1J on the camera frame 4J, the supporting member 113J is inserted into the opening 15J of the camera frame 4J from a side remote from the shutter until the contacting surface 71J of the photo interrupter contacts the stepped contacting surface 20J of the camera frame 4J, and then the supporting member 113J is fixed to the camera frame 4J by any fixing means as mentioned above.
Next, referring to FIGS. 17 and 18, a description is made on a film feeding control device, with a photo interrupter and a mounting structure for mounting the photo interrupter on a camera frame, according to a ninth embodiment of the present invention.
FIG. 17 illustrates the photo interrupter 1K as a perspective view, and FIG. 18 illustrates its mounting structure as a fragmentary sectional view.
As shown in the figures, a supporting member 113K of the photo interrupter 1K has no flange-like projecting part like one shown in the fifth, sixth and seventh embodiments; Instead, camera frame 4K has an opening 15K, into which the supporting member 113K is inserted and where the opening is formed as a contacting surface 20K tapering inwardly towards the shutter or photographing lens. The peripheral surface 112K of the supporting member 113K, corresponding to the contacting surface 20K of the opening 15K of the camera frame 4K, is also formed as a contacting surface 71K tapering inwardly towards the shutter or photographing lens.
In order to mount the photo interrupter 1K on the camera frame 4K, the supporting member 113K is inserted into the opening 15K of the camera frame 4K from a side remote from the shutter until the contacting surface 71K of the photo interrupter 1K contacts the contacting surface 20K of the camera frame 4K, and then the supporting member 113K is fixed to the camera frame 4K by any fixing means as mentioned above, with a surface 111K, on the side facing the shutter or photographing lens, of the supporting member 113K of the photo interrupter 1K being level with a surface 41K, on the same side, of the part of the camera frame 4K.
According to the mounting structure, contacting surfaces 20K and 71K in the tapering form of the supporting member 113K of the photo interrupter 1K and the mounting part of the camera frame 4K prevents light coming in through the photographing lens and passing between the photo interrupter 1K and the camera frame 41K to undesirably expose the film to light.
Although the present invention has been fully described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications are apparent to those skilled in the art.
For example, although the film feeding control device with the photo interrupter and the mounting structure according to the embodiments above mentioned, is applied to the camera, the film feeding control device with the photo interrupter and the mounting structure of the present invention may also be applied to a printing apparatus.
Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims unless they depart therefrom. | A control device for feeding and positioning a film precisely, in a camera, a printing apparatus, etc., includes a photo interrupter with a light emitter, a light detector for detecting a light emitted from the light emitter, and a holding member for keeping both the light emitter and the light detector in position; a frame with a guiding member for guiding a film having a longitudinal edge with a plurality of perforations which travels between the light emitter and the light detector of the photo interrupter; a perforation detector for detecting a perforation based upon a signal outputted from the light detector, which outputs the signal each time a perforation of the film edge passes a location corresponding to an optical axis existing between the light emitter and the light detector; and a controller for controlling a film feeding operation in accordance with the detection of a perforation by the perforation detector. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to chest compression devices and in particular to a high frequency chest wall oscillator device.
[0002] Manual percussion techniques of chest physiotherapy have been used for a variety of diseases, such as cystic fibrosis, emphysema, asthma and chronic bronchitis, to remove excess mucus that collects in the lungs. To bypass dependency on a caregiver to provide this therapy, chest compression devices have been developed to produce High Frequency Chest Wall Oscillation (HFCWO), a very successful method of airway clearance.
[0003] The device most widely used to produce HFCWO is THE VEST™ airway clearance system by Advanced Respiratory, Inc. (f/k/a American Biosystems, Inc.), the assignee of the present application. A description of the pneumatically driven system is found in the Van Brunt et al. Patent, U.S. Pat. No. 6,036,662, which is assigned to Advanced Respiratory, Inc. Additional information regarding HFCWO and THE VEST™ system is found on the Internet at www.thevest.com. Other pneumatic chest compression devices have been described by Warwick in U.S. Pat. No. 4,838,263 and by Hansen in U.S. Pat. Nos. 5,543,081 and 6,254,556 and Int. Pub. No. WO 02/06673.
[0004] These HFCWO systems may be used in the home, however, successful use in the home is dependent on regular use of the device by the patient. Patient compliance is also important to obtain insurance reimbursement. Ease of use is an important factor in gaining acceptable patient compliance.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention is an improved method of providing high frequency chest wall oscillations to a patient. The method includes generating oscillating pneumatic pressure having a steady state pressure component and an oscillating pressure component and applying an oscillating compressive force to the patient's chest that includes a steady state force component corresponding to the steady state pressure component and an oscillating force component corresponding to the oscillating pressure component. The frequency of the oscillations change according to a predetermined pattern while maintaining the steady state pressure and force components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a perspective of the HFCWO system of the present invention.
[0007] [0007]FIG. 2 is a perspective view of the air pulse generator of the present invention.
[0008] [0008]FIG. 3 is a front view of the user interface.
[0009] [0009]FIG. 4 is a table summarizing STEP and SWEEP modes.
[0010] [0010]FIG. 5 is a table summarizing modes of the air pulse generator.
[0011] [0011]FIG. 6 is a perspective view of one embodiment of the control switch.
[0012] [0012]FIG. 7 is a perspective view of a second embodiment of the control switch.
[0013] [0013]FIG. 8 is a perspective view of the inside of the air pulse generator with a front portion of the shell removed.
[0014] [0014]FIG. 9 is an exploded view of the inside of the front portion of the shell.
[0015] [0015]FIG. 10 is a perspective view of the inside of the back portion of the shell.
[0016] [0016]FIG. 11 is a perspective view of the air pulse module.
[0017] [0017]FIG. 12 is a perspective view of the back side of the air pulse module.
[0018] [0018]FIG. 13 is a perspective view of the air chamber shell.
[0019] [0019]FIG. 14 is a perspective view of the crankshaft assembly within the air pulse module.
[0020] [0020]FIG. 15 is an exploded view of the crankshaft assembly.
[0021] [0021]FIG. 16 is a perspective view of the heatsink on the control board.
[0022] [0022]FIG. 17 is a perspective view of the electronic circuitry on the control board.
[0023] [0023]FIG. 18 is a block diagram of a control system of the present invention.
[0024] [0024]FIG. 19 is an electrical schematic diagram of the AC Mains circuit.
[0025] [0025]FIG. 20 is an electrical schematic diagram of the Switching Power Supply circuitry.
[0026] [0026]FIG. 21 is an electrical schematic diagram of the Power Up Clear & Fault Reset circuitry.
[0027] [0027]FIG. 22 is an electrical schematic diagram of the Diaphragm Motor controller.
[0028] [0028]FIG. 23 is an electrical schematic diagram of the Blower Motor controller.
[0029] [0029]FIG. 24 is a graph illustrating the performance of the present invention using an adult large vest for HFCWO.
[0030] [0030]FIG. 25 is a graph illustrating the performance of the present invention using an adult medium vest for HFCWO.
[0031] [0031]FIG. 26 is a graph illustrating the performance of the present invention using an adult small vest for HFCWO.
[0032] [0032]FIG. 27 is a graph illustrating the performance of the present invention using a child large vest for HFCWO.
[0033] [0033]FIG. 28 is a graph illustrating the performance of the present invention using a child medium vest for HFCWO.
DETAILED DESCRIPTION
[0034] [0034]FIG. 1 shows a pneumatic HFCWO system of the present invention. FIG. 1 shows patient P having chest C and system 10 which includes inflatable vest 12 , hoses 14 , and air pulse generator 16 . Vest 12 is positioned on chest C of patient P. Hoses 14 are fluidly connected to vest 12 and air pulse generator 16 .
[0035] In operation, air pulse generator 16 provides air pulses and a bias pressure to vest 12 . The air pulses oscillate vest 12 , while the bias pressure keeps vest 12 inflated. Vest 12 applies an oscillating compressive force to chest C of patient P. Thus, system 10 produces HFCWO to clear mucous or induce deep sputum from the lungs of patient P.
[0036] Air pulse generator 16 produces a pressure having a steady state air pressure component (or “bias line pressure”) and an oscillating air pressure component. The pressure is a resulting composite waveform of the oscillating air pressure component and the steady state air pressure component. The oscillating air pressure component is substantially comprised of air pulses, while the steady state air pressure component is substantially comprised of bias line pressure.
[0037] The force generated on the chest C by vest 12 has an oscillatory force component and a steady state force component. The steady state force component corresponds to the steady state air pressure component, and the oscillating force component corresponds to the oscillating air pressure component. In a preferred embodiment, the steady state air pressure is greater than atmospheric pressure with the oscillatory air pressure riding on the steady state air pressure. With this embodiment, the resulting composite waveform provides an entire oscillation cycle of vest 12 that is effective at moving chest C of patient P, because there is no point at which pressure applied to chest C by vest 12 is below atmospheric pressure. Chest movement can only be induced while vest 12 has an effective pressure (i.e. greater than atmospheric pressure) on chest C.
[0038] [0038]FIG. 2 shows the preferred embodiment of air pulse generator 16 . Air pulse generator 16 includes shell or housing 18 having back portion 20 with handle 22 , front portion 24 and seam 26 . Front portion 24 further includes user interface 28 , air openings 30 , switch port 32 and control switch 34 having connection plug 36 , tube 38 and control bulb 40 . Handle 22 is connected on back portion 20 of shell 18 . Front portion 24 is removably connected to back portion 20 along seam 26 . Connection plug 36 connects to front portion 24 via switch port 32 , and connection plug 36 fluidly connects to control bulb 40 via tube 38 .
[0039] Enclosure or shell 18 is composed of molded plastic such as polyvinyl chloride (PVC). Shell 18 is preferably about 13.5 in. wide, about 9.2 in. high and about 9.2 in. deep and provides the outer covering for air pulse generator 16 . Air pulse generator 16 preferably has a volume of about 1,200 in. 3 , a foot print of about 125 in. 2 and weighs about 17 lbs., which is significantly smaller and lighter than prior art HFCWO air pulse generators. These dimensions easily meet airline carry-on restrictions. Most airlines require that a carry-on weigh less than 40 lbs. and have a total length, width and height of less than 45 in., but restrictions vary from airline to airline. Typically, airlines also require that a carry-on have dimensions less than 9 in.×14 in.×22 in.
[0040] In comparison, THE VEST™ system, as previously described, is about 22 in. high, 14.5 in. wide and 10.2 in. deep. THE VEST™ system, has a volume of about 3,300 in. 3 , a footprint of about 150 in. 2 and weighs about 34 lbs.
[0041] Another HFCWO device, the Medpulse 2000 ™, from Electromed of New Prague, Minn. (various versions of which are depicted in U.S. Pat. No. 6,254,556 and Int. Pub. No. WO 02/06673) is about 20.5 in. wide, 16.75 in. deep and 9 in. high. The Medpulse 2000 ™ has a volume of about 3,100 in. 3 , a footprint of about 345 in. 2 and also weighs about 34 lbs.
[0042] In operation, user interface 28 allows patient P to control air pulse generator 16 . Air openings 30 connect hoses 14 to generator 16 . Switch port 32 allows connection plug 36 to connect to air pulse generator 16 . Patient P controls activation/deactivation of air pulse generator 16 through control switch 34 .
[0043] User interface 28 is shown in more detail in FIG. 3. User interface 28 includes display panel 110 and keypad 112 having the following buttons: ON button 114 , OFF button 116 , UL (Upper Left) 118 , LL (Lower Left) 120 , UM (Upper Middle) 122 , LM (Lower Middle) 124 , UR (Upper Right) 126 and LR (Lower Right) 128 .
[0044] Display panel 110 is preferably an LCD panel display, although other displays, such as LED, could also be used. Display panel 110 shows the status of air pulse generator 16 and options available for usage. A single line of up to 24 characters is displayed. The characters are in a 5×8 pixel arrangement with each character measuring about 6 mm (0.24 in.)×14.54 mm (0.57 in.). A standard set of alphanumeric characters plus special symbols are used, and special characters that use any of the 40 (5×8) pixels are programmable. Display panel 110 is backlit for better character definition for all or some modes.
[0045] Keypad 112 is preferably an elastomeric or rubber eight button keypad that surrounds display panel 110 . ON button 114 is located on the left side of display panel 110 , and OFF button 116 is located on the right side of display panel 110 . UL 118 , UM 122 and UR 126 are located along the top of display panel 110 , and LL 120 , LM 124 and LR 128 are located along the bottom of display panel 110 .
[0046] Patient P may modify operation of air pulse generator 16 . Air pulse generator 16 also provides feed back to patient P as to its status. The messages are displayed as text on display panel 110 .
[0047] Buttons 114 - 128 on user interface 28 are programmed based on the particular operating mode that is presently active. In particular, in showing operating mode choices, the arrow buttons are programed to wrap around. When showing time selection, frequency selection and pressure selection, the arrow buttons are programed to not wrap around.
[0048] The function of UL 118 , LL 120 , UM 122 , LM 124 , UR 126 and LR 128 varies depending on the current mode of air pulse generator 16 . Each button is programmed to control various functions including the frequency of the oscillating air pressure component, or air pulses, the steady state air pressure component, or bias line pressure, and a timer, which deactivates air pulse generator 16 and will be more fully described below.
[0049] User interface 28 also allows operation of air pulse generator 16 in several different modes, such as MANUAL, SWEEP or STEP. Any one of which is programmable as a default mode that automatically operates when ON button 114 is activated.
[0050] MANUAL mode allows air pulse generator 16 to be manually programmed to set the oscillation frequency, bias line pressure and treatment time. MANUAL mode is similar to operation of the control knobs on THE VEST™ system. The oscillation frequency is set to a value ranging from 5 Hz to 20 Hz with a default frequency of 12 Hz. Likewise, the pressure control is set to a value ranging from 0 to 10 with a default pressure of 3. Treatment time is also set to a value ranging from 0 to 99 min with a default time of 10 min. Typically, treatment times are no more than 30 min.
[0051] SWEEP mode presets air pulse generator 16 to sweep over a range of oscillation frequencies while maintaining the same bias or steady state air pressure component. SWEEP mode provides three different sweep ranges, although any number or range of frequencies are programmable through user interface 28 . The table shown in FIG. 4 summarizes and illustrates the three different sweep ranges, which are: HIGH, which sweeps the oscillation frequency between 10 to 20 Hz; NORMAL, which sweeps the oscillation frequency between 7 and 17 Hz and LOW, which sweeps the oscillation frequency between 5 and 15 Hz. In each of these modes, the oscillation frequency sweeps between the two end points incrementally changing the oscillation frequency. The oscillation frequency incrementally increases until it reaches the high frequency, then incrementally decreases the oscillation frequency to the low frequency, then the oscillation frequency incrementally increases again (FIG. 4). Alternatively, the oscillation frequency incrementally increases to the high frequency then returns to the low frequency and incrementally increases to the high frequency. The incremental increasing and decreasing continues throughout the treatment, or until the settings are reset. It is believed that the low frequencies are more effective at clearing small airways, and high frequencies more effective at clearing larger airways. The speed of the sweep is programmable through user interface 28 or preset. Preferably, the sweep speed is 1 cycle per 5 minutes. The default pressure setting in SWEEP mode is 3 with patient P able to modify the setting from 1 to 4 for comfort.
[0052] STEP mode presets air pulse generator 16 to step over a range of oscillation frequencies while maintaining the same bias or steady state air pressure component. STEP mode provides three different step ranges, although any number or range of frequencies is programmable through user interface 28 . Again, the table shown in FIG. 4 summarizes and illustrates the different ranges of STEP mode, which are: HIGH, which steps through the oscillation frequencies 10 Hz, 13 Hz, 16 Hz and 19 Hz; NORMAL, which steps through the oscillation frequencies 8 Hz, 11 Hz, 14 Hz and 17 Hz and LOW, which steps through the oscillation frequencies 5 Hz, 8 Hz, 11 Hz and 14 Hz. In each of these modes the oscillation frequencies step from the low frequency to the high frequency, changing the oscillation frequency a fixed amount after a fixed period of time. The oscillation frequency increases by steps until it reaches the high frequency, then decreases the oscillation frequency until the low frequency is reached. If desired, the oscillation frequency increases by steps again. The pattern of increasing and decreasing continues throughout the treatment or until the settings are reset. The fixed step amount of oscillation frequency change and the fixed period between oscillation frequency changes is programmable through user interface 28 , or the fixed step amount and the fixed period are preset. Preferably, the fixed step amount is 3 Hz, and the fixed step time period is 5 minutes. The default mode for STEP and SWEEP modes is NORMAL, and the default pressure is 3 with patient P able to modify the pressure from 1 to 4.
[0053] The table in FIG. 5 summarizes default mode settings and buttons 118 - 128 functionality in specific modes. The first column lists each mode. Columns 2 - 6 list the default settings for different parameters of HFCWO while in the various modes. Columns 7 - 9 list the function of buttons 118 - 128 while in the various modes.
[0054] The following operating modes are software supported by air pulse generator 16 : A) UNPLUGGED, B) IDLE, C) AUTO READY, D) AUTO RUN, E) AUTO PAUSED, F) PROGRAM ADJUST, G) PROGRAM RUN, H) MANUAL ADJUST, I) ERROR, J) Pulsing therapy modes including SWEEP, STEP and MANUAL and K) status and user messages including pressure adjust and frequency adjust, session run time (including pulsing and pause time) and accumulated run time (updated in memory every one minute).
[0055] In UNPLUGGED mode, display panel 110 is blank and air pulse generator 16 is disconnected from the supply mains.
[0056] In IDLE mode, air pulse generator 16 is plugged in and both blower motor 50 and diaphragm motor 64 are non-operational. Display panel 110 is not back lit, but the displayed message can be read and indicates accumulated run time (either both pulsing or pause time or only pulsing time).
[0057] The operation of control switch 34 is also programmed through user interface 28 . Control switch 34 is used in either an ON/OFF mode or a CONSTANTLY ON mode. The CONSTANTLY ON mode requires that control switch 34 be constantly depressed in order to activate air pulse generator 16 . The ON/OFF mode activates or deactivates air pulse generator 16 each time control switch 34 is pressed. The ON button 114 can also be used alternatively or to duplicate the functions of control switch 34 .
[0058] Buttons 114 - 128 and control switch 34 have the following functionality in IDLE mode: A) control switch 34 causes air pulse generator 16 to enter AUTO RUN mode using the default settings, B) ON button 114 causes air pulse generator 16 to enter AUTO READY mode, C) OFF button 116 has no effect and air pulse generator 16 remains in IDLE mode and D) buttons 118 - 128 are nonfunctional.
[0059] In AUTO READY mode, air pulse generator 16 pressurizes vest 12 for four seconds to the standby pressure level of 0.1 psi+0.05/−0.0.03 psi, and the backlit display panel 110 toggles between the default-remaining session time (e.g. “SWEEP NORMAL 20 MIN”) and status (e.g. “READY-PRESS AIR SWITCH”) messages every two seconds. Air pulse generator 16 continues alternating messages in AUTO READY mode for two minutes unless operator action occurs. After two minutes, air pulse generator 16 enters IDLE mode where vest 12 deflates, and a message displaying “INCOMPLETE XX MIN REMAIN” is displayed for five seconds.
[0060] Buttons 114 - 128 and control switch 34 have the following functionality in AUTO READY mode: A) control switch 34 causes air pulse generator 16 to enter AUTO RUN mode, B) ON button 114 causes air pulse generator 16 to enter PROGRAM ADJUST mode, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode and D) buttons 118 - 128 are nonfunctional. Air pulse generator 16 returns to IDLE mode after two minutes of inactivity and displays “INCOMPLETE XX MIN REMAIN.”
[0061] In AUTO RUN mode, air pulse generator 16 inflates vest 12 for four seconds and then begins oscillation by initially performing a pressure characterization. During pressure characterization, sinusoidal pressure pulses are supplied over an average static pressure. During the initial few slow oscillation pulses of air pulse generator 16 during RUN mode, air pulse generator 16 monitors the system pressure and makes an adjustment to the average static pressure to compensate for different vest sizes and varying vest tightness. Patient P may be allowed to modify this average static pressure.
[0062] The pressure in vest 12 is comparable to the pressure in the air chamber of air pulse generator 16 at low frequencies such as 5 Hz. The correlation between the pressure in the air chamber and the pressure in vest 12 is not as comparable at high frequencies such as 15 or 20 Hz. This method allows the pressure in vest 12 to be accurately measured and maintained by taking measurements in the air chamber instead of taking measurements in vest 12 . Eliminating electronics in the vest portion increases safety. Once the average static pressure is determined, the pressure is maintained by maintaining the speed of the blower providing the bias line pressure with the tip speed of the blower fan. By using a blower with a flat pressure curve over the range of air flow, the average static pressure is maintained by simply maintaining the speed of the blower.
[0063] Oscillation proceeds using the default settings of SWEEP NORMAL for a duration of 20 minutes, while the backlit display panel 110 shows relative pressure (using vertical bars) and remaining session time. The message is displayed while air pulse generator 16 is delivering pulsed air pressure to vest 12 . The time counts down to zero in whole minute increments. When the session is complete, air pulse generator 16 reverts to IDLE mode and displays the message “SESSION COMPLETE” for five seconds.
[0064] Buttons 114 - 128 and control switch 34 have the following functionality in AUTO RUN mode: A) control switch 34 causes air pulse generator 16 to enter AUTO PAUSE mode, B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 adjust vest pressure and E) buttons 122 - 128 are nonfunctional.
[0065] In AUTO PAUSED mode, air pulse generator 16 lowers vest pressure to the standby pressure level. Display panel 110 toggles between the default mode-remaining session time (e.g. “SWEEP NORMAL XX MIN”) and air pulse generator 16 status (e.g. “PAUSED PRESSED AIR SWITCH”) messages every two seconds. Air pulse generator 16 continues alternating messages in AUTO PAUSED mode for two minutes unless operator action occurs. After two minutes of inactivity, air pulse generator 16 enters IDLE mode causing vest 12 to deflate, and the message “INCOMPLETE XX MIN REMAIN” is displayed for five seconds.
[0066] Buttons 114 - 128 and control switch 34 have the following functionality in AUTO PAUSED mode: A) control switch 34 causes air pulse generator 16 to enter AUTO RUN mode, continuing the paused therapy session, B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode and D) buttons 118 - 128 are nonfunctional.
[0067] PROGRAM ADJUST mode maintains the vest pressure established in AUTO READY mode, or lowers the vest pressure to the standby pressure level if pausing from RUN mode. If proceeding from AUTO READY mode, display panel 110 will toggle between “SWEEP NORMAL 20 MIN” and “READY-PRESS AIR SWITCH” messages every two seconds. If paused from PROGRAM RUN mode, display panel 110 toggles between the current settings of “MODE-FREQ MODIFIER-REMAINING SESSION TIME” (e.g. “SWEEP NORMAL 5 MIN”, “STEP HI 17 MIN”, OR “MANUAL ADJUST ?”) and “PAUSED-PRESS AIR SWITCH” messages every two seconds.
[0068] The different modes (SWEEP, STEP and MANUAL) are accessed using UL 118 and LL 120 . When SWEEP and STEP modes are displayed, the frequency modifiers (HIGH, LOW and NORMAL) are adjusted using UM 122 and LM 124 , and the session time (in minutes) is set using UR 126 and LR 128 . As the modes and modifiers are changed, they replace the “SWEEP NORMAL TIME” message. The mode message continues to alternate with the “READY-PRESS AIR SWITCH” or “PAUSED-PRESS AIR SWITCH” messages every two seconds. (Note: “READY” is used when PROGRAM ADJUST mode is reached from AUTO READY mode, and “PAUSED” is used when reached from RUN mode.) Pressing control switch 34 at any time causes air pulse generator 16 to proceed to PROGRAM RUN mode using the displayed settings. If time is zero when control switch 34 is pressed, air pulse generator 16 reverts to IDLE mode. Pressing UL 118 , UM 122 , LL 120 or LM 124 while in “MANUAL ADJUST?” transfers air pulse generator 16 to MANUAL ADJUST mode where frequency, pressure and session time can be adjusted. Messages continue alternating in PROGRAM ADJUST mode for two minutes unless operator action occurs. After two minutes, air pulse generator 16 reverts to IDLE mode where vest 12 deflates, and a message “INCOMPLETE XX MIN REMAIN” is displayed for five seconds.
[0069] Buttons 114 - 128 and control switch 34 have the following functionality in PROGRAM ADJUST mode: A) control switch 34 causes air pulse generator 16 to enter RUN mode (Actual RUN mode depends on setting at time of control switch 34 actuation. If control switch 34 is actuated with the session time at zero, air pulse generator 16 will reset to the IDLE mode.), B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 toggle SWEEP, STEP and MANUAL modes, E) UM 122 and LM 124 adjust the frequency in SWEEP and STEP modes and cause transfer to MANUAL ADJUST in MANUAL mode and F) UR 126 and LR 128 adjust the time in SWEEP and STEP modes and cause transfer to MANUAL ADJUST in MANUAL mode. Air pulse generator 16 returns to IDLE mode after two minutes of inactivity displaying “INCOMPLETE XX MIN REMAIN.”
[0070] MANUAL ADJUST mode maintains vest 12 inflation at standby pressure and pulsing action remains stopped. The backlit display panel 110 shows the default or previously paused session information of frequency setting in Hertz, relative pressure and remaining session time in minutes. Adjustments to each of the parameters (frequency, pressure or time) are made by pressing the respective up or down arrow buttons.
[0071] Buttons 114 - 128 and control switch 34 have the following functionality in MANUAL ADJUST mode: A) control switch 34 causes air pulse generator 16 to enter MANUAL RUN mode (if control switch 34 is activated with the session time at zero, air pulse generator 16 will revert to IDLE mode), B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 adjust frequency in Hertz, E) UM 122 and LM 124 adjust relative pressure and F) UR 126 and LR 128 adjust session time in minutes.
[0072] Air pulse generator 16 returns to IDLE mode after two minutes. If the session time has elapsed, air pulse generator 16 returns to PROGRAM ADJUST mode displaying “SESSION COMPLETE” for five seconds and then displaying “MANUAL ADJUST?”
[0073] In PROGRAM RUN mode, vest 12 inflates for four seconds and air pulse generator 16 begins pulsing in the selected mode: SWEEP, STEP or MANUAL. Each mode is described below in further detail.
[0074] In MANUAL RUN mode, vest 12 inflates for four seconds and air pulse generator 16 begins pulsing the selected or default parameters. No pressure characterization is required in MANUAL RUN mode. Display panel 110 is backlit and shows frequency settings in Hertz, relative pressure setting and remaining session time in minutes. The message is displayed while air pulse generator 16 is delivering pulsed air pressure to vest 12 . The time counts down to zero as whole minute increments. Adjustments to each of the parameters can be made by pressing the adjacent up or down arrow buttons.
[0075] Buttons 114 - 128 and control switch 34 have the following functionality in MANUAL RUN mode: A) control switch 34 causes air pulse generator 16 to enter PROGRAM ADJUST mode and the settings are remembered, B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 adjust frequency in Hertz, E) UM 122 and LM 124 adjust relative vest pressure and F) UR 126 and LR 128 adjust time in minutes.
[0076] Once the session time is completed, air pulse generator 16 returns to PROGRAM ADJUST mode with initial session settings. When the session timer counts to zero, the pulsing stops, vest pressure drops to standby, and air pulse generator 16 resets to the session values previously entered. If air pulse generator 16 is further reset to IDLE mode, the session values of frequency, pressure and time are lost, and the default values are loaded.
[0077] In SWEEP RUN and STEP RUN modes, air pulse generator 16 inflates vest 12 for four seconds and then begins oscillation by initially performing the pressure characterization described above. Oscillation proceeds through the pre-selected or default sweep settings while the backlit display panel 110 shows relative pressure (using vertical bars) and remaining session time. The message on display panel 110 is displayed while air pulse generator 16 is delivering pulsed air pressure to vest 12 . The time counts down to zero in whole minute increments.
[0078] Buttons 114 - 128 and control switch 34 have the following functionality in SWEEP RUN and STEP RUN modes: A) control switch 34 causes air pulse generator 16 to enter PROGRAM ADJUST mode, B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 adjust vest pressure and E) buttons 122 - 128 are nonfunctional.
[0079] Once time is completed, air pulse generator 16 returns to IDLE mode and displays “SESSION COMPLETE” for five seconds. Pulsing stops, vest 12 deflates, session settings are lost, and the default values are loaded if SWEEP RUN or STEP RUN mode is re-entered.
[0080] When an error is detected, air pulse generator 16 reverts to IDLE mode and displays the non-backlit error message “See Manual.” Only UNPLUGGED mode is allowed. If air pulse generator 16 is unplugged and replugged, the message clears, and air pulse generator 16 attempts to run again. Buttons 114 - 128 and control switch 34 have no effect. Air pulse generator 16 continues to alternate Error and Call messages.
[0081] Air pulse generator 16 provides a static pressure produced by a centrifugal blower with an electric feedback speed control loop for controlling the pressure. A pressure offset is generated during the startup period, which compensates for the different bladder sizes available in the assorted vest options. Average minimum output pressure is 0.28 psi minium, the average maximum output pressure is 0.70 psi minimum, and the average IDLE output pressure is 0.1 psi nominal and the maximum pressure is 1.2 psi. The pressure setting and the actual operating average pressure tolerance is 0.2 psi.
[0082] The air pulse frequency is generated by a DC brushless motor driving a double linkage connected to two natural rubber diagrams, which is described in more detail below. The minimum air pulse frequency is 5 Hz, and the maximum air pulse frequency is 20 Hz. The pulse frequency delivered by air pulse generator 16 is 20% of the selected parameter. The maximum peak pressure, measured at the input port of vest 12 , does not exceed 1.2 psi at any pulse frequency (5-20 Hz), using any vest size and any pressure setting.
[0083] The pressure oscillates causing pressure fluctuations that are the result of dual diaphragm oscillations of a fixed volume displacement of 29.2 in. 3 per cycle. The pressure fluctuations at vest 12 are: A) a minimum level of 0 psi, B) a maximum level of 1.2 psi maximum, C) a maximum of 0.45 psi minimum and D) a minimum pressure delta of 0.15 psi.
[0084] [0084]FIG. 6 shows one embodiment of control switch 34 in more detail. FIG. 6 includes shell 18 with switch port 32 and control switch 34 having connection plug 36 , tube 38 and control bulb 40 . Connection plug 36 connects control switch 34 to air pulse generator 16 .
[0085] Control switch 34 is similar to control switches used on prior art devices, such as the pneumatic control switch used with THE VEST™ airway clearance system from Advance Respiratory, Inc., St. Paul, Minn. Control switch 34 is activated by compressing control bulb 40 , such as with a hand or a foot of patient P. Upon compression, control bulb 40 sends an air pulse through tube 38 to a pneumatic switch, which activates/deactivates air pulse generator 16 . Control switch 34 operates as a toggle switch when depressed and released.
[0086] [0086]FIG. 7 shows a second embodiment of control switch 34 . Here, control switch 34 includes connection plug 36 and button bulb 42 . Button bulb 42 is a small pneumatic bulb comprised of plastic, such as 60 durometer PVC, directly connected to connection plug 36 . Button bulb 42 may have a bleed hole to relieve pressure. Control switch 34 is inserted in switch port 32 of shell 18 . Button bulb 42 eliminates the need for tube 38 and provides an on/off/pause control next to user interface 28 for convenience and ease of use. Similar to the first embodiment described in FIG. 6, control switch 34 shown in FIG. 7 sends an air pulse to a pneumatic switch, which activates/deactivates air pulse generator 16 . Again, control switch 34 operates as a toggle switch when depressed and released.
[0087] [0087]FIG. 8 shows air pulse generator 16 with front portion 24 removed. Air pulse generator 16 includes back portion 20 with handle 22 , air pulse module 44 , mounting plate 46 and main control board 60 . Air pulse module 44 further includes blower motor 50 , blower 52 , tube 54 and air chamber assembly 56 with air ports 58 , first diaphragm assembly 68 and second diaphragm assembly 70 . In the one embodiment, mounting plate 46 secures air pulse module 44 to shell 18 . Blower motor 50 is connected to blower 52 . Tube 54 fluidly connects blower 52 to air chamber assembly 56 , and first and second diaphragm assemblies 68 and 70 are positioned on opposite sides of air chamber assembly 56 . Main control board 60 is preferably secured within shell 18 opposite mounting plate 46 .
[0088] The oscillatory air pressure component is created by the pulsing action of first and second diaphragm assemblies 68 and 70 , which oscillates the air within air chamber assembly 56 at a selected frequency. The oscillatory pressure created by first and second diaphragm 68 and 70 follows a sinusoidal waveform pattern.
[0089] To create the steady state air pressure, blower motor 50 powers blower 52 to provide a bias line pressure to air chamber assembly 56 through tube 54 . Air within air chamber assembly 56 oscillates to provide the air pulses to vest 12 . Blower motor 50 and blower 52 may be, for example, an Ametek model 119319 or Torrington 1970-95-0168. Preferably, the steady state air pressure created by blower 52 is greater than atmospheric pressure, so that a whole oscillatory cycle is effective at moving chest C of patient P.
[0090] [0090]FIG. 9 shows an exploded view of front portion 24 of shell 18 . Front portion 24 includes keypad 112 , surround 113 , anchors 111 , display panel 110 , secondary control board 29 , fasteners 109 , air openings 30 and seal 62 . Keypad 112 fits into surround 113 , which fits onto the outside of front portion 24 . Anchors 111 are on the inside of front portion 24 such that display panel 110 fits between anchors 111 to secure display panel 110 in place. Secondary control board 29 is attached on the back side of display panel 110 and contains electronic circuitry for user interface 28 , which is detailed below. Fasteners 109 secure keypad 112 , surround 113 , anchors 111 and display panel 10 with secondary control board 29 together to form user interface 28 . Fasteners 109 further secure user interface 28 to front portion 24 .
[0091] Seal 62 is positioned between the front of air pulse module 44 and front portion 24 . Seal 62 is fitted around air openings 30 and air ports 58 to form an air tight connection between hoses 14 and air pulse module 44 .
[0092] When air pulse generator 16 is operating, essentially all of the pulsed air is transferred from air pulse module 44 to hoses 14 . Seal 62 is preferably comprised of an elastomer such as black nitrile having a durometer of 80+/− 5 . However, seal 62 may also be comprised of closed cell foam tape, or black vinyl type foam.
[0093] [0093]FIG. 10 is an inside view of back portion 20 of shell 18 . Back portion 20 includes vent 71 and support 72 . Support 72 is positioned between the back of air pulse module 44 and back portion 20 to secure air pulse module 44 within shell 18 and reduce noise and vibration produced by air pulse generator 16 . Support 72 is also designed such that air circulates around diaphragm motor 64 (FIG. 12) to dissipate heat, thus preventing diaphragm motor 64 from overheating. Support 72 is preferably one piece but may be comprised of two or more individual supports. Support 72 is comprised of an elastomer such as black nitrile having a durometer of 60+/− 5 shaped to conform to the surrounding parts but may alternatively be comprised of closed cell foam tape or black vinyl type foam.
[0094] Vent 71 is a region of back portion 20 having openings through shell 18 . Vent 71 is positioned such that heat from diaphragm motor 64 , secondary control board 29 and/or main control board 60 is released through vent 71 to prevent overheating.
[0095] [0095]FIG. 11 shows the front of air pulse module 44 with more clarity. Air pulse module 44 includes blower motor 50 , blower 52 , tube 54 and air chamber assembly 56 with air ports 58 , first diaphragm assembly 68 and second diaphragm assembly 70 . Refer to FIG. 8 for a description of the general function of air pulse module 44 .
[0096] [0096]FIG. 12 shows the back of air pulse module 44 . Air pulse module 44 includes blower motor 50 , blower 52 , tube 54 and air chamber assembly 56 having diaphragm motor 64 , air chamber shell 66 , first diaphragm assembly 68 and second diaphragm assembly 70 . First diaphragm assembly 68 further includes plate 68 a and diaphragm seal 68 b . Second diaphragm assembly 70 further includes plate 70 a (not shown) and diaphragm seal 70 b.
[0097] Diaphragm motor 64 is directly mounted on air chamber shell 66 at the back of air pulse module 44 . Diaphragm motor 64 may be an Aspen Motion Research Part No. 11702 or an equivalent motor. First diaphragm assembly 68 and second diaphragm assembly 70 are movably attached on opposite sides of air chamber shell 66 .
[0098] Diaphragm seals 68 b and 70 b have an annular U shape and are comprised of a flexible material such as natural rubber, silicon rubber, or nitrite rubber. Plates 68 a and 70 a are comprised of metal, such as aluminum, and are substantially flat. Diaphragm seals 68 b and 70 b provide a fluid type seal between plates 68 a and 70 a , respectively, and air chamber shell 66 . Air chamber shell 66 , first diaphragm assembly 68 , second diaphragm assembly 70 and diaphragm motor 64 substantially define an air chamber. In operation, diaphragm motor 64 powers movement of first diaphragm assembly 68 and second diaphragm assembly 70 to oscillate air within the air chamber, which is detailed below.
[0099] [0099]FIG. 13 is a front view of air chamber shell 66 . Air chamber shell 66 , with curvilinear walls 66 a and 66 b , is comprised of first portion 74 , second portion 76 , top joint 78 , bottom joint 80 , first diaphragm opening 82 (not shown) and second diaphragm opening 84 . First portion 74 further includes air ports 58 and blower inlet 86 . Second portion 76 further includes motor mount 90 and motor opening 92 .
[0100] First portion 74 and second portion 76 are secured together along top joint 78 and bottom joint 80 to form air chamber shell 66 . Formation of air chamber shell 66 also defines first diaphragm opening 82 and second diaphragm opening 84 on either side of air chamber shell 66 . First diaphragm assembly 68 and second diaphragm assembly 70 (FIG. 11) are positioned over first diaphragm opening 82 and second diaphragm opening 84 , respectively, and are substantially parallel to each other.
[0101] Preferably, first portion 74 is comprised of plastic and second portion 76 is comprised of metal. The plastic reduces the weight of air pulse generator 16 , while the metal dissipates heat from diaphragm motor 64 to prevent overheating.
[0102] Air ports 58 discharge air from the air chamber of air chamber assembly 56 and fluidly connect with air openings 30 of shell 18 , such as by physically aligning with air openings 30 via seal 62 . Blower inlet 86 fluidly connects with the discharge of blower 52 , such as with a pipe or tube 54 (FIG. 11) to transfer air pressure to the air chamber.
[0103] Air chamber shell 66 has at least one of curvilinear walls 66 a and 66 b . Curvilinear walls 66 a and 66 b smooth the air flow movement between diaphragm openings 82 and 84 . Curvilinear walls 66 a and 66 b have a substantially parabolic shape, but other curvilinear shapes, such as more circular curvilinear shapes, also smooth the air flow movement. The smoothed air flow movement reduces noise and vibration over prior art air pulse generators.
[0104] Within second portion 76 , diaphragm motor 64 is mounted to motor mount 88 . Diaphragm motor 64 fluidly seals motor opening 90 to further define the air chamber within air chamber assembly 56 .
[0105] [0105]FIG. 14 shows the crankshaft assembly within air pulse module 44 . Air pulse module 44 includes crankshaft assembly 92 , first diaphragm assembly 68 and second diaphragm assembly 70 . When in use, crankshaft assembly 92 operates, as described below in reference to FIG. 15, to move first diaphragm assembly 68 and second diaphragm assembly 70 in a manner that oscillates air within the air chamber.
[0106] [0106]FIG. 15 is an exploded view of crankshaft assembly 92 . FIG. 15 shows crankshaft assembly 92 , diaphragm motor 64 with drive shaft 96 , air chamber shell 66 , plates 68 a and 70 a and line of motion 108 . Crankshaft assembly 92 further includes flywheel 94 having opening 94 a centered on one face and opening 94 b off-set on the opposite face, c-ring 97 , stub shaft 98 , member 100 having bearing 100 a and opening 100 b, c -ring 101 , cam 102 having openings 102 a and 102 b, c -ring 103 , member 106 having bearing 106 a and opening 106 b , stub shaft 104 and c-ring 105 .
[0107] Drive shaft 96 is attached to diaphragm motor 64 at one end and attached at the other end to opening 94 a of flywheel 94 . Stub shaft 98 is attached to flywheel 94 at opening 94 b . C-ring 97 secures stub shaft 98 within opening 94 b . Bearing 100 a is set within one end of member 100 allowing stub shaft 98 to pass through opening 100 b . Bearing 100 a allows stub shaft 98 to rotate within member 100 . C-ring 101 secures stub shaft 98 within opening 10 b . Stub shaft 98 is secured off-center through opening 102 a of cam 102 by c-ring 101 . Stub shaft 104 is secured off-center through opening 102 b to the opposite face of cam 102 by c-ring 103 such that stub shafts 98 and 104 are positioned equally but oppositely spaced from the center of cam 102 . Bearing 106 b is set within one end of member 106 allowing stub shaft 104 to pass through opening 106 a . Stub shaft 104 is secured to member 106 by c-ring 105 but is able to rotate within member 106 . Member 100 is rigidly or integrally attached to plate 70 a at an end opposite of bearing 100 a , and member 106 is similarly rigidly or integrally attached to plate 68 a at an end opposite of bearing 106 b.
[0108] In operation, diaphragm motor 64 turns drive shaft 96 which, in turn, rotates flywheel 94 causing stub shaft 98 to rotate in a circular fashion. The rotary motion generated by stub shaft 98 is converted to a generally reciprocating motion, shown by line of motion 108 , via member 100 . The reciprocating motion of member 100 in turn reciprocates plate 70 a generally along line of motion 108 .
[0109] The rotary motion of stub shaft 98 is transferred to cam 102 causing cam 102 to rotate, and, in turn, stub shaft 104 rotates in an identical circular fashion. The rotary motion generated by stub shaft 104 is converted to a generally reciprocating motion, shown by line of motion 108 , via member 106 . The reciprocating motion of member 106 in turn reciprocates plate 68 a generally along line of motion 108 .
[0110] The generally reciprocating motion exhibited by members 100 and 106 is more precisely defined as elliptical motion. The elliptical motion is transferred to plates 68 a and 70 a such that plates 68 a and 70 a “wobble” relative to line of motion 108 . When first diaphragm assembly 68 and second diaphragm assembly 70 are fully assembled, such as shown in FIG. 14, the flexible nature of diaphragm seals 68 b and 70 b allow plates 68 a and 70 a to tip inwardly and outwardly as they reciprocate in and out of diaphragm openings 82 and 84 , respectively, relative to air chamber shell 66 . In addition, crankshaft assembly 92 operates such that plates 68 a and 70 a reciprocate in opposite directions relative to each other. The reciprocating motion of plates 68 a and 70 a create the oscillatory air pressure component for delivering HFCWO to patient P.
[0111] Using a pair of reciprocating diaphragms or plates 68 a and 70 a helps to balance the vibration forces that are created by air pulse generator 16 . The use of more than one diaphragm assembly would appear to add size and weight. However, adding a second diaphragm assembly in combination with improved motor control, as discussed above, results in a net weight savings. The reduction in vibration forces due to the balancing nature of opposed reciprocating diaphragm assemblies 68 and 70 allows for a reduced flywheel resulting in significant weight savings. Balanced motions allow for reduced peaks and variations in force which produce less noise and vibration and allow lighter and smaller mechanical components.
[0112] The air chamber defined by air chamber shell 66 , first diaphragm assembly 68 , second diaphragm assembly 70 and diaphragm motor 64 has a volume of about 130 in. 3 and an effective diaphragm area of about 56 in. 2 . The effective diaphragm area is defined as the sum of the area of diaphragm openings 82 and 84 . In comparison, THE VEST™ system has an effective diaphragm area of about 78 in. 2 and an air chamber volume of about 39 in. 3 , and the Medpulse 2000™ system has an effective diaphragm area of about 144 in. 2 and an air chamber volume of about 182 in. 3 .
[0113] The air chamber of air pulse generator 16 has a VA ratio of about 2.32. The VA ratio is defined as the air chamber volume divided by the effective diaphragm area. In comparison, THE VEST™ system has a VA ratio of about 0.5, and the Medpulse 2000™ system has a VA ratio of about 1.26.
[0114] Plates 68 a and 70 a reciprocate with a stroke length of about 0.5 in. In comparison, THE VEST™ system has a stroke length of about 0.375 in., and the Medpulse 2000™ system has a stroke length of about 0.312 in.
[0115] [0115]FIG. 16 shows main control board 60 having heatsink 129 . In the one embodiment, air pulse generator 16 includes heatsink 129 for dissipating internal heat from main control board 60 . Heatsink 129 is made of metal and absorbs and dissipates heat from circuitry (FIG. 17) on the opposite side of main control board 60 .
[0116] Alternatively, air from blower 52 may be diverted to cool main control board 60 . However, the efficiency of blower 52 is compromised with this embodiment.
[0117] [0117]FIG. 17 shows the electronic circuitry of main control board 60 in more detail. Main control board 60 includes AC/DC Power module M 1 , Switching Power Supply inductor L 1 , Switching Power Supply capacitors C 3 and C 4 , Diaphragm Output Voltage capacitor C 13 , Blower Output Voltage capacitor C 14 , AC Power input J 1 , Diaphragm Motor connector J 3 , Blower Motor connector J 2 and User Interface connector J 4 .
[0118] The input power electrical system allows air pulse generator 16 to operate within specifications when the mains voltage is about 100-265 VAC, and the mains frequency is about 50 or 60 Hz+/−1 Hz. Air pulse generator 16 requires 3 Amps maximum. The rated running current is 2.5 Amps at 120 VAC or 0.25 Amps at 240 VAC. Typical idle current (plugged in but not running) is 30 mAmps at 120 VAC or 15 mAmps at 240 VAC. Ground Leakage current does not exceed 300 μAmps. The rated operating power is 300 watts, and the idle power is less than 4 watts.
[0119] The input power electrical system is designed to accommodate power irregularities as listed by UL 2601/EN 60601. In addition, it provides the required filtering for air pulse generator 16 to meet the requirements of EN 55011 (CISPR 11 ) Class B. The power inlet module provides filtering and fuse protection of both line and neutral, meeting the requirements of UL 2601/EN 60601.
[0120] Connection to AC mains is supplied by a 6 ft. long minimum detachable power cord meeting the appropriate agency approvals including UL 2601/EN 60601. Power cords in the United States are “Hospital Grade” power cords.
[0121] The internal circuitry, described in more detail below, utilizes the mains AC input voltage and converts it to DC power for use by the various components. The internal power supply circuitry produces 5 VDC+/−3%, 12 VDC+/−3%, 18 VDC and 80 VDC. The 18 and 80 volt supplies are variable voltages (and, therefore, have no tolerance rating) that are microprocessor controlled to provide the correct blower and diaphragm motor speeds. The low voltage 5 and 12 volt supplies are for the display and control logic, microprocessor and related circuitry. The 5 and 12 volt supplies have a relatively small current requirement and are designed to be on when air pulse generator 16 is plugged in.
[0122] Switching Power Supply inductor L 1 generates the required current to produce a of 6 VDC to 18 VDC for brushless blower motor 50 . The maximum current draw is 4 Amps. This variable voltage is controlled by a feedback loop comprised of microprocessor based Switching Power Supply, motor voltage comparater, motor controller and Hall Effect motor sensor speed.
[0123] Switching Power Supply inductor L 1 generates the required current to produce a voltage of 15 VDC to 80 VDC for diaphragm motor 64 . The maximum current draw is 2 amps. This variable voltage is controlled by a feedback loop comprised of microprocessor based Switching Power Supply, motor voltage comparater, motor controller and Hall Effect motor sensor speed.
[0124] The backlight of display panel 110 requires 5 VDC at 500 mAmps. This circuitry is on only when air pulse generator 16 is plugged in and not in IDLE mode.
[0125] Air pulse generator 16 is controlled through user interface 28 using a combination of software and hardware. Patient P controls air pulse generator 16 via buttons 114 - 128 as described above. The status, settings and user messages are displayed on display panel 110 .
[0126] [0126]FIG. 18 is a block diagram showing a control system of air pulse generator 16 . The control system includes User Interface control 200 , Power Supply control 202 , Diagram Motor control 204 , Blower Motor control 206 , Real Time clock 208 , FLASH memory 210 , and external port 212 . User Interface control 200 monitors inputs from buttons 114 - 128 and from control switch 34 and provides outputs to control the operation of display panel 110 of user interface 28 . In addition, User Interface control 200 coordinates the operation of Power Supply control 202 , Diaphragm Motor control 204 , and Blower Motor control 206 .
[0127] User Interface control 200 provides a diaphragm power request signal and a blower power request signal to Power Supply control 202 . The power request signals are analog signals which represent a desired motor drive voltage to be supplied to diaphragm motor 64 and blower motor 50 , respectively.
[0128] User Interface control 200 receives a Hall-A signal from one Hall sensor of blower motor 50 and a composite Hall pulse train from Diaphragm Motor control 204 . The Hall-A signal is used by User Interface control 200 to monitor the speed of blower motor 50 . The composite Hall pulse train, which provides pulses for each signal transition of each of three Hall sensors of diaphragm motor 64 allows User Interface control 200 to monitor instantaneous speed of diaphragm motor 64 . The composite Hall pulse train allows User Interface control 200 to monitor diaphragm instantaneous speed for every 12 degrees of rotation of diaphragm motor 64 . Since diaphragm motor 64 is rotating at a relatively low speed (up to about 20 cycles per second maximum) and is subjected to uneven loads during each cycle, there is a need for monitoring instantaneous speed of diaphragm motor 64 closely in order to insure stable operation.
[0129] Based upon the desired operating parameters which have been set by patient P through buttons 114 - 128 and the sensed motor speeds provided by the composite Hall pulse train from Diaphragm Motor control 204 and the Hall-A sensor signal from blower motor 64 , User Interface control 200 controls the rate of diaphragm power requests and the blower power requests supplied to Power Supply control 202 . This can be accomplished by direct UIC 200 control or by the UIC 200 producing a refernce voltage to the motor voltage comparater.
[0130] User Interface control 200 also receives a diaphragm pressure signal from a pressure sensor connected to the air chamber. The pressure signal is used as described above to derive a relationship between air chamber and vest pressure.
[0131] Power Supply control 202 , Diaphragm Motor control 204 , and Blower Motor control 206 are located on main control board 60 shown in FIG. 17. User Interface control 200 , Real Time clock 208 and FLASH memory 210 are located on secondary control board 29 shown in FIG. 9.
[0132] Under normal operation, the software monitors requests from user interface 28 and control switch 34 and generates the appropriate electrical signals that operate air pulse generator 16 at the user specified parameters. In addition, the software maintains a timer to allow reporting of therapy session time and total usage time.
[0133] Control switch 34 is an input method to activate pulsing of air, alternatively ON switch 114 may be used to activate pulsing of air. The software provides user control to operate air pulse generator 16 in the various modes described above. Pausing during a therapy session to cough, remove mucus or take medication is controlled by the software via control switch 34 . Lack of input by patient P while air pulse generator 16 is paused causes the software to begin IDLE mode.
[0134] The software also operates a timer that provides the user information about the current therapy session. The remaining session time is displayed on display panel 110 . Session time consists of either both pulsing and paused time or just pause time, and the time is displayed in minutes (e.g. 17 Minutes To Go).
[0135] The software additionally operates another timer that provides cumulative operating hours. Compliance information is displayed on display panel 110 each time air pulse generator 16 is plugged in and in IDLE mode. Cumulative operating time includes both pulsing and paused time, and the time is displayed in hours and tenths of hours (e.g. Total Use 635.6 Hours).
[0136] An I/O data port is available for interfacing to air pulse generator 16 through user interface 28 . The interface is an I/O data port serial protocol accessible via a special adapter designed to connect to the main board via a stereo jack style plug. All microprocessors are selected such that they have the 110 data port bus inherent in their design. The I/O data port bus master is the User Interface control (UIC) 200 and the slaves are the Power Supply control (PSC) 202 , the Blower Motor control (BMC) 206 and the Diaphragm Motor control (DMC) 204 . See FIG. 18.
[0137] The I/O data port allows the following functionality: A) user compliance information, specifically, a time and date stamp (cumulative operating time), is stored in memory for reading via user interface 28 or the I/O data port. Air pulse generator 16 contains memory capable of storing six months of cumulative operating time. Once the memory is full, storage of new information will overwrite the oldest data and maintain the most recent information.
[0138] B) Operating parameters are loaded in the microcontroller memory. Downloading the functional parameters (frequency, pressure and time) via this port is available to automate manufacturing final test and checkout.
[0139] C) Operational states and failures of air pulse generator 16 are transferred to user interface 28 or to the I/O data port for troubleshooting or customer feedback.
[0140] D) Software upgrades may be transferred to the microcontroller via the I/O data port.
[0141] The software is written in a Microchip PIC compatible version of the C programming language and may contain some assembly language. Executable code is generated by the HI-TECH C compiler specifically designed for the Microchip PIC controller family. The code is tested utilizing the MPLAB simulator from Micrchip, a proto-type version of hardware, and a PIC-ICE (in-circuit emulator) from Phyton.
[0142] Air pulse generator 16 uses Microchip microcontrollers (or microprocessors) running with an oscillator speed of 8 MHz minimum to host the required software. These microcontrollers are selected based on the required functionality while allowing for future development. PSC 202 , BMC 206 , DMC 204 and UIC 200 are four microprocessor controllers used.
[0143] PSC 202 software delays startup for ⅓ second to allow charging of capacitors, receives requests from the DMC 204 and the BMC 206 , controls the switching of the power supply capacitors and selects the appropriate switch for the output.
[0144] BMC 206 software controls commutation for blower motor 50 , receives blower motor 50 .
[0145] DMC 204 software controls commutation for diaphragm motor 64 , and sense motor speed information such as the composite Hall pulse train to the UIC 200 .
[0146] UIC 200 software manages display panel 110 , reads button presses, times the session and stops air pulse generator 16 when finished, maintains cumulative operating time, sends pressure and frequency requests to the DMC 204 and BMC 206 , writes parameters to FLASH memory 210 (using I/O data port), reads default parameter/messages from on board memory on the UIC 200 or from FLASH memory 210 (using I/O data port), reads messages/commands from an external port (using I/O data port), reads/writes Real Time Clock 208 (using I/O data port) and analyzes diaphragm pressure measurement.
[0147] External memory, such as FLASH memory 210 or on chip memory such as on UIC 200 stores patient use information, default parameter limits and display messages. All program instructions and variables are contained in the microcontroller on chip memory.
[0148] [0148]FIG. 19 is an electrical schematic diagram of AC Mains circuit 220 , which is a portion of power supply control 202 . AC Mains circuit includes AC Power Input connector J 1 with terminals J 1 - 1 , J 1 - 2 and J 1 - 3 , Positive Phase Power circuit 222 , Negative Phase Power circuit 224 , AC/DC Converter circuit 226 and Power On circuit 228 .
[0149] AC Mains circuit 220 receives AC line power at connector J 1 and supplies power to drive diaphragm motor 64 and blower motor 50 (+PHASE PWR and −PHASE PWR). In addition, AC Mains circuit 220 produces +5 V and +12 V signals which are used by the circuitry of the control system shown in FIG. 18.
[0150] Positive Phase Power circuit 222 includes resistor R 1 , diodes D 1 and D 2 , capacitors C 1 and C 3 , and fuse F 1 . Circuit 222 stores electrical power from the AC mains line power on capacitor C 1 . Approximately a 170 volt DC voltage is established at the +PHASE power output of circuit 222 .
[0151] Similarly, circuit 224 produces the −PHASE power value based upon the other half cycle of AC power. Circuit 224 includes resistor R 2 , diodes D 3 and D 4 , capacitors C 2 and C 4 , and fuse F 2 . Circuit 224 stores electrical power from the AC mains line power on capacitor C 2 . A voltage of approximately 170 volts DC is established as the −PHASE power signal.
[0152] The +PHASE power and −PHASE power are supplied alternatively based upon the +PHASE signal which is derived from terminal J 1 - 1 of connector J 1 . The +PHASE signal allows switching circuitry of Power Supply control 202 to alternately draw power from the +PHASE power and the −PHASE power in such a way that power is drawn from whichever capacitor is currently not being charged. This provides isolation between the AC line and the remaining circuitry of the control system, without the need for expensive and heavy line noise reduction circuitry.
[0153] The DC voltage levels used by the circuitry of the control system are produced by AC/DC circuit 226 , which includes AC/DC module M 1 and capacitors C 5 and C 6 . Module M 1 is a conventional AC to DC converter.
[0154] Also shown in FIG. 19 is Line Surge protector Z 1 . It is connected between terminals J 1 - 1 and J 1 - 3 of connector J 1 .
[0155] AC Mains circuit 220 also includes Power On circuit 228 which includes resistors R 3 and R 4 , relay K 1 , transistor Q 1 , and diode D 5 .
[0156] Power On circuit 228 utilizes relay K 1 in combination resistor R 3 to provide a ⅓ second delay in startup. This allows capacitors C 1 and C 2 to precharge. Allowing ⅓ second for startup delay and 5 RC time constants for capacitors to fully charge, the resistance of resistor R 3 is calculated as follows:
R =(0.33)/(5×560 μF)
R= 118 Ohms(use 100 Ohms)
[0157] Choosing 100 Ohms limits I rms to 2.65 A (at V rms =265 volts). 560μF capacitors were sized for +/−PHASE power to stay above 100V with ripple at I max (which occurs at V min ). At 100 VAC in , VDC max =140volts. If VDC min 100 VDC, then VDC avg =120 VDC. With 300 watts max power, I c3/c4 =300 watts/120 volts=2.5 amps. Each capacitor will be discharging for ½ an AC cycle (60 Hz) or 8.3 msec. The size of the capacitor required is calculated as follows: C=i(t)/V=(2.5)(0.0083)/40=519μF (V=Vmax−Vmin=140−100=40). Diode D 5 protects transistor Q 1 from flyback current induced from relay K 1 .
[0158] [0158]FIG. 20 shows Switching Power Supply circuitry 230 , which uses the +PHASE power and −PHASE power received from AC Mains circuit 220 to produce variable voltages used to control the speed of diaphragm motor 64 and blower motor 50 . Switching Power Supply circuitry 230 reduces electrical noise and allows several dynamically variable voltages to be produced by a single switching structure. The variable voltage used to control diaphragm motor 64 is labeled DIAPH_PWR, and the variable voltage used to control blower motor 50 is labeled BLOWER_PWR.
[0159] Switching Power Supply circuit 230 includes +PHASE Switching circuit 232 , −PHASE Switching circuit 234 , Switching Power Supply inductor L 1 , Phase Detection Input circuit 236 , microprocessor IC 8 , Diaphragm Power Storage capacitor C 13 , Blower Power Storage capacitor C 14 , Diaphragm Power Charging circuit 238 , Blower Power Charging circuit 240 , Voltage Fault Sensing circuit 242 , 5V/12V convertors M 2 , M 3 , and M 4 , and crystal oscillator X 1 .
[0160] Switching circuits 232 and 234 produce 10 Amp pulses which are supplied through inductor L 1 . When the +PHASE signal received by Phase Detection Input circuit 236 indicates that the −PHASE capacitors are being charged, circuit 232 supplies the to amp pulses. Conversely, when the +PHASE signal supplied from circuit 236 to the RAO input of microprocessor ICS indicates that the +PHASE power storage capacitors are being charged, microprocessor IC 8 activates circuit 234 to supply the current pulses using the −PHASE power. In this way, current is drawn from the +PHASE and −PHASE storage capacitors only during the times when they are not being charged. +Phase Switching circuit 232 includes diode D 6 , transistor Q 2 , Current Sensing driver IC 3 , resistors R 5 and R 111 , capacitors C 40 and C 8 and Current Sensing resistor R 7 .
[0161] The +PHASE power is supplied through diode D 6 to transistor Q 2 . IC 3 is a high voltage, high speed power driver which supplies a control plus to a gate of Q 2 to allow current from +PHASE power to flow through diode D 6 , transistor Q 2 and Sensing resistor R 7 to inductor L 1 . Microprocessor IC 8 activates IC 3 based upon the +PHASE sense signal by supplying an input signal to the input terminal IN of IC 3 . Q 2 is turned on by IC 3 for a time duration to produce a 10 amp pulse. IC 3 senses the current through Sensing resistor R 7 to control the current pulses.
[0162] −Phase Switching circuit 234 is similar to +Phase Switching circuit 232 . It includes diode D 7 , transistor Q 3 , Current Sensing driver IC 4 , resistors R 6 and R 112 , capacitor C 41 , and Current Sensing resistor R 8 .
[0163] When IC 4 is turned on by microprocessor IC 8 , it switches transistor Q 3 on and off to produce 10 amp pulses, which are sensed by IC 4 using Sensing resistor R 8 . The 10 amp pulses are supplied through R 8 to inductor L 1 .
[0164] Phase Detection Input circuit 236 includes resistors R 9 and R 10 , capacitor C 100 and diodes D 101 and D 102 . The +PHASE signal is received from AC Mains circuit 220 and is supplied to the RAO input of microprocessor ICS.
[0165] Microprocessor IC 8 controls the charging of capacitor C 13 by Charging circuit 238 depending upon whether the diaphragm power request, DIAPH_PWR_REQ, signal at input RB 4 is high or low. If the signal is high, circuit 238 is activated so that current pulses supplied through inductor L 1 are used to charge capacitor C 13 .
[0166] Similarly, charging of capacitor C 14 is controlled by microcontroller IC 8 through Charging circuit 238 as a function of the BLOWER_PWR_REQ signal input at RB 5 . When circuit 240 is activated, current from inductor L 1 is supplied to capacitor C 14 to increase the BLOWER_PWR voltage.
[0167] Diaphragm Power Charging circuit 238 includes resistor R 1 , Optoisolator driver IC 6 , diode D 8 , resistors R 13 and R 14 , and transistor Q 4 . When the output of IC 8 at RBO goes high, IC 6 is activated to turn on transistor Q 4 . That allows current pulses from L 1 to pass through Q 4 and charge Diaphragm Power Storage capacitor C 13 . As the pulses are received, the voltage on capacitor C 13 will tend to increase. When the diaphragm power request signal supplied to IC 8 goes low, circuit 238 turns off and charging of capacitor C 13 ceases.
[0168] Blower Power Charging circuit 240 is similar to Diaphragm Power Charging circuit 238 . It includes resistor R 12 , optoisolator driver IC 7 , diode D 9 , resistors R 15 and R 16 , and transistor Q 5 . Microprocessor IC 8 turns on IC 7 and Q 5 in response to the BLOWER_PWR_REQ signal being high. As long as that signal stays high, transistor Q 5 is turned on and current pulses from L 1 are used to charge capacitor C 14 .
[0169] Voltage Fault Sensing circuit 242 senses over voltage conditions on either capacitor C 13 or C 14 . Voltage Fault Sensing circuit 242 includes zener diodes D 13 and Dl 4 , resistors R 17 , R 18 , and R 19 , capacitor C 15 , and transistor Q 29 . The output of circuit 242 is a /V fault signal which is high as long as the voltage on C 13 does not exceed the break down voltage of zener diode D 13 , or the lower power voltage on capacitor C 14 does not exceed the break down voltage of zener diode D 14 .
[0170] [0170]FIG. 21 shows additional components of the Power Supply control 202 .
[0171] Power Up Clear & Fault Reset circuit 250 provides a fault reset signal to microprocessor IC 8 during power up conditions and in the event of a fault. Circuit 250 includes diode D 28 , resistors R 53 , R 54 , R 55 , and R 56 , capacitor C 22 , transistor Q 30 , and gates U 15 -Ul 8 and power on Reset Pulse generator U 19 . The two fault conditions sensed by circuit 250 based upon the L 1 _LOW_SIDE signal drive from the low voltage side of inductor L 1 (see FIG. 20) and the /V FAULT signal produced by circuit 242 of FIG. 20.
[0172] Also shown in FIG. 21 is connector J 4 , which provides electrical connections between User Interface control 200 and Power Supply control 202 , Diaphragm Motor control 204 and Blower Motor control 206 . User Interface control 200 is on a separate circuit board, such as secondary control board 29 , from controls 202 , 204 , and 206 , which may be located on main control board 60 . FIG. 21 also shows Diaphragm Power Comparater circuit 252 and Blower Power Comparater circuit 254 .
[0173] As shown in FIG. 21, circuit 252 includes resistors R 61 -R 64 , R 67 , and R 68 and comparator U 21 . Diaphragm Power Comparator circuit 252 produces the DIAPH_PWR_REQ input to microprocessor IC 8 as a function of a DIAPHRAGM_PWR_REQ voltage supplied by User Interface control 200 through connector J 4 , and the DIAPH_PWR voltage stored on capacitor C 13 .
[0174] User Interface control 200 generates the DIAPHRAGM_PWR_REQ signal as a function of the desired oscillation frequency set by patient P (or automatically determined) and the sensed diaphragm motor speed based upon the composite Hall pulse train. The DIAPHRAGM_PWR_REQ signal is a speed command voltage which is compared to the stored voltage DIAP_PWR on capacitor C 13 . As long as DIAPH_PWR is less then the DIAPHRAGM_PWR_REQ level, the output DIAPH_PWR_REQ is high. As long as that signal is high, microprocessor IC 8 turns Charging circuit 238 on to allow current pulses to be supplied to capacitor C 13 . When DIAPH_PWR exceeds the speed command signal DIAPHRAGM_PWR_REQ, the output of circuit 252 goes low, which causes microprocessor ICS to turn off Charging circuit 238 .
[0175] Blower Power Comparator circuit 254 is generally similar to Diaphragm Power comparator 252 . It includes resistors R 57 -R 60 , R 65 , and R 66 and comparator U 20 .
[0176] The speed command signal for blower motor 50 is BLOWER_REQ which is produced by User Interface control 200 as a function of the bias line pressure setting selected by patient P and the blower speeds as indicated by the Hall-A feed back signal from blower motor 50 . That speed command signal is compared to the voltage on capacitor C 14 , BLOWER_PWR. As long as BLOWER_PWR is less than the BLOWER_REQ command, the output of circuit 242 , BLOWER_PWR_REQ is high. That causes microprocessor IC 8 to turn on Charging circuit 240 to charge capacitor C 14 . When the command voltage BLOWER_REQ is reached or exceeded by BLOWER_PWR, the output of Comparator circuit 254 goes low, which causes microprocessor ICS to turn off Charging circuit 240 .
[0177] [0177]FIG. 22 shows Diaphragm Motor control 204 , which includes microprocessor IC 10 , crystal oscillator X 3 , connector J 3 (which includes terminals J 3 - 1 through J 3 - 8 ), Phase A Drive circuit 250 A, Phase B Drive circuit 250 B, and Phase C Drive circuit 250 C, and Hall Effect Sensor Interface circuit 260 .
[0178] Diaphragm Motor control 204 receives the variable voltage DIAPH_PWR from Power Supply control 202 . That variable voltage has supplied each of the three Phase Drive circuits 250 A, 250 B, 250 C. Microprocessor IC 10 acts as a sequencer or commutator to selectively turn on and off transistors of Drive circuits 250 A, 250 B, and 250 C to cause rotation of diaphragm motor 64 . The commutation is based upon on the Hall Effect sensor signals S A , S B and S C which are received from the three Hall Effect sensors of the BC diaphragm motor. The Hall Effect sensor signals are supplied through terminals J 3 - 6 through J 3 - 8 to inputs of microprocessor IC 10
[0179] In addition, microprocessor IC 10 supplies the HALL_TRANSITION signal which is the composite Hall pulse train supplied to User Interface control 200 , so that User Interface control 200 can determine the speed of diaphragm motor 64 .
[0180] Drive circuit 250 A is controlled by RB 1 and RB 2 outputs of microprocessor IC 10 . It includes resistors R 39 , R 42 , R 45 and R 48 , diodes D 22 and D 25 , capacitor C 19 , ferrite chip L 10 , transistor Q 22 , and Power Switching transistors Q 16 and Q 17 .
[0181] Phase B Drive circuit 250 B is controlled by RB 4 and RB 5 outputs of microprocessor IC 10 . It includes resistors R 40 , R 43 , R 46 , and R 49 , diodes D 23 and D 26 , capacitor C 20 , ferrite chip L 11 , transistor Q 23 and Power Switching transistors Q 18 and Q 19 .
[0182] Similarly, Phase C Drive circuit 250 C is controlled by RB 6 and RB 7 outputs of microprocessor IC 10 . It includes resistors R 41 , R 44 , R 47 , and R 50 , diodes D 24 and D 27 , capacitor C 21 , ferrite chip L 12 , transistor Q 24 , and Power Switching transistors Q 20 and Q 21 .
[0183] Hall Effect Sensor Interface circuit 260 includes ferrite chips L 13 -L 17 and Pull Up resistors R 106 -R 108 .
[0184] [0184]FIG. 23 is a schematic diagram of Blower Motor control 206 . It includes microprocessor IC 9 , Phase A Drive circuit 270 A, Phase B Drive circuit 270 B, and Phase C Drive circuit 270 C, and Hall Effect Sensor Interface circuit 280 and crystal oscillator X 2 .
[0185] Microprocessor IC 9 controls Phase A, B, and C Drive circuits 270 A- 270 C as a sequencer or commutator based upon the Hall Effect sensor signals SA, SB and S C . Drive circuits 270 A- 270 C selectively supply the variable voltage BLOWER-PWR through the phase A, phase B, and phase C windings of blower motor 50 . The operation of Blower Motor control 206 is similar to that of Diaphragm Motor control 204 with one exception. Because blower motor 50 runs at a much higher speed than diaphragm motor 64 , a single Hall Effect sensor signal Blower_Hall_A can be supplied to User Interface control 202 as the speed feedback signal.
[0186] Drive circuit 270 A is controlled by RB 1 and RB 2 outputs of microprocessor IC 9 . Drive circuit 270 A includes resistors R 27 , R 30 , R 33 and RR 36 , diodes D 16 and D 19 , capacitor C 16 , ferrite chip L 2 , transistor Q 13 and Power Switching resistors Q 7 A and Q 7 B.
[0187] Drive circuit 270 B is controlled by RB 4 and RB 5 outputs of microprocessor IC 9 . Drive circuit 270 B includes resistors R 28 , R 31 , R 34 and R 37 , diodes D 17 and D 20 , capacitor C 17 , ferrite chip L 3 , transistor Q 14 and Power Switching transistors Q 9 A and Q 9 B.
[0188] Similarly, Phase C Drive circuit 270 C is controlled by RB 6 and RB 7 outputs of microprocessor IC 9 . It includes resistors R 29 , R 32 , R 35 , and R 38 , diodes D 18 and D 21 , capacitor C 18 , ferrite chip L 4 , transistor Q 15 , and Power Switching transistors Q 11 A and Q 11 B.
[0189] FIGS. 24 - 28 are graphs illustrating the performance of air pulse generator 16 with and without internal heat dissipation compared to prior art air pulse generators. A prior art air pulse generator, 103 ; air pulse generator 16 with air from blower 52 diverted to cool main control board 60 , 104 cool; and air pulse generator 16 without diversion of air from blower 52 , 104 were performance tested at 5 Hz, 10 Hz, 15 Hz and 20 Hz. The testing consists of measuring pressure inside a vest's air reserve (bladder) with a Viatron pressure transducer attached to the vest's connector port, and the output of the transducer is connected to an oscilloscope. A vest is connected to each of the air pulse generators and the observed pulse maximum (PMAX) and pulse minimum (PMIN) are recorded at each frequency, with the exception that 104 cool was not tested at 5 Hz. The delta, or pressure stroke, is calculated by subtracting the PMIN from PMAX.
[0190] [0190]FIG. 24 shows the results using an adult large vest, FIG. 25 is the results using an adult medium vest, FIG. 26 is the results using an adult small vest, FIG. 27 is the results using a child large vest and FIG. 28 is the results using a child medium vest. As depicted in each of the graphs, 104 and 104 cool exhibit pressure consistent with the prior art air pulse generator.
[0191] Although the present invention has been described with reference to preferred embodiments, workers 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. | An improved method of producing high frequency chest wall oscillations (HFCWO) includes generating oscillating pneumatic pressure and applying an oscillating force to a patient's chest that corresponds to the oscillating pneumatic pressure. The frequency of oscillations changes according to a prescribed treatment regimen. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/958,077, filed Oct. 4, 2004, now U.S. Pat. No. 7,606,230, which claims the benefit of U.S. Provisional Patent Application No. 60/569,728, filed May 10, 2004, the disclosures thereof incorporated by reference herein in their entirety.
BACKGROUND
The present invention relates generally to network communications. More particularly, the present invention relates to link aggregation in a network device.
The growing popularity of high-speed data communications has led to an increasing demand for high-bandwidth data channels that exceed the bandwidth of existing communication links. A solution that has enjoyed widespread acceptance is link aggregation, often referred to as “layer-2 trunking” or “trunking.”
Link aggregation is a method of combining multiple physical data communication links to form a single logical link, thereby increasing the capacity and availability of the communication channels between network devices such as servers, switches, end stations, and other network-enabled devices. For example, two or more Gigabit Ethernet or Fast Ethernet connections between two network devices can be combined to increase bandwidth capability and to create resilient and redundant links.
Link aggregation also provides load balancing, which is especially important for networks where it is difficult to predict the volume of data directed to each network device. Link aggregation distributes processing and communications activity evenly across a network so that no single network device is overwhelmed.
Link aggregation is documented in the Institute of Electrical and Electronics Engineers (IEEE) standard 802.3ad, which is incorporated by reference herein in its entirety.
However, conventional network devices employ silicon mechanisms to provide link aggregation, and so are limited in the number of trunks they can provide. Furthermore, many conventional network devices do not permit link aggregation at all.
SUMMARY
In general, in one aspect, the invention features a wireless network apparatus and corresponding method and computer program. It comprises a plurality of ports to transmit and receive data flows comprising packets of data; a memory to store a routing table; a forwarding engine to transfer the packets of data between the ports according to the routing table; and a processor to define a routing interface comprising a selected group of the ports, map a selected media access control (MAC) address to the routing interface, disable link aggregation between the ports in the routing interface, disable bridging between the ports in the routing interface, and modify the routing table to direct each of the data flows having the MAC address as a destination address to one of the ports in the routing interface.
Particular implementations can include one or more of the following features. The processor modifies the routing table entries for the ports in the routing interface to provide load balancing among the ports in the routing interface. The load balancing is based on Equal Cost Multi-Path Routing Protocol (ECMP). To define a routing interface, the processor allocates a virtual local-area network (ULAN) to the selected group of the ports. A multi-layer switch comprises the network device.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 shows a multi-layer switch in communication with a server over network links according to a preferred embodiment.
FIG. 2 shows a process for the multi-layer switch of FIG. 1 to establish a routed trunk with the server of FIG. 1 according to a preferred embodiment.
The leading digit(s) of each reference numeral used in this specification indicates the number of the drawing in which the reference numeral first appears.
DETAILED DESCRIPTION
Embodiments of the present invention employ routing techniques, for example in a multi-layer switch, to implement link aggregation without using conventional layer-2 link aggregation techniques, thereby creating what are referred to herein as “routed trunks.” A significant advantage of these routed trunks is that the number of routed trunks a switch can employ is not restricted by any link aggregation limit of the switch. Large numbers of routed trunks are especially useful when communicating with a large number of servers, which often requires a number of trunks that exceeds the link aggregation limit of conventional switches.
Network devices employing the routed trunks of the present invention are compatible with existing networks such as the Internet. The techniques disclosed herein are internal to the device employing them, and are transparent to other devices which can, but need not, employ those techniques. Thus embodiments of the present invention have broad applicability.
FIG. 1 shows a multi-layer switch 100 in communication with a network device 112 such as a server over network links 102 according to a preferred embodiment. A multi-layer switch is a switch that combines aspects of data link layer switches and network-layer switches, as is well-known in the relevant arts. But although embodiments of the present invention are described with respect to a multilayer switch, these embodiments are applicable to other sorts of network devices such as routers and the like. In addition, although embodiments of the present invention are described as establishing routed trunks with a server, these embodiments are equally applicable in establishing routed trunks with other sorts of network devices such as network switches and the like.
Multi-layer switch 100 comprises a plurality of ports 104 , a forwarding engine 106 , a processor 108 , and a memory 110 . Ports 104 transmit and receive data flows comprising packets of data. A data flow is an ordered set of packets transmitted from one network device to another, as is well-known in the relevant arts. Forwarding engine 106 transfers the packets between ports 104 according to entries in routing tables stored in memory 110 according to techniques well-known in the relevant arts. Processor 108 creates and modifies the routing tables according to other well-known techniques such as learning.
FIG. 2 shows a process 200 for multi-layer switch 100 to establish a routed trunk with server 112 according to a preferred embodiment. First a group 114 of the ports 104 that are in communication with server 112 is selected for routed link aggregation (step 202 ). The group 114 of ports 104 can be selected by the user manually or with the help of some automated process such as the link aggregation control protocol (LACP) documented in the Institute of Electrical and Electronics Engineers (IEEE) standard 802.3ad, which is incorporated by reference herein in its entirety.
Processor 108 then defines a routing interface comprising the selected group 114 of ports 104 according to techniques well-known in the relevant arts (step 204 ). In some embodiments, the routing interface is defined by allocating a virtual local area network (VLAN) to the selected group 114 of ports 104 . VLANs are documented in the Institute of Electrical and Electronics Engineers (IEEE) standard 802.3q, which is incorporated by reference herein in its entirety.
Processor 108 assigns one of the media access control (MAC) addresses belonging to multi-layer switch 100 to the routing interface (step 206 ).
As mentioned above, the routed trunks of the present invention provide the benefits and appearance of conventional link aggregation without employing conventional trunking, thereby permitting more trunks that conventional switches allow. Therefore, to prevent multi-layer switch 100 from employing conventional layer-2 trunking, processor 108 disables layer-2 link aggregation between the ports 104 in the routing interface (step 208 ).
If bridging were enabled between the ports 104 in the selected group 114 , traffic received from server 112 by one port 104 in the group 114 could be sent back to server 112 by one or more of the other ports 104 in the group 114 . To prevent this problem, processor 108 disables bridging between the ports 104 in the routing interface (step 210 ).
As mentioned above, a data flow is an ordered set of packets transmitted from one network device to another. As long as the order of the packets in each data flow is preserved, a network switch can employ any mechanism for trunking. To ensure that the packet order is preserved, processor 108 modifies the routing table to direct each of the data flows having the routing interface's MAC address as a destination address to one of the ports 104 in the routing interface (step 212 ).
Processor 108 optionally modifies the routing table entries in memory 110 for the ports 104 in the routing interface to provide load balancing among the ports 104 in the routing interface. One well-known routing protocol that can be used for load balancing is the Equal Cost Multi-Path Routing Protocol (ECMP), which provides multiple routed paths to an end destination. Again, as long as packet order is preserved within each data flow, any load-balancing technique can be used, while still maintaining compliance with applicable standards such as IEEE standards.
The routed trunk comprising the links between the selected group 114 of ports 104 and server 112 now performs in the same manner as a conventional trunk. Server 112 need not perform routed trunking, and indeed needs no knowledge of the routed trunking. To server 112 , the routed trunk appears the same as a conventional layer-2 trunk. The techniques described above can be used to establish additional routed trunks to server 112 or to other servers. Because these techniques are implemented using layer-3 mechanisms, the maximum number of trunks that multi-layer switch 100 can provide is limited only by the size of the routing table, which can be very large, rather than by the silicon area of switch 100 , as is the case in conventional layer-2 trunking.
The invention can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention can be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention can be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program can be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language can be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory. Generally, a computer will include one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks.
Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits).
A number of implementations of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other implementations are within the scope of the following claims. | A network device includes a plurality of ports configured to transmit and receive packets of data. A memory is configured to store a routing table. A forwarding engine is configured to transfer the packets of data between the plurality of ports based on the routing table. A processor is configured to define a routing interface. The routing interface comprises a group of the plurality of ports. The processor is configured to assign a media access control (MAC) address to the routing interface. The processor is configured to modify the routing table to direct each packet of data having the media access control (MAC) address as a destination address to a port in the routing interface. | 8 |
DESCRIPTION
This is a continuation-in-part of the co-pending application Ser. No. 364,129, filed on Mar. 31, 1982, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to sewing machines and, more particularly, to an optical switching arrangement within a sewing machine.
There are a number of known optical switching arrangements for sewing machines in the prior art. For example, such arrangements are known for signalling a sewing machine operator as to the impending depletion of bobbin thread. This is desirable in order to warn an operator of impending bobbin thread exhaustion which might interfere with the appearance of a long seam. A number of these arrangements utilize a light source and a light detector arranged so that when there is thread on the bobbin the optical path from the light source to the light detector is blocked, this path being opened when the amount of thread remaining on the bobbin is depleted below some threshold value. Upon the occurrence of this latter condition, appropriate circuitry activates an alarm, or indicator, that warns the operator that the amount of thread remaining on the bobbin is below the predetermined threshold. Many of these arrangements have frequently been of limited reliability due to the effect of stray light producing erroneous triggering of the low bobbin thread warning alarm. Most attempts to eliminate the effect of stray light from such sources as room lighting and sewing machine mounted work guiding lights have been limited to enclosing the loop taker cavity in which the light sensitive photo detector resides with an opaque bed slide and spraying the cavity with a flat black paint treatment to reduce internal reflections from reaching the light detector. Other attempts have involved defining a narrow optical path from the light source to the light detector and providing shielding about the lift detector to block all light other than that which emanates from the light source. While these prior arrangements are somewhat effective, they still allow some amount of ambient light to penetrate and they have the further problem that the light level is diminished by the shielding. Further, most of these prior arrangements utilize a relatively expensive subminiature incandescent lamp.
Another application utilizing optical switching in a sewing machine is for buttonholing. In particular, a movable buttonhole foot may carry reflective means, the movement of which is sensed as the foot is moved by the fabric feeding movement of a feed dog against the garment being sewn. Mounted on the sewing head is a light source and light detector, both focused down toward the reflective means. It is apparent that the light detector is exposed to stray ambient light.
It is therefore an object of the present invention to provide an improved optical switching arrangement for a sewing machine.
It is a further object of this invention to provide a low bobbin thread detection and indication system which is both reliable and cost effective.
It is another object of this invention to provide an optical buttonhole switching arrangement for a sewing machine which is both reliable and cost effective.
SUMMARY OF THE INVENTION
The foregoing and additional objects are attained in accordance with the principles of this invention by providing in a sewing machine having a control system, an improved means responsive to the condition of an element for providing a signal to the control system, the condition responsive means including a light source and a light detector. The inventive arrangement includes means for providing a modulation signal, means utilizing the modulation signal for driving the light source, and means utilizing the modulation signal for examining the output of the light detector.
In accordance with an aspect of this invention, the modulation signal providing means includes an oscillator.
In accordance with a further aspect of this invention, the light source includes an infrared light emitting diode.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be more readily apparent upon reading the following description in conjunction with the drawings in which like reference characters in different figures thereof denote like elements and wherein:
FIG. 1 is an enlarged view of a portion of the head end and loop taker of a sewing machine shown partially in section in order to show more detail thereof and in which an embodiment of this invention may be incorporated;
FIG. 2 is a plan view of the loop taker and bobbin area of the sewing machine shown in FIG. 1 indicating the placement of a light detector and box therefor and a light source;
FIG. 3 is a block diagram of circuitry operating in accordance with the principles of this invention;
FIG. 4 is a detailed circuit diagram of a preferred implementation for the system shown in FIG. 3; and
FIG. 5 is a perspective view of a buttonhole presser foot, light source and light detector, which may be utilized in another embodiment of this invention.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 shows a portion of a sewing machine having a bed 12 and a sewing head 18 overhanging the bed 12. The bed 12 is formed with a cavity 13 in which a loop taker 14 is rotatably carried on one extremity of a shaft 15 oriented so as to have a vertical axis. The shaft 15 is driven by bevel gears 20 which are driven in the usual manner by the main sewing machine drive motor (not shown). The loop taker 14 rotates in timed synchronization to the reciprocation of the needle bar 16, the needle 17 carried by the needle bar 16 being driven in endwise reciprocation through a work material supported in the bed 12 for cooperation with the loop taker 14 carried therein in the formation of stitches. A feed dog 19 is visible which is a portion of a feeding system (not shown) for feeding work material under the sewing needle 17 in order to generate a pattern of stitches. The work material is pressed against the feed dog 19 by a presser foot 22 supported on the end of a presser bar 23 which is urged downwardly in a manner well known in the sewing machine art. A throat plate 24 supports the work material and is fashioned with an orifice (not shown) through which the sewing needle 17 may project. The throat plate 24 is further formed with slots 25 through which the feed dog 19 may extend.
The loop taker 14 supports on a race 27 thereof a bobbin case 28. The bobbin case 28 is restrained from rotary motion with the loop taker 14 by a position plate 52 (FIG. 2). The bobbin case 28 is fashioned with a cavity 29 within which is supported a bobbin 30 for the carrying of lower thread for a lockstitch. A further explanation of the loop taker 14, the bobbin case 28 and the bobbin 30 arrangement and how thread may be wound thereupon may be had by reference to U.S. Pat. No. 3,693,566. The teachings of this patent have been modified somewhat by extending the bobbin case 28 above the level of the loop taker 14 in order that bores 32, 33 might extend therethrough roughly tangent the hub 31 of the bobbin 30 (FIG. 2). The purpose of the bores 32, 33 is to allow the passage of light from a light source 35 as focused by a lens 36. The light rays extending from the bore 33 pass through orifices 38 in a mask box 40, which box 40 supports a light detector 42 on an inner wall thereof aligned with the orifices 38 and the bores 32, 33. A printed circuit board 44 is affixed to the bed 12 by means of a screw 45 and the mask box 40 is supported on the printed circuit board 44 with the light detector 42 having electrical connections thereto.
Referring now to FIG. 2, there is shown a plan view of the left side of the bed 12 showing the cavity 13 therein with the throat plate 24 removed and with a bed slide 50 thereof slid back to expose the loop taker 14, the bobbin case 28 and the bobbin 30. There is also visible a portion of the position plate 52 and a position finger 54 which serve to retain the bobbin case 28 in a stationary position against rotation with the loop taker 14 while permitting thread to be cast thereabout.
It will be readily appreciated by one skilled in the art of sewing that it is inconvenient to exhaust the supply of bobbin thread while in the middle of a sewing project. Inasmuch as the bobbin is located within the sewing machine bed 12 over which is draped the garment or fabric being sewn, it will be appreciated that it is difficult to readily observe the quantity of thread remaining on the bobbin while carrying out the sewing process. To the end of alleviating the problems attendant with observing the quantity of bobbin thread, there is provided an indicator, illustratively a light emitting diode 61, preferably mounted on the head 18 of the sewing machine where it is readily visible to an operator, for informing the operator when the amount of thread remaining on the bobbin falls below a predetermined threshold. FIG. 3 is a system block diagram of circuitry for controlling the illumination of the indicator 61 in response to the amount of thread remaining on the bobbin 30. In accordance with the principles of this invention, an infra-red light emitting diode is utilized as the light source 35. The use of such a device provides two distinct advantages. First, it is considerably less expensive than a subminiature incandescent lamp. Second, lint is much less able to block the infra-red radiation than the visible light from an incandescent lamp. The present invention contemplates modulating the emission from the light emitting diode 35 so that this emission can be differentiated from ambient radiation by a frequency sensitive filter. The output from the filter is demodulated to produce a signal showing whether or not the emission from the light emitting diode 35 is interrupted by a sufficient amount of thread remaining wound on the bobbin 30.
In accordance with the principles of this invention, both the modulation and demodulation (detection) functions are performed by a simple phase locked loop circuit 63. Thus, as shown in FIG. 3, the phase locked loop 63 uses the same oscillator circuit 65 for both modulation and demodulation. Accordingly, there is no filter required, per se, since the use of a single oscillator for both modulation and demodulation results in inherently synchronous operation. Thus, the oscillator 65 causes a driver 67 to drive the light emitting diode 35. The light detector 42 provides a current depending upon the amount of radiant energy impinging thereon. This current is changed to a voltage by the current to voltage converter 69, whose output is coupled to the phase locked loop 63. When the phase locked loop 63 receives a sufficient signal from the converter 69 to indicate that the path between the light source 35 and the light detector 42 is clear of bobbin thread, it provides a signal to the indicator 61, to inform the operator of the impending depletion of bobbin thread.
Referring now to FIG. 4, shown therein is a preferred implementation of the system depicted in block diagram form in FIG. 3. The function of the phase locked loop 63 is preferably performed by a single integrated circuit chip, illustratively a type LM567/LM567C Tone Decoder manufactured by National Semiconductor. The light source 35 is preferably an infra-red light emitting diode. The light detector 42 is preferably a phototransistor. The indicator 61 is preferably a light emitting diode. The driver 67 preferably comprises the transistor 71 and the resistors 73 and 75. The current to voltage converter 69 is preferably a resistor.
In FIG. 4, the numbers within the block 63 refer to the manufacturer's terminal numbers. The numbers in parentheses next to the resistors and the capacitors are the resistance values, in ohms, and the capacitance values, in microfarads, for a preferred circuit embodiment which operates at a frequency of 2,300 Hertz.
FIG. 5 illustrates an optical buttonhole mechanism similar to that disclosed in U.S. Pat. No. 4,216,732, the contents of which are hereby incorporated by reference as is fully set forth herein. For purposes of understanding the present invention, the buttonhole foot 80 includes a fixed reflective area 82 and a movable reflective area 84, the distance between which corresponds to the desired length of a buttonhole being sewn, as is well known in the art. Mounted on the head 86 of the sewing machine is a light source 88 and light detector 90, both of which are focused to substantially the same point 92 along the path of travel of the reflective areas 82, 84. Accordingly, when one of the reflective areas 82, 84 is positioned at the point 92, the light from the light source 88 is reflected therefrom and received by the light detector 90. (It is noted that the positions of the light detector 90 and the light source 88 may be reversed). The light source 88 and the light detector 90 may be connected in a circuit configuration like that shown in FIG. 4, with the output from the terminal 8 of the phase locked loop circuit 63 being utilized in the conventional manner for advancing the buttonhole sequence. This described arrangement provides the desired result that ambient light reflected from the areas 82, 84 is inherently filtered out.
Accordingly, there has been disclosed an improved optical switching arrangement for a sewing machine. It is understood that the above-described embodiment is merely illustrative of the application of the principles of this invention. Numerous other embodiments may be devised by those skilled in the art without departing from the spirit and scope of this invention, as defined by the appended claims. For example, the aforedescribed arrangement may also be adapted for use in an optical edge guiding system to reduce the effects of stray light. | An optical switching arrangement for a sewing machine when used as a low bobbin thread detection and indicating system utilizes an infra-red light emitting diode and a phototransistor arranged on opposite sides of the bobbin so that an amount of bobbin thread greater than a predetermined threshold interrupts the light path from the light emitting diode to the phototransistor. A single integrated circuit chip is utilized to modulate the emission from the light emitting diode and to demodulate the output of the phototransistor to differentiate the detected emission from ambient radiation. The same basic configuration is also applied to an optical buttonhole switching arrangement. | 3 |
BACKGROUND OF THE INVENTION
[0001] The present application concerns a procedure for the reworking of an open-end spinning apparatus as well as a bearing arrangement for a spin rotor of an open end spinning apparatus. Open-end rotor spinning apparatuses for open-end spinning machines, for example, such as are made by the firm W. Schlafhorst AG & Co. and Rieter Ingolstadt Spinning Machine Construction AG, are generally comprised of a multiplicity of spinning elements as well as a plurality of apparatuses for the winding of the spun yarn. Such a spinning unit possesses a spin rotor, which, by means of a drive motor, is set into rotational motion. Of considerable importance in this matter is the manner in which the spin rotor is carried on its bearings.
[0002] The bearing assembly for the rotor shaft divides itself into a radial and an axial bearing system. In the case of the radial bearing, the spin rotor is set into a V-shaped notch between two support disks. The axial bearing arrangement, and the reaction to the axial force caused by the spin rotor which this generates during operation, is contained on a thrust bearing. Until a few years previously, the axial thrust bearing in the case of machines of the above described manufacturers, and thereby a substantial part of this type of spinning machines, was equipped with a ball on which the rotor shaft rested while turning. The necessary lubrication of this ball was carried out with the aid of an appropriate lubricant.
[0003] These types of axial bearing arrangements, however, have the disadvantage that, in order to enable the important rotation of the ball, special demands were called for in regard to the lubrication. In the majority of cases, for this reason, these balls were placed above an oil bath or an oil-containing medium for lubrication. Besides the continuous rotation of the ball, and therewith the danger of considerable abrasive wear, this kind of axial rotor bearing arrangement had the additional disadvantage that lubricant, because of the vibration and high RPM of the rotor shaft, migrated out of the bearing box and contaminated the spinning machine, i.e., the spinning apparatus. Because of the oily surfaces in the bearing area, it happened that fine dusts and fibers of the spinning process could agglomerate on the machine and encrust themselves. This buildup could then lead to disadvantages in the formation of yarn. Such waste material patches that loosened themselves could enter into the to-be-spun fiber material and cause subsequent contamination and non-uniformities in the product.
[0004] Moreover, these contaminating deposits had the disadvantage that a large maintenance expense continually accrued. Thus, at regular periods, a cleaning of the spinning machine as well as a monitoring of the lubrication supply of the axial bearing had to be done. Under these circumstances, it was often necessary to refill the lubricant containers, which increased the maintenance time even more.
[0005] In order to set aside the disadvantages of spinning machines with open-end spin rotors supported by bearings of this kind, the state of the technology developed a different approach to axial bearing systems. The arrangement of the bearings for the spin rotors was done without the ball and further allowed the removal of the lubrication, which contaminated the fibers. This type of bearing support has been made known by EP 0 435 016 A2.
[0006] Following the introduction of this type of pneumatically driven axial thrust bearing system, which avoided the above described disadvantages, attempts were made to substitute these modern bearing arrangements with simplified ball axial thrust bearings, where the construction of the bearing assembly was simple to the extent that an exchange of these two bearing systems could be carried out. For this required construction, the improved version of the pneumatic axial thrust bearing arrangement was used, and the ball axial thrust bearing was simply installed in the receiving enclosure of this modern pneumatic bearing. By this means, a version (minimized in size) of the known oil lubricated, ball axial thrust bearing assembly was pushed into the receiving housing for the modern pneumatic axial bearing system. Through this kind of retrofit of the bearing assembly with conventional systems, the desired advantages of the modern axial bearing methods were circumvented in order to substitute for them apparatuses which were constructed according to the older types of bearings. This kind of bearing design still, as demanded by its components, called for an oil-based lubrication. Instead of refitting the obsolete bearing system with modern pneumatic bearings, the state of the technology, contrary to this, surprisingly simply retrofitted the modern and improved bearing system with the old.
OBJECTS AND SUMMARY OF THE INVENTION
[0007] Thus, it is a principal object of the invention to allow many thousands of spinning apparatuses now in operation with an oil-media lubrication system of the rotor to be reworked without great cost by an appropriate procedure and an apparatus to execute the procedure. The reworking would permit the spinning apparatuses to meet the demands, which have been placed on spinning machines without the necessity of replacing the complete spinning apparatus or machine. The investion amounts for the modernization are held to a minimum and remain restricted to the necessary components. Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
[0008] The present purpose of the invention is solved by dismounting the bearing block from the open-end spinning apparatus, separating the axial bearing from the bearing block, and replacing it with an axial bearing carrier for an aerostatic axial bearing equipped with a matching surface on the bearing block. The reworking allows, in this operation, only a small expenditure of time and money in comparison to the substitution of new spinning machines or a new, modernized open-end spinning machine for machines containing the axial ball bearings.
[0009] Reworked open-end rotor spinning machines retain essentially the same advantages in regard to the character of the bearing assemblies as do newly purchased open-end rotor spinning machines already equipped with the recently installed pneumatic axial bearing system for the spin rotor. For the rework, essentially only the bearing block of the open-end rotor apparatus to be reworked needs to be dismantled, following which, in a simple manner, the axial bearing assembly found on the block can be separated, and, in accord with the invention, replaced with an axial pneumatic bearing carrying block.
[0010] The reworking can even be accelerated by, for example, doing the reworking section by section. The corresponding parts of the rotor bearing assembly on the open-end spinning machine can be removed and reworked in one section, while the other sections of the spinning machine remain in operation. In another advantageous method, already reworked bearing assemblies can be held on the ready, so that, upon the next removal of the original bearing, the new component can serve as an immediate replacement. Thus, only a very short break in production would occur. The now removed original bearing assemblies, can be reworked at an optional time and place, so that, subsequently, these reworked assemblies can be exchanged piece for piece for existing original bearing assemblies.
[0011] In an advantageous development of the invented procedure, the removal of the ball axial thrust bearing assembly can be effected by machine cutting, for instance, by sawing or milling, or even by non-machine cutting such as by laser or by electron beam. In this way, a plane of separation, i.e., a separating surface, is generated quickly and advantageously, which can be immediately turned to rework operations. Preferably, this follows as an additional step in the procedure. Also, the plane surface is generated with a minimum of roughness depth, which advantageously serves as a matching surface for another complementary surface. Such a plane surface improves the fitting of the axial bearing block surface to the existing bearing block.
[0012] The separation of the ball axial bearing is carried out favorably in such a manner that the plane in which the separation occurred lies parallel to the plane in which the support disks lie, that is, that plane which is formed by the support disk pair proximal to the rotor, or the support disk pair proximal to the shaft end. Advantageously, the separation can be made between the two planes of the two above mentioned pairs of support disks. An advantageous separation line can be achieved by having the line in its course suddenly bend, and run perpendicular to the above described planes of the support disks.
[0013] The axial bearing carrier is advantageously designed with a corresponding matching surface, so that the separating surface is appropriate for the fitting of the axial bearing carrier onto the existing bearing block. This match is especially true, when the bearing block has been correspondingly machined. In a further advantageous development of the procedure, the separating surfaces are provided with fastening means for their union. In this way, the advantage is gained that the fastening of the axial bearing carrier is simple and quick, as well as being exact in surface match. In a particularly favorable option, the fastening means includes a boring, which preferably possesses an inner threading. Thereby, the fixing of the axial bearing carrier onto the existing bearing block is very simple, i.e., with threaded bolts.
[0014] By means of the invented bearing arrangement, an economical bearing has been constructed, the bearing block of which retains the advantages of the original bearing system of the spin rotor by means of support disks and at the same time inherently possesses the advantages of a pneumatic axial bearing of the spin rotor. For this purpose, the axial bearing carrier is equipped with a receptor for a bearing surface of a pneumatic axial bearing. By means of the construction of a matching surface, no further measures are required for the installation of the bearing surface of the axial bearing to the spin rotor, at least that call for a change of the angularity of the bearing surface in relation to the axis of the rotor shaft.
[0015] In a particularly advantageous development of the bearings, the separating and the matching surfaces are simultaneously shaped, so that they, in connection with the axial bearing carrier, assure that no adjustments are necessary which alter the placement of the bearing surface in the axial direction of the spin rotor. This is particularly favorable, since no time for such adjustment can be lost and, moreover, no special knowledge is required of the maintenance personnel. The separation surface is machined for this reason in accord with the invention. The separation surface forms a centering and positioning surface of the bearing plate of the axial bearing for the rotor shaft, which will be rotationally carried thereon.
[0016] In a particularly advantageous improvement of the invention, the separation surface is provided with fastening means with the help of which the fastening of the bearing carrier is simple and advantageous. In a particularly advantageous development of the invention, this fastening means is a boring provided with a thread. In a further advantageous improvement of the invention, the separation surface possesses a centering means for the centering, or alignment, of the bearing carrier onto the existing bearing block. For example, these centering means might be centering pins, or complementary borings for the same. By these alignment means, a rapid and sure centering of the bearing carrier on the existing bearing block can be carried out during the installation. These alignment means simplify the mounting and accelerate the installation of the bearing components and thereupon the rework of the open-end rotor spin apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the following, the invention will be described with the aid of the drawings.
[0018] [0018]FIG. 1 shows a bearing assembly of an open-end rotor spinning apparatus before the reworking;
[0019] [0019]FIG. 2 shows the reworked view of the assembly of FIG. 1, following the installation of the axial bearing carrier of an aerostatic axial bearing;
[0020] [0020]FIG. 3 shows the ball axial thrust bearing of FIG. 1 in a cross-sectional view; and
[0021] [0021]FIG. 4 shows the axial bearing carrier of FIG. 1 in a perspective presentation.
DETAILED DESCRIPTION
[0022] Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are shown in the figures. Each example is provided to explain the invention, and not as a limitation of the invention. In fact, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. It is intended that the present invention cover such modifications and variations.
[0023] [0023]FIG. 1, in combination with FIG. 3, shows the bearing arrangement of an open-end spinning apparatus, in accord with the state of the technology, with a ball axial thrust bearing 13 prior to the rework operation. The bearing arrangement 10 comprises one bearing block 11 on which the support disks 12 as well as the ball axial bearing 13 are placed. Such a bearing arrangement, for instance, is made known by DE 41 21 387 A1, (see FIG. 2 of that patent). In the bearing system of FIG. 1, the support disks 12 are arranged pairwise, so that they present two V-notches 121 in which the rotor shaft is carried. At the end remote from the ball axial bearing 13 , the rotor shaft 14 carries the open-end spin rotor 140 . Due to a (not shown) driving element, which, in the state of the technology is largely based on tangential belts, the spin rotor 140 is driven by the rotor shaft 14 and set into rotation. Respectively, two support disks 12 bound to one another are driven by an axle 15 and carried on support disk bearing 16 . The support disk bearings 16 are received in a semicircular recess 17 . By means of clamp 18 , the support disk bearings 16 are pressed into the recess 17 of the bearing block 11 and there retained. The clamp 18 , at the same time, is affixed to the bearing block 11 . The axles 15 of the support disks 12 are slightly skewed in relation to one another to the effect that the V-notch between the support disks 121 generates an axial thrust against the rotor shaft 14 , which rests on the V-notch of the disks, in the direction of the ball axial thrust bearing 13 of the bearing assembly 10 .
[0024] The ball axial bearing 13 possesses a container 19 which is closed by a cover 20 . Within the container 19 , a ball 5 is found at the elevation of and abutting the rotor shaft 14 . The ball supports itself on the side remote from the rotor shaft 14 on a recessed detent 21 , which accepts the ball in a cuplike receiver. The recessed detent 21 can be adjusted with an adjustment screw 22 , which is locked by means of the nut 220 .
[0025] For the necessary lubrication of the ball 5 , the ball axial bearing 13 possesses a container 3 , which is remote from the cover. The container 3 holds the lubricant 31 which lubricates the ball during its rotation. The lubricant 31 is brought to the point of lubrication of the ball 5 by means of a wick 32 .
[0026] The bearing block 11 is fastened to the spinning machine framing 24 by means of the fastening screws 23 , which is shown only schematically. For the proposed rework of the open-end spinning apparatus, the bearing block 11 must first be removed from the spinning machine, and thus demounted from the spinning apparatus by the loosening of the fastening screws 23 . For this purpose, it is advantageous to stop the rotor driving means (not shown), so that the bearing block with the support disks 12 and the ball axial bearing 13 can be taken out of the spinning machine. Prior to this step, advantageously, the spin rotor 140 with its rotor shaft 14 have already removed from the bearing assembly 10 . After the removal of the bearing assembly 10 and the removal of the clamp 18 , the support disks 12 also are removed from the bearing block 11 for the sake of simplicity, so that further operational steps on the bearing block 11 can be carried out without difficulty.
[0027] The next work step in the rework program on the open-end spinning machine will be the necessary removal of the ball axial bearing 13 from the bearing block 11 . This removal is accomplished by the literal cutting off of the ball axial bearing 13 , for instance, by sawing. The cut is to be made along one of the separation lines marked, for example, as A to E, whereby the left and the right side of the bearing block 11 can possess the same, or different section lines (A, B, C, D, E). Because of the cutting off of the ball axial bearing 13 , there arises along the cutoff lines (A to E) a separation surface to which connects the axial bearing carrier 4 , which has an accommodating counter surface to accommodate a pneumatic axial bearing (See FIG. 2).
[0028] The bearing assembly 10 from FIG. 2 is a re-worked bearing assembly in accord with the invention. By the cutting off of the ball thrust axial bearing ( 13 ) (see FIG. 1), the separation surface 25 is so free that an axial bearing carrier 4 of the bearing surface 41 for a pneumatic axial bearing 42 can be placed thereon in accord with the invention. The separation surface 3 , as shown in FIG. 2, is remachined after the cutting off of the ball axial bearing 13 , so that the cut surface 3 has a smooth flat surface onto which the axial bearing carrier 4 with its matching surface 45 can make a seamless joining. The machining of the separation surface 3 is carried out in the embodiment of FIG. 2 by means of machine cutting, that is, by milling. By the machining, the separation surface receives the requirement for the bearings of the support disks 12 and subsequent to this the rotor shaft 14 which is carried on the support disks 12 . The separation surface then serves as a detent surface matching the complementary surface 45 of the axial bearing carrier 4 .
[0029] The separation surface 3 , which, in FIG. 2 is formed from two partial surfaces located respectively right and left of the V-notch of the bearing block 11 , possesses two means of fastening 440 , which are indicated in FIG. 2 by means of a dotted line. The fastening means comprises, respectively, a boring through which a threaded bolt can be run until it extends into the axial bearing carrier 4 . The axial bearing carrier 4 lies with its matching surface 45 on the separating surface 3 of the bearing block 11 . Separation surface 3 and matching surface 45 have been shaped to be complementary to one another. On this account, the bearing surface 41 of the pneumatic axial bearing 42 falls into its correct position following the assembly of the axial bearing carrier 4 in relation to the rest of the bearing components, and especially in relation to the free end of the rotor shaft 14 .
[0030] In the assembly of the axial bearing carrier 4 , and in the recess 46 for the axial bearing 42 , an assembly opening has been introduced that shows the position in which the matching surface 45 and the separation surface 43 must be affixed together by the fastening means 44 . For the axial adjustment of the pneumatic axial bearing 42 in relation to the end of the rotor shaft, the clamping element 46 is in the shape of a clenched fist, so that the pneumatic axial bearing 42 can be fastened in the correct axial position with the clamp screw 47 on the axial bearing carrier 4 . The axial bearing carrier 4 possesses respectively two fastening means 44 . However, it is quite possible to also install these in a bearing block that has fastening means formed in a different manner.
[0031] [0031]FIG. 3 shows the ball axial bearing of FIG. 1 in a cross-sectional view. The rotor shaft 14 lies, when in operation, against the ball 5 . For this purpose, the rotor shaft 14 has a recessed, cup-like detent which bears against the ball 5 . The ball 5 for its part abuts the adjustment screw 22 . The adjustment screw 22 is locked by means of the nut 220 , and thus is non-rotatable. For the lubrication of the ball 5 , a container for holding lubricant 31 is located below the ball. The lubricant is oil, which, is brought into contact with the surface of the ball 5 by means of a wick 32 . A chamber 19 of the ball axial bearing 13 , which is located above the oil container, is closed from above by the cover 20 . The rotor shaft 14 extends into this chamber 19 through a penetrative opening, whereby it is encompassed by a surrounding shell 33 which aids in preventing the leakage of oil to the surroundings.
[0032] Alternative to the methods and ways depicted in FIGS. 1 and 2 for the separation of the ball axial bearing 13 , it is entirely possible, that first the ball is removed from the ball axial bearing 13 , and subsequently, in the interior of chamber 19 , an axial bearing carrier is placed with a receiving module for the pneumatic axial bearing. For this purpose, the shell 33 as well as the ball retainer 51 must be removed. Ball retainer 51 limits the mobility of the ball 5 in the ball axial bearing. Then, on the cut surface of the shell 33 , which now becomes a separation surface 300 , there would be a matching complementary surface 45 of a correspondingly finished axial bearing carrier 4 (not shown).
[0033] In an additional embodiment for the removal of the ball axial bearing 13 , the interior of the chamber 19 is machine finished to cylindrical form and on the now ring shaped separation surface 300 , for instance, an annular axial bearing carrier 4 (not shown) is installed that takes up the bearing surface of a pneumatic axial bearing. The separation surfaces of the various embodiments of separation of the ball axial bearing are to fulfill their function, however, in the same manner as shown in FIGS. 1 and 2.
[0034] [0034]FIG. 4 shows the axial bearing carrier in accord with the invention and as it is installed in FIG. 2. The axial bearing carrier possesses, respectfully, right and left from the axial bearing 42 , a matching surface 45 , with which it is positioned on the separation surface of a reworked bearing system. In order that installation may be made with various bearing blocks, for example, or from different spinning machine models, the axial bearing carrier 4 of FIG. 4 exhibits respectively two fastening means 44 . Respectively, the upper means is a blind boring which is provided with an internal thread. Again respectively, the lower means is shown as a through boring through which a bolt of the proper size can be screwed for fastening into the matching reworked bearing block. Besides the use of the boring as a fastening means, it can also serve for the exact positioning of the axial bearing carrier. To this purpose, for instance, a drift pin or positioning pin can be employed in the boring, which works together with a corresponding working separation surface of a reworked bearing block.
[0035] For the affixing of the pneumatic axial bearing 42 on the axial bearing carrier 4 , the axial bearing carrier 4 possesses a clamp 46 designed in the form of a clenched fist. By means of bolt 460 , the sheath-like designed axial bearing 42 with its bearing plate 41 is fastened upon the ball axial bearing carrier. By means of the advantageous formation of axial carrier 42 and the clamp 46 , the bearing plate can be located simply in its axial direction, axial being in reference to the axis of the rotor shaft. In operation, the axial bearing is provided with compressed air through a (not shown) air-feed line on the side of the bearing plate opposite to the bearing surface 41 . Besides the described embodiments for separation and changes in the bearing arrangements, other embodiments are also possible. These other embodiments need only to refer to the above described features to be able to make use of the pneumatic axial bearing and to position it correctly.
[0036] It will be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents. | The present invention concerns a procedure for the reworking of a open-end spinning apparatus for a spin rotor, which is carried in the V-notch between support disks and is supported by a ball axial thrust bearing. Where the reworking is concerned, the bearing block of the open-end spinning apparatus is dismounted, the ball axial thrust bearing is removed from the bearing block and in accord with the invention, is replaced by an aerostatic bearing in the bearing block. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a semiconductor memory device, and more particularly to an arrangement of I/O lines (input/output lines) that connects the bit lines in a memory cell array with common data bus lines provided along the periphery of a semiconductor chip.
DESCRIPTION OF THE PRIOR ART
A semiconductor memory device comprises a memory cell array which includes a plurality of memory cells arranged in an array in which bit lines and word lines are respectively connected to the memory cells. A row decoder and a column decoder are arranged adjacent to said memory cell array for selecting a given memory cell. An I/O line is provided as a channel for reading data from and writing data to the memory cell selected by the row decoder and the column decoder. The I/O line is connected at one end to the bit lines via a selection switch and to the common data bus at the other end via a buffer circuit and an I/O line selection circuit, the common data bus being connected to an input/output pad which in turn is provided at the periphery of the semiconductor chip.
In a semiconductor memory device, one chip generally comprises a plurality of such memory arrays. For example, a 4 Mega bit dynamic random access memory (hereinafter referred to as DRAM) is a semiconductor memory device with the chip size of approximately 6×15 mm 2 which includes 16 memory cell arrays of 256 rows×1024 columns, i.e. 256 K bit, in a lateral arrangement.
By using plural memory cell arrays to shorten the bit line, capacity of the bit line can be reduced to thereby increase the speed of data read-out and write-in operations. In a memory cell array of a semiconductor memory device of such construction, the side which is parallel in the word line direction is longer than the side which is parallel in the bit line direction. Thus, when a plurality of memory cell arrays having such configuration are to be arranged, they are arranged with their longer sides adjoining one another.
When a plurality of memory cell arrays are provided, buffer circuits and I/O line selection circuits that are disposed between the common data buses and the I/O lines are also provided adjacent to the memory cell arrays in a plural number corresponding to the number of the memory cell arrays. On the other hand, signal lines that supply control signals to these buffer circuits and I/O line selection circuits are preferably small in number and shorter in length in view of signal delays or ease of wiring. The buffer circuits and the I/O line selection circuits are disposed at locations where they can be easily connected to the common control signal lines, or specifically, only on the longer side of a semiconductor chip.
With the above arrangement of the memory cell arrays, the direction of the longer side of the chip is the direction of the each bit line for the memory cell array. The I/O lines adjacent to each memory cell array run parallel to the word lines and are led out in the direction in which the buffer circuits and the I/O selection circuits are arranged, or toward one of the longer sides of the semiconductor chip. The common data buses run along one of the longer sides, and the I/O lines that are led out are connected to the common data buses via the buffer circuit and the I/O selection circuit respectively.
Each of the common data bus is connected to the input/output pad which is arranged along the periphery of the semiconductor chip via the input/output buffer circuit. Two input/output pads are provided on a longer side of the semiconductor chip in case of, for example, a DRAM of 1 M word×4 bit structure.
As mentioned above, since the I/O lines are led perpendicularly to one of the longer sides of the semiconductor chip, the common data bus that is connected to the input/output pads provided on the side of the other longer side must be extended along both the longer and the shorter sides of the chip, resulting in an inconveniently extensive length. The length of a common data bus becomes therefore highly dependent on the arrangement of the input/output pads.
In the prior art, as a common data bus can be very long depending on the positional arrangement of the input/output pads, the performance of the semiconductor memory device is restricted by the data bus with the longest wiring, hampering the implementation of a high speed operation.
BRIEF SUMMARY OF THE INVENTION
Objects of the Invention
An object of the present invention is to provide a semiconductor memory device of which data buses are not determined in length by the position of input/output pads to thereby enhance the speed of operation.
SUMMARY OF THE INVENTION
The semiconductor memory device according to the present invention comprises memory cell arrays each including plural memory cells, a plurality of bit lines and of word lines respectively connected to each memory cell wherein a predetermined memory cell is selected by a combination of a row decoder and a column decoder, and I/O lines running parallel in the direction of the word lines and connected to a given number of the plural bit lines via a selection circuit, said plural bit lines being divided into a first bit line group and a second bit line group respectively in a predetermined number of lines, the I/O lines including a first I/O line which is connected to a given number of bit lines in the first bit line group and a second I/O line which is connected to a given number of bit lines in the second bit line group respectively via selection circuits, and the first I/O line extending in the direction opposite to the direction of the second I/O line.
The first I/O line and the second I/O line are connected respectively to a first and a second common data buses via I/O line selection circuits. The first and the second common data buses are connected to input/ output pads that are respectively arranged on both of the longer sides of the semiconductor chip.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other objects, features and advantages of this invention will become more apparent by reference to the following detailed description of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a plan view to show the entire construction of a semiconductor memory device according to the first embodiment of the present invention.
FIG. 2 is a detailed plan view to show a part of the semiconductor memory device shown in FIG. 1.
FIG. 3 is a circuit diagram to show a portion of the circuit construction of the semiconductor memory device shown in FIG. 2.
FIG. 4 is a circuit diagram to show a portion of the circuit construction of the semiconductor memory device shown in FIG. 2.
FIG. 5 is a plan view to show a portion of the construction of a semiconductor memory device according to the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The first embodiment of a semiconductor memory device according to the present invention will now be described referring to FIG. 1. A 4 Mbit DRAM is taken up as an example. FIG. 1 is a plan view of a semiconductor chip 1 which comprises a DRAM of 1 M word×4 bit construction on a 20-pin SOJ package. On a die-pad 11 is disposed a semiconductor chip of approximately 6×15 mm 2 , on which electrode pads P1, P2, P3 . . . P20 are connected respectively to external leads 13 via bonding wires 14. The semiconductor chip 1, the die-pad 11 and the external leads 13 are sealed with a resin to form an SOJ package 12 of approximately 7×9 mm 2 .
A single lateral row of 16 memory cell arrays 4 each comprising 256 rows×1024 columns, i.e. 256 Kbit, is arranged inside the semiconductor chip 1, forming a 4 Mbit memory cell array as a whole. For each of the memory cell array 4, a set of a row decoder 2 and a column decoder 3 is provided. Sides of each memory cell array 4 which run parallel to the direction of the word line are longer than the sides that run parallel to the bit line. Therefore, the memory cell arrays are arranged with their sides in the direction of the word line adjoining to one another.
As a data channel for reading-out and writing-in data in one of the memory cell arrays 4 selected by the row decoder 2 and the column decoder 3, I/O lines 10a and 10b are disposed adjacent to the array 4 in parallel with the word line. An I/O line comprises a first I/O line 10a and a second I/O line 10b which extend in opposite directions toward the two opposing longer sides of the semiconductor chip. The I/O lines 10a and 10b are connected to the bit lines via a selection switch which is controlled by the column decoder 3 within the cell array region, and further connected to either one of the common data buses 2a or 2b provided respectively along the longer sides of the chip 1 outside the cell array region but near said longer sides via a buffer circuit 5 and a I/O line selection circuit 6. The common data buses 2a and 2b are connected to the input/output pads DQ1, DQ2, DQ3 and DQ4 that are provided in the number of two on each of the opposite longer sides of the chip 1 via input/output buffers 7-0, 7-1, 7-2 and 7-3.
This embodiment will be described in more detail referring to FIG. 2. FIG. 2 is a partially enlarged view to show the details of the two cell arrays located on the right and left ends of the semiconductor memory device shown in FIG. 1, 14 cell arrays therebetween being omitted. The same component elements are given the same reference numbers.
Since the bit lines constituting one memory cell array 4 are divided into the first and the second groups of a given number (512 lines in this embodiment) of bit lines, the memory cell array 4 is divided into two regions of 4a and 4b. The I/O lines comprise correspondingly the first I/O lines 10a connected to the first bit line group and the second I/O lines 10b connected to the second bit line group. The first and the second I/O lines 10a and 10b each comprise two pairs of I/O line consisting of two signal lines that are complementary to each other, and extend in opposite directions from the substantial center toward the opposing longer sides of the semiconductor chip 1 in parallel to the word line of the cell array 4. These I/O lines are connected to I/O line selection circuits 6a and 6b respectively.
The I/O line selection circuits 6a, 6b connect either one of the two I/O line pairs on one end to one of the I/O line pairs at the other end depending on the control signal. The I/O pair at the other end is connected to the buffer circuit 5a or 5b. The buffer circuit 5a or 5b amplifier the potential of one of the I/O line pairs and controls supply of this amplified potential to either of the common data buses 2a or 2b (in case of read-out operation). Alternately the buffer circuit amplifies the data supplied from the common data buses 2a, 2b and transmits the same to the I/O line pairs as a set of complementary data.
The common data buses 2a, 2b each comprise two signal lines, are disposed along the two opposing longer sides of the semiconductor chip 1, and are connected with plural predetermined buffer circuits 5.
In the case of 4 bit output as in this embodiment, data input/output operations with the external device require 4 input/output pads. The input/output pads DQ0, DQ1, DQ2 and DQ3 are provided on the two opposing longer sides of the chip in the number of two. The input/output pad DQ0 is connected to one of the signal lines of the common data bus 2b via the input/output buffer 7-0. The input/output pad DQ1 is connected to the other signal line of the common data bus 2b via the input/output buffer 7-1. Similarly, the input/output pad DQ2 is connected to one of the signal lines of the common data bus 2a via the input/output buffer 7-2, and the input/output pad DQ3 to the other signal line of the common data bus 2a via the input/output buffer 7-3.
A control signal generator 21 is provided on one of the shorter sides of the semiconductor chip 1 and supplies control signals such as the one for controlling the selection operations of the I/O line selection circuits 6a, 6b provided respectively on the two opposing longer sides of the chip 1, and the one for activating the buffer circuits 5a, and 5b.
The above described construction reasonably reduces the entire length of the data line starting from the I/O lines 10a, 10b connected to the bit lines to the input/output pads DQ0, DQ1, DQ2 and DQ3 for reading and writing. In other words, the data line extending from the memory cell array 4 to the input/output pads DQ2, DQ3 provided along one of the longer sides of the semiconductor chip 1 is a channel extending from the first I/O line 10a connected to the first bit line group to the input/output pads DQ2, DQ3 via the common data bus 2a and the buffers 7-2, 7-3, and the data line extending to the input/output pads DQ0, DQ1 on the other longer side is a channel extending from the second I/O line 10b connected to the second bit line group to the input/output pads DQ0, DQ1 via the common data bus 2b and the buffers 7-0, 7-1. As the data line layout comprising these two channels is symmetric with respect to the boundary between the memory cell arrays 4a and 4b, the entire data line length for one of the input/output pad groups (e.g. DQ2 and DQ3), unlike the prior art, will not be longer than the data line for the other group (e.g. DQ0 and DQ1). Further, since the length of the I/O lines 10a, 10b corresponds to one half of the length of the side of the memory cell array 4 in the word line direction and becomes therefore half the length in the prior art, the length of the data line itself can also be reduced.
This means reduction of the data line length extending from the I/O lines connected to the bit lines to the input/output pads for reading and writing, and thus the capacity of the entire data line can be reduced, and the speed of operations of the semiconductor memory device can be increased.
As all the I/O lines in the prior art extended toward either one of the longer sides of the semconductor chip, one memory cell array required a region wide enough to accommodate 4 pairs of I/O lines, or 8 signal lines. According to the embodiment of the present invention, the first I/O line 10a and the second I/O line 10b each comprising four signal lines are provided to extend in the opposite directions, the width of the region for accommodating the I/O lines can be reduced to one half, contributing to integration of the semiconductor memory device.
As the I/O line selection circuits and the buffer circuits are provided on both of the two opposing longer sides of the semiconductor chip 1 in this embodiment, the number of lines for supplying control signals to these circuits become layer than in the prior art. However, the performance of a semiconductor memory device is determined mainly by the time involved in the data read-out, and the increase in the operational speed achieved by the reduced data line length outweighs the increased number of lines for the control signals.
Referring to FIGS. 3 and 4, one embodiment of circuit construction shown in FIG. 2 will be explained in more detail. FIG. 3 is a circuit diagram to show the specific construction of the circuit for the memory cell array 4, a selection switch SE, and I/O lines 10a and 10b. The same component elements as in FIGS. 1 and 2 are given the same reference numbers.
The memory cell array 4 is an array of so-called one-transistor one-capacitor type cell MSs, each of which comprising one N-channel MOS transistor and one capacitor element. Total of 1024 bit lines is divided into a first bit line group B1 and a second bit line group B2 with 512 lines each, so that the memory cell array 4 is divided into two regions 4a and 4b. In each of the bit line groups Ba and B2, bit lines BL each comprising a pair of lines are connected to respective sense amplifiers SA. The row decoder 2 (FIGS. 1, 2) selects one of the word lines WL. The column decoder 3 supplies selection signals to the selection circuit SE to select two sense amplifiers SA in each of the bit line groups B1 and B2. In other words, for each one of the sense amplifiers SA, four bit line pairs are selected by the selection switch SE from plural bit line pairs connected each with two bit lines, and two pairs of them are connected to the I/O line 10a and the remaining two pairs are connected to the I/O line 10b. The selection switch SE comprises a group of transistors which receive selection signals from the column decoder via gates and whose drain-source channel is provided between the input/output terminal of the sense amplifier SA and the I/O lines 10a, 10b. Two of the four bit line pairs selected by the column decoder 3 and the selection switch SE are connected to two pairs of signal lines 101a, 101b and signal lines 102a, 102b constituting the first I/O line 10a, while the remaining two pairs are connected to the second I/O line 10b.
Referring to FIG. 4, a specific construction of the circuit including the I/O line selection circuit 6a, buffer circuit 5a, input/output buffer 7-3 on the side of the first I/O line 10a will be described. The same component elements as in FIGS. 1 and 2 are given the same reference numbers.
The I/O line selection circuit 6a includes an I/O line selection circuit 6a-1 which operates during reading-out and an I/O line selection circuit 6a-2 which operates during writing-in The I/O line selection circuit 6a-1 for reading includes transistors Q1 and Q2 which receive on gates control signal SLa from the control signal generator 21 (FIG. 2) and of which source/drain parts are provided between signal lines 101a and 103a and between signal lines 101b and 103b, and transistors Q3 and Q4 which receive on gates control signal SLb from the generator 21 and of which source/drain paths are provided between signal lines 102a and 103a and between signal lines 102b and 103b so as to select either one of the two pairs of signal lines 101a, 101b and 102a, 102b of the first I/O line 10a according to the control signals SLa, SLb and to connect the selected one with the signal line pair of 103a, 103b. It further includes pull-up transistors Q61, Q62, Q63 and Q64 for each of the signal lines 101a, 101b, 102a and 102b.
The I/O line selection circuit 6a-2 for writing includes transistors Q65 and Q66 which receive control signal SLc from the control signal generator 21 (FIG. 2) at their gates and of which source/drain paths are provided between signal lines 101a and 104a and between signal lines 101b and 104b, and transistors Q67 and Q68 which receive control signal SLd from the generator at their gates and of which source/drain paths are provides between signal lines 102a and 104a and between signal/lines 102b and 104b so as to select either one of the two pairs of signal lines 101a, 101b and 102a, 102b of the first I/O line 101 and to connect the selected one to the pair of signal lines 104a and 104b. The buffer circuit 5a includes a buffer circuit 5a-1 which operates for reading-out and a buffer circuit 5a-2 which operates for writing-in. The buffer circuit 5a-1 includes two differential circuits 51 and 52 of the same structure and three inverters 53, 54 and 55. The first differential circuit 51 includes transistors Q7 and Q8 which connects a pair of signal lines 103a, 103b to gates respectively and generates differential pair, is loaded by a current mirror circuit comprising transistors Q5 and Q6, and is activated with an activation signal AC supplied from the generator 21. The second differential circuit 52 is connected for one more stage with the first differential circuit 51, and the second differential circuit 52 is connected on one of the input/outputs thereof to an input of a transfer gate TG via the three inverter circuits for output 53, 54 and 55. The transfer gate TG1 determines by control whether or not to connect the input/output to the common data bus 2a in accordance with the control signal SLc.
The buffer circuit 51-2 for writing-in on the other hand, includes a NAND gate 56 and three inverters 57, 58 and 59. The NAND gate 56 simplifies and inverts the writing-in data supplied to the common data bus 2a in accordance with the control signal SLf supplied from the generator 21. One of the outputs from the NAND gate 56 is outputted to the signal line 104b via the inverters 57, 58 while the other output therefrom is outputted to the signal line 105a via the inverter 59. This makes the levels of the signal lines 104a and 104b complementary to one another.
The common data bus 2a is connected to the input/output pad DQ3 via an output buffer 71 and an input buffer 72 within the buffer circuit 7-3. In the output buffer 71, the output data signal is further amplified by the inverters 71 and 72, and turned into two complementary signals by the NAND gate 74 which receives as inputs the amplified signal and a control signal φ1 supplied from the control signal generator 21 and by the NAND gate 75 which receives as inputs the amplified signal and the inversion of the control signal φ1. These complementary signals are applied at the gate of a P channel transistor Q10 of which source/drain path constituting the CMOS circuit at the final output stage and connected between the power source and an output and at the gate of a N channel transistor Q11 of which source/drain path is connected between an output and the ground potential, and the output signal therefrom is supplied to an I/O pad DQ3. The output of the output buffer 71 is held at high impedance by the control signal φ1 and separated from the input/output pad DQ3 except for during reading out of data.
At the input buffer 72, the write-in data supplied at the input/output pad DQ3 is further amplified by the inverters 76 and 77. The transfer gate TG2 controls whether or not the amplified signal should be connected to a latch circuit comprising inverters 79 and 80 in accordance with the control signal φ2. As the transfer gate TG2 is turned off by the control signal φ2, the transfer gate TG3 also controlled by the signal φ2 becomes active and the write-in data is latched by the latch circuit. The latched data is further amplified by an NAND gate 81 and an inverter 82 whose outputs are controlled by a control signal φ3. The NAND gate 84 which receives as input the amplified signal and a control signal φ4 and the NAND gate 85 which receives as inputs the amplified signal and an inversion of the control signal φ4 generate two complementary signals therefrom. The complementary signals are applied at the gate of a P channel transistor Q12 whose source-drain channel constituting CMOs is connected between the power source and an output and at the gate of an N channel transistor Q13 whose source-drain channel is connected between an output and the grounded potential, and the output signals therefrom are supplied to the common data bus 2a. The output of the output buffer 72 is held at high impedance by the control signal φ4 and separated from the common data bus 2a except for during the reading-out of data.
Other buffer circuits 7-0, 7-1 and 7-2 are of the same construction as the buffer circuit 7-3, and are respectively connected to the input/output pads DQ0, DQ1, DQ2 and DQ3 whose respective input/outputs are disposed on the side of the opposing longer sides of the semiconductor chip in the unit of two.
Referring to FIG. 5, the second embodiment of the present invention will now be described. The second embodiment differs from the first embodiment shown in FIG. 2 in that the common data buses are divided into four sets 30, 31, 32 and 33, each set comprising two complementary signal line pairs, or four signal lines, that the output signals from the buffer circuits 35a and 35b that supply signals to respective common data buses are complementary to each other, or two outputs, and that each of the common data buses 30, 31, 32 and 33 is provided with a common data bus selection circuit 9. The common data bus selection circuit 9 selects one of the two common data bus pairs that are connected thereto, amplifies one of the signals of the selected data bus and transmits the same to the buffer circuit 7. Alternately, the circuit 9 amplifies the write-in data from the buffer circuit 7 to generate complementary data, and transmits the same to the selected common data bus pair. Other features of the construction are identical with the embodiment shown in FIGS. 1 through 4.
The buffer circuits 35a and 35b may be constructed as the known two-way buffers. The common data bus selection circuit 9 may be constructed similarly to the I/O line selection circuit 6a-1 and the buffer circuit 5a-1 shown in FIG. 4, so as to enable it to select one of the two signal line pairs and to amplify the same.
According to the present invention, memory cell arrays belonging to respective input/output pads DQ0, DQl, DQ2 and DQ3 can be distinctly blocked so that noises from the adjacent arrays during read-out can be easily dealt with.
The present invention has been described with respect to DRAM, but it is applicable to SRAM (static RAM) I/O circuit, and PROM (programmable read-only memory), EPROM (erasable PROM) and EEPROM (electrically erasable PROM) read out circuits.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover any modifications or embodiments as fall within the true scope of the invention. | The semiconductor memory device according to the present invention comprises a plurality of memory cell arrays having a plurality of memory cells and a plurality of bit liens and word lines connected respectively thereto, and I/O lines which run in the direction of the word line and are connected with a given number of bit lines of the bit lines via a selection circuit, the bit lines being divided into a first and a second bit line groups of a given number of lines, the I/O lines having a first I/O line connected to a given number of lines in the first bit line group via the selection circuit and a second I/O line connected to a given number of lines in the second bit line group via the selection circuit, and the first and second I/O lines are provided to extend in opposite directions. Because of the construction as mentioned above, the arrangement and the location of the input/output pads do not affect the length of the signal line extending from the bit lines to the input/output pads, thereby preventing the data bus from becoming redundantly long and enabling high speed operations. | 6 |
BACKGROUND OF THE INVENTION
Conduit systems, particularly those used to conduct seawater as used on watercraft, including submarines, are subject to galvanic corrosion due to the use of dissimilar metals in the system. Galvanic corrosion in seawater conduit systems is controlled, and substantially eliminated, by the use of dielectric isolators which interrupt the electrical continuity between conduit system components.
However, conduit systems employing galvanic isolators which are presently available employ a plurality of "loose" and unassociated components which require assembly during installation of the system. Such use of a number of small components is troublesome, creates inventory problems due to the number of parts required, and introduces the possibility of incorrectly assembling galvanic isolator fittings which would permit failure, and possible catastrophic results.
It is an object of the invention to provide a galvanic isolator conduit fitting which is of relatively simple and economic construction and wherein the fitting assembly is unitary with respect to shipping and inventory purposes.
A further object of the invention is to provide a galvanic isolator conduit fitting utilizing conduit attachment means at the opposite ends of a body and a dielectric isolator insulates at least one of the attachments means from the fitting body.
Yet another object of the invention is to provide a galvanic isolator conduit fitting wherein conduit attachment means are located at each end of a conduit body and the attachment means at one end of the body is rotatably adjustable with respect to the remainder of the body to permit alignment of bolt holes, and other misalignment problems that may exist.
An additional object of the invention is to provide a galvanic isolator conduit fitting employing a dielectric elastomer to interrupt electrical conductivity, the elastimer being bonded to its support component.
In the practice of the invention a conduit fitting includes a body having attachment ends located at each body end. The ends may include flanges or other attachment structure wherein the fitting may be incorporated into a conduit system.
One of the attachment ends is connected to a body end through a thin elastomeric shield or boot which encompasses an outwardly radially extending shoulder defined on the associated fitting end. The associated attachment end includes structure for associating with the elastomer encompassed shoulder and mechanical means associated with the attachment end supports the attachment end on the body in an electrically insulated relationship. The attachment means and the associated elastomer encompassed shoulder are configured to constitute a unitary assembly wherein shipping and inventorying the fitting maintains all of the required fitting components together as a unit in preparation for installation.
In an embodiment of the invention a fitting attachment end associated with the elastomer includes a bearing mounted upon the elastomer to permit rotative adjustment of the attachment end relative to the associated fitting body end for alignment and assembly purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and advantages of the invention will be appreciated from the following description and accompanying drawings wherein:
FIG. 1 is an elevational, diametrical sectional view of an elbow conduit fitting in accord with the invention,
FIG. 2 is an elevational sectional view taken along Section II--II of FIG. 1,
FIG. 3 is an elevational, diametrical sectional view of another embodiment of a conduit fitting incorporating the concepts of the invention,
FIG. 4 is an elevational sectional view taken along Section IV--IV of FIG. 3,
FIG. 5 is an elevational, diametrical sectional view of a galvanic isolator conduit fitting embodiment incorporating the invention wherein rotative adjustment between a fitting attachment end and the fitting body may be made,
FIG. 6 is an elevational sectional taken along Section VI--VI of FIG. 5, and
FIG. 7 is an enlarged, detailed, sectional view of the embodiment of FIG. 5 illustrating the configuration of the attachment shoulder, elastomer and bearing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A basic version of a galvanic isolator conduit fitting utilizing the concepts of the invention is shown in FIGS. 1 and 2. The overall fitting 10 includes a body 12, which, in the disclosed embodiment, constitutes a 90° elbow. The body 10 includes flat ends 14 and 16 and an internal passage 18. At its upper end as shown in FIG. 1, the fitting 10 includes attachment end 20 having a passage 22 which aligns with passage 18, and the attachment end 20 includes a flat end 24 which engages the body end 14 and at this junction the body 12 and attachment end 20 are welded together in a fluid tight relationship.
The attachment end 20 includes a radial flange 26 having a plurality of bolt holes 28 defined therein whereby bolts may be used to attach the flange 26 to the flange of the adjacent conduit fitting, not shown.
The other fitting attachment end 30 includes a passage 32 which is aligned with body passage 18 at end 34 which engages the body end 16 and the attachment end 30 is welded to the body 12 at the junction of end edges 16 and 34. The attachment end 30 includes a radially outwardly extending shoulder 36 which is defined by a radial end surface 38 perpendicular to the axis of the passage 32. The shoulder 36 also includes a generally cylindrical peripheral surface 40 and an oblique inner surface 42 intersects the periphery 40 defining the third surface of the shoulder. The attachment end exterior surface 44 adjacent the shoulder 36 is cylindrical.
Galvanic isolation is achieved by the dielectric rubber elastomer 46 which is of a configuration complementary to surfaces 38, 40, 42 and 44, and the elastomer is bonded to these attachment end surfaces in an intregal manner. The elastomer 46 may be formed of rubber or rubber-like materials, or epoxy or polyethylene.
A face plate 48 of an annular configuration is bonded to the radial portion of the elastomer engaging shoulder surface 38, and the face plate also includes a cylindrical axially extending portion 50 overlying the elastomer engaging the shoulder periphery 40 to which it is bonded.
An annular mounting flange 52 encircles the shoulder 36, elastomer 46 and face plate 48, and the mounting flange 52 includes a central recess which is defined by the cylindrical axially extending surface 54, the oblique radially disposed surface 56 and the cylindrical surface 58 which engages the face plate periphery 50. Together, the surfaces 54, 56 and 58 define a concentric recess within the mounting flange 52. The elastomer 46 is also bonded to surfaces 54, 56 and 58.
The mounting flange 52 is provided with a plurality of bolt holes 60 whereby the adjacent conduit fitting shown in dotted lines which includes a flange 62 may be attached to the mounting flange by bolts 64. The adjacent fitting flange shown in dotted lines includes a recess receiving O-ring 66 which engages the face place 48 in a sealed relationship.
In the construction of the fitting 10, the attachment end 20 is welded to the body end 14 and the attachment end 30 is welded to body end 16. To prevent the heat of the welding from adversely affecting the bonding of the elastomer 46 to its contiguous surfaces the metal welding occurs before the elastomer bonding takes place.
The above described assembly sequence assures that the mounting flange 52 will be firmly mounted upon the body 12 and the elastomer 46 and face plate 48 will all be in place. The fact that the diameter of shoulder 36 is greater than the diameter of surface 54 makes the assembly "fail safe", and the elastomer is preferably loaded under compression to insure against structural failure even if the bonding fails. Also, the elastomer limits leakage as it will function as a gasket. Thus, the assembly shown in full lines in FIG. 1 constitutes a unitary galvanic isolator conduit fitting which may be packaged and inventoried as a unit.
It will be readily appreciated from FIGS. 1 and 2 that attachment of the mounting flange 52 to the associated conduit fitting flange by means of bolts 64 will produce an electrical isolation between the mounting flange 52 and the body 12 preventing electrical or galvanic flow between the mounting flange 52 and the flange 26. The construction provides a high strength, low cost, concise fitting capable of effective galvanic isolation.
A variation of the concept of the invention is shown in the fitting illustrated in FIGS. 3 and 4 wherein components similar to those previously described are indicated by primed reference numerals.
In this embodiment the fitting 58 includes a body 12' having an attachment end 20' welded thereto which includes flange 26'. At its other end, the fitting body 12' includes the attachment end 30' having a shoulder 36' defined by surfaces 38' 40' and 42' similar to those previously described.
The mounting flange 70 includes a bore 72 which aligns with the passage of the attachment end 30' and the radial flange extension 74 includes bolt holes for attachment of the fitting to a typical conduit fitting of similar configuration, not shown.
The mounting flange 70 also includes a collar or shoulder 76 which is the mirror image of the shoulder 36' and is defined by corresponding surfaces including a radial end surface 78 identical to the previously described end surface 38'.
The elastomer 80 is formed of a rubber dielectric material and includes identical wing portions 82 extending from a base portion 84. A homogenous radial separation elastomer portion 86 extends inwardly from the base 84 separating the surfaces 38' and 78.
A clamping band encircles the shoulders 36' and 76 and the elastomer 80 and consists of semicircular portions 88 and 90 each of which include radially extending ears 92 through which the clamping bolts 94, extend, FIG. 4.
The assembly of the fitting 68 will be readily appreciated. Upon the shoulders 36' and 76 being related in an opposed relationship and the elastomer 80 located upon the shoulders, the clamp portions 88 and 90 are placed upon the elastomer and tightly clamped together by bolts 94. Prior to tightening the bolts 94 the flange 70 may be rotated about its axis to the desired rotational position with respect to body 12' and upon tightening the bolts 94 a high strength mechanical interconnection between the attachment end 30 and the mounting flange 70 is achieved. As the dielectric elastomer 80 insulates the attachment end 30' from the mounting flange 70, and likewise insulates the clamp relative to the other fitting components, this embodiment of the invention, likewise, forms an effective barrier against galvanic conduction and corrosion.
A third version of a fitting incorporating the inventive concepts is shown in FIGS. 5-7. In this embodiment components similar to those previously described are indicated by double primed reference numerals.
The fitting 96 includes an elbow configuration body 12" upon which the attachment end 20" is welded. In FIG. 5 a flanged component of the associated conduit system is represented in dotted lines comprising the flange 98 wherein bolts 100 attach the flange 98 to the attachment end 20". It will be appreciated that a similar flange would normally be associated with the attachment end 20 and 20' of the previously described embodiments.
The other end of the fitting includes the attachment end 30" having the previously described shoulder 36" extending therefrom which is encompassed by the elastomer 46" bonded thereto as described with respect to FIG. 1. A metal bearing 102 is bonded to the elastomer and is of a configuration which will be readily appreciated from FIGS. 5-7. The bearing 102 is formed of metal and completely encompasses the elastomer 46" and is bonded thereto. The radial portion of the bearing is defined by surface 104 which is bonded to the radial surface of the elastomer, and the bearing includes a bore 106 in alignment with the bore of the attachment end 30". A mounting flange 62" of the adjacent conduit fitting is shown in dotted lines and bolts 64" interconnect the mounting flange 52" to the flange 62".
The recess defined in the mounting flange 52" which receives the shoulder 36", the elastomer 46" and the bearing 102 as defined by the surfaces 54", 56" and 58" are slightly larger in diameter than the outer dimensions of the bearing 102 whereby reception of the bearing within the mounting flange recess permits rotation of the mounting flange on the bearing and the attachment end 30". Thus, the mounting flange 52" may be rotatably positioned on the attachment end 30" prior to tightening of the bolts 64". This rotation permits proper alignment of the mounting flanges interconnected by the bolts.
It will be appreciated that the embodiment of FIGS. 5-7 effectively establishes insulation between the mounting flange 52" and the other fitting components 12", 20" and 30", and this embodiment also galvanically isolates the conduit fittings associated with mounting flange 62" from those attached to the flange 98.
As with the previously described embodiments, the components shown in FIGS. 5-7 are assembled in such a way that they constitute a unit and the bearing 102 cannot separate from the elastomer 46", nor can the elastomer separate from the shoulder 36". The presence of the shoulder surface 42' and the mounting flange recess surface 56" limits axial movement of the mounting flange 52" to the left, FIG. 5, and the fitting components cannot be separated from each other and the entire fitting can be shipped, packaged and inventoried as a single unit.
It is appreciated that various modifications to the inventive concepts may be apparent to those skilled in the art without departing from the spirit and scope of the invention. | A conduit fitting for use in conduit systems having attachment structure at each end which is galvanically isolated from each other to prevent galvanic corrosion and deterioration. The fitting components are assembled to constitute a unit to facilitate handling and inventory. | 8 |
NATURE OF THE INVENTION
This invention relates to lubricant and liquid fuel compositions. More specifically it is concerned with the borated reaction products of polyalkenyl-substituted succinimides, aldehydes, and triazoles useful as multifunctional detergents, dispersants, and antioxidants in lubricant compositions as well as fuel compositions.
BACKGROUND OF THE INVENTION
Impurities occuring due to the particular lubricant and/or fuel utilized in internal combustion and diesel engines can produce soluble and insoluble materials which can be responsible for deposits on vital engine parts. Other impurities may result from handling and the corrosion of storage vessels and may even be introduced by the refiner to prevent or solve other problems such as oxidation. These impurities can also result in the formation of deposits in the engine. The eventual result is poor engine performance with increased noise, starting problems and decreased power output and fuel economy. A primary purpose of this invention accordingly is to provide an additive for lubricants and liquid hydrocarbyl fuels, which will help reduce engine deposits and improve the stability and cleanliness of lube oil and fuel compositions.
Polyisobutenyl succinimides are well known in the art as detergent dispersant additives for lubricants. Post reaction of these succinimides to incorporate other functionality is also known; U.S. Pat. Nos. 4,636,322; 4,713,187; 4,713,191 and 4,747,964 are recent examples. The products described in these patents, however, do not contain triazoles, which are known to possess several properties such as anti-corrosion, antiwear, metal passivation, etc. These properties will also be exhibited by the products of this patent application which contain triazoles. The incorporated boron will add additional layers of multifunctionality to the product, for example friction reducing properties. The multifunctional additives described below have applications in mineral and synthetic oils as well as in greases and fuels. However, no art is known to applicants which discloses or suggests borated triazole-substituted polyalkenyl succinimides as multifunctional lubricant or fuel additives.
SUMMARY OF THE INVENTION
Briefly stated this invention comprises a lubricant composition or fuel containing a major portion of a lubricant or fuel and a minor portion of an additive which is the borated reaction product of a polyalkenyl-substituted succinimide, an aldehyde, and a triazole. The invention further comprises the method for making the additive composition. The additive itself is a multifunctional additive having detergent/dispersant, anti-rust, anti-wear, and friction reducing activity.
DESCRIPTION OF THE INVENTION
As indicated above this invention comprises a lubricant or liquid hydrocarbyl fuel composition containing the borated reaction product of a polyalkenyl-substituted succinimide, an aldehyde, and a triazole. The substituted or modified succinimides have the following generalized structural formula: ##STR1## where R is an alkyl or alkenyl group of 9 to 150 carbon atoms, and X is 1 to 4. Although polyisobutylene is a particularly preferred substituent, other non-limiting substituents are polypropylene, other polyolefins, as well as monomeric olefins.
The triazoles have the following generalized structural formula: ##STR2## where R 1 is hydrogen or an alkyl, aryl, arylalkyl, or alkylaryl group of 1 to 12 carbon atoms. A preferred triazole is tolyltriazole.
The aldehyde used in preparing the reaction product can be alkyl, aryl, alkylaryl, or arylalkyl containing 1 to 12 carbon atoms. Included are benzaldehyde, salicylaldehyde, and 2-ethylhexanal. Also included are formaldehyde and paraformaldehyde which is more preferred.
Triazoles are attached to alkyl succinimides using an aldehyde as shown below in the suggested, but not limiting, structure. The polyalkenyl-substituted succinimide, aldehyde, and triazole are reacted preferably at a temperature of 100° C. to 200° C. at ambient pressure. If desired the reaction can be conducted in a carrier solvent such as xylene or toluene and in a non-reactive atmosphere. Although we do not wish to be bound by it, it is thought that the non-borated reaction product may have the below generalized structural formula: ##STR3## where R is an alkyl or alkenyl group of 9 to 150 carbon atoms, R 1 and R 2 are each hydrogen or an alkyl, aryl, arylalkyl, alkylarlyl group of 1 to 12 carbon atoms, y is greater than 0, and x+y is equal to 1 to 4.
The amines used to make the succinimides include but are not limited to poly(ethyleneamines) such as diethylene triamine, triethylene tetramine, tetraethylene pentamine, and pentaethylene hexamine. Other polyamines such as poly(propyleneaminesl and other amines which contain at least three nitrogens, each of which being primary or secondary can be used.
The reaction products described above are then borated by reaction with boric acid or other suitable borating agent to add additional desirable properties. However, the borating agent may be added to the reaction at any convenient point. Suitable borating agents in addition to boric acid include metaborates, trialkyl borates, borate esters or any suitable boronating agent known in the art. An excess of boronating or borating agent may be used if desired. Generally speaking, the substituted succinimide, aldehyde, triazole and boronating agent are reacted in a mole ratio respectively of 1:0.1:0.1:0.1 and 1:4:4:4, preferably 1:1:1:1 to 1:2:2:2.
In preparing a suitable lubricant composition the additive is added at a rate of between about 0.01% to 10% by weight of the total composition. The additive is added to fuel in range of 25-1000 pounds per thousand barrels of fuel.
It is to be understood that the compositions described herein can also contain other materials. For example, corrosion inhibitors, co-antioxidants, and the like can be used.
In general, the mineral oils, both paraffinic, naphthenic and mixtures thereof, employed as a lubricating oil or as the grease vehicle, can be of any suitable lubricating viscosity range, as for example, from about 45 SSU at 100° F. to about 6000 SSU at 100° F., and preferably from about 50 to about 250 SSU at 210° F. These oils may have viscosity indexes ranging to 100 or higher. Viscosity indexes from about 70 to about 95 are preferred. The average molecular weights of these oils can range from about 250 to about 800.
Where the lubricant is employed as a grease, the lubricating oil is generally used in an amount sufficient to balance the total grease composition, after accounting for the desired quantity of the thickening agent, and other additive components included in the grease formulation. A wide variety of materials can be employed as thickening or gelling agents. These can include any of the conventional metal salts or soaps, such as calcium, or lithium stearates or hydroxystearates, which are dispersed in the lubricating vehicle in grease-forming quantities in an amount to impart to the resulting grease composition the desired consistency. Other thickening agents that can be employed in the grease formulation comprise the non-soap thickeners, such as surface-modified clays and silicas, aryl ureas, calcium complexes and similar materials. In general, grease thickeners can be employed which do not melt and dissolve when used at the required temperature within a particular environment; however, in all other respects, any material which is normally employed for thickening or gelling hydrocarbon fluids for forming grease can be used in preparing the aforementioned improved grease in accordance with the present invention.
In instances where synthetic oils, or synthetic oils employed as the vehicle for the grease, are desired in preference to mineral oils, or in preference to mixtures of mineral and synthetic oils, various synthetic oils may be utilized successfully. Typical synthetic oil vehicles include polyisobutylenes, polybutenes, hydrogenated polydecenes, polypropylene glycol, polyethylene glycol, trimethylol propane esters, neopentyl and pentaerythritol esters, di(2-ethylhexyl) sebacate, di(2-ethylhexyl) adipate, dibutyl phthalate, fluorocarbons, silicate esters, silanes, esters of phosphorus containing acids, liquid ureas, ferrocene derivatives, hydrogenated synthetic oils, chain-type polyphenyls, siloxanes and silicones (polysiloxanes) and alkyl-substituted diphenyl ethers typified by a butyl-substituted bis(p-phenoxy phenyl) ether, and phenoxy phenylethers.
It is to be understood that the grease compositions described herein can also contain other materials, e.g., corrosion inhibitors, extreme pressure agents, viscosity index improvers, antioxidants, antiwear agents and the like can be used. These include, but are not limited to, phenates, sulfonates, succinimides, zinc dialkyl or diaryl dithiophosphates, and the like.
Suitable liquid fuels include liquid hydrocarbon fuels or oxygenated fuels. Accordingly, these hydrocarbyl or hydrocarbyloxy fuels include gasoline, fuel oils, diesel oils and alcohol fuels such as methyl and ethyl alcohol, gasohol and ethers and mixtures thereof.
EXAMPLE 1
6.7 gm (0.05 mole) of tolyltriazole, 146.5 gm (0.05 mole) of a polyisobutenyl succinimide (the reaction product of tetraethylene pentamine and a polyisobutenyl succinic anhydride which is the reaction product of maleic anhydride and a 920 MW polyisobutylene), and 150 ml of toluene were charged to a 1000 ml reactor equipped with an N 2 inlet, mechanical stirrer, thermometer, and a Dean Stark trap. The temperature was raised to 75° C. and 1.5 gm (0.05 mole) paraformaldehyde was added. The reaction was brought to reflux. After five hours at 135° C., 1.0 ml of water had been collected. The reaction was cooled to room temperature and 3.1 g (0.05 mole) boric acid and 50 ml toluene were added. The mixture was brought to reflux. After three hours at 125° C., 1.3 ml of water had been collected. The reaction was filtered through a bed of celite and the solvent was removed by rotary evaporation. The resultant vary viscous brown product contained 0.24% boron.
EXAMPLE 2
The procedure from Example 1 was followed with the following exception: The polyisobutenyl siccinimide to tolytriazole to paraformaldehyde to boric acid was changed from 1:1:1:1 to 1:2:2:2. The resultant product contained 0.29% boron.
EXAMPLE 3
The procedure from Example 1 was followed with the following exception: The polyisobutenyl siccinimide used was made from a 460 MW polyisobutylene. The resultant product contained 0.54% boron.
EVALUATION
The following examples were evaluated in the B-10 Oxidation Test to show the antioxidant capabilites of these multifunctional additives at 1% level in a solvent paraffinic neutral base oil. The Oxidation Test may be summarized as follows: Basically the lubricant is subjected to a stream of air which is bubbled through the oil formulation at the rate of five liters per hour at 325° F. for 40 hours. Present in the composition are samples of metals commonly used in engine construction, namely iron, copper, aluminum and lead, see U.S. Pat. No. 3,682,980 incorporated herein by reference for further details.
B-10 Catalytic Oxidation Test
325° F., 40 Hours
______________________________________B-10 Catalytic Oxidation Test325° F., 40 HoursItem % Δ KV______________________________________Base Oil (100% solvent 136.0paraffinic neutral mineral oil)1% Example 1 in above base oil 92.71% Example 3 in above base oil 70.1______________________________________
The test data clearly documents the improved products and compositions of the present invention. | Disclosed is an additive for lubricant or fuel compositions comprising the boronated reaction product of polyalkenyl-substituted succinimides, aldehydes and triazoles. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to high pressure pumps which operate above 10,000 p.s.i. of the type having a reciprocating plunger or shaft portion.
2. Description of the Prior Art
Pumps for pumping liquids and gases under high pressures typically have one or more cylinders, each cylinder having a reciprocating piston or plunger within. Usually a piston refers to a body which moves within a cylinder having seals or rings which are attached to and travel with the piston. A plunger usually moves relative to a seal attached to a cylinder. Normally a closure having a port therethrough is attached to the distal end of the cylinder. Leakage of fluid around the piston or plunger can typically be prevented by various seals and packings. The seals range from simple O-rings to multiple rings of various materials such as elastomers, polymers, rubber, reinforced combinations thereof, brass and teflon. Such a complex seal is disclosed, for example, in U.S. Pat. No. 2,991,003 to R. S. Peterson.
Very often seals are positioned between the moving plunger and the cylinder wall. Consequently, there is relative movement between the seal and the plunger. The art has recognized that if known types of plunger sealing rings are constructed of a soft enough material to provide an effective seal, the seals rapidly become worn and lose their efficiency. On the other hand, if the seals are constructed of a relatively hard material to withstand wear they generally do not provide a good seal. In addition, hard seals may cause scratching or galling of the surfaces which slide past the seal. As the pressure of the pumped fluid is increased the problem of seals is magnified. As a result, in many pumps the pressure is limited by the effectiveness of the seals.
The art has attempted to reduce the wearing and galling problems associated with harder seals by increasing the hardness of the cylinder or plunger surfaces. This can be done by various surface hardening treatments, coating the wall with carbide or using higher strength alloys. All of these techniques increase the cost of the pump and make manufacturing more difficult. Carbide coatings are also brittle and are intolerant of high tensile stress. Furthermore, in some pumps the corrosiveness of the working fluid may limit the choice of alloys. Consequently, there is a need for a relatively low cost sealing system for high pressure pumps particularly for those pumps which operate at pressures above 10,000 p.s.i. There is also a need for a sealing system which is not dependent upon the metals chosen for the cylinder.
Professor Bridgeman in his book The Physics of High Pressure, McMillan Publishing Company, N.Y., 1931, proposed a seal which relied upon a principle of unsupported area sometimes called Bridgeman's principle. Bridgeman states that in order to effect a seal, the hydrostatic pressure in the packing must be maintained at a pressure higher than pressure to be sealed. Prior to the present invention, the art has made only limited application of Bridgeman's principle to piston designs particularly high pressure pumps. For example, in U.S. Pat. No. 4,382,750 to Robertson et al. a free piston compressor for gases and liquids is disclosed in which the positive pressure of the incoming fluid holds a free piston against the piston rod during the intake stroke. Leakage of hydraulic fluid around the piston is prevented by a packing and associated bushing. Although the operation of this bushing and packing are not explained in the specification, one can see from the drawings that Bridgeman's principle is applicable to this system.
The art has commonly relied upon mechanically loaded packings, such as Amagat's fully enclosed packing for high pressure pumps. In a mechanically loaded design, the axial load is supplied by a preloaded gland or flange and is not increased by increasing operating pressure. Under such conditions, the packing wears at much the same rate at low pressure as it does under high pressure. This occurs because the packing pressure does not depend upon the operating pressure. Likewise, operating pressure is limited to something less than the preload pressure of the packing. Consequently, operations at high pressure, 60,000 p.s.i. for example, in systems that have mechanically loaded seals require seals having tremendous preloads. For that reason, there is need for a high pressure pump which does not require a highly preloaded packing and which can operate at pressures of 60,000 p.s.i. and higher.
SUMMARY OF THE INVENTION
I provide a cylinder having an arrangement of seals for a high pressure pump which is not limited by the strengths of the material under load. My seal will work up to the point of failure of the boundary components, the high pressure cylinder, bushing, sleeve, cap or spacer whichever fails first. My cylinders are usable in a variety of applications such as, but not limited to liquid pumps, gas compressors, and apparatus having reciprocating or rotary shaft seals as well as those having stationary shaft seals. My system may be used in conjunction with any shaft seal or packing configuration which requires actual loading to be effective. Consequently, one can use flat washers, tapered washers or any combination of these.
My seals are adapted for a system having a plunger which moves within a cylinder having at one end a cap with a central port through which fluid may be pumped at high pressure. I prefer to provide a sleeve surrounding the outer circumference of the plunger. The sleeve extends the length of the cylinder so that one end of the sleeve will overlap the cap at one end of the cylinder and the second end of the sleeve will always overlap the plunger throughout its stroke. I prefer to provide a first seal at the plunger end of the sleeve and a second seal at the cap end of the sleeve. These seals are rings which surround either the piston or the cap. Beyond the cap seal I provide a vented channel between the cylinder wall and the cap. In the channel I provide a spacer which surrounds the cap and is sized to create a first cavity between the cap and the spacer and a second cavity and between the spacer and the cylinder wall. I provide a vent through the spacer which connects the two cavities and a second vent through the cylinder wall which vents the second cavity to atmosphere. This venting provides the unsupported area for the seal. Finally, I provide a third seal on the other end of the spacer between the cap and the cylinder wall. In the preferred embodiment, the seals, spacer, cap, cylinder and sleeve are all sized to utilize Bridgeman's principle and provide effective seals for high pressure systems.
Other objects and advantages of the invention will become apparent as a description of the drawings and preferred embodiments thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view partially in section of a hydraulic pump cylinder which utilizes my seals;
FIG. 2 is an enlarged view, partially in section, of a portion of the embodiment of FIG. 1;
FIG. 3 is another enlarged view, partially in section, of a portion of the embodiment of FIG. 1 and in which certain pertinent diameters are labeled;
FIG. 4 is a diagram showing the forces acting on the cap of the hydraulic pump cylinder of FIG. 1;
FIG. 5 is a fragmentary view of a hydraulic pump cylinder similar to that shown in FIG. 1, but having a second preferred seal arrangement; and
FIG. 6 is a fragmentary view similar to FIG. 5, but having a third preferred seal arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, I provide a reciprocating piston 10 having plungers 12 and 13 attached on opposite sides. Piston 10 reciprocates in cylinder 14. Movement of the piston within cylinder 14 is accomplished by fluid which flows through orifice 15 or orifice 16 depending upon the direction of movement. Plungers 12 and 13 are attached to piston 10 and move within cylinders 20 and 30. Appropriate valves and other fittings (not shown) may be connected to the distal end of each cylinder 20 and 30. Cylinders 20 and 30 are mere images of one another. Consequently, only cylinder 20 need be described. Within cylinder 20 I provide a sleeve 22 which surrounds plunger 12. Sleeve 22 is sized so that when plunger 12 is in its retracted or right most position sleeve 22 will extend past the end of the plunger. Sleeve 22 is also sized to overlap a cap 40 having an outlet port 39. At one end of sleeve 22 I provide a first seal 24. A second seal 26 is provided at the opposite end of sleeve 22 and surrounding cap 40. Within cylinder wall 20 and adjacent to cap 40, I provide a channel 42. I prefer to construct cap 40 so as to have an enlarged portion which extends into channel 42 and a collar 43 at one end. The collar 43 is sized so as to close the channel 42 radially between the cap and the cylinder wall. Within the channel 42 I prefer to provide a spacer 44 which is sized so as to define a first cavity 46 between the cap and the spacer and a second cavity 47 between the spacer and the cylinder wall. Within the spacer 44 I provide at least one vent 45 which permits fluid to flow between the two cavities. I also provide a vent 50 through the cylinder wall which vents the cavity to atmosphere. This venting arrangement creates a system whereby the first cavity 46 between the cap 40 and the spacer 44 and the second cavity 47 between the spacer 44 and cylinder wall will always be at atmospheric pressure. The length of the channel 42 as well as the size of the first and second cavities 46 and 47 are not important as long as they allow axial freedom of movement of the spacer 44 with respect to the cylinder and the cap with respect to the spacer within the channel 42. I further prefer to provide a third seal 28 between the cap and the cylinder wall. This seal 28 and the second seal 26 are positioned so as to be at opposite ends of the spacer 44. The seals can be made from a variety of thermoplastic and elastomeric materials. The choice of materials will depend upon compatibility of the material with the working fluid. The seals may also be comprised of one or more rings or washers of the same or different materials. A plug or closure 52 at the distal end of the cylinder 20 with fluid passageway for the inlet and pumped fluid, completes the assembly.
To understand the operation of my seals one must consider the pressure which acts on each seal. These pressures are related to the surface area of each seal which in turn is a function of the diameters of the cylinder, plunger sleeve and cap.
In FIG. 3, I provide a diagram of the embodiment of FIG. 1 with the components and pertinent diameters labeled. In the drawing
d 1 is the smallest inside diameter of the cylinder,
d 2 is the largest diameter of the cap,
d 3 is the diameter of the middle section of the cap,
d 4 is the smallest diameter of the cap,
d r is the diameter of the plunger 12.
In general d r =d 4
The first, second and third seals 24, 26 and 28 are labeled in FIG. 3 with the designations A, B and C, respectively. In this system the pressures acting on the seals A, B and C can be expressed as P A , P B and P C , respectively. Let P i be the operating pressure of the pump. It is convenient to define the packing pressure ratios: ##EQU1##
Referring to the free body diagram of the cap shown as FIG. 4, the process pressure P i acting on the area of a cap of diameter d 2 , is counterbalanced by two forces. The first force F 1 is that of process pressure acting on the area of diameter d 4 . The second force F 2 is supplied at C by the pressure of a deformable seal acting on the difference in area of diameters d 2 and d 4 . Since d 2 is greater than d 3 and d 3 is greater than d 4 , the pressure in the seal at C, P c , must be greater than the process pressure P c .
This second force F 2 is transmitted axially through the spacer to the packing at B. Diameter d 1 is selected such that the packing pressure at B, P b , which is a result of this transmitted force, is always proportionally greater than the working pressure P i .
The second force F 2 at B is also transmitted axially through the sleeve to the rod seal at A. If d 4 =d r then P A =P B ; and the rod seal pressure (P A ) is also greater than the process pressure, P i and R A =R B . This neglects the effects of friction which I have found, by experiment, to be insignificant.
The pressures and forces just discussed can be derived from the following calculations. A diagram of the forces acting on the cap is shown in FIG. 4. From the force balance on the cap, ##EQU2## Which allows the selection of diameters.
The separation of pressure between seals B and C and axial freedom of movement between the cap, spacer, sleeve and cylinder must be maintained. Separation of pressure is achieved by porting the annular space between the cap and the spacer and between the spacer and pump cylinder through the spacer and pump cylinder. This prevents pressure build-up in these annuli that would prevent pressure activation of these seals.
These annuli also allow relative axial movement between the cap, spacer and pump cylinder to compensate for packing wear and elasticity.
In my system I have a pressure energized rod seal. The pressure in the packing is always greater than the working pressure. Diameters d 1 , d 2 , d 3 and d 4 can be chosen to give any seal pressure ratio desired. My seal is suitable for reciprocating applications or rotating applications or both. In my system packing pressure varies in proportion to applied pressure and is always greater than the working pressure. Because it is pressure activated, the seal is suitable for extremely high pressures. The packing may be preloaded by suitably placed springs for enhanced operation at low pressures, however, other seals may be more economical for pumps operating at pressures below 3,000 to 5,000 p.s.i.
In FIGS. 5 and 6 I have shown other present preferred embodiments of my cylinder which do not use a spacer. The pump cylinder of these embodiments is generally the same as that shown in FIG. 1. However, the cap and adjacent seals are modified as shown in these figures. Despite these differences, the same principles of operation apply to all embodiments.
In the embodiment of FIG. 5 I provide a cylinder 20 and sleeve 22 as in the previous embodiment. At the end of the sleeve 22 which is adjacent the cap 124 I provide a seal 126. Cylinder 20 has a channel 42. Cap 124 is sized to have a base 143, a body portion 141 which fits into channel 42, a shoulder 139 which fits into the main bore of cylinder 20 and a head 137 which fits into sleeve 22. Another seal 128 is provided between cylinder 20 and the body 141 of cap 142. Cap 124 is positioned in cylinder 20 to define a cavity 145. This cavity is vented by vent 50.
A somewhat different cap is used in the embodiment of FIG. 6. This cap has a base 143, a body 141 and a shoulder 139 which abuts sleeve 22. A first seal 127 is provided between the shoulder 139 and the cylinder 20. A second seal 128 is provided between the cylinder 20 and body 141 of the cap.
In my system loading of the packing is independent of the packing volume because the packing pressure is maintained and automatically adjusts for wear.
The packing set may include metallic anti-extrusion rings in addition to the polymer rings. Also, the rings may be of non-rectangular cross section (tapered, diamond shaped, etc.).
Packing wear is minimized because the packing pressure is not constant. Instead, the packing pressure is proportional to the working pressure and is only enough to effect the seal. This is superior to a preloaded packing design, where the packing pressure is always high.
Under my seals the highest pressure attainable is limited only by the strengths of the packing boundaries. That is, the seal will work up to the point of failure of the high pressure cylinder, plunger, cap, bushing or sleeve, whatever fails first.
My seals are usable in a variety of applications, such as, but not limited to liquid pumps, gas compressors and pumps having reciprocating or rotary-shaft seals as well as those having stationary shaft seals. However, I envision that my system will be most useful for high-pressure water intensifiers for use in waterjet cutting. In my system one may use any shaft seal or packing configuration which requires axial loading to be effective. These include, but are not limited to flat washers, tapered washers, or any combination thereof.
The advantage of a stationary seal on a moving plunger is well-known in the industry. Whereas the high pressure cylinder is primarily stressed in tension, the plunger is primarily stressed in compression. This allows the use of extremely wear-resistant materials such as carbides or ceramics for the plunger which, although very strong in compression, may fail under relatively low tensile stress. In a piston pump (seal moving with the piston), as opposed to a plunger pump (plunger moving through stationary seal), selection of materials for the cylinder is limited by the often conflicting requirements for wear resistance, corrosion resistance, ductility and high strength. In my system, less rigid wear resistance, ductility and strength requirements exist which allows greater freedom of choice for cylinder materials.
Although I have disclosed certain present preferred embodiments of my system it should be understood that the invention is not limited thereto, but may be variously embodied within the scope of the following claims. | An improved cylinder for pumps of the type where a plunger moves within a cylinder forcing fluid through a port in a cap fitted into one end of the cylinder. A multiple diameter cap encircled by a multiple diameter sleeve transmits the pressure force acting on the largest surface area of the cap through the sleeve to a smaller area acting on the packing seal. Since the pressure multiplied by the area is a constant, a higher pressure is applied to a smaller area at the seals; and with a higher pressure acting on the seals than existing in the working fluid, a seal is created to prevent passage of the fluid. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to the assignment of wireless communications mobile terminals to particular cells, and more particularly to the assignment of mobile terminals to particular cells during group calls.
Wireless communications mobile terminals, such as cellular phones and the like, provide a wide variety of services. One increasingly popular service is so-called conference or group call service, wherein a plurality of users having different terminals (mobile or otherwise) are connected together and able to transmit and receive to all of the other active members of a user group. To implement group call functionality in wireless communications system, a user group identification (UGID) code is typically assigned to each of a number of different subsets of mobile terminals. See, for example application Ser. No. 09/192,185, entitled “User Group Indication and Status Change In Radiocommunications Systems,” which is incorporated herein by reference.
From a system point of view, one advantage of group calls is that multiple mobile terminals may be able to share a single downlink traffic channel within a given cell, rather than having to have separate downlink traffic channels assigned for each mobile terminal. Further, multiple mobile terminals within a given cell involved in a group call may also be able to share a single uplink traffic channel with some technologies. Focusing on just the downlink channel for simplicity of illustration, assume five mobile terminals (MT 1 -MT 5 ) are active in the group call and present in the same cell (C 1 ) and two other mobile terminals (MT 6 -MT 7 ) are active in the same group call in another cell (C 2 ). All the mobile terminals in one cell (e.g., C 1 or C 2 ) are typically able to share a single downlink traffic channel assigned to the group call session, rather than having to have separate downlink traffic channels assigned to each mobile terminal. This may result in only two traffic channels being used—one in each cell—rather than seven different traffic channels. From a system point of view, the five channels not used may be assigned to other tasks, thereby allowing for greater overall system capacity utilization.
From time to time during a group call session, a mobile terminal may move from one cell's geographic area to another cell's geographic area and/or the signal quality in a given cell may degrade to a point approaching unacceptable levels. In either case, it may be necessary for the mobile terminal to be assigned to a different cell in order to maintain acceptable performance. That is, the mobile terminal may need to change from communicating with the wireless communications system via base station X to communicating with the wireless communications system via base station Y (or the equivalent in satellite based systems). In circuit switch systems, this process is typically referred to as “handoff,” and is typically controlled by the wireless communications system in a manner well known in the art. In packet data systems, this process is typically referred to as “cell reselection,” and is typically controlled by the mobile terminal in a manner likewise well known in the art.
If the result of the change in cell assignment is that the mobile terminal is assigned to a cell not otherwise actively engaged in the group call, the new cell must allocate a traffic channel under its control to the group call so that the “newly arrived” mobile terminal may continue to participate in the group call. Thus, in the example given above, if mobile terminal MT 3 is moving out of cell C 1 , it will eventually need to have its cell assignment changed via what is known generically as a cell assignment change procedure. If the result is MT 3 being assigned to a new cell C 3 , then cell C 3 must allocate a traffic channel to MT 3 so that MT 3 can remain active in the group call. In such a situation, the total number of traffic channels needed for the group call session would increase from two to three. Because more channels are being consumed by the group call, the overall capacity of the wireless communications system is reduced. If, on the other hand, mobile terminal MT 3 is instead assigned to cell C 2 , where MT 6 and MT 7 are already present and active in the group call, then MT 3 may simply join MT 6 and MT 7 on their shared channel. In this scenario, the number of channels used by the group call does not change, and the change in cell assignment for MT 3 results in essentially no net loss in capacity to the wireless communications system.
From the above, it is clear that minimizing the number of cells that mobile terminals involved in a given group call are assigned to helps preserve the overall capacity of a wireless communications system. However, the existing cell assignment procedures do not take group call participation into account when assigning a mobile terminal to a cell. Thus, there is a need for an improved cell assignment procedure that recognizes that mobile terminals that are active in a group call should be kept in the same cells to the extent reasonably possible.
SUMMARY OF THE INVENTION
The cell assignment process of the present invention strives to minimize the number of cells assigned to mobile terminals involved in any given group call session. When a cell assignment trigger event, also known as a handoff trigger event or a cell reselection trigger event, is encountered during a group call, the decision whether to change cells or not is based at least in part upon whether the relevant cell is already participating in that group call session with another mobile terminal. If so, the cell assignment process preferentially selects such a cell for switching to, or avoids changing cell assignment if already assigned there.
In one embodiment, the present invention preferentially selects cells already participating in the group call session when changing cell assignments. In other embodiments, the present invention avoids reassigning the mobile terminal in response to encountering a trigger event when several conditions are met. These conditions include, generally, the current cell both having at least minimally acceptable performance and currently supporting at least one other mobile terminal of the same group call session, and also that no candidate cells are currently supporting the same group call session. If the three conditions are met, the cell assignment of the mobile terminal is not changed; otherwise the cell assignment of the mobile terminal is changed. In addition, other embodiments of the present invention actively seek out other cells involved in the group call session and seek to change the cell assignments of the mobile terminals involved in the group call session to those cells, even when the signal quality may be acceptable in the current cell. Thus, the mobile terminals involved in the group call session are gradually urged toward congregating in the fewest possible cells under the circumstances.
The decision whether to make the new cell assignment may be made in the mobile terminal or in the wireless communications system with the present invention. Further, the present approach functions in both circuit-switched and packet-data environments. Additionally, one optional aspect of the present invention is to give mobile terminals involved in group call sessions preferential priority when switching cells so as to help minimize disruption to the group call session. Thus, the present invention helps provide better service with less of a system capacity penalty for group call sessions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representation of one embodiment of a wireless communications system wherein the present invention may be practiced.
FIG. 2 is a simplified flow chart showing the overall process flow of one embodiment of the present invention.
FIG. 3 is a simplified flow chart showing the overall process flow of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, like reference characters designate like or corresponding parts throughout the several views. Referring now to the drawings, the improved cell assignment method of the present invention is described. Cell assignment according to the present invention is useful in wireless communications systems, such as that shown schematically in FIG. 1 . The wireless communications system, which is indicated generally by the numeral 10 , includes a plurality of base stations 12 , which are connected via a mobile services switching center (MSC) 14 to a terrestrial communications network such as the Public Switched Telephone Network (PSTN) 16 . Each base station 12 is located in and provides service to a geographic region referred to as a cell. In general, there is one base station 12 for each cell within a given system. Within each cell, there may be a plurality of mobile terminals 20 that communicate via a radio link with the base station 12 . The base station 12 allows the user of the mobile terminal 20 to communicate with other mobile terminals 20 , or with users connected to the PSTN 18 . The MSC 14 routes calls to and from the mobile terminal 20 through the appropriate base station 12 . Information concerning the location and activity status of the mobile terminal 20 may be stored in a Home Location Register (not shown) and/or a Visitor Location Register (not shown) connected to the MSC 14 in a manner well known in the art. A group call services server (GCS) 18 is connected to the MSCs 14 and PSTN 16 for managing the call setup activities for group calling features in a manner well known in the art. When the wireless communications system 10 receives a group call request, the request is forwarded to the GCS 18 . The other components of the system 10 cooperate with the GCS 18 to facilitate the group call.
It is worth noting that a different system architecture is often used for packet data sessions, such as that used in GPRS and Mobile IP. As such, there may be no involvement from the MSC 14 . In essence, the base station 12 is connected to a packet data node, and then to the public packet data network through additional nodes to reach the internet. Furthermore, the concepts of the present invention are applicable to all current and future wireless communication systems, including cdma2000 and WCDMA.
Mobile terminals 20 may communicate with the wireless communications system 10 via what are essentially two types of cellular communication techniques, circuit-switched and packet-switched. A circuit-switched connection is a circuit connection that is established and maintained, usually on demand, between two or more stations to allow the exclusive use of the circuit until the connection is released. A packet-switched connection is a logical connection that is established between two or more stations to allow the routing and transfer of data in the form of packets. The channel is occupied during the transmission of a packet only. Upon completion of the transmission, the channel is made available for the transmission of other packets for the same or other stations. Channel selection procedures, and thus cell assignment procedures, typically vary depending on whether circuit-switched or packet-switched connections are used.
When a mobile terminal 20 is actively involved in a circuit-switched group call session, the present invention may follow the process flow shown in FIG. 2. A list of candidate cells for reassignment is stored (box 110 ). This list may be what is known as a Neighbor List, or the list may take other forms. The intention of the candidate list is to provide a subset of all possible cells that includes the most likely cells that the mobile terminal 20 should be assigned to. Typically, the wireless communications system 10 stores this list and also broadcasts the list to mobile terminals 20 for storage in the mobile terminals 20 . The candidate list may be established before or during the group call session and may change during the group call session, particularly as the mobile terminal 20 moves from one cell to another. The cells on the candidate list are examined to see if they are currently participating in the group call session (box 120 ). For instance, the wireless communications system 10 may simply keep track of all cells currently involved in the group call session and compare the candidate list against this active list. Alternatively, the mobile terminal 20 may monitor the candidate cells, looking for signs of activity in the group call session, such as the presence of the appropriate UGID in a broadcast message. Further still, the wireless communications system 10 may track the cells currently involved in the group call session and transmit this information to the mobile terminal 20 , such as in message directed to all mobile terminals 20 active in the group call session, or in a message directed to only that mobile terminal 20 . Obviously, the list of active cells should be updated frequently to insure that the latest information is being used.
The main portion of the FIG. 2 process begins when a trigger event is encountered (box 130 ). A trigger event is an event that suggests that consideration should be given to the mobile terminal 20 changing cell assignment. For instance, a mobile terminal 20 may note that the signal quality in a given cell is degrading to a point approaching unacceptable levels, such as might be encountered when a mobile terminal 20 approaches a cell boundary. The trigger event may be encountered by the mobile terminal 20 or by the wireless communications system 10 . If the trigger event is encountered by the mobile terminal 20 , the mobile terminal 20 may communicate this situation to the wireless communications system 10 , and vice-versa. Further, it should be noted that box 130 is shown in FIG. 2 as occurring after boxes 110 and 120 for ease of description, but this is not required and box 130 may occur before box 120 or box 110 .
In response to the trigger event, the cell assignment for the mobile terminal 20 is examined and changed if appropriate. In one embodiment, shown in FIG. 2, the cell assignment is changed (box 190 ) unless three conditions are met. First, the current cell must have at least minimally acceptable performance (box 140 ). Because the trigger event is typically encountered when the signal performance is degrading, but still above the minimally acceptable level by some guard amount, it is possible that the signal performance of the current cell will be low enough to constitute a trigger event, but high enough to continue with the current cell for some time. Next, the current cell must be currently supporting at least one other mobile terminal 20 in the same group call session (box 150 ). Finally, no candidate cells of the candidate list (other than the current cell if it is included in the candidate list) must be currently supporting the same group call session (box 160 ). If the three conditions are met, the cell assignment of the mobile terminal 20 is not changed (box 170 ); otherwise the cell assignment of the mobile terminal 20 is changed (box 190 ).
Typically, the wireless communications system 10 is the entity performing the analysis of boxes 140 - 160 ; thus, the wireless communications system 10 typically communicates the change in cell assignment to the mobile terminal 20 by transmitting a cell change instruction to the mobile terminal 20 in a manner well known in the art and appropriate for the protocol being used. For circuit-switched call sessions, this type of instruction is typically referred to as a “handoff” message. The mobile terminal 20 then establishes communications in the new cell as in a manner well known in the art.
It is preferred that the mobile terminal 20 receive preferential treatment from the new cell when changing cell assignments during a group call session. That is, the being-switched mobile terminal 20 should be given greater than normal priority in the “new” cell. For example, if cells typically have a queue for new-to-them calls, the being-switched mobile terminal 20 may be given a preferential position in that queue, or be able to bypass that queue all together. Alternatively, if cells typically reserve a certain number of channels for special purposes, such as for emergency (“911”) calls, while allowing the remaining channels to be freely assigned, the being-switched mobile terminal 20 may be given one of the reserved channels, rather than waiting for one of the regular channels.
Preferably, when the mobile terminal 20 changes cells (box 190 ), it changes to a cell already participating in that group call session. For instance, if there are several candidate cells that would be at least acceptable, the mobile terminal 20 should be assigned preferentially to a cell already participating in that group call session with another mobile terminal 20 . In essence, the candidate cells active in the group call session are given more “weight,” or stated another way are more “attractive.”
It should be noted that the process outlined immediately above results in cell re-assignments being avoided for mobile terminals 20 involved in group call sessions, except when necessary. Thus, the process may be thought of as a cell re-assignment avoidance scheme where the attractiveness of a cell to a mobile involved in a group call session is based at least in part upon whether that cell is already participating in that group call session with another mobile terminal 20 . If so, the cell is more attractive to that mobile terminal 20 and more attractive cells are more likely to be switched into (or retain) mobile terminals 20 involved in that group call session.
When a mobile terminal 20 is actively involved in a packet-data group call session, the present invention also follows a process flow similar to that shown in FIG. 2 . However, in packet-data call sessions, it is much more likely that the mobile terminal 20 will retain control of cell assignments rather than the wireless communications system 10 . Because of this, the mobile terminal 20 typically receives the listing of which candidate cells are active in the group call in a message from the wireless communications system 10 . This message may take a wide variety of forms, including a broadcast message containing a simple bit map to be compared against a Neighbor List, indicating which cells are active in the group call session. Alternatively, the message may be an addressed message directed at just that mobile terminal 20 or at several mobile terminals 20 , such as all those active in the group call session. Likewise, the wireless communications system 10 may send a message that includes an adjustment to a bias weighting parameter used by a cell assignment routine resident on the mobile terminal 20 that deters changes in cell assignment. For instance, in ANSI- 136 systems, a suitable bias weighting parameter is the variable known as SERV 13 SS. In such a manner, the mobile terminal 20 may retain control of the cell assignment process, but be influenced by the wireless communications system 10 to preferentially switch into, or remain with, cells involved in that group call session. Of course, in some packet-data situations, the wireless communications system 10 may control the cell assignment process. Either way, the improved cell assignment process of the present invention tends to minimize the number of cells assigned to mobile terminals 20 involved in any given packet-data group call session.
In some embodiments, the cell assignments mobile terminals 20 involved in a group call session are changed, even when the signal quality may be acceptable in the current cell. As shown in FIG. 3, this active congregation process shares many steps with the process of FIG. 2; differing mainly in that no “trigger event” is required to initiate the cell assignment analysis procedure. Instead, once the mobile terminal 20 becomes involved with the group call session (box 115 ), an active search process begins. Armed with knowledge of which candidate cells are active in the same group call (box 120 ), an examination is made of the current cell. If the current cell is supporting another mobile terminal active in the same group call, the current cell assignment is kept (box 170 ). If not, the process looks to see if any other candidate cells of the candidate list (other than the current cell if it is included in the candidate list) are currently supporting the same group call session (box 160 ). If not, then the current cell assignment is kept (box 170 ). If so, the signal quality of the candidate cells that are otherwise supporting the same group call are examined. If any one of such cells have better than at least minimally acceptable signal performance (box 180 ), then the cell assignment is changed to one of such cells (box 190 ). If not, the current cell assignment is kept (box 170 ). Of course, the cell assignment of box 190 may preferably be to the cell otherwise supporting the same group call that has the best signal quality, or to the one having the most available capacity, or the like. In addition, some level above the minimally acceptable level of signal quality may be used as the decision criterion in box 180 .
Because no degradation in signal quality is required to change the cell assignment under the process of FIG. 3, this active congregation method may result in mobile terminals active in group call sessions changing cell assignments even when the signal quality, and all other aspects, of the current cell are otherwise good, except for absence of other mobile terminals involved in the group call session. Thus, a mobile terminal active in a group call session may change from one “good” cell to another equally “good” cell for no other reason than to congregate with other mobile terminals also involved in the group call session. In addition, under some circumstances, a mobile terminal active in a group call session may change from one “good” cell to a lower quality, even barely marginal, cell for the same reason. Such an approach may be particularly suited to situations involving an overlay/underlay or hierarchical cell layouts. Of course, suitable anti-hysteresis measures should be employed, such as minimum time delays between cell assignment changes, to avoid tying up resources by having mobile terminals chase each other from cell to cell in an endless loop.
While not required, the both the cell re-assignment avoidance aspect and the active congregation aspect are preferably practiced simultaneously. In this fashion, the improved cell assignment process of the present invention may most quickly minimize the number of cells assigned to mobile terminals 20 involved in any given group call session.
The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the spirit and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein. | A cell assignment process strives to minimize the number of cells assigned to mobile terminals involved in any given group call session in both circuit-switched and packet-data environments. In one embodiment, when a cell assignment trigger event is encountered during a group call, the decision whether to change cells or not is based at least in part upon whether the relevant cell is already participating in that group call session with another mobile terminal or not. If so, the cell assignment process preferentially selects such a cell for switching to or avoids changing cell assignment if already assigned there. In another embodiment other cells involved in the group call session are actively sought out and the cell assignments of the mobile terminals involved in the group call session are changed to those cells, even when the signal quality may be acceptable in the current cell. The mobile terminals involved in group call sessions may optionally be given preferential priority when switching cells so as to help minimize disruption to the group call session. Thus, the mobile terminals involved in the group call session are gradually urged toward congregating in the fewest possible cells under the circumstances. Accordingly, the present invention helps provide better service with less of a system capacity penalty for group call sessions. | 7 |
This application is the national phase under 35 U.S.C. § 371 of PCT International Application No. PCT/EP00/03275 which has an International filing date of Apr. 12, 2000, which designated the United States of America, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an electric circuit, in particular for a medium-voltage power converter, having at least four semiconductor switches that form a series circuit and are connected to poles of a direct voltage, a diode being connected in antiparallel with each of the semiconductor switches, and a capacitor being connected in parallel with the two middle semiconductor switches of the series circuit, having a pole of an output voltage that is connected in the middle to the series circuit, and having a control unit for sequentially driving the semiconductor switches. The invention likewise relates to a corresponding method for operating an electric circuit, in particular for a medium-voltage power converter.
2. Related Art
Such an electric circuit is generally known and is used, in particular, in medium-voltage power converters. The direct voltage is connected to the outer two taps of the semiconductor switches forming a series circuit, and the output voltage is present at their common, middle tap. The semiconductor switches are switched by a control unit one after another into their conducting and their blocking states. The resulting AC voltage includes of a sequence of pulses.
Asymmetric voltage splits between the various semiconductor switches can occur because of the ever present differences between the performance quantities of the semiconductor switches connected in series, and this can lead to overloadings of the individual semiconductor switches. Likewise, as a consequence of switching over the semiconductor switches the voltage jump of the individual pulses of the output voltage is very large, and this can lead to overvoltage peaks. These disadvantages are removed or at least lessened in the case of known power converters with substantial outlay on circuitry.
SUMMARY OF THE INVENTION
It is an object of the invention to create an electric circuit and a method of the type mentioned at the beginning hereof which generate low overvoltage peaks buth without requiring a special outlay.
According to the present invention, the object is achieved in the case of an electric circuit of the type mentioned at the beginning hereof by virtue of the fact that a time period between a transition of two semiconductor switches into a respectively conducting state is very short. The object is achieved correspondingly in the case of a method of the type mentioned at the beginning hereof.
It is possible with the aid of the circuit according to the present invention to design individual pulses of an output voltage in a stair-step fashion. The result is thus a stair-stepped variation in the edges of the output voltage, in particular. This means at the same time that only a portion of the total direct voltage is switched at one and the same instant in the case of the output voltage. The voltage jumps of the individual stair steps of the output voltage are therefore smaller than in the case of the known circuit. This leads to lower overvoltage peaks and rates of rise of voltage in the case of the output voltage.
The outlay required by the present invention on circuitry is limited substantially by comparison with the known art to a different drive of the semiconductor switches.
In an advantageous embodiment of the present invention, the time period between the transition of two semiconductor switches is selected as a function of the switching time of one of the semiconductor switches and/or the resonant frequency of the load, if appropriate including the cables present. The time period between the transition of two semiconductor switches is preferably between approximately 0.01 microseconds and approximately 10 microseconds, preferably approximately 2 microseconds. A reduction is thereby achieved in the resulting rate of voltage rise and in the overvoltage peaks at the load.
The time period between two successive stair steps of the output voltage is fixed in this way. Such a short time interval between the stair steps according to the present invention is attended by the substantial advantage that because of the short time interval the capacitors via which a current flows during this interval are loaded only slightly. It is therefore not necessary to provide large capacitors, and so the outlay on circuitry in this regard remains low and can even be reduced by comparison with the known art.
In an advantageous development of the invention, a provision is made of corresponding further semiconductor switches, diodes and capacitors, it being possible for the control unit to control the semiconductor switches of the series circuit into the conducting state one after another. The individual pulses of the output voltage can thereby be designed as finely as desired in terms of the stair steps. At the same time, overvoltage peaks can be further reduced because voltage jumps become ever smaller.
It is particularly advantageous if the capacitance of the capacitor or the capacitors is very small. As already mentioned, this further reduces the outlay on implementing the output voltage of fine stair steps according to the present invention.
In an advantageous refinement of the present invention, the time period between the transition of two neighboring semiconductor switches into the respectively conducting state is a long one, in particular between approximately 100 microseconds and approximately 500 microseconds, preferably approximately 250 microseconds.
In pictorial terms, this long time period generates an offset in the stair-step output voltage. This offset entails the advantage that current harmonics which would arise per se at the usual operating frequencies of the semiconductor switches from approximately 500 Hz to approximately 1000 Hz are strongly damped or reduced to a lesser extent. The diminished current harmonics are achieved in this case in essence only by driving the semiconductor switches appropriately, and so to this extent there is no need for special outlay on circuitry.
The present invention also includes a method for operating an electric circuit in particular for a medium-voltage power converter, the circuit being provided with a plurality of semiconductor switches that form a series circuit and are connected to poles of a direct voltage, a diode being connected in antiparallel to each of the semiconductor switches, a capacitor being connected in parallel in each case starting from the two middle semiconductor switches, the circuit being provided with a pole of an output voltage that is connected in the middle to the series circuit, the semiconductor switches being controlled into their conducting state one after another, and the time period between the transition of two semiconductor switches into the respectively conducting state being very short.
The stair-step course of the output voltage already described is generated with the aid of the abovementioned method according to the present invention. As likewise already mentioned, this essentially requires only one appropriate drive of the semiconductor switches, in which case it is possible to generate either quickly successive stair steps or offsets that are spaced further apart, depending on the time intervals between these drives.
Further features, possible applications and advantages of the present invention emerge from the following description of exemplary embodiments of the invention, which are illustrated in the figures of the drawing. Here, all the features described or illustrated form the subject matter of the present invention per se or in any desired combination, independently of their combination in the patent claims or their back referral and independently of their formulation and/or representation in the description and/or in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a schematic circuit diagram of a first exemplary embodiment of an electric circuit according to the present invention;
FIG. 2 illustrates a schematic timing diagram of the output voltage of the circuit of FIG. 1 ;
FIG. 3 illustrates a schematic circuit diagram of a second exemplary embodiment of an electric circuit according to the present invention;
FIG. 4 illustrates a schematic circuit diagram of a third exemplary embodiment of an electric circuit according to the present invention;
FIG. 5 illustrates a schematic timing diagram of the output voltage of the circuit of FIG. 3 ; and
FIG. 6 shows a schematic timing diagram of the output voltage of the circuit of FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Illustrated in FIG. 1 is an electric circuit 10 that may be used, in particular, in a medium-voltage power converter and with which, for example, an electric motor is fed as a load.
The direct voltage Ud that is polarized according to the data in FIG. 1 is applied on the input side to the circuit 10 . The direct voltage Ud can be in a range from approximately 1 kV to approximately 100 kV, preferably at approximately 16 kV. The circuit 10 transforms the direct voltage Ud into an AC voltage Ua that includes a sequence of pulses.
Three such circuits 10 with the aid of which one phase of a three-phase AC voltage is generated in each case are normally present in a medium-voltage power converter.
Twelve semiconductor switches 11 to 22 are connected in series in the circuit 10 between the positive pole and the negative pole of the direct voltage Ud. The semiconductor switches 11 to 22 are driven by a control unit that is not illustrated in FIG. 1 .
A diode 23 to 34 is connected in antiparallel to each of the semiconductor switches 11 to 22 .
A capacitor 35 is connected to the associated diodes 28 , 29 in parallel with the two semiconductor switches 16 , 17 . A capacitor 36 is connected to the associated diodes 27 to 30 in parallel with the four semiconductor switches 15 to 18 . A capacitor 37 is connected to the associated diodes 26 to 31 in parallel with the six semiconductor switches 14 to 19 . A capacitor 38 is connected to the associated diodes 25 to 32 in parallel with the eight semiconductor switches 13 to 20 . Finally, a capacitor 39 is connected to the associated diodes 24 to 33 in parallel with the ten semiconductor switches 12 to 21 .
As specified in FIG. 1 , it is assumed that the capacitors 35 to 39 are charged to the following voltages: the capacitor 35 is charged to ⅙ of the direct voltage Ud, the capacitor 36 is charged to ⅓ of the direct voltage Ud, the capacitor 37 is charged to ½ of the direct voltage Ud, the capacitor 38 is charged to ⅔ of the direct voltage Ud, and, finally, the capacitor 39 is charged to ⅚ of the direct voltage Ud. This charging of the capacitors 35 to 39 is achieved by appropriate measures in terms of circuitry.
A timing diagram of a pulse of the AC voltage Ua is illustrated against time t in FIG. 2 . It is assumed that at an instant t 0 all the semiconductor switches 11 to 16 are blocked, and all the semiconductor switches 17 to 22 are conducting. It is also assumed that the output voltage Ua is equal to − 3/6 Ud at the instant t 0 , and an output current Ia flows to the load via the diodes 29 to 34 . It is likewise assumed that complementary semiconductor switches are always switched, that is to say, for example, the semiconductor switch 11 is blocked and then the semiconductor switch 22 is switched to be conducting, or the semiconductor switch 11 is switched to be conducting and then the semiconductor switch 22 is blocked.
When at the instant t 1 , for example, the semiconductor switch 11 is controlled to be conducting and the semiconductor switch 22 is blocked, and the semiconductor switches 12 to 16 remain blocked while the semiconductor switches 17 to 21 remain conducting, a current flows from the positive pole of the direct voltage Ud via the semiconductor switch 11 , via the capacitor 39 and via the diodes 33 , 32 , 31 , 30 and 29 to the pole of the output voltage Ua.
It is sensible to start with driving the semiconductor switch 11 when the capacitor 39 has a voltage lower than ⅚ Ud and the absolute value of the deviation is the largest of all the capacitors, since this capacitor 39 is charged when the semiconductor switch 11 is closed. It is possible in this way to control the symmetry of the capacitor voltages via the sequence of driving the semiconductor switches and via the time delay.
Because of the capacitor 39 charged to ⅚ of the direct voltage Ud, only − 2/6 Ud of the direct voltage − 3/6 Ud still remain as output voltage Ua at this instant t 1 . This is illustrated in FIG. 2 by the corresponding stair step at the instant t 1 .
After the instant t 1 , the abovementioned current would charge the capacitor 39 from ⅚ to the total direct voltage Ud. Before this is the case, however, at an instant t 2 the semiconductor switch 21 is also blocked in addition to the blocked semiconductor switch 22 , and the next semiconductor switch 12 is also controlled to be conducting in addition to the closed semiconductor switch 11 , the other semiconductor switches 13 to 16 remaining blocked, and the semiconductor switches 17 to 20 remaining conducting. The consequence of this is that a current flows from the positive pole of the direct voltage 3/6 Ud via the semiconductor switches 11 and 12 , via the capacitor 38 and via the diodes 32 , 31 , 30 and 29 to the pole of the output voltage Ua.
Because of the capacitor 38 charged to ⅔ of the direct voltage Ud, only −⅙ Ud of the total direct voltage Ud present still remain as output voltage Ua at this instant t 2 . This is illustrated in FIG. 2 by the corresponding further stair step at the instant t 2 .
This method is continued until the semiconductor switches 11 to 16 are controlled to be conducting and the semiconductor switches 17 to 22 are blocked, and thus the positive pole of the direct voltage 3/6 Ud is connected directly to the pole of the output voltage Ua via the semiconductor switches 11 to 16 . This then effects in FIG. 2 at an instant t 6 a last stair step to the total direct voltage 3/6 Ud. The total direct voltage 3/6 Ud is therefore present as output voltage Ua at the instant t 6 .
Overall, the output voltage Ua has therefore risen from a first level, specifically −Ud/2, in six stair steps to a second level, specifically the direct voltage Ud/2.
Thereafter, the semiconductor switches 11 to 16 are controlled again into their blocked state, and the semiconductor switches 17 to 22 are controlled again into their conducting state. The consequence of this is that the output voltage Ua goes back again to Ud/2 in a stair-step fashion. The stair steps correspond in this case in the reverse direction to the stair steps shown in FIG. 2 .
Overall, a pulse has thereby been generated in the output voltage Ua of the circuit 10 . In this case, the switch-on edge and the switch-off edge of this pulse are of stair-step design.
The sequence of the driving of the semiconductor 3 switches 11 to 22 in FIG. 1 is designed, insofar as it relates to the generation of positive and negative edges, as a function of the charge state of the associated capacitors 35 to 39 . Here, this sequence has no influence on the stair-step shape of the voltage generated.
Overall, the above-described driving of the semiconductor switches 11 to 22 from the direct voltage Ud on the input side can be used to generate the output voltage Ua in the shape of pulses, the switch-on and switch-off edges of these pulses respectively being of stair-step design.
The time interval between the individual instants at which the semiconductor switches 11 to 22 are reversed one after another is very short. In particular, this time interval is selected as a function of the switching time of the semiconductor switches 11 to 22 used and/or of the resonant frequency of the load, if appropriate including the cables present. In particular, this time interval can be selected such that the overvoltage peaks at the load are minimized. For example, the time interval is in a range between approximately 0.01 microseconds and approximately 10 microseconds. As is also specified in FIG. 2 , this period is preferably 2 microseconds.
The capacitances of the capacitors 35 to 39 can be selected to be relatively small on the basis of the existing time intervals between the individual instants at which the semiconductor switches 11 to 22 are reversed one after another. They can be calculated in this case using the following equation:
C =( I ×delta t )/delta U a
Here, C is the capacitance to be calculated, I is the charging current through the respective capacitor, delta t is the time interval between the individual instants at which the semiconductor switches 11 to 22 are reversed one after another, for example 2 microseconds, and delta U is approximately 10% of the nominal voltage of the associated capacitor.
The sequence of the driving of the individual series-connected semiconductor switches of a half group should preferably be determined by which capacitors have the voltage deviating most from their nominal value. It is possible in this way respectively to introduce a current flow through the capacitors that recharges the capacitors such that the asymmetric voltage is counteracted.
In each of the previously described stair steps, only ⅙, that is to say approximately 17%, of the total direct voltage Ud is passed on to the output voltage Ua. The result of this is that possible overvoltage peaks, for example, in a downstream electric motor, are caused only by these stair steps. The electric motor need therefore not be designed for overvoltage peaks that would occur upon the switching of the total direct voltage Ud.
FIGS. 3 and 4 illustrate electric circuits 50 and 60 that largely correspond to the electric circuit 10 of FIG. 1 . Identical components are therefore marked with identical reference numerals.
The timing diagram of FIG. 5 belongs to the circuit 50 of FIG. 3 , and the timing diagram of FIG. 6 belongs to the circuit 60 of FIG. 4 . The timing diagrams of FIGS. 5 and 6 are similar to the timing diagram of FIG. 2 . Identical features are therefore provided with identical designations.
As a difference from the circuit 10 of FIG. 1 , in the circuit 50 of FIG. 3 a larger capacitor 51 is provided instead of the capacitor 37 . Moreover, in accordance with the timing diagram of FIG. 5 a longer time interval is provided between the instants t 3 and t 4 than in the case of the timing diagram of FIG. 2 .
In the case of FIG. 5 , the time interval between, for example, the instants t 1 and t 2 is 2 microseconds, for example, as before. The time interval between the instants t 3 and t 4 is, however, greater by a factor of approximately 100. This time interval is, for example, in a range from approximately 100 microseconds to approximately 1000 microseconds. The time interval is preferably approximately 250 microseconds, as is also specified in FIG. 5 .
The result of this is that the stair steps already known from FIG. 2 are likewise present at the instants t 1 and t 2 in FIG. 5 . However, because of the longer time interval, an offset 52 is present in FIG. 5 between the instants t 3 and t 4 .
During this offset 52 , a current flows from the positive pole of the direct voltage Ud via the semiconductor switches 11 , 12 and 13 , via the capacitor 51 and via the diodes 31 , 30 and 29 to the pole of the output voltage Ua. Because of the longer time interval between the instants t 3 and t 4 , this current flows longer than between, for example, the instants t 1 and t 2 . This current flowing for a longer time interval imposes a higher load on the capacitor 51 of FIG. 3 than the capacitor 37 of FIG. 1 . For this reason, the capacitance of the capacitor 51 is selected to be larger than the capacitance of the capacitor 37 . It can, in turn, be calculated with the aid of the equation already specified, the larger value of the capacitance resulting from the larger delta t.
The output voltage Ua therefore rises in the case of the circuit 50 from the first level, specifically −Ud/2, via three stair steps to a second level, specifically the offset 52 , and from there in a further three stair steps to a third level, specifically to the direct voltage Ud/2.
When the circuit 50 of FIG. 3 is used in a medium-voltage power converter, the semiconductor switches 11 to 22 , for example appropriate IGBTs, can usually be operated with an operating frequency from approximately 500 Hz to approximately 1000 Hz. In the case of two-stage inverters, the consequence of these operating frequencies is current harmonics in the output-side current of the AC voltage that are not insubstantial.
In accordance with FIG. 5 , the intermediate circuit voltage is switched from positive to negative with a longer offset 52 , and this leads to a reduction in the voltage harmonics. In the case of the circuit 50 of FIG. 3 with the associated offset 52 according to FIG. 5 , the output-side current therefore has smaller current harmonics than in the case of the circuit 10 of FIG. 1 .
As a difference from the circuit 10 of FIG. 1 , in the circuit 60 of FIG. 4 two larger capacitors 61 and 62 are provided instead of the capacitors 38 and 36 . The capacitance of the capacitors 61 , 62 corresponds approximately to the capacitance of the capacitor 51 of FIG. 3 .
Furthermore, in accordance with FIG. 6 a longer time interval is provided in each case between the instants t 2 and t 3 and between the instants t 4 and t 5 than in the case of FIG. 2 . This longer time interval corresponds approximately to that of FIG. 5 .
The consequence of this is that two offsets 63 and 64 are present in accordance with FIG. 6 , which is associated with the circuit 60 .
The output voltage Ua therefore rises in the case of the circuit 60 from the first level, specifically −Ud/2, via two stair steps to a second level, specifically the offset 63 , from there in a further two stair steps to a third level, specifically the offset 64 , and from there in a further two stair steps to a fourth level, specifically to the direct voltage Ud/2.
In the case of the circuit 60 of FIG. 4 with the associated offsets 63 and 64 according to FIG. 6 , the output-side current of the AC voltage therefore has still smaller current harmonics than in the case of the circuit 50 of FIG. 3 .
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | Disclosed is an electric circuit, in particular for a medium voltage power converter. The circuit has at least four semiconductor switches which form a series connection and which are connected to poles of a direct current voltage (Ud). A diode is connected in parallel in an inverse direction to each semiconductor switch. A capacitor is connected in parallel to the two semiconductors in the middle of the series connection. The circuit is provided with a pole of an output potential (Ua) which is connected centrally in the series connection. The circuit has a control device for successively controlling the semiconductor switches. The time interval between the transition of two of the semiconductor switches into their respective controlling states is minimal. | 7 |
BACKGROUND
[0001] The present invention relates to a method for determining the compaction state of a subgrade to be compacted by means of a roller compactor having at least one compactor drum rotatable about an axis of rotation.
[0002] In order to compact a subgrade such as for the application of pavement in road construction, roller compactors are used which, using the weight of their footprint exerted in an essentially vertical direction by one or more compactor drums, enable the compression of the subgrade and, consequently, an increase in the degree of compaction. In order to improve the compaction result, it is known to associate one or more compactor drums of a roller compactor with an oscillation-inducing arrangement, which, due to the generation of periodically oscillating torque, the compactor drum will be put into a corresponding periodic oscillating motion or rather oscillating rotation, meaning an alternating reciprocal motion around the rotational axis of the drum. Given the rotational motion of the compactor drum inherently present with the forward motion of the roller compactor, this oscillating rotation of the compactor drum will be transferred to the rotational axis of the compactor drum.
[0003] From DE 35 90 610 C2, the deduction of a degree of compaction is known given the progress over time of the oscillating torque generated in a compactor drum created by the generation of an oscillating rotation, specifically the measured horizontal acceleration of the compactor drum's axis.
[0004] DE 37 07 684 C2 discloses a method for determining the degree of compaction of a subgrade to be compacted using a compactor drum. This method measures the vertical acceleration of a compactor drum set into vertically vibrating motion by a vibrating arrangement. Since the vertical movement of the compactor drum changes as the level of compaction increases, the trend in the vertical acceleration of the compactor drum can be used to provide an indication of the compaction state of a subgrade to be compacted.
BRIEF DESCRIPTION
[0005] It is the object of the present invention to provide a method for determining the compaction state of a subgrade, which, using simple means, allows for the ability to determine the exact compaction state of a subgrade to be compacted during the performance of the compaction process.
[0006] This problem will be solved by a method according to the invention for determining the compaction state of a subgrade to be compacted using a roller compactor comprising at least one compactor drum rotatable about a drum axis of rotation, whereby at least one drum of said roller compactor is associated with an oscillation-inducing arrangement for inducing an oscillating rotation in said compactor drum in order to generate an oscillating torque on the drum axis of rotation, whereby the method comprises the following steps:
a) during at least one period of oscillating movement of the compactor drum, repeatedly determining the acceleration of the compactor drum in a first direction, representing a first acceleration value, b) in association with each first acceleration value, determining the acceleration of the compactor drum in a second direction representing a second acceleration value in order to provide pairs of acceleration values, each consisting of a first acceleration value and an associated second acceleration value, c) for at least one oscillation period, defining a compaction state value representing the compaction state of the subgrade based upon the period of oscillation determined for said acceleration value pairs.
[0010] The present invention is based upon the knowledge that, during the performance of the compaction process by means of a rotary oscillation being induced in the compactor drum due in turn to the influence of the oscillating rotation transferred as a result of the rolling motion of the compactor drum, said compactor drum will move within the depression that it has itself created in an up-and-down motion, meaning that it will accelerate in a vertical direction which is essentially at a right angle to the surface of the subgrade to be compacted. This results in a periodic change in the vertical acceleration of the compactor drum, whereby the frequency of the vertical acceleration or rather the vertical motion is equal to twice the frequency of the oscillating motion. Given the acceleration value pairs generated during a particular period of oscillation, which, as a whole, reflect the trend of the acceleration in both directions during said oscillation period, the compaction state of a subgrade to be compacted can be deduced.
[0011] In the method according to the invention, it is advantageously provided that step c) for determining the compaction condition value will comprise the area of a curve defined by consecutive plots of acceleration value pairs on a graph of acceleration values during an oscillation period, whereby the acceleration value graph is defined by a first graph axis associated with the first acceleration values and a second graph axis associated with the second acceleration values. Since the extent of the acceleration in the horizontal direction is primarily determined by the oscillating torque exerted upon the compactor drum, while the vertical acceleration primarily depends upon how firm the subgrade is and how strongly the compactor drum is pressing into the subgrade to be compacted, thereby moving up and down during the course of an oscillating motion, the plot of acceleration value pairs recorded during an oscillation period represents an area whose size depends upon the compaction state of the subgrade.
[0012] The first direction advantageously corresponds to a generally horizontal direction and the second direction advantageously corresponds to a generally vertical direction. It should be pointed out here that, in terms of the present invention, the horizontal direction can be regarded as a direction generally parallel to the plane of the surface to be compacted, while the vertical direction can be regarded as the direction generally orthogonal to said plane of the surface or subgrade to be compacted.
[0013] In order to be able to determine the extent of the area encompassed by the plotted pairs of acceleration values using simple mathematical means, the method according to the invention may additionally provide that, regarding step c):
an acceleration value pair vibration will be defined based upon a sequence of acceleration value pairs along the first axis of the graph, whereby acceleration value pairs from a first group of acceleration value pairs and a second group of acceleration value pairs will be assigned in such a way that the acceleration value pairs from the first group will generally represent the upper end of the acceleration value pair vibration curve, and the acceleration value pairs from the second group will generally represent the lower end of the acceleration value pair vibration curve. based upon the first group of acceleration value pairs, an upper envelope is determined, and, based on the second group of acceleration value pairs, a lower envelope is determined, the area value will generally be defined as being the area bordered by the upper envelope and the lower envelope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention is described hereinafter in reference to the enclosed drawings. Shown are:
[0018] FIG. 1 a side view and figurative representation of the surface to be compacted by a compactor drum;
[0019] FIG. 2 a graph of the period of oscillation of a compactor drum as shown in FIG. 1 showing a number of acceleration value pairs determined therein, and an acceleration value pair curve spanning the acceleration pair values as determined in chronological order;
[0020] FIG. 3 a graph corresponding to that of FIG. 2 , in which the acceleration value pairs determined for the period of oscillation are arranged in a different way in order clarify the acceleration value pair vibration;
[0021] FIG. 4 a graph, which, based on the arrangement of the acceleration value pairs according to FIG. 3 , shows an upper envelope and a lower envelope for the acceleration value pair vibration;
[0022] FIG. 5 the progress of a compaction state value determined by the method according to the invention following an increasing number of passes over a subgrade to be compacted.
[0023] FIG. 6 plotted with respect to the number of passes, the progress of a compaction state value determined by the method according to the invention, as well as a degree of compaction determined by measurements made at the subgrade.
DETAILED DESCRIPTION
[0024] FIG. 1 shows a side view and figurative representation of a compactor drum 10 of a roller compactor. Provided within the area of the compactor drum 10 enclosed by the drum mantle 12 is an oscillation-inducing arrangement (not visible in the Figures), which may comprise a plurality of axes parallel to the compactor drum for the rotation of eccentric masses driven around an axis of rotation D. By means of the oscillation-inducing arrangement, an oscillating torque is generated, which induces the compactor drum 10 to perform an oscillating rotation O around the axis of rotation D. During the compaction process, meaning during the forward motion of the roller compactor in the direction of travel F, this oscillating rotation in the rolling motion of the compactor drum 10 is transferred along the rolling direction R.
[0025] By way of example, acceleration sensors 16 , 18 may be provided in the area of a bearing shell 14 of the compactor drum 10 . In doing so, the acceleration sensor 16 for registering the acceleration of the compactor drum 10 in a horizontal direction H may be of such design that it lies along a direction substantially parallel to the plane of the subgrade U to be compacted. The acceleration sensor 18 may be designed or arranged in order to detect a vertical acceleration a v meaning an acceleration in a vertical direction V, which is substantially orthogonal to the horizontal direction H and thus also orthogonal to the subgrade to be compacted. The output signals provided by the two acceleration sensors 16 , 18 can be transmitted to a data acquisition/analysis unit 20 .
[0026] It should be pointed out here that the acceleration may also take place in other areas of the compactor drum 10 such as the interior of the drum mantle 12 , which would then require the respective extrapolation of the horizontal or vertical acceleration through coordinate transformation.
[0027] The horizontal acceleration a h and the vertical acceleration a v will be recorded repeatedly during a particular period of oscillating movement O. The sampling rate should be at least ten times that of the oscillation frequency of the compactor drum 10 , so that, during each period of oscillating movement O, at least ten acceleration value pairs will be recorded or determined, each with a horizontal acceleration a h representing a first acceleration value and a vertical acceleration value a v representing a second acceleration value. In the process, both acceleration values in a respective pair of acceleration values are ideally values for vertical acceleration and horizontal acceleration recorded at the same time.
[0028] During the rolling motion atop the subgrade U to be compacted, a discernible depression M forms beneath the compactor drum 10 in FIG. 1 , which is restricted both toward the direction of travel F and opposite to the direction of travel F through the respective accumulations of material A 1 and A 2 . In the course of the oscillating movement of the compactor drum 10 , said compactor drum 10 oscillates back and forth within the depression M and, in so doing, experiences not only the acceleration generated by the oscillating torque in a horizontal direction H, but also by the periodic rolling onto and off of the accumulations of material A 1 and A 2 , therefore an acceleration in the vertical direction V. During each period of oscillation, the compactor drum 10 is moved by each of the two accumulations of material A 1 and A 2 , once up and once down, so that the frequency of the vertical acceleration is double the frequency of the horizontal acceleration.
[0029] FIG. 2 shows a graph or coordinate system, in which the first acceleration value, meaning the horizontal acceleration a h , is assigned to the horizontal axis, and the second acceleration value, meaning the vertical acceleration a v , is assigned to the vertical axis. FIG. 2 shows a plurality of the respective acceleration value pairs B P , wherein each acceleration value pair B P is represented by a horizontal acceleration value a h and an associated vertical acceleration value a v recorded at essentially the same time. FIG. 2 shows acceleration value pairs B P for one period of oscillating movement O of the compactor drum 10 . The sequence of the acceleration value pairs B P over time, which are determined or recorded in chronological order, defines an acceleration value pair curve K, the shape of which generally resembles that of an “8” on its side. This shape is due to the fact that, as was previously set out, two periods of vertical acceleration occur during a period of oscillating movement O, meaning between the two extremes of the horizontal acceleration value a h , so the sign for the vertical acceleration changes a total of four times.
[0030] During the process of compaction, the degree of compaction of the subgrade to be compacted U gradually increases with the number of passes by the roller compactor. Given increasing compaction, the extent to which the compactor drum 10 can press into the subgrade U decreases, which corresponds to a decrease in the depth of the depression M and a decrease in the amount of the accumulations of material A 1 and A 2 . Given the decrease in the depth of the depression and the amount of the accumulations of material A 1 and A 2 , the firmness of the subgrade U increases. Not only the depth of the depression M and the amount of the accumulations of material A 1 and A 2 but also the firmness of the ground upon which the compactor drum 10 performs its oscillating movement O will affect the values for horizontal acceleration a h and vertical acceleration a v occurring during a particular period of oscillating movement O. It was determined that the area defined by the acceleration values pair curve K likewise increases with an increasing degree of firmness, specifically because the horizontal acceleration a h increases as the firmness of the subgrade increases, thus making the sideways “8” wider. Taking the acceleration value pairs determined during a particular period of oscillating movement O into account, it thus becomes possible to draw conclusions about the subgrade U to be compacted, specifically by determining the size of the area defined by the acceleration value pairs B P or the acceleration value pair curve K in the acceleration pair graph in FIG. 2 .
[0031] There are various ways of determining this area. For example, instead of arranging or combining the acceleration value pairs B P one after the other in chronological order in order to obtain the acceleration pair curve K shown in FIG. 2 , one may rather select, for instance, alternating acceleration value pairs beginning with the smallest value for horizontal acceleration a h , which will form a local minimum or maximum, in order to define a fictional acceleration value pair vibration S, as is illustrated in FIG. 3 . In the process, for example, one might proceed by utilizing a corresponding sequence of acceleration pairs B P alternating with an acceleration value pair B P for defining a local minimum, being a lower end S U , and a local maximum, being an upper end S O . For example, if the chronological sequence of the provided acceleration value pairs B P should result in a grouping, within which two or more acceleration value pairs, each defining a lower end point, are located between two upper end points S O , then that acceleration value pair B P , which in fact defines the local minimum or, as the case may be, the local maximum, can be utilized for the purpose of determining the acceleration value pair vibration S.
[0032] As a whole, the acceleration value pairs which define the acceleration value pair vibration S are to be divided into two groups, namely one group G 1 , which includes the acceleration value pairs B p defining the respective upper end S O , and a second group G 2 , which includes the acceleration value pairs B P defining the lower end S U . In the process, the two outermost horizontal acceleration values may advantageously be assigned to groups G 1 and G 2 , respectively.
[0033] On the basis of the respective acceleration value pairs B P assigned to each of the groups G 1 and G 2 , appropriate mathematical methods are used to determine an upper envelope E O and a lower envelope E U for the acceleration value pair vibration S.
[0034] As determined according to the invention, the size of the area FL, which is an indicator of the compaction state of the subgrade U to be compacted, can now be calculated as the area enclosed between both ends of the envelope E O and E U . In doing so, for example, an area calculation can be made through numerical integration using the trapezoidal rule. The area value, the unit for which is m 2 /s 4 , thus constitutes a compaction control value, meaning a dynamic continuous compaction control value, which may be recorded or determined during the compaction process. As an example, this value may be rescaled along with compaction process parameters or machine parameters such as the compactor drum diameter, the linear load on the vibrating mass itself, or the eccentric moment in order to obtain variables which are easily manageable or more comparable.
[0035] FIG. 5 , given the length of a subgrade U to be compacted as represented by lengthwise GPS areas, shows the progress of the area size FL as determined in the manner described in the foregoing, which is indicated in FIG. 5 as FDVK [continuous compaction control], the value for which can be clearly seen to shift continuously upwards with an increasing number of passes. Weak points are present in two local regions L 1 and L 2 , these being places where, for reasons such as a lack of subgrade preparation, no substantial compression may be achieved.
[0036] FIG. 6 shows a comparison between the FDVK [continuous compaction control] area value recorded using the method according to the invention and a value determined using a standardized measurement procedure with a dynamic deformation modulus corresponding to Evd. The progress of these two values proceeds in a nearly comparable manner as the number of crossings increases, thus making it evident that the use of the method according to the invention makes a variable available which allows precise conclusions to be made about the actual degree of compaction existing in the subgrade to be compacted in real time, thus during the compaction process.
[0037] Finally, it should be pointed out that, as regards the foregoing reference to the graphs or coordinate systems in FIGS. 2 to 4 and the acceleration value pairs or curves entered therein, the determination of the area value does not, in fact, require entering the respective acceleration values or acceleration value pairs into graphs and evaluating said graphs, but is instead carried out on the basis of mathematical procedures, which, however, are able to be shown via the various graphs and the curves entered therein. Therefore, in terms of the present invention, for example, this does not mean that an acceleration value pair vibration will be plotted on a graph—or merely plotted on a graph—in the process of defining such an acceleration value pair vibration, but rather that values or coordinate points relevant to said vibration will be determined and utilized in further mathematical procedures. | A method for determining the compaction state of a subgrade to be compacted using a roller compactor comprising at least one compactor drum having an oscillation-inducing arrangement and rotatable about a drum axis of rotation comprising the following steps: during at least one period of oscillating movement of the compactor drum, repeatedly determining the acceleration of the compactor drum in an first direction, representing a first acceleration value; in association with each first acceleration value, determining an acceleration of the compactor drum in a second direction representing a second acceleration value in order to provide acceleration value pairs, each consisting of a first acceleration value and a second associated acceleration value; and for at least one oscillation period, defining a compaction state value representing the compaction state of the subgrade based upon the period of oscillation determined for said acceleration value pairs. | 4 |
TECHNICAL FIELD
The present invention relates generally to electronic devices and, more specifically, to a circuit for providing a redundant bond pad for probing semiconductor devices.
BACKGROUND OF THE INVENTION
As seen in FIG. 1, one or more dies are formed in a conventional manner on a wafer which, in turn, is formed from a semiconductor material such as silicon. Each die has an integrated circuit or device that has been formed but not yet detached from the wafer. Further, each die on the wafer can be tested by placing a set of mechanical probes in physical contact with the die's bond pads. The bond pads provide a connection point for testing the integrated circuitry formed on the die. The probes apply voltages to the input bond pads and measure the resulting output electrical signals on the output bond pads. Not all bond pads on a die, however, are easily accessible by these devices. Given the dies' arrangement in FIG. 1, for example, it is generally easier to probe the long sides of the die; the short sides of the die are usually too close to the other dies to allow sufficient clearance for testing purposes. Thus, it can be difficult to test circuits that are coupled to an inaccessible bond pad.
Requiring bond pads to be located only in the areas accessible during testing may lead to inefficient and complex circuit layouts. One known solution, as shown in FIG. 3, is to attach another bond pad, one that can be reached by a testing device, to the same wire used by the original bond pad. This solution, however, tends to increase the input capacitance. Attempts at minimizing this capacitance will result in the use of more die space.
A second known solution is to multiplex (mux) two input buffers together, as illustrated in FIG. 4, once again allowing an testable bond pad to access circuitry. With this mux circuit, however, signals from the original pad take longer to reach the die's integrated circuitry. In addition, if input is designed to be received from multiple input buffers in a parallel configuration, this muxing solution would require duplicating large portions of the input circuitry, once again taking up a great deal of die space.
SUMMARY OF THE INVENTION
The present invention provides a circuit allowing an alternate access point to be used in testing the integrated circuitry, wherein the circuitry is usually accessed at another point that is difficult to reach with testing equipment. The resulting advantage of this implementation is that the circuit may be easily tested. As another advantage, the circuit may operate during testing at the same polarity input as used in normal operations of the die without an increase in capacitance. Moreover, the preferred embodiments of this invention may be used to test the circuit without appreciably slowing down the time to input signals. Further, the invention will not require the duplication of circuitry related to the input of data. For purposes of testing in one preferred implementation, the circuit also prevents the use of an input pad employed during normal operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a semiconductor wafer with dies formed thereon as is known in the art.
FIG. 2 is a top view of a die of FIG. 1.
FIG. 3 is a block diagram demonstrating a solution in the prior art for testing the circuitry on a die.
FIG. 4 is a block diagram demonstrating a second such solution in the prior art.
FIG. 5a is a schematic diagram of one exemplary embodiment in accordance with the present invention.
FIG. 5b is an top-down view of a transistor configured for protection against electrostatic discharge.
FIG. 5c is a schematic diagram of the exemplary embodiment of FIG. 5a as used with a modified operations circuit.
FIG. 6a is a schematic diagram of a second exemplary embodiment of the present invention.
FIG. 6b is a more detailed schematic diagram of the exemplary embodiment in FIG. 6a.
FIG. 7 is a schematic diagram of a third exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 illustrates the top view of a die 12 that is formed in a conventional manner on a wafer. For purposes of clarity, the wafer and additional dies that may be formed on that wafer have been omitted from FIG. 2. The sides of die 12 contain input bond pads 15, to which external lead wires can be bonded. The bond pads 15 connect to operations circuits 14, such as row address or decoding circuits, within the die 12. It is understood in the art that a die could contain many such bond pads 15 and operations circuits 14. Duplication of these elements has been limited in FIG. 2 for purposes of clarity. Some bond pads 15 are more easily accessible by testing devices than are others. One element affecting accessibility is the spacing between dies 12. For purposes of distinguishing the accessibility of bond pads as illustrated in FIG. 1, areas where the bond pads are more easily accessible are labeled "16," whereas areas where bond pads are relatively inaccessible are denoted by "18."
Occasionally, a particular die 12 is configured so that, during a normal operations mode, an operations circuit 14 is connected to an input bond pad 20 that is in an inaccessible area 18 concerning testing devices. Given such inaccessibility, it can be difficult to apply signals to the operations circuit 14 during a test mode. This is particularly true during the probe of dies that are still part of a wafer. Through the current invention, however, a probe bond pad 22 in an accessible area 16 can be connected to the operations circuit 14 during the test mode, thereby allowing for easy testing.
An exemplary testing circuit 24, described below in detail and illustrated in FIG. 5a, is used to connect the probe pad 22 to the operations circuit 14 during the test mode for that circuit. The operation of the testing circuit 24 is controlled by an enable signal. In the preferred embodiment, this signal is provided by the testing device through a Test Mode Enable bond pad 26. Thus, during the test mode, the testing device transmits the enable signal by way of the Test Mode Enable bond pad 26. In response, the testing circuit 24 couples the probe bond pad 22 to the operations circuit 14, which is normally driven by signals applied to input bond pad 20.
FIG. 5a is a schematic diagram of one embodiment of the testing circuit 24. The testing circuit 24 contains a first conducting path 28 from the input bond pad 20 to the operations circuit 14. The first conducting path 28 is also coupled to the drain of a first n-channel transistor Q2, which has a source coupled to ground. This first n-channel transistor Q2 is also configured for electrostatic discharge (ESD) protection, as illustrated in FIG. 5b. As with standard transistors of this type, the first n-channel transistor Q2 is comprised of a first conductive strip 50, which, in this case, leads to the first conducting path 28 and, ultimately, to input bond pad 20. A second conductive strip 52 leads to ground, and a gate 54 is interposed between the first and second conductive strips 50 and 52. Further, there exists an n+ active area 56 between the gate 54 and the first conductive strip 50. This n+ active area 56 is preferably in a vertical arrangement with said first conductive strip 50 and communicates with that strip 50 via a series of contacts 58. Unlike standard transistors, this n+ active area 56 is sufficiently large enough to create a relatively high active area resistance, generally around 1 KΩ, thereby preventing ESD damage.
Returning to FIG. 5a, a second conducting path 32 connects the probe bond pad 22 with a NOR gate 34. The second conducting path 32 is also coupled to the drain of a second n-channel transistor Q4. A third conducting path 38 couples the Test Mode Enable bond pad 26 with a first inverter 40. Between these two devices, however, the third conducting path 38 is also coupled with the gate 54 of the first n-channel transistor Q2 as well as a low-bleed current device, known to those skilled in the art as a long L device 42. The first inverter 40 has an input coupled to the third conducting path 38 and an output coupled to the gate of the second n-channel transistor Q4. The NOR gate 34 has a first input 44, which receives an enabling signal for the operations circuit 14. The NOR gate 34 also has a second input coupled to the second conducting path 32, and an output. Finally, the circuit contains a second inverter 46, which has an input coupled to the output of the NOR gate 34. The output of the second inverter 46 is coupled with the operations circuit 14.
During normal use of the operations circuit 14, the Test Mode Enable bond pad 26 is not receiving an enabling signal from any testing device. Therefore, the long L device 42 serves to bleed to ground any remaining low current within the third conducting path 38. The lack of current in the third conducting path 38 turns off the first n-channel transistor Q2. With the first n-channel transistor Q2 off, the first conducting path 28 may freely transmit signals from the input bond pad 20 to the operations circuit 14. In the schematic illustrated in FIG. 5a, the signal transmitted by the input bond pad 20 is an external Row Address Strobe (XRAS*) signal. Further, operations circuit 14 is an input buffer which accepts the industry standard input levels of the transmitted XRAS* signal and modifies them to internal V cc and ground levels. It is known that such a circuit may have different configurations. The operations circuit in FIG. 5c demonstrates an alternate configuration, wherein optional transistors have been omitted, including those used for further tuning the XRAS* signal.
Returning to the third conducting path 38, the lack of current in that path results in a logic 0 value transmitted to the first inverter 40. It follows that the output of the first inverter is at logic 1, which turns on the second n-channel transistor Q4. Once activated, the second n-channel transistor Q4 bleeds current from the second conducting path 32, thereby grounding any signals from probe bond pad 22.
Because the second conducting path 32 is at logic 0 during normal operations mode, the signal reaching the operations circuit 14 from the second inverter 46 will match the control logic signals received by the first input 44 of the NOR gate 34. For example, given a logic 1 value received by the first input 44 and the logic 0 of the second input, the output of the NOR gate will be a logic 0, which will be inverted by the second inverter 46 to logic 1. This logic 1 will serve as an input for the operations circuit 14. If, on the other hand, the first input 44 receives a logic 0, the two logic 0 inputs for the NOR gate 34 result in a logic 1 output, which is inverted by the second inverter to result in a logic 0 being input into the operations circuit 14.
During the test mode of the operations circuit 14, the Test Mode Enable bond pad 26 is driven with a sufficient voltage to overcome the bleeding effects of the long L device 42 and send a signal of logic 1 to the third conducting path 38. This signal turns on the first n-channel transistor Q2, thereby grounding any input signal that would come from the input bond pad 20. The logic 1 signal of the third conducting path 38 also goes through the first inverter 40. The resulting logic 0 value turns off the second n-channel transistor Q4 that had been grounding signals from the probe bond pad 22. As a result, signals such as XRAS* that once issued from the input bond pad 20 may now be input using the more accessible probe bond pad 22. The NOR gate 34 receives both a signal enabling the operations circuit 14 as well as transmissions from the probe bond pad 22. The NOR gate 34 output is inverted by the second inverter 46, and the result is entered into the operations circuit 14.
In another embodiment illustrated in FIG. 6a and 6b, a second input buffer 48 may be used with the probe bond pad 22 in order to preserve a trip point equivalent to that of other bond pads 15. In this embodiment, the second input buffer 48 has a configuration similar to that of the operations circuit 14 of FIG. 5c.
In a third embodiment, shown in FIG. 7, the signals that passed through the NOR gate 34 and the second inverter 46 in earlier embodiments are instead coupled directly into the operations circuit 14 with the addition of one n-channel transistor Q6 and one p-channel transistor Q8. This embodiment has the benefit of allowing multiple points of access for test signals, rather than requiring all of the test signals to be input at only one location. This is not the most preferred embodiment, however, as the additional transistors Q6 and Q8 require additional die space.
One of ordinary skill in the art can appreciate that, although specific embodiments of this invention have been described above for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. For example, the testing circuit could be modified so that a single Test Mode Enable pad could enable a plurality of probe bond pads, while simultaneously grounding the corresponding input bond pads. It is also possible to configure the testing circuit to provide for probe bond pads for measuring the output of an operations circuit in the event the output bond pad is inaccessible. Accordingly, the invention is not limited except as stated in the claims. | An integrated device includes a redundant bond pad for accessing internal circuitry in the event that the main bond pad for that circuitry is difficult to access with testing equipment. Signals from the redundant bond pad are biased to ground during normal operations of the integrated device. In order to test the relevant internal circuitry, a voltage is applied to a Test Mode Enable bond pad, overcoming the bias that grounds the redundant bond pad. In addition, the signal from the Test Mode Enable bond pad serves to ground any transmission from the main bond pad. As a result, the redundant bond pad may be used to test the relevant internal circuitry given its accessible location in relation to the testing equipment. | 6 |
FIELD OF THE INVENTION
The present invention relates to the field of data-transmission networks, and more particularly, to a synchronous data transmission, particularly in accordance with a synchronous digital hierarchy (SDH) standard. More particularly, the present invention relates to a detector for detecting timing in a data flow.
BACKGROUND OF THE INVENTION
The synchronous digital hierarchy (SDH) standard prescribes the following predetermined transmission rates: 51.84 Mbit/s (base rate), 155.52 Mbit/s, 622.08 Mbit/s, etc. All of the prescribed transmission rates are whole multiples of the base rate.
The G.703 recommendation issued by the CCITT committee of the International Telecommunication Union (ITU) prescribes the electrical and physical characteristics of the hierarchy digital interfaces to be used for interconnecting components of digital networks which conform to the SDH standard. In particular, recommendation G.703 prescribes the type of data coding to be used for each transmission rate. For example, for 155.52 Mbit/s transmission/receiving interfaces, coded mark inversion (CMI) coding should be used. These interfaces are also known as bidirectional or transceiver interfaces.
CMI coding is a coding with two levels, A1<A2, in which a binary 0 is encoded to have the two levels A1 and A2 in succession, each for a time equal to half of the bit-time. A binary 1 is encoded by one of the two levels A1, A2 which is maintained throughout the bit-time. The two levels A1, A2 are alternated for successive binary is. The encoded CMI signal is therefore characterized in that, in the middle of the bit-time, there are no transitions or there are transitions with leading edges. Conversely, at the beginning of the bit-time, there may be either upward or downward transitions.
In general, in data-transmission networks there is a need to synchronize a component of the network with a data flow coming from a remote unit. This need arises, for example, in interfaces which are associated with digital circuits for processing data received and/or to be transmitted and which, typically, operate on data which is encoded differently. For example, the data may be coded in accordance with non-return-to-zero (NRZ) coding.
During receiving, the interface therefore has to receive a signal containing CMI-encoded data from a remote analog interface by a transmission/receiving channel formed, for example, by a pair of coaxial cables. The interface must also recognize the data, convert it into NRZ, and supply it to the digital circuits for processing. During transmission, the interface receives NRZ-encoded data from the digital processing circuits, recognizes the data, converts it into CMI, and provides the data on the transmission/receiving channel.
Timing detectors are used for synchronizing a component of the transmission network, such as an interface of the type described above for a flow of data arriving from a remote unit, for example. Due to the characteristics of CMI coding which, as stated, also has transitions in the middle of the bit-time, known timing detectors require local clock signals with a frequency of twice the frequency of the flow of data arriving, i.e., twice the data rate, to be able to produce the two transitions within the bit-time which are typical of CMI coding. In the example of a 155.52 Mbit/s data flow corresponding to a bit-time of 6.43 ns, the local clock signals have a frequency of 311.04 MHz.
SUMMARY OF THE INVENTION
In view of the foregoing background, it is therefore an object of the present invention to provide a detector for detecting timing in a data flow which does not require local clock signals with a frequency greater than that of the data flow itself.
This and other objects, features and advantages in accordance with the present invention are provided by a detector for detecting timing in a digital data flow with a predetermined bit-time, and with a coding that provides at a beginning of the bit-time no transition, or a transition of a first type, or a transition of a second type, and provides in a middle of the bit-time no transition, or the transition of the first type.
The detector comprises a first circuit for generating four timing signals each having a period substantially equal to the bit-time. The four timing signals are out of phase with one another by ¼ period. A second circuit samples the four timing signals upon each transition of the first type in the data flow, and determines based upon the sampling whether two of the four timing signals forming a pair of reference signals that are out of phase by ½ period are advanced or delayed relative to the timing of the data flow. The second circuit also controls the first circuit to delay or advance the four timing signals based upon the pair of reference signals.
The second circuit comprises a sampling circuit, and a decoding circuit connected to the sampling circuit for decoding the sampled four timing signals. The sampling circuit preferably comprises four bistable elements, each bistable element being associated with a respective timing signal and being clocked by the transitions of the first type in the data flow. The decoding circuit preferably comprises a logic circuit connected to respective outputs of the four bistable elements for determining whether the pair of reference signals is advanced or delayed relative to the timing of the data flow.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and the advantages of the present invention will become clearer from the following detailed description of an embodiment thereof, illustrated purely by way of a non-limiting example in the appended drawings, in which:
FIG. 1 is a block diagram of a circuit comprising a timing detector for detecting the timing in a data flow according to the present invention;
FIG. 2 is a block diagram of the timing detector according to the present invention;
FIG. 3 is a schematic diagram of one embodiment of the timing detector illustrated in FIG. 2 ;
FIG. 4 is a graph illustrating the operating principle of the timing detector according to the present invention;
FIG. 5 is a block diagram of a data-transmission network including a timing detector according to the present invention;
FIG. 6 is a block diagram of a receiving/transmission interface included in the network illustrated in FIG. 4 ; and
FIG. 7 is a block diagram in greater detail of two functional blocks of the interface illustrated in FIG. 6 , one of which includes a timing detector according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 , a circuit for detecting timing in a data flow BK comprises a circuit 1 for generating a local clock signal CK. The local clock signal CK is supplied to a circuit 2 to obtain, from the signal, four local timing signals Q 1 , Q 2 , Q 3 , Q 4 having the same period T. This period is equal or substantially equal to the bit-time of the data flow BK. The signals Q 1 –Q 4 are out of phase with one another by T/4. The signal Q 2 is delayed by T/4 relative to the signal Q 1 . The signal Q 3 is delayed by T/4 relative to the signal Q 2 , and by T/2 relative to the signal Q 1 . That is, the signal Q 3 is in quadrature relative to the signal Q 2 . The signal Q 4 is delayed by T/4 relative to the signal Q 3 .
The four signals Q 1 –Q 4 are supplied to a timing detector 3 which also receives the data flow BK, the timing of which is to be detected. The detector 3 generates a signal +/− which is supplied to the circuit 2 . A first level of the signal +/− indicates to the circuit 2 that the signal Q 1 is delayed relative to the timing of the data flow BK and should be advanced. Conversely, a second level of the signal +/− indicates to the circuit 2 that the signal Q 1 is advanced relative to the timing of the data flow BK and should be delayed.
If the signal Q 1 is advanced or delayed, the signals Q 2 –Q 4 are also consequently advanced or delayed. Their delays relative to the signal Q 1 are kept constant. Once the signal Q 1 is synchronized with the timing of the data flow BK, it can be used by other circuit blocks to perform processing on the data flow BK. An example of using signal Q 1 is provided below.
FIG. 2 shows a block diagram of the circuit 3 of FIG. 1 . The timing detector comprises a sampling circuit 100 which samples the four signals Q 1 –Q 4 in synchronization with the leading edges of the signal BK, and supplies sampled signals Q 1 C–Q 4 C to a decoding circuit 101 which decodes the states of the sampled signals Q 1 C–Q 4 C to activate the signal +/−.
An implementation of the circuit of FIG. 2 , which is in no way limiting, is shown in FIG. 3 . The circuit comprises four D-type flip-flops FF 1 –FF 4 which receive the signals Q 1 –Q 4 at their respective data inputs D, whereas their sampling inputs receive in common the data flow BK. A reset signal RES is also supplied to the reset inputs of the flips-flops FF 1 –FF 4 for re-establishing certain starting conditions.
The output Q 1 ′, the negated output Q 2 N′ of the flip-flops FF 1 and FF 2 , the output Q 3 ′, and the negated output Q 4 N′ of the flip-flops FF 3 , FF 4 are supplied to an AND-NOR-INVERTER logic gate 4 . The logic complement of the output of the logic gate 4 forms the signal +/−.
The circuit of FIG. 3 performs the logic function:
+/−=Q1′ AND Q2N′ OR Q 3 ′ AND Q4N′
After the flip-flops have been loaded with the values applied to their inputs, Q 1 ′, Q 2 N′, Q 3 ′, Q 4 N′ are respectively equal to Q 1 , Q 2 N, Q 3 , Q 4 N.
Since, one of the signals Q 1 and Q 3 and one of the signals Q 2 and Q 4 is always complementary to the respective other signal, the circuit of FIG. 3 has the following truth table:
Q4
Q3
Q2
Q1
+/−
0
0
1
1
0
0
1
1
0
1
1
0
0
1
1
1
1
0
0
0
The operating principle of the above-described timing detector will now be explained with reference to the timing graph of FIG. 4 . The data flow BK acts as a sampling signal for the flip-flops FF 1 –FF 4 . At the leading edges of the signal BK, the logic states applied to the inputs D of the flip-flops FF 1 –FF 4 are stored and supplied as outputs. Prior to the time instant t 1 , the four signals Q 1 –Q 4 are assumed to be represented by the continuous lines. The signal Q 1 , which is to be synchronized with the timing of the data flow BK, is advanced by Δt.
At the leading edge of the signal BK (time instant t 1 ) which, in the example shown, is formed by the transition in the middle of the bit-time typical of a logic 0 signal. The states of the signals are Q 1 =1, Q 2 =0, Q 3 =0, and Q 4 =1. On the basis of the truth table given above, the above-mentioned states correspond to signal +/−=1 which indicates to the circuit 2 that the signal Q 1 is advanced and should be delayed.
The circuit 2 consequently provides for the signal Q 1 and, correspondingly, for the signals Q 2 –Q 4 to be delayed. The lines with single dots in FIG. 4 indicate the edges of the signals Q 1 –Q 4 as they would be if the circuit 2 did not intervene to delay them.
At the time instant t 2 corresponding to the next leading edge of the signal BK which, in the example, is again the transition in the middle of a bit-period of a logic 0 signal. The signal Q 1 is still advanced relative to the data flow BK. The flip-flops FF 1 –FF 4 sample and load the new states of the signals Q 1 –Q 4 . Since the new state coincides with the previous one, the signal +/− generated is again a 1, and the circuit 2 therefore once more provides for the signal Q 1 and, consequently, for the signals Q 2 –Q 4 to be delayed. In FIG. 4 , the lines with double dots indicate the edges of the signals Q 1 –Q 4 as they would be after the first intervention of the circuit 2 .
The next leading edge of the signal BK at the time instant t 3 , which corresponds to a logic 1 signal, is at the beginning of the bit-time. The flip-flops FF 1 –FF 4 sample the new state of the signals Q 1 –Q 4 which, on the basis of the truth table given above, again correspond to a logic 1 on the signal +/−. The four signals Q 1 –Q 4 are therefore delayed again. At the instant t 3 , the signals Q 3 and Q 4 are utilized for locking onto the transition at the beginning of the bit-time.
The signals Q 1 and Q 3 are thus progressively and dynamically kept in synchronization with the leading edges of the signal BK. The synchronization is both at the beginning and in the middle of the bit-time. Locking with the timing of the data flow is thus achieved. The signals Q 1 and Q 3 may be used by other circuit blocks for synchronizing the blocks with the timing of the data flow that is arriving. The signals Q 2 and Q 4 may be used by the circuit blocks to perform sampling of the data flow every half bit-time.
An advantage of the timing detector according to the present invention is that it does not require local timing signals with a frequency of twice the bit frequency of the data flow, the timing of which is to be detected. The four signals Q 1 –Q 4 , which are out of phase with one another by one quarter of the bit-time, and all of the transitions of the CMI-coded signal with leading edges may be used for synchronization. That is, both the transitions at the beginning of the bit-time (corresponding to logic 1 signals) and those in the middle of the bit-time (corresponding to logic 0 signals) may be used. For example, the signals Q 1 and Q 2 serve for locking with the transitions in the middle of the bit-time, and the signals Q 3 and Q 4 serve for locking with the transitions at the beginning of the bit-time.
Although in the example described, the four signals Q 1 –Q 4 have duty cycles equal to 50%. The use of the four signals Q 1 –Q 4 which are out of phase by one quarter of the bit-time also enables the timing detector to operate independently of the duty cycle of the local timing signals Q 1 –Q 4 , and to be insensitive to changes in the duty cycle of the signals Q 1 –Q 4 .
The following FIGS. 5–7 illustrate one possible application of the timing detector according to the present invention. FIG. 5 shows schematically a data-transmission network, and in particular, a network conforming to the synchronous digital hierarchy (SDH) standard. A bidirectional, synchronous interface 5 , i.e., a transmission and receiving interface, receives digital data with CMI coding from a remote far end analog interface 7 on a first channel 6 a , such as a coaxial cable, for example.
The interface 5 in turn transmits a flow of digital data with CMI coding to the remote interface 7 on a second channel 6 b also formed, for example, by a coaxial cable. For the interface 5 , the channel 6 a is the receiving channel (RX), and the channel 6 b is the transmission channel (TX). The interface 5 communicates with digital circuitry 8 for processing the data received and to be transmitted. Similarly, the remote interface 7 is associated with respective digital circuitry 9 .
As shown in FIG. 6 , the interface 5 comprises an equalizer circuit 10 for module and phase equalization of the signal received on the receiving channel RX. A signal RXEQ output from the equalizer circuit 10 with CMI coding is supplied in parallel to a circuit 11 for recovering the timing signal during receiving, and to a decoding circuit 12 . The decoding circuit 12 decodes the CMI-coded signal RXEQ into a corresponding signal RXNRZ with NRZ coding, for example, that is suitable for supply to the digital circuitry 8 .
The circuit 11 for recovering the timing signal during receiving also receives n timing signals CKL–CKn of equal period T, delayed relative to one another by T/n, where T is the bit-time. In the case of a 155.52 Mbit/s synchronous receiving/transmission interface, the bit-time is about 6.43 ns. For example, there are sixteen signals CK 1 –CKn, with a signal CKi+1 being delayed by T/16 relative to a signal CKi. The signals CK 1 –CKn are generated by a delay locking circuit 13 or a delay locked loop (DLL) supplied with a clock signal CK of period T.
The clock signal CK is in turn generated by a local circuit 14 which generates a pair of differential signals TXCKA, TXCKB conforming to the low voltage differential signal levels (LVDS) which are transformed into the signal CK conforming to the CMOS levels (e.g., 3.3 V or 5 V) by an LVDS/CMOS input buffer 15 . The circuit 14 may, for example, be within the digital circuitry 8 and is used to generate a pair of differential signals TXDA, TXDB representing the flow of bits to be transmitted.
The NRZ-coded signals TXDA, TXDB are transformed by the input buffer 15 into a signal DATA. This signal DATA is still NRZ-coded and is transformed by an NRZ to CMI encoding circuit 16 synchronized with a timing signal CKTX. The timing signal is generated by the digital circuitry 8 , and has a frequency equal to that of the signal CK, but a duty cycle which is guaranteed to be substantially equal to 50%. A subsequent driver circuit 17 receives the signal from the encoding circuit 16 and provides the signal TX to be transmitted.
The circuit 11 for recovering the timing signal during receiving generates a recovered timing signal CKR which is supplied to the decoding circuit 12 . This circuit has to be synchronized with the flow of bits received to be able to decode the CMI signal to NRZ.
The signal RXNRZ and the signal CKR are also supplied to the digital circuitry 8 after their levels have been transformed from CMOS to LVDS by a CMOS/LVDS output buffer 18 . This output buffer 18 is similar to the input buffer 15 , and transforms the signal RXRNZ into a pair of differential signals RXDA, RXDB and the signal CKR into a pair of differential signals RXCKA, RXCKB.
FIG. 7 shows the delay locking circuit 13 and the timing-signal recovery circuit 11 in greater detail. The circuit 13 is composed of a chain of n (e.g., n=16) delay elements T 1 –Tn in cascade. These delay elements are controlled by a logic unit 19 which receives an output signal 20 from a phase comparator 21 . The chain of delay elements T 1 –Tn form a controlled delay line. The overall delay introduced by the delay line T 1 –Tn is controlled so that the delay is equal to one period T of the signal CK.
The phase comparator 21 receives as inputs and compares the signal CK and the signal CKn at the output of the last delay element Tn of the chain. The output signal 20 of the phase comparator 21 depends on the phase difference detected between the signals CK and Ckn. The logic unit 19 controls the delay elements T 1 –Tn so that the delay introduced by each of delay elements is such that the signal CKn is in phase the with signal CK, less one period T.
The outputs CK 1 –CKn of the n delay elements T 1 –Tn are supplied to a selection circuit 22 . The selection circuit 22 is basically a multiplier in the recovery circuit 11 . Of the n (n=16 in the example) input signals CK 1 –CKn, the multiplier 22 outputs four signals Q 1 –Q 4 delayed relative to one another by T/4. The four signals Q 1 –Q 4 are supplied to a timing detector 23 according to the present invention.
The timing detector 23 is of the type described above, which also receives the signal RXEQ with CMI coding. The timing detector 23 controls the selector 22 by the signal +/− as described above, in a manner such that the signal Q 1 , which corresponds to the signal CKR that is supplied to the decoder 12 , is synchronized with the data flow during receiving.
The clock signal is thus recovered from the signal received and can be supplied to the CMI to NRZ decoding circuit 12 . In other words, during receiving, the interface is synchronized with the flow of data received. The interface described has the advantage of requiring only one local timing signal, i.e., a single time base, which is used both for transmission and for the recovery of the clock signal during receiving.
The timing of the interface both during receiving and during transmission is thus entrusted to a single time base. This eliminates the need to provide two local oscillators with frequencies close to one another, and hence the risk of crosstalk between the two timing signals. A saving in terms of components and power absorbed is also achieved. Variations of and/or additions to the embodiments described above and illustrated may be provided, without departing from the scope of the present invention. | A detector detects timing in a digital data flow with a bit-time equal to T. A first circuit generates four local timing signals each having periods substantially equal to the bit-time. Each of the four local timing signals are out of phase with one another by ¼ period. A second circuit samples the four local timing signals upon each transition of a first type for determining, based upon the sampling, whether two of the four local timing signals forming a pair of reference signals that are out of phase by ½ period are advanced or delayed relative to the timing of the data flow. The second circuit controls the first circuit for delaying or advancing the four local timing signals based upon the pair of reference signals. | 7 |
BACKGROUND OF THE INVENTION
In spinning machines, such as rotor spinning machines for example, a method is known by which negative pressure is produced at different locations of the spinning machine by means of a negative-pressure source so as to be able to carry out maintenance or to move or treat the yarn or the fiber sliver in a purposeful manner. For the individual activities, different components are required so that special work can be carried out optimally. The components are e.g. yarn storage, suction nozzles, yarn end preparers, devices for the feeding of fiber sliver into the spinning machine or devices to constitute a yarn reserve on a bobbin. Often such components are installed in a service unit which can travel alongside the spinning machine. As soon as the service unit detects a spinning station in need of maintenance, it stops and carries out maintenance. It is then standard practice for the service unit to carry with it either a source of negative pressure or to establish a connection to the spinning machine through which negative pressure is conducted into the service unit. In order to feed the negative pressure in a targeted manner to the component needing it, a negative-pressure distributor is provided which subjects the individual components with negative pressure as needed. The connections of the individual components are each provided with a valve which reacts to a control signal in such a manner that it either allows negative pressure to reach the individual component through the negative-pressure channel, or shuts off the negative pressure. Therefore a valve which is actuated is required for each component. This plurality of components is very costly and furthermore requires a great regulating effort so that the different valves are actuated in the correct time sequence and for the correct duration.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore a principal object of the invention to create a simple, operationally secure and inexpensive device by means of which different components can be supplied with negative pressure from a central negative-pressure source. Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
The objects are attained through the characteristics of the invention. A distributor consists of a housing with connections for the negative pressure ducts as well as with a connection for the negative pressure channel. The housing is provided with a valve for the opening and closing of the connection of the negative pressure channel with at least one of the negative pressure ducts of the components. A distribution of the negative pressure among the individual components needing it is effected with advantageously few elements. Thanks to the small number of relatively easily produced elements, a less expensive and operationally more reliable distributor of negative pressure is above all created. With one single valve it is now possible to supply the negative pressure ducts in a targeted manner with negative pressure or to shut them off from the negative pressure. With few movable elements, low wear and low malfunction incidence is ensured. The apparatus according to the invention thus ensures that a reliable, low-maintenance, and low-cost element is used for the distribution of negative pressure.
If the connections of the negative pressure ducts of the components are essentially arranged next to each other in the housing in the sequence in which they are needed in a work cycle, this ensures in a simple manner that the negative pressure can be switched over rapidly from one negative pressure duct to the other. A typical work cycle is the piecing in a spinning machine, e.g. an open-end rotor spinning machine. Here the work phases provided are e.g. the aspiration, the cutting, preparing, storing and surrendering of the yarn end. If each of the connections of the negative pressure ducts is associated with the corresponding component which is next in line to be subjected to negative pressure, it is only necessary to displace the valve by one position in order to subject the component which is next in the work cycle with negative pressure.
If the connections of the negative pressure ducts have different cross-sectional surfaces, different flow velocities can be obtained in the negative pressure ducts. Thus it is possible to obtain better flowing conditions for different tasks such as e.g. yarn end preparation. Furthermore the utilization of smaller and larger cross-sectional surfaces creates the possibility for several negative pressure ducts to be opened at the same time. Here it is advantageous to place the connections in different planes, as the connections can be placed even closer to each other in this manner insofar as the cross-sectional surfaces are circular, for example. In such an arrangement the different connections are open in one position of the valve and can thus be subjected to negative pressure.
If the valve has a conical opening in cross-section for the connection between the negative pressure channel and at least one of the connections of the negative pressure ducts of the components, it is ensured that the valve creates favorable flow conditions. The flow losses in the valve or in the distributor can be minimized in this manner. Furthermore, the possibility is created for the valve to contact on one side different connections of the negative pressure ducts, while it always provides an opening to the negative pressure channel on the other side. Here it is especially advantageous if the greater width of the conical opening of the valve is facing the connection of the negative pressure channel. The conical opening can also be used to special advantage as part of a yarn storage into which the yarn is aspired and from which it is drawn off again as required.
If the smaller width of the conical opening has a cross-section which is at least equal to the largest cross-section of the connections of the negative-pressure ducts of the components, optimal flow through the negative-pressure duct is always ensured. By shifting the smaller width of the conical opening relative to the connection of the negative-pressure duct, a reduction of the cross-sectional surface is made possible.
In order to obtain a robust, simple and low-maintenance drive for the valve, a gear motor is advantageously selected. This makes it possible to use proven standard components which furthermore reduces costs. With the gear motor it is possible to precisely control the position of the valve. With an appropriate transmission of the gears, the tolerances in positioning as well as precision in repeatability are sufficient.
The device is especially simple and reliable if the valve is a rotary valve. In this manner it is possible, through a simple rotational movement, under certain conditions even in one direction only, to make all connections between the negative pressure lines and the narrow opening of the valve controllable. Furthermore, a closing of the distributor can be obtained with the same movement, in that the rotary valve assumes a position in which no passage from the negative-pressure channel into one of the negative-pressure lines takes place.
An especially simple possibility for the positioning of the rotary valve is provided when a positioning disk interacting with a sensor is installed on said rotary valve. The sensor is advantageously a limit switch which scans different switching flags arranged at the radius of the positioning disk. Through the arrangement of the switching flags, the control of the drive is able to go to certain positions or to stop at certain positions until an activity has been carried out. The individual positions correspond to the connections of the negative-pressure lines and are assigned to these. Depending on programming, the gear motor is able to stop for a given predetermined time in the presence, but also in the absence, of a switching flag and to continue moving the rotary valve on to the next stop only at the end of that time or upon receiving a different signal. If the positioning disk is substantially of circular configuration, the switching flags are located at the radius of the positioning disk. In case that the valve can be displaced in a linear manner, it is advantageous for the positioning disk to be rectangular. In that case the switching flags are to be installed on the outer sides of the positioning disk.
In order to ensure that the yarn end does not interfere with the operation of the distributor by being aspired into the moving parts or into the negative-pressure channel, it is advantageous to provide a yarn cutting device in the area of the connection of the negative-pressure channel. A yarn cutting device in which a displaceable knife is installed in the cross-section of the connection of the negative-pressure channel has proven advantageous. A yarn end extending into the negative-pressure channel is severed by means of this displaceable knife and can be aspired through the negative-pressure channel and be conveyed into a waste container.
It is an especially great advantage, particularly in a spinning machine with several work stations, that the distributor is installed in a service unit traveling alongside the spinning machine. In this manner, the utilization of identical components, such as the distributor, need not be used several times in the machine, thus increasing its cost.
The invention is described below through examples of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a spinning machine with a traveling service unit;
FIG. 2 shows a distributor in cross-section;
FIG. 3 shows a positioning disk;
FIGS. 4a to 4f show different positions of a rotary valve in the distributor; and
FIG. 5 shows a distributor with a yarn cutting device in cross-section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. It is intended that the present invention cover such modifications and variations as come within the score of the appended claims and their equivalents.
In FIG. 1 a spinning machine 1, here an open-end rotor spinning machine, is shown. A service unit 5 is able to travel on the spinning machine 1 via a holding device. The service unit 5 controls and services the plurality of spinning stations provided next to each other on the spinning machine. Each spinning station is provided, among other things, with a winding device with a bobbin 7. A central negative-pressure channel 2 is installed in the longitudinal direction of the spinning machine 1. The negative pressure is produced in the negative-pressure channel 2 by means of a source of negative pressure which is not shown. At each spinning station a connection 4 is provided which provides the spinning station with a connection to the central negative-pressure channel 2. In the service unit 5 a negative-pressure channel 15 is provided as a connecting segment which can be shifted to the connection 4 of the spinning machine 1. As soon as the connection is established, the negative pressure from the central negative-pressure channel 2 appears in the connecting pipe 4 and in the negative-pressure channel 15 and thereby in a distributor 3. As shall be explained in further detail below, several negative-pressure lines are connected to the distributor 3. FIG. 1 of the example of an embodiment shows a negative-pressure line letting out in a suction pipe 6. This suction pipe 6 can be used to aspire a yarn end on the bobbin 7 and to prepare it for a piecing process. Advantageously, each device or component in the service unit which works with negative pressure, is provided with its own negative-pressure line up to distributor 3. As soon as one of the components requires negative pressure for its activity, the distributor 3 is switched in such a manner that negative pressure from the negative-pressure channel 2 enters the appertaining negative pressure line going to the component through the connecting pipes 4, the negative-pressure channel 15, and the distributor 3.
In another advantageous embodiment, a source of negative pressure with a negative-pressure channel 15 instead of the negative-pressure channel 2 and the connecting pipe 4 are installed in the service unit 5. The source of negative pressure and the negative-pressure channel 15 are moved alongside the spinning machine 1 in this case, together with the service unit 5.
Components connected to the distributor 3 via negative-pressure lines may be suction nozzles for yarns or for fiber sliver. They may be provided for the preparation of yarn ends or for the formation of yarn reserve and yarn storage. In special piecing processes working with fiber flow deflection, the component can serve as a suction trunk to aspire from an opening roller or a fiber feeding channel. The components may be located in the service unit 5 as well as in the spinning machine 1. The same applies to the distributor 3. The distributor 3 can also be used in other spinning machines, such as e.g. winding machines or ring spinning machines.
When the service unit 5 is not at the connecting pipe 4 of a given spinning station, the connecting pipe 4 is closed by means of a valve. The closing of the connecting pipe 4 ensures that no unnecessary negative-pressure losses occur in the negative-pressure channel 2. Only the passing of the service unit 5 or docking of the service unit 5 at a spinning station establishes a connection between the connecting pipe 4 and the negative-pressure channel 15.
FIG. 2 shows a distributor 3 in cross-section. The distributor 3 consists of a pot-shaped housing 10 in the sides of which openings are made for the negative-pressure lines and the negative-pressure channel 15. In the drawing, the openings of the negative-pressure line 11 and of the negative-pressure line 12 can be seen. Additional negative-pressure lines are located behind a side of a rotary valve 18 and are not visible in this drawing. The housing 10 is closed by a cover 16 by means of screws 17. The connection between the two parts should be as tight as possible in order to avoid losses in negative pressure. The negative-pressure lines 11, 12, 13 and 14 are opened or covered and thereby closed by the rotary valve 18. This also applies to the negative-pressure channel 15 which is connected to the source of negative pressure (not shown). The rotary valve 18 can swivel around its axis 19 in such a manner that it establishes a connection between the negative-pressure channel 15 and one or several of the negative-pressure lines 11, 12, 13 or 14. The rotary valve 18 can furthermore be brought into a position in which the negative-pressure channel 15 is closed, so that none of the negative-pressure lines 11, 12, 13 or 14 is supplied with negative pressure.
In the present example of an embodiment as shown in FIG. 2, the rotary valve 18 of the distributor 3 is driven and adjusted via a motor 20 and gearing 21. Motor 20 and gearing 21 are secured on a platform 22 on the cover 16. The drive shaft 23 of gearing 21 is connected to the rotary valve 18 in the axis 19 of said rotary valve 18. The rotary valve 18 can be rotated into any desired position by actuating the motor 20.
A positioning disk 26 is connected by means of screws 25 permanently to the rotary valve 18 or to the shaft 23. The positioning disk 26 interacts with a limit switch 27. The motor 20 is controlled via the limit switch 27. The needed position of the rotary valve 18 is set on the positioning disk 26. When the rotor and gearing 21 rotates the shaft 19, the rotary valve 18 and the positioning disk 26, the rotary valve 18 is rotated until the limit switch 27 detects a change in state of the positioning disk 26 and switches off the motor 20. Following a predetermined time period or based on another signal, the motor 20 is switched on again and moves forward in steps by one or several positions of the positioning disk 26.
FIG. 3 shows a positioning disk 26 with a bore 28. The bore 28 serves to center the positioning disk 26 relative to the shaft 23 of the gearing 21. It is important for the positioning disk 26 to be non-rotatably connected to the rotary valve 18 or the shaft 23. This is achieved by means of a groove and spring connection and/or by means of screws 25. This ensures that precise positioning of the rotary valve 18 relative to the negative-pressure lines 11, 12, 13 and 14 as well as negative-pressure channel 15 is achieved.
Switching flags 29 and 30 are placed at the periphery of the positioning disk 26. The switching flags 29 and 30 interact with the limit switch 27. In the present example, the limit switch 27 is made in the form of a double proximity switch, and this means that two proximity switches are installed in the limit switch. One of the proximity switches of the limit switch 27 interacts with the inner switching flag 29 and the other proximity switch with the outer switching flags 30. Through a logical linking of the signals of the two proximity switches in the limit switch 27, the control of the motor 20 is made possible. The logical linking may be of such nature that the motor is stopped when a proximity switch for the outer switching flag 30 and the inner switching flag 29 is affected. It is also possible to provide a circuit in which the motor 20 is stopped when only the outer switching flag 30 is affected. In a variant of the switching flag, in which only the inner switching flag 29 is installed on the switching flags 29 and 30, it can be decided for the rotary valve 18 has closed the distributor 3. Starting from this position, the controls of the rotary valve 18 or of the motor 23 is able to deduce that the rotary valve 18 is in its starting position. This ensures that in case of power failure, shut-down or other influences due to which the device must be adjusted again, a zero point is determined from which the device can be started anew. The installation of the switching flags 29 and 30 at the periphery of the positioning disk 26 can be effected according to the requirements or according to the connections of the negative-pressure lines 11, 12, 13 and 14 and of the negative-pressure channel 15. In addition, other forms of the positioning disks and of the switching flags are also possible. It is important here that the interaction between positioning disk 26 and limit switch 27 ensures a secure position of the rotary valve 18 before the connections of the negative-pressure lines, even after a failure.
In FIGS. 4a to 4f, the functioning of the device according to the invention is described through an example of an embodiment. In the housing 10 of the distributor 3, the negative-pressure lines 11, 12, 13 and 14 as well as the negative-pressure channel 15 are installed. The negative-pressure lines 11 to 14 have in part different diameters. The negative-pressure line 12 is shown offset in the drawing plane relative to the other negative-pressure lines 11, 13 and 14. The placement of the negative-pressure lines 11 to 14 relative to the negative-pressure channel 15 must be such that in at least one position of the rotary valve 18 no connection exists between the negative-pressure channel 15 and any of the negative-pressure lines 11 to 14. On the other hand, a suitable form of the rotary valve 18 must ensure that a connection between the negative-pressure channel 15 and only one of the negative-pressure lines 11, 12, 13 or 14 is established. It is also advantageous if the narrow opening 32 is of such dimension relative to the cross-sections of the negative-pressure lines 11, 12, 13 and 14 that it is able to open also several negative-pressure lines in certain positions. The wide opening 31, on the contrary, must be sized so that it opens the negative-pressure channel 15 every time the narrow opening 32 is in the area of one of the negative-pressure lines 11 to 14. For this reason, an open cross-section of the rotary valve 18 with an essentially conical form has therefore proven to be advantageous. This also ensures that a minimum of flow losses are produced in the rotary valve 18, since the flow in such a form is able to go without great deflections from the negative-pressure lines 11 to 14 into the negative-pressure channel 15.
FIG. 4a shows the basic position of the rotary valve 18 of the distributor 3. In this starting position the negative-pressure channel 15 is closed. The negative-pressure lines 11 to 14 are not fed negative pressure. Although the negative-pressure lines 11 and 12 are not directly closed by the side of rotary valve 18, no negative pressure enters these negative-pressure lines 11 and 12 since the second side of the rotary valve 18 closes the negative-pressure channel 15.
To achieve a good seal between the rotary valve 18 and the negative-pressure channel 15 or the negative-pressure lines 11 to 14, it is necessary for the housing 10 of the distributor 3 to be pressed very tightly against the walls of the rotary valve 18. This can be achieved by means of a precise finishing or by means of sealing lips which are inserted into the rotary valve 18. Under some conditions it may, however, also be admissible that the seal of the individual lines not be totally tight since the negative pressure appears at the negative-pressure channel 15 only when the service unit 5 has docked at the negative-pressure channel 2 of the spinning machine 1 or at the connecting pipe 4 if the distributor 3 is installed in a service unit 5. Alternatively, the negative-pressure source which is located in the service unit 5 only operates when the service unit 5 has docked at a spinning station of the spinning machine 1 and requires negative pressure for its service activities.
FIG. 4b shows a position of the rotary valve 18 in which the negative-pressure line 14 is connected to the negative-pressure channel 15. In this position the negative-pressure lines 11 to 13 are closed by a side of the rotary valve 18. The negative-pressure line 14 may be used to supply a fiber sliver feeding apparatus for instance, in which the fiber sliver being presented to the spinning station is aspired and is introduced into the spinning station.
In FIG. 4c the narrow opening 32 of the rotary valve 18 is assigned to the negative-pressure line 13. In this manner a connection between the negative-pressure line 13 and the negative-pressure channel 15 is created. The negative-pressure lines 11 and 12 are closed by a side of the rotary valve 18 and the negative-pressure line by another side of the rotary valve 18. The negative-pressure line 13 may be used for example to provide negative pressure to a suction nozzle by means of which a yarn end is located on a bobbin.
Once the yarn end on the bobbin has been aspired, it continues to be held in the suction nozzle and is fed to a yarn preparation station device. In the yarn preparation device, the yarn end is prepared for subsequent piecing. To carry out the process step "holding the yarn end" and "preparing the yarn end", the rotary valve 18 is rotated in such a manner as shown in FIG. 4d, that the narrow opening 32 is assigned to the negative-pressure line 12 and to the negative-pressure line 13. In this manner, the yarn end is held by the negative pressure in the negative-pressure line 13 and is prepared through the negative pressure in the negative-pressure line 12. In this position the negative-pressure line 11 is closed by one side of the rotary valve 18 and the negative-pressure line 14 by the other side of the rotary valve 18. The narrow opening 32 of the rotary valve 18 lies in the area of the negative-pressure line 12 and of the negative-pressure line 13 and thus provides both lines with negative pressure.
In FIG. 4e the rotary valve 18 is shifted by another position. In this drawing the narrow opening 32 is located in front of the negative-pressure line 11 and the negative-pressure line 12. In the embodiment described above, the negative-pressure line 12 is thus provided with negative pressure for the preparation of the yarn end. Furthermore negative pressure is provided to the negative-pressure line 11. The negative-pressure line 11 may be connected to a yarn storage in which a yarn is held in a given position for piecing. In this position the negative-pressure lines 13 and 14 are completely closed by a side of the rotary valve 18.
In FIG. 4f the rotary valve 18 is in a position in which only the negative-pressure line 11 is subjected to negative pressure. The negative-pressure lines 12, 13 and 14 are closed by one side of the rotary valve 18. A yarn storage in which the yarn is placed during piecing or after piecing to receive excess yarn is connected to the negative-pressure line 11. Following piecing, the rotary valve 18 can again be moved back into the position shown in FIG. 4a, so that the distributor 3 closes off the negative pressure appearing at the negative-pressure channel 15.
In particular in the positions of FIGS. 4c to 4f, it is possible that a yarn end or a yarn loop is sucked into the distributor 3 and is stored temporarily. In order to prevent the aspired yarn segment from blocking the distributor 3 or from hindering the rotary valve 18 in its mobility, and also to prevent a yarn end to be carried along from the service unit 5 on its way alongside the spinning machine 1 and from being unwound from the bobbin, it is advantageous, according to FIG. 5, to provide a yarn cutting device. The yarn cutting device consists of a pneumatic cylinder 33 on which a rod 34 is installed. The rod 34 which can be moved back and forth has a knife 35 at its end. The rod 34 moves the knife 35 in a guide 36. The guide 36 has an opening 37 in the area of the negative-pressure channel 15. While the distributor 3 operates as shown in FIGS. 4b to 4f, the knife 35 is in a retracted position which is not shown. In this manner the opening 37 of the guide 36 is open and a yarn can be aspired through the negative-pressure line, the open cross-section of the negative-pressure channel 15 and through the opening 37. Before the end of the work cycle the pneumatic cylinder 33 is actuated and moves the knife 35 in the guide 36 at a right angle to the negative-pressure pressure channel 15 into the shown position. Thereby a yarn which is in the area of the yarn cutting device is severed. The severed yarn end is aspired through the negative-pressure channel 15 and continues moving into a waste container which is not shown. The other portion of the yarn continues to remain in one of the negative-pressure line 11 to 13 and in the rotary valve 18. It can then be drawn off for further processing from the negative-pressure line.
Another manner of operation consists in the device aspiring a yarn end as far as into the negative-pressure channel 15. As soon as the yarn end is in the area of a sensor 38 which is located in the negative-pressure channel 15, a signal is transmitted to the yarn cutting device. This signal causes the pneumatic cylinder 33 to be actuated and the knife 35 cuts the yarn at a defined location. The yarn end located on the side of the negative-pressure channel 15 is removed into the waste container while the yarn end on the side of the distributor 3 has a defined length. In this manner a targeted continued processing by means of one of the actors or handling devices is made possible.
The sensor 38 is advantageously located in a bend of the negative-pressure channel 15. This ensures that the aspired yarn end is located in proximity of the sensor 38 and that the sensor 38 will recognize the aspired yarn end without fail.
For a good seal or for easy and reliable rotation of the rotary valve 18, it is advantageous for pockets 40 to be provided in the sides of the rotary valve 18. These pockets 40 reliably prevent a jamming of the rotary valve 18 in the housing 10 by aspired fiber particles or yarn segments. The fibers or yarn remnants have sufficient room available in the pockets 40 so that the rotation of the rotary valve 18 remains possible. The pockets 40 are cleaned by the negative pressure in the negative-pressure channel 15 during a rotation along the connection of the negative-pressure channel 15.
Instead of the rotary valve 18, it is in principle also possible to provide a valve in the distributor 3 which is displaced in a linear manner. In that case, the negative-pressure channel 15 is located in an essentially rectangular housing 10 on one side of said housing 10 and the negative-pressure lines 11 to 14 are located on the side across from the negative-pressure channel 15. In a linear displacement of the valve, individual or several negative-pressure lines 11 to 14 are opened or closed in the same manner as in the previous example of an embodiment. The movement of the valve is however easily realized with the rotary valve 18 in the embodiment shown, since fewer and simpler components are needed for the displacement of the valve in a rotary valve 18. In a linear valve, instead of a positioning disk 26, an essentially rectangular positioning plate would be required in order to provide the limit switch 27 with appropriate signals.
The negative pressure components may also be other than those handling devices described above. Thus all the devices which operate with negative pressure for the actuation of another device or directly for the treatment of a yarn can be supplied through the distributor 3. One could think here, among other things, of cutting devices, clamping devices or cleaning devices. Several actors which are to be subjected simultaneously to negative pressure can also be connected to one single connection of the negative-pressure line. It is also possible to connect one actor which is needed several times in the work cycle to several connections and thus to cause the valve to be moved on in steps in one direction. 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 scope and spirit of the invention. It is intended that the present invention cover such modifications and variations as come within the scope of the claims and their equivalents. | A negative pressure distribution system for a textile spinning machine includes a negative pressure channel and a plurality of lines configured to deliver negative pressure to a device in the textile machine to carry out a desired task. A distributor is disposed between the negative pressure channel and the negative pressure lines. The distributor includes a housing having a variably positionable valve within the housing. The valve is positionable between a closed position wherein the negative pressure lines are pneumatically isolated from the negative pressure channel and a plurality of operable positions wherein at least one of the negative pressure lines is in communication with the negative pressure channel through the housing. | 3 |
FIELD OF THE INVENTION
[0001] The invention relates to substituted hydroxybiphenylcarboxylic acids, and to their physiologically tolerated salts.
BACKGROUND OF THE INVENTION
[0002] Compounds of similar structure have been described in the prior art, and their use for the treatment of diabetes has been described in WO 99/58518. Further compounds of similar structure are disclosed in WO 2004/099170, EP 0 490 820 and WO 01/70678.
[0003] The invention was based on the object of providing compounds with which it is possible to prevent and treat Diabetes mellitus. The compounds were intended for this purpose to display a therapeutically utilizable blood glucose-lowering effect.
SUMMARY OF THE INVENTION
[0004] The object is achieved by providing novel compounds of the formula I,
in which:
R1 is selected from —(C 1 -C 6 )-alkyl, —(C 1 -C 4 )-alkyl-O—(C 1 -C 4 )-alkyl, —(C 2 -C 6 )-alkenyl, —(C 3 -C 8 )-cycloalkyl, -aryl, —(C 1 -C 6 )-alkyl-aryl, —(C 2 -C 6 )-alkenyl-aryl, —(C 1 -C 6 )-alkyl-cycloalkyl, and —(C 2 -C 6 )-alkenyl-cycloalkyl, where the alkyl, alkenyl, aryl and cycloalkyl radicals may be substituted by a substituent selected from F, Cl, Br, I, CF 3 , NO 2 , N 3 , CN, COOH, COO(C 1 -C 6 )alkyl, CONH 2 , CONH(C 1 -C 6 )alkyl, CON[(C 1 -C 6 )alkyl] 2 , cycloalkyl, (C 2 -C 6 )-alkenyl, (C 2 -C 6 )-alkynyl, O—(C 1 -C 6 )-alkyl O—CO—(C 1 -C 6 )-alkyl, O—CO—(C 1 -C 6 )-aryl, and O—CO—(C 1 -C 6 )-heterocycle; as well as PO 3 H 2 , SO 3 H, SO 2 —NH 2 , SO 2 NH(C 1 -C 6 )-alkyl, SO 2 N[(C 1 -C 6 )-alkyl] 2 , S—(C 1 -C 6 )-alkyl, S—(CH 2 ) n -aryl, S—(CH 2 ) n -heterocycle, SO—(C 1 -C 6 )-alkyl, SO—(CH 2 )n-aryl, SO—(CH 2 ) n -heterocycle, SO 2 —(C 1 -C 6 )-alkyl, SO 2 —(CH 2 ) n -aryl, SO 2 —(CH 2 ) n -heterocycle, SO 2 -NH(CH 2 ) n -aryl, SO 2 —NH(CH 2 ) n -heterocycle, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -aryl, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -heterocycle, SO 2 —N((CH 2 ) n -aryl) 2 , SO 2 —N((CH 2 ) n -(heterocycle) 2 where n may be 0-6, and the aryl radical or heterocyclic radical may be substituted up to twice by a substituent selected from F, Cl, Br, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 ; C(NH)(NH 2 ), NH 2 , NH—(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , NH(C 1 -C 7 )-acyl, NH—CO—(C 1 -C 6 )-alkyl, NH—COO—(C 1 -C 6 )-alkyl, NH—CO-aryl, NH—CO-heterocycle, NH—COO-aryl, NH—COO-heterocycle, NH—CO—NH—(C 1 -C 6 )-alkyl, NH—CO—NH-aryl, NH—CO—NH-heterocycle, N(C 1 -C 6 )-alkyl —CO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —COO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —CO-aryl, N(C 1 -C 6 )-alkyl —CO-heterocycle, N(C 1 -C 6 )-alkyl —COO-aryl, N(C 1 -C 6 )-alkyl —COO-heterocycle, N(C 1 -C 6 )-alkyl —CO—NH—(C 1 -C 6 )-alkyl), N(C 1 -C 6 )-alkyl —CO—NH-aryl, N(C 1 -C 6 )-alkyl —CO—NH-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N((C 1 -C 6 )-alkyl)-CO-N((C 1 -C 6 )-alkyl)-aryl, N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N-(aryl) 2 , N((C 1 -C 6 )-alkyl)-CO—N-(heterocycle) 2 , N(aryl)-CO—(C 1 -C 6 )-alkyl, N(heterocycle)-CO—(C 1 -C 6 )-alkyl, N(aryl)-COO—(C 1 -C 6 )-alkyl, N(heterocycle)-COO—(C 1 -C 6 )-alkyl, N(aryl)-CO-aryl, N(heterocycle)-CO-aryl, N(aryl)-COO-aryl, N(heterocycle)-COO-aryl, N(aryl)-CO—NH—(C 1 -C 6 )-alkyl), N(heterocycle)-CO—NH—(C 1 -C 6 )-alkyl), N(aryl)-CO—NH-aryl, N(heterocycle)-CO—NH-aryl, N(aryl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(heterocycle)-CO—N-(C 1 -C 6 )-alkyl) 2 , N(aryl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(heterocycle)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(aryl)-CO—N-(aryl) 2 , N(heterocycle)-CO—N-(aryl) 2 , aryl, O—(CH 2 ) n -aryl, and O—(CH 2 ) n -heterocycle, where n may be 0-6, where the aryl radical or heterocyclic radical may be substituted one to 3 times by a substituent selected from F, Cl, Br, I, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 , NH(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , SO 2 —CH 3 , COOH, COO—(C 1 -C 6 )-alkyl, and CONH 2 ; R2 is selected from —(C 1 -C 6 )-alkyl, —(C 1 -C 4 )-alkyl-O—(C 1 -C 4 )-alkyl, —(C 2 -C 6 )-alkenyl, —(C 3 -C 8 )-cycloalkyl, —(C 1 -C 6 )-alkyl-aryl, —(C 2 -C 6 )-alkenyl-aryl, heterocycle, —(C 1 -C 6 )-alkyl-heterocycle, —(C 2 -C 6 )-alkenyl-heterocycle, —(C 1 -C 6 )-alkyl-cycloalkyl, and —(C 2 -C 6 )-alkenyl-cycloalkyl, where the alkyl, alkenyl, aryl, heterocyclyl and cycloalkyl radicals may be substituted by a substituent selected from F, Cl, Br, I, CF 3 , NO 2 , N 3 , CN, COOH, COO(C 1 -C 6 )alkyl, CONH 2 , CONH(C 1 -C 6 )alkyl, CON[(C 1 -C 6 )alkyl] 2 , cycloalkyl, (C 2 -C 6 )-alkenyl, (C 2 -C 6 )-alkynyl, O—(C 1 -C 6 )-alkyl O—CO—(C 1 -C 6 )-alkyl, O—CO—(C 1 -C 6 )-aryl, and O—CO—(C 1 -C 6 )-heterocycle; as well as PO 3 H 2 , SO 3 H, SO 2 —NH 2 , SO 2 NH(C 1 -C 6 )-alkyl, SO 2 N[(C 1 -C 6 )-alkyl] 2 , S—(C 1 -C 6 )-alkyl, S—(CH 2 ) n -aryl, S—(CH 2 ) n -heterocycle, SO—(C 1 -C 6 )-alkyl, SO—(CH 2 ) n -aryl, SO—(CH 2 ) n -heterocycle, SO 2 —(C 1 -C 6 )-alkyl, SO 2 —(CH 2 ) n -aryl, SO 2 —(CH 2 ) n -heterocycle, SO 2 —NH(CH 2 ) n -aryl, SO 2 —NH(CH 2 ) n -heterocycle, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -aryl, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -heterocycle, SO 2 —N((CH 2 ) n -aryl) 2 , and SO 2 —N((CH 2 ) n -(heterocycle) 2 , where n may be 0-6, and the aryl radical or heterocyclic radical may be substituted up to twice by a substituent selected from F, Cl, Br, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, and NH 2 ; as well as C(NH)(NH 2 ), NH 2 , NH—(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , NH(C 1 -C 7 )-acyl, NH—CO—(C 1 -C 6 )-alkyl, NH—COO—(C 1 -C 6 )-alkyl, NH—CO-aryl, NH—CO-heterocycle, NH—COO-aryl, NH—COO-heterocycle, NH—CO—NH—(C 1 -C 6 )-alkyl, NH—CO—NH-aryl, NH—CO—NH-heterocycle, N(C 1 -C 6 )-alkyl —CO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —COO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —CO-aryl, N(C 1 -C 6 )-alkyl —CO-heterocycle, N(C 1 -C 6 )-alkyl —COO-aryl, N(C 1 -C 6 )-alkyl —COO-heterocycle, N(C 1 -C 6 )-alkyl —CO—NH—(C 1 -C 6 )-alkyl), N(C 1 -C 6 )-alkyl —CO—NH-aryl, N(C 1 -C 6 )-alkyl —CO—NH-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N-(aryl) 2 , N((C 1 -C 6 )-alkyl)-CO—N-(heterocycle) 2 , N(aryl)-CO—(C 1 -C 6 )-alkyl, N(heterocycle)-CO—(C 1 -C 6 )-alkyl, N(aryl)-COO—(C 1 -C 6 )-alkyl, N(heterocycle)-COO—(C 1 -C 6 )-alkyl, N(aryl)-CO-aryl, N(heterocycle)-CO-aryl, N(aryl)-COO-aryl, N(heterocycle)-COO-aryl, N(aryl)-CO—NH—(C 1 -C 6 )-alkyl), N(heterocycle)-CO—NH—(C 1 -C 6 )-alkyl), N(aryl)-CO—NH-aryl, N(heterocycle)-CO—NH-aryl, N(aryl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(heterocycle)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(aryl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(heterocycle)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(aryl)-CO—N-(aryl) 2 , N(heterocycle)-CO—N-(aryl) 2 , aryl, O—(CH 2 ) n -aryl, and O—(CH 2 ) n -heterocycle, where n may be 0-6, where the aryl radical or heterocyclic radical may be substituted one to 3 times by a substituent selected from F, Cl, Br, I, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 , NH(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , SO 2 -CH 3 , COOH, COO—(C 1 -C 6 )-alkyl, and CONH 2 ; A is selected from a bond, O, NH, and S; and the physiologically tolerated salts thereof.
DETAILED DESCRIPTION
[0010] Preference is given to compounds of the formula I in which the radicals R1, R2 and A have the following meaning:
R1 is selected from —(C 1 -C 6 )-alkyl, —(C 1 -C 4 )-alkyl-O—(C 1 -C 4 )-alkyl, —(C 2 -C 6 )-alkenyl, —(C 3 -C 8 )-cycloalkyl, -aryl, —(C 1 -C 6 )-alkyl-aryl, —(C 2 -C 6 )-alkenyl-aryl, —(C 1 -C 6 )-alkyl-cycloalkyl, and —(C 2 -C 6 )-alkenyl-cycloalkyl, where the alkyl, alkenyl, aryl and cycloalkyl radicals may be substituted by a substituent selected from F, Cl, Br, I, (C 1 -C 6 )alkyl, O—(C 1 -C 6 )-alkyl; R2 is selected from —(C 1 -C 6 )-alkyl, —(C 1 -C 4 )-alkyl-O—(C 1 -C 4 )-alkyl, —(C 2 -C 6 )-alkenyl, —(C 3 -C 8 )-cycloalkyl, —(C 1 -C 6 )-alkyl-aryl, —(C 2 -C 6 )-alkenyl-aryl, heterocycle, —(C 1 -C 6 )-alkyl-heterocycle, —(C 2 -C 6 )-alkenyl-heterocycle, —(C 1 -C 6 )-alkyl-cycloalkyl, and —(C 2 -C 6 )-alkenyl-cycloalkyl, where the alkyl, alkenyl, aryl, heterocyclyl and cycloalkyl radicals may be substituted by a substituent selected from F, Cl, Br, I, (C 1 -C 6 )alkyl, and O—(C 1 -C 6 )-alkyl; and A is a bond; and the physiologically tolerated salts thereof.
[0015] Particular preference is given to compounds of the formula I in which the radicals R1, R2 and A have the following meanings:
R1 is selected from —(C 1 -C 6 )-alkyl, —(C 1 -C 6 )-alkyl-phenyl, —(C 1 -C 6 )-alkyl—(C 3 -C 8 )-cycloalkyl, and —(C 3 -C 8 )-cycloalkyl, where the alkyl, phenyl and cycloalkyl radicals may be substituted by a substituent selected from F, Cl, Br, I, (C 1 -C 6 )alkyl, and O—(C 1 -C 6 )-alkyl; R2 is selected from —(C 1 -C 6 )-alkyl, —(C 1 -C 6 )-alkyl-phenyl, —(C 1 -C 6 )-alkyl—(C 3 -C 8 )-cycloalkyl, —(C 3 -C 8 ) cycloalkyl, —(C 2 -C 6 )-alkenyl-phenyl, and -heterocycle, where the alkyl, phenyl, heterocyclyl and cycloalkyl radicals may be substituted by a substituent selected from F, Cl, Br, I, (C 1 -C 6 )alkyl, and O—(C 1 -C 6 )-alkyl; and A is a bond; and the physiologically tolerated salts thereof.
[0020] Very particular preference is given to compounds of the formula I in which the radicals R1, R2 and A have the following meanings:
R1 is selected from —CH 2 -phenyl, —CH 2 —(C 3 -C 8 )-cycloalkyl, —(C 3 -C 8 )-cycloalkyl, where the phenyl and cycloalkyl radicals may be substituted by F, Cl, Br, I, (C 1 -C 6 )alkyl, and O—(C 1 -C 6 )-alkyl; R2 is selected from —CH 2 -phenyl, —CH 2 —(C 3 -C 8 )-cycloalkyl, —(C 3 -C 8 )-cycloalkyl, —(C 2 -C 6 )-alkenyl-phenyl, —CH 2 -heterocycle, -heterocycle, where the phenyl, heterocyclyl and cycloalkyl radicals may be substituted by F, Cl, Br, I, (C 1 -C 6 )alkyl, O—(C 1 -C 6 )-alkyl; and A is a bond; and the physiologically tolerated salts thereof.
[0025] The invention relates to compounds of the formula I in the form of their racemates, racemic mixtures and pure enantiomers and to their diastereomers and mixtures thereof.
[0026] If radicals or substituents may occur more than once in the compounds of the formula I, they may all, independently of one another, have the stated meanings and be identical or different. Pharmaceutically acceptable salts are, because their solubility in water is greater than that of the initial or basic compounds, particularly suitable for medical applications. These salts must have a pharmaceutically acceptable anion or cation. Suitable pharmaceutically acceptable acid addition salts of the compounds of the invention are salts of inorganic acids such as hydro-chloric acid, hydrobromic, phosphoric, metaphosphoric, nitric and sulfuric acid, and of organic acids such as, for example, acetic acid, benzenesulfonic, benzoic, citric, ethane-sulfonic, fumaric, gluconic, glycolic, isethionic, lactic, lactobionic, maleic, malic, methanesulfonic, succinic, p-toluenesulfonic and tartaric acid. Suitable pharmaceutically acceptable basic salts are ammonium salts, alkali metal salts (such as sodium and potassium salts), alkaline earth metal salts (such as magnesium and calcium salts), trometamol (2-amino-2-hydroxymethyl-1,3-propanediol), diethanolamine, lysine or ethylenediamine.
[0027] Salts with a pharmaceutically unacceptable anion such as, for example, trifluoroacetate likewise belong within the framework of the invention as useful intermediates for the preparation or purification of pharmaceutically acceptable salts and/or for use in nontherapeutic, for example in vitro, applications.
[0028] The term “physiologically functional derivative” used herein refers to any physiologically tolerated derivative of a compound of the formula I of the invention, for example an ester, which on administration to a mammal such as, for example, a human is able to form (directly or indirectly) a compound of the formula I or an active metabolite thereof.
[0029] Physiologically functional derivatives include prodrugs of the compounds of the invention, as described, for example, in H. Okada et al., Chem. Pharm. Bull. 1994, 42, 57-61. Such prodrugs can be metabolized in vivo to a compound of the invention. These prodrugs may themselves be active or not.
[0030] The compounds of the invention may also exist in various polymorphous forms, for example as amorphous and crystalline polymorphous forms. All polymorphous forms of the compounds of the invention belong within the framework of the invention and are a further aspect of the invention.
[0031] All references to “compounds of formula I” hereinafter refer to compounds of the formula I as described above, and their salts, solvates and physiologically functional derivatives as described herein.
[0032] An alkyl radical means a straight-chain or branched hydrocarbon chain having one or more carbons, such as, for example, methyl, ethyl, isopropyl, tert-butyl, hexyl.
[0033] The alkyl radicals may be substituted one or more times by suitable groups such as, for example: F, Cl, Br, I, CF 3 , NO 2 , N 3 , CN, COOH, COO(C 1 -C 6 )alkyl, CONH 2 , CONH(C 1 -C 6 )alkyl, CON[(C 1 -C 6 )alkyl] 2 , cycloalkyl, (C 2 -C 6 )-alkenyl, (C 2 -C 6 )-alkynyl, O—(C 1 -C 6 )-alkyl O—CO—(C 1 -C 6 )-alkyl, O—CO—(C 1 -C 6 )-aryl, O—CO—(C 1 -C 6 )-heterocycle;
PO 3 H 2 , SO 3 H, SO 2 —NH 2 , SO 2 NH(C 1 -C 6 )-alkyl, SO 2 N[(C 1 -C 6 )-alkyl] 2 , S—(C 1 -C 6 )-alkyl, S—(CH 2 ) n -aryl, S—(CH 2 ) n -heterocycle, SO—(C 1 -C 6 )-alkyl, SO—(CH 2 )n-aryl, SO—(CH 2 ) n -heterocycle, SO 2 -—(C 1 -C 6 )-alkyl, SO 2 —(CH 2 ) n -aryl, SO 2 —(CH 2 ) n -heterocycle, SO 2 —NH(CH 2 ) n -aryl, SO 2 —NH(CH 2 ) n -heterocycle, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -aryl, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -heterocycle, SO 2 —N((CH 2 ) n -aryl) 2 , SO 2 —N((CH 2 ) n -(heterocycle) 2 where n may be 0-6, and the aryl radical or heterocyclic radical may be substituted up to twice by F, Cl, Br, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 ; C(NH)(NH 2 ), NH 2 , NH—(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , NH(C 1 -C 7 )-acyl, NH—CO—(C 1 -C 6 )-alkyl, NH—COO—(C 1 -C 6 )-alkyl, NH—CO-aryl, NH—CO-heterocycle, NH—COO-aryl, NH—COO-heterocycle, NH—CO—NH—(C 1 -C 6 )-alkyl, NH—CO—NH-aryl, NH—CO—NH-heterocycle, N(C 1 -C 6 )-alkyl —CO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —COO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —CO-aryl, N(C 1 -C 6 )-alkyl —CO-heterocycle, N(C 1 -C 6 )-alkyl —COO-aryl, N(C 1 -C 6 )-alkyl —COO-heterocycle, N(C 1 -C 6 )-alkyl —CO—NH—(C 1 -C 6 )-alkyl), N(C 1 -C 6 )-alkyl —CO—NH-aryl, N(C 1 -C 6 )-alkyl —CO—NH-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N-(aryl) 2 , N((C 1 -C 6 )-alkyl)-CO—N-(heterocycle) 2 , N(aryl)-CO—(C 1 -C 6 )-alkyl, N(heterocycle)-CO—(C 1 -C 6 )-alkyl, N(aryl)-COO—(C 1 -C 6 )-alkyl, N(heterocycle)-COO—(C 1 -C 6 )-alkyl, N(aryl)-CO-aryl, N(heterocycle)-CO-aryl, N(aryl)-COO-aryl, N(heterocycle)-COO-aryl, N(aryl)-CO—NH—(C 1 -C 6 )-alkyl), N(heterocycle)-CO—NH—(C 1 -C 6 )-alkyl), N(aryl)-CO—NH-aryl, N(heterocycle)-CO—NH-aryl, N(aryl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(heterocycle)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(aryl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(heterocycle)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(aryl)-CO—N-(aryl) 2 , N(heterocycle)-CO—N-(aryl) 2 , aryl, O—(CH 2 ) n -aryl, O—(CH 2 ) n -heterocycle, where n may be 0-6, where the aryl radical or heterocyclic radical may be substituted one to 3 times by F, Cl, Br, I, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 , NH(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , SO 2 -CH 3 , COOH, COO—(C 1 -C 6 )-alkyl, CONH 2 .
[0036] An alkenyl radical means a straight-chain or branched hydrocarbon chain having two or more carbons and one or more double bonds, such as, for example, vinyl, allyl, pentenyl.
[0037] The alkenyl radicals may be substituted one or more times by suitable groups such as, for example: F, Cl, Br, I, CF 3 , NO 2 , N 3 , CN, COOH, COO(C 1 -C 6 )alkyl, CONH 2 , CONH(C 1 -C 6 )alkyl, CON[(C 1 -C 6 )alkyl] 2 , cycloalkyl, (C 1 -C 10 )-alkyl, (C 2 -C 6 )-alkynyl, O—(C 1 -C 6 )-alkyl O—CO—(C 1 -C 6 )-alkyl, O—CO—(C 1 -C 6 )-aryl, O—CO—(C 1 -C 6 )-heterocycle;
PO 3 H 2 , SO 3 H, SO 2 —NH 2 , SO 2 NH(C 1 -C 6 )-alkyl, SO 2 N[(C 1 -C 6 )-alkyl] 2 , S—(C 1 -C 6 )-alkyl, S—(CH 2 ) n -aryl, S—(CH 2 ) n -heterocycle, SO—(C 1 -C 6 )-alkyl, SO—(CH 2 ) n -aryl, SO—(CH 2 ) n -heterocycle, SO 2 —(C 1 -C 6 )-alkyl, SO 2 —(CH 2 ) n -aryl, SO 2 —(CH 2 ) n -heterocycle, SO 2 —NH(CH 2 ) n -aryl, SO 2 —NH(CH 2 ) n -heterocycle, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -aryl, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -heterocycle, SO 2 —N((CH 2 ) n -aryl) 2 , SO 2 —N((CH 2 ) n -(heterocycle) 2 where n may be 0-6, and the aryl radical or heterocyclic radical may be substituted up to twice by F, Cl, Br, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 ; C(NH)(NH 2 ), NH 2 , NH—(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , NH(C 1 -C 7 )-acyl, NH—CO—(C 1 -C 6 )-alkyl, NH—COO—(C 1 -C 6 )-alkyl, NH—CO-aryl, NH—CO-heterocycle, NH—COO-aryl, NH—COO-heterocycle, NH—CO—NH—(C 1 -C 6 )-alkyl, NH—CO—NH-aryl, NH—CO—NH-heterocycle, N(C 1 -C 6 )-alkyl —CO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —COO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —CO-aryl, N(C 1 -C 6 )-alkyl —CO-heterocycle, N(C 1 -C 6 )-alkyl —COO-aryl, N(C 1 -C 6 )-alkyl —COO-heterocycle, N(C 1 -C 6 )-alkyl —CO—NH—(C 1 -C 6 )-alkyl), N(C 1 -C 6 )-alkyl —CO—NH-aryl, N(C 1 -C 6 )-alkyl —CO—NH-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N-(aryl) 2 , N((C 1 -C 6 )-alkyl)-CO—N-(heterocycle) 2 , N(aryl)-CO—(C 1 -C 6 )-alkyl, N(heterocycle)-CO—(C 1 -C 6 )-alkyl, N(aryl)-COO—(C 1 -C 6 )-alkyl, N(heterocycle)-COO—(C 1 -C 6 )-alkyl, N(aryl)-CO-aryl, N(heterocycle)-CO-aryl, N(aryl)-COO-aryl, N(heterocycle)-COO-aryl, N(aryl)-CO—NH—(C 1 -C 6 )-alkyl), N(heterocycle)-CO—NH—(C 1 -C 6 )-alkyl), N(aryl)-CO—NH-aryl, N(heterocycle)-CO—NH-aryl, N(aryl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(heterocycle)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(aryl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(heterocycle)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(aryl)-CO—N-(aryl) 2 , N(heterocycle)-CO—N-(aryl) 2 , aryl, O—(CH 2 ) n -aryl, O—(CH 2 ) n -heterocycle, where n may be 0-6, where the aryl radical or heterocyclic radical may be substituted one to 3 times by F, Cl, Br, I, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 , NH(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , SO 2 -CH 3 , COOH, COO—(C 1 -C 6 )-alkyl, CONH 2 .
[0040] An alkynyl radical means a straight-chain or branched hydrocarbon chain having two or more carbons and one or more triple bonds, such as, for example, ethynyl, propynyl, hexynyl.
[0041] The alkynyl radicals may be substituted one or more times by suitable groups such as, for example: F, Cl, Br, I, CF 3 , NO 2 , N 3 , CN, COOH, COO(C 1 -C 6 )alkyl, CONH 2 , CONH(C 1 -C 6 )alkyl, CON[(C 1 -C 6 )alkyl] 2 , cycloalkyl, (C 2 -C 6 )-alkenyl, (C 1 -C 10 )-alkyl, O—(C 1 -C 6 )-alkyl O—CO—(C 1 -C 6 )-alkyl, O—CO—(C 1 -C 6 )-aryl, O—CO—(C 1 -C 6 )-heterocycle;
PO 3 H 2 , SO 3 H, SO 2 —NH 2 , SO 2 NH(C 1 -C 6 )-alkyl, SO 2 N[(C 1 -C 6 )-alkyl] 2 , S—(C 1 -C 6 )-alkyl, S—(CH 2 ) n -aryl, S—(CH 2 ) n -heterocycle, SO—(C 1 -C 6 )-alkyl, SO—(CH 2 ) n -aryl, SO—(CH 2 ) n -heterocycle, SO 2 —(C 1 -C 6 )-alkyl, SO 2 —(CH 2 ) n -aryl, SO 2 —(CH 2 ) n -heterocycle, SO 2 —NH(CH 2 ) n -aryl, SO 2 —NH(CH 2 ) n -heterocycle, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -aryl, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -heterocycle, SO 2 —N((CH 2 ) n -aryl) 2 , SO 2 —N((CH 2 ) n -(heterocycle) 2 where n may be 0-6, and the aryl radical or heterocyclic radical may be substituted up to twice by F, Cl, Br, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 ; C(NH)(NH 2 ), NH 2 , NH—(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , NH(C 1 -C 7 )-acyl, NH—CO—(C 1 -C 6 )-alkyl, NH—COO—(C 1 -C 6 )-alkyl, NH—CO-aryl, NH—CO-heterocycle, NH—COO-aryl, NH—COO-heterocycle, NH—CO—NH—(C 1 -C 6 )-alkyl, NH—CO—NH-aryl, NH—CO—NH-heterocycle, N(C 1 -C 6 )-alkyl —CO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —COO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —CO-aryl, N(C 1 -C 6 )-alkyl —CO-heterocycle, N(C 1 -C 6 )-alkyl —COO-aryl, N(C 1 -C 6 )-alkyl —COO-heterocycle, N(C 1 -C 6 )-alkyl —CO—NH—(C 1 -C 6 )-alkyl), N(C 1 -C 6 )-alkyl —CO—NH-aryl, N(C 1 -C 6 )-alkyl —CO—NH-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N-(aryl) 2 , N((C 1 -C 6 )-alkyl)-CO—N-(heterocycle) 2 , N(aryl)-CO—(C 1 -C 6 )-alkyl, N(heterocycle)-CO—(C 1 -C 6 )-alkyl, N(aryl)-COO—(C 1 -C 6 )-alkyl, N(heterocycle)-COO—(C 1 -C 6 )-alkyl, N(aryl)-CO-aryl, N(heterocycle)-CO-aryl, N(aryl)-COO-aryl, N(heterocycle)-COO-aryl, N(aryl)-CO—NH—(C 1 -C 6 )-alkyl), N(heterocycle)-CO—NH—(C 1 -C 6 )-alkyl), N(aryl)-CO—NH-aryl, N(heterocycle)-CO—NH-aryl, N(aryl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(heterocycle)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(aryl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(heterocycle)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(aryl)-CO—N-(aryl) 2 , N(heterocycle)-CO—N-(aryl) 2 , aryl, O—(CH 2 ) n -aryl, O—(CH 2 ) n -heterocycle, where n may be 0-6, where the aryl radical or heterocyclic radical may be substituted one to 3 times by F, Cl, Br, I, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 , NH(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , SO 2 -CH 3 , COOH, COO—(C 1 -C 6 )-alkyl, CONH 2 .
[0044] An aryl radical means a phenyl, naphthyl-, biphenyl-, tetrahydronaphthyl-, alpha- or beta- tetralon-, indanyl- or indan-1-on-yl radical.
[0045] The aryl radicals may be substituted one or more times by suitable groups such as, for example: F, Cl, Br, I, CF 3 , NO 2 , N 3 , CN, COOH, COO(C 1 -C 6 )alkyl, CONH 2 , CONH(C 1 -C 6 )alkyl, CON[(C 1 -C 6 )alkyl] 2 , cycloalkyl, (C 1 -C 10 )-alkyl, (C 2 -C 6 )-alkenyl, (C 2 -C 6 )-alkynyl, O—(C 1 -C 6 )-alkyl O—CO—(C 1 -C 6 )-alkyl, O—CO—(C 1 -C 6 )-aryl, O—CO—(C 1 -C 6 )-heterocycle;
PO 3 H 2 , SO 3 H, SO 2 —NH 2 , SO 2 NH(C 1 -C 6 )-alkyl, SO 2 N[(C 1 -C 6 )-alkyl] 2 , S—(C 1 -C 6 )-alkyl, S—(CH 2 ) n -aryl, S—(CH 2 ) n -heterocycle, SO—(C 1 -C 6 )-alkyl, SO—(CH 2 ) n -aryl, SO—(CH 2 ) n -heterocycle, SO 2 —(C 1 -C 6 )-alkyl, SO 2 —(CH 2 ) n -aryl, SO 2 —(CH 2 ) n -heterocycle, SO 2 —NH(CH 2 ) n -aryl, SO 2 —NH(CH 2 ) n -heterocycle, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -aryl, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -heterocycle, SO 2 —N((CH 2 ) n -aryl) 2 , SO 2 —N((CH 2 ) n -(heterocycle) 2 where n may be 0-6, and the aryl radical or heterocyclic radical may be substituted up to twice by F, Cl, Br, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 ; C(NH)(NH 2 ), NH 2 , NH—(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , NH(C 1 -C 7 )-acyl, NH—CO—(C 1 -C 6 )-alkyl, NH—COO—(C 1 -C 6 )-alkyl, NH—CO-aryl, NH—CO-heterocycle, NH—COO-aryl, NH—COO-heterocycle, NH—CO—NH—(C 1 -C 6 )-alkyl, NH—CO—NH-aryl, NH—CO—NH-heterocycle, N(C 1 -C 6 )-alkyl —CO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —COO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —CO-aryl, N(C 1 -C 6 )-alkyl —CO-heterocycle, N(C 1 -C 6 )-alkyl —COO-aryl, N(C 1 -C 6 )-alkyl —COO-heterocycle, N(C 1 -C 6 )-alkyl —CO—NH—(C 1 -C 6 )-alkyl), N(C 1 -C 6 )-alkyl —CO—NH-aryl, N(C 1 -C 6 )-alkyl —CO—NH-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N-(aryl) 2 , N((C 1 -C 6 )-alkyl)-CO—N-(heterocycle) 2 , N(aryl)-CO—(C 1 -C 6 )-alkyl, N(heterocycle)-CO—(C 1 -C 6 )-alkyl, N(aryl)-COO—(C 1 -C 6 )-alkyl, N(heterocycle)-COO—(C 1 -C 6 )-alkyl, N(aryl)-CO-aryl, N(heterocycle)-CO-aryl, N(aryl)-COO-aryl, N(heterocycle)-COO-aryl, N(aryl)-CO—NH—(C 1 -C 6 )-alkyl), N(heterocycle)-CO—NH—(C 1 -C 6 )-alkyl), N(aryl)-CO—NH-aryl, N(heterocycle)-CO—NH-aryl, N(aryl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(heterocycle)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(aryl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(heterocycle)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(aryl)-CO—N-(aryl) 2 , N(heterocycle)-CO—N-(aryl) 2 , aryl, O—(CH 2 ) n -aryl, O—(CH 2 ) n -heterocycle, where n may be 0-6, where the aryl radical or heterocyclic radical may be substituted one to 3 times by F, Cl, Br, I, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 , NH(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , SO 2 -CH 3 , COOH, COO—(C 1 -C 6 )-alkyl, CONH 2 .
[0048] A cycloalkyl radical means a ring system which comprises one or more rings, which is in saturated or partially unsaturated (with one or two double bonds) form and which is composed exclusively of carbon atoms, such as, for example, cyclopropyl, cyclopentyl, cyclopentenyl, cyclohexyl or adamantyl.
[0049] The cycloalkyl radicals radicals may be substituted one or more times by suitable groups such as, for example: F, Cl, Br, I, CF 3 , NO 2 , N 3 , CN, COOH, COO(C 1 -C 6 )alkyl, CONH 2 , CONH(C 1 -C 6 )alkyl, CON[(C 1 -C 6 )alkyl] 2 , cycloalkyl, (C 1 -C 10 )-alkyl, (C 2 -C 6 )-alkenyl, (C 2 -C 6 )-alkynyl, O—(C 1 -C 6 )-alkyl O—CO—(C 1 -C 6 )-alkyl, O—CO—(C 1 -C 6 )-aryl, O—CO—(C 1 -C 6 )-heterocycle;
PO 3 H 2 , SO 3 H, SO 2 —NH 2 , SO 2 NH(C 1 -C 6 )-alkyl, SO 2 N[(C 1 -C 6 )-alkyl] 2 , S—(C 1 -C 6 )-alkyl, S—(CH 2 ) n -aryl, S—(CH 2 ) n -heterocycle, SO—(C 1 -C 6 )-alkyl, SO—(CH 2 ) n -aryl, SO—(CH 2 ) n -heterocycle, SO 2 —(C 1 -C 6 )-alkyl, SO 2 —(CH 2 ) n -aryl, SO 2 —(CH 2 ) n -heterocycle, SO 2 —NH(CH 2 ) n -aryl, SO 2 —NH(CH 2 ) n -heterocycle, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -aryl, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -heterocycle, SO 2 —N((CH 2 ) n -aryl) 2 , SO 2 —N((CH 2 ) n -(heterocycle) 2 where n may be 0-6, and the aryl radical or heterocyclic radical may be substituted up to twice by F, Cl, Br, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 ; C(NH)(NH 2 ), NH 2 , NH—(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , NH(C 1 -C 7 )-acyl, NH—CO—(C 1 -C 6 )-alkyl, NH—COO—(C 1 -C 6 )-alkyl, NH—CO-aryl, NH—CO-heterocycle, NH—COO-aryl, NH—COO-heterocycle, NH—CO—NH—(C 1 -C 6 )-alkyl, NH—CO—NH-aryl, NH—CO—NH-heterocycle, N(C 1 -C 6 )-alkyl —CO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —COO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —CO-aryl, N(C 1 -C 6 )-alkyl —CO-heterocycle, N(C 1 -C 6 )-alkyl —COO-aryl, N(C 1 -C 6 )-alkyl —COO-heterocycle, N(C 1 -C 6 )-alkyl —CO—NH—(C 1 -C 6 )-alkyl), N(C 1 -C 6 )-alkyl —CO—NH-aryl, N(C 1 -C 6 )-alkyl —CO—NH-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N-(aryl) 2 , N((C 1 -C 6 )-alkyl)-CO—N-(heterocycle) 2 , N(aryl)-CO—(C 1 -C 6 )-alkyl, N(heterocycle)-CO—(C 1 -C 6 )-alkyl, N(aryl)-COO—(C 1 -C 6 )-alkyl, N(heterocycle)-COO—(C 1 -C 6 )-alkyl, N(aryl)-CO-aryl, N(heterocycle)-CO-aryl, N(aryl)-COO-aryl, N(heterocycle)-COO-aryl, N(aryl)-CO—NH—(C 1 -C 6 )-alkyl), N(heterocycle)-CO—NH—(C 1 -C 6 )-alkyl), N(aryl)-CO—NH-aryl, N(heterocycle)-CO—NH-aryl, N(aryl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(heterocycle)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(aryl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(heterocycle)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(aryl)-CO—N-(aryl) 2 , N(heterocycle)-CO—N-(aryl) 2 , aryl, O—(CH 2 ) n -aryl, O—(CH 2 ) n -heterocycle, where n may be 0-6, where the aryl radical or heterocyclic radical may be substituted one to 3 times by F, Cl, Br, I, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 , NH(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , SO 2 —CH 3 , COOH, COO—(C 1 -C 6 )-alkyl, CONH 2 .
[0052] Heterocycle or heterocyclic radical means rings and ring systems which, apart from carbon, also comprise heteroatoms such as, for example, nitrogen, oxygen or sulfur. Also included in this definition are ring systems in which the heterocycle or the heterocyclic radical is fused to benzene nuclei.
[0053] Suitable “heterocyclic rings” or “heterocyclic radicals” are acridinyl, azocinyl, benzimidazolyl, benzofuryl, benzothienyl, benzothiophenyl, benzodioxolyl, benzoxazolyl, benzthiazolyl, benztriazolyl, benztetrazolyl, benzisoxazolyl, benzisothiazolyl, benzimidazalinyl, carbazolyl, 4aH—Carbazolyl, carbolinyl, quinazolinyl, quinolinyl, 4H-quinolizinyl, quinoxalinyl, quinuclidinyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, 2H,6H-1,5,2-dithiazinyl, dihydrofuro[2,3-b]-tetrahydrofuran, furyl, furazanyl, imidazolidinyl, imidazolinyl, imidazolyl, 1H-indazolyl, indolinyl, indolizinyl, indolyl, 3H-indolyl, isobenzofuranyl, isochromanyl, isoindazolyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxadiazolyl, 1,2,3-oxadiazolyl, 1,2,4-oxadiazolyl, 1,2,5-oxadiazolyl, 1,3,4-oxadiazolyl, oxazolidinyl, oxazolyl, oxazolidinyl, pyrimidinyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purynyl, pyranyl, pyrazinyl, pyroazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyridooxazoles, pyridoimidazoles, pyridothiazoles, pyridinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, 2H-pyrrolyl, pyrrolyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, 6H-1,2,5-thiadazinyl, thiazolyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,2,5-thiadiazolyl, 1,3,4-thiadiazolyl, thienyl, triazolyl, tetrazolyl and xanthenyl.
[0054] Pyridyl stands for 2-, 3- and 4-pyridyl. Thienyl stands both for 2- and 3-thienyl. Furyl stands both for 2- and 3-furyl.
[0055] Also included are the corresponding N-oxides of these compounds, that is to say, for example, 1-oxy-2-, 3- or 4-pyridyl.
[0056] Also included are derivatives of these heterocycles which are benzo-fused one or more times. The heterocyclic rings or heterocyclic radicals may be substituted one or more times by suitable groups such as, for example: F, Cl, Br, I, CF 3 , NO 2 , N 3 , CN, COOH, COO(C 1 -C 6 )alkyl, CONH 2 , CONH(C 1 -C 6 )alkyl, CON[(C 1 -C 6 )alkyl] 2 , cycloalkyl, (C 1 -C 10 )-alkyl, (C 2 -C 6 )-alkenyl, (C 2 -C 6 )-alkynyl, O—(C 1 -C 6 )-alkyl O—CO—(C 1 -C 6 )-alkyl, O—CO—(C 1 -C 6 )-aryl, O—CO—(C 1 -C 6 )-heterocycle;
PO 3 H 2 , SO 3 H, SO 2 —NH 2 , SO 2 NH(C 1 -C 6 )-alkyl, SO 2 N[(C 1 -C 6 )-alkyl] 2 , S—(C 1 -C 6 )-alkyl, S—(CH 2 ) n -aryl, S—(CH 2 ) n -heterocycle, SO—(C 1 -C 6 )-alkyl, SO—(CH 2 ) n -aryl, SO—(CH 2 ) n -heterocycle, SO 2 —(C 1 -C 6 )-alkyl, SO 2 —(CH 2 ) n -aryl, SO 2 —(CH 2 ) n -heterocycle, SO 2 —NH(CH 2 ) n -aryl, SO 2 —NH(CH 2 ) n -heterocycle, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -aryl, SO 2 —N(C 1 -C 6 )-alkyl)(CH 2 ) n -heterocycle, SO 2 —N((CH 2 ) n -aryl) 2 , SO 2 —N((CH 2 ) n -(heterocycle) 2 where n may be 0-6, and the aryl radical or heterocyclic radical may be substituted up to twice by F, Cl, Br, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 ; C(NH)(NH 2 ), NH 2 , NH—(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , NH(C 1 -C 7 )-acyl, NH—CO—(C 1 -C 6 )-alkyl, NH—COO—(C 1 -C 6 )-alkyl, NH—CO-aryl, NH—CO-heterocycle, NH—COO-aryl, NH—COO-heterocycle, NH—CO—NH—(C 1 -C 6 )-alkyl, NH—CO—NH-aryl, NH—CO—NH-heterocycle, N(C 1 -C 6 )-alkyl —CO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —COO—(C 1 -C 6 )-alkyl, N(C 1 -C 6 )-alkyl —CO-aryl, N(C 1 -C 6 )-alkyl —CO-heterocycle, N(C 1 -C 6 )-alkyl —COO-aryl, N(C 1 -C 6 )-alkyl —COO-heterocycle, N(C 1 -C 6 )-alkyl —CO—NH—(C 1 -C 6 )-alkyl), N(C 1 -C 6 )-alkyl —CO—NH-aryl, N(C 1 -C 6 )-alkyl —CO—NH-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N((C 1 -C 6 )-alkyl)-CO—N((C 1 -C 6 )-alkyl)-heterocycle, N((C 1 -C 6 )-alkyl)-CO—N-(aryl) 2 , N((C 1 -C 6 )-alkyl)-CO—N-(heterocycle) 2 , N(aryl)-CO—(C 1 -C 6 )-alkyl, N(heterocycle)-CO—(C 1 -C 6 )-alkyl, N(aryl)-COO—(C 1 -C 6 )-alkyl, N(heterocycle)-COO—(C 1 -C 6 )-alkyl, N(aryl)-CO-aryl, N(heterocycle)-CO-aryl, N(aryl)-COO-aryl, N(heterocycle)-COO-aryl, N(aryl)-CO—NH—(C 1 -C 6 )-alkyl), N(heterocycle)-CO—NH—(C 1 -C 6 )-alkyl), N(aryl)-CO—NH-aryl, N(heterocycle)-CO—NH-aryl, N(aryl)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(heterocycle)-CO—N—(C 1 -C 6 )-alkyl) 2 , N(aryl)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(heterocycle)-CO—N((C 1 -C 6 )-alkyl)-aryl, N(aryl)-CO—N-(aryl) 2 , N(heterocycle)-CO—N-(aryl) 2 , aryl, O—(CH 2 )n-aryl, O—(CH 2 ) n -heterocycle, where n may be 0-6, where the aryl radical or heterocyclic radical may be substituted one to 3 times by F, Cl, Br, I, OH, CF 3 , NO 2 , CN, OCF 3 , O—(C 1 -C 6 )-alkyl, (C 1 -C 6 )-alkyl, NH 2 , NH(C 1 -C 6 )-alkyl, N((C 1 -C 6 )-alkyl) 2 , SO 2 -CH 3 , COOH, COO—(C 1 -C 6 )-alkyl, CONH 2 .
[0059] The amount of a compound of formula I necessary to achieve the desired biological effect depends on a number of factors, for example the specific compound chosen, the intended use, the mode of administration and the clinical condition of the patient. The daily dose is generally in the range from 0.3 mg to 100 mg (typically from 3 mg to 50 mg) per day and per kilogram of bodyweight, for example 3-10 mg/kg/day. An intravenous dose may be, for example, in the range from 0.3 mg to 1.0 mg/kg, which can suitably be administered as infusion of 10 ng to 100 ng per kilogram and per minute. Suitable infusion solutions for these purposes may contain, for example, from 0.1 ng to 10 mg, typically from 1 ng to 10 mg, per milliliter. Single doses may contain, for example, from 1 mg to 10 g of the active ingredient. Thus, ampoules for injections may contain, for example, from 1 mg to 100 mg, and single-dose formulations which can be administered orally, such as, for example, capsules or tablets, may contain, for example, from 1.0 to 1000 mg, typically from 10 to 600 mg. For the therapy of the abovementioned conditions, the compounds of formula I may be used as the compound itself, but they are preferably in the form of a pharmaceutical composition with an acceptable carrier. The carrier must, of course, be acceptable in the sense that it is compatible with the other ingredients of the composition and is not harmful for the patient's health. The carrier may be a solid or a liquid or both and is preferably formulated with the compound as a single dose, for example as a tablet, which may contain from 0.05% to 95% by weight of the active ingredient. Other pharmaceutically active substances may likewise be present, including other compounds of formula I. The pharmaceutical compositions of the invention can be produced by one of the known pharmaceutical methods, which essentially consist of mixing the ingredients with pharmacologically acceptable carriers and/or excipients.
[0060] Pharmaceutical compositions of the invention are those suitable for oral, rectal, topical, peroral (for example sublingual) and parenteral (for example subcutaneous, intramuscular, intradermal or intravenous) administration, although the most suitable mode of administration depends in each individual case on the nature and severity of the condition to be treated and on the nature of the compound of formula I used in each case. Coated formulations and coated slow-release formulations also belong within the framework of the invention. Preference is given to acid- and gastric juice-resistant formulations. Suitable coatings resistant to gastric juice comprise cellulose acetate phthalate, polyvinyl acetate phthalate, hydroxypropylmethylcellulose phthalate and anionic polymers of methacrylic acid and methyl methacrylate.
[0061] Suitable pharmaceutical compounds for oral administration may be in the form of separate units such as, for example, capsules, cachets, suckable tablets or tablets, each of which contain a defined amount of the compound of formula I; as powders or granules, as solution or suspension in an aqueous or nonaqueous liquid; or as an oil-in-water or water-in-oil emulsion. These compositions may, as already mentioned, be prepared by any suitable pharmaceutical method which includes a step in which the active ingredient and the carrier (which may consist of one or more additional ingredients) are brought into contact. The compositions are generally produced by uniform and homogeneous mixing of the active ingredient with a liquid and/or finely divided solid carrier, after which the product is shaped if necessary. Thus, for example, a tablet can be produced by compressing or molding a powder or granules of the compound, where appropriate with one or more additional ingredients. Compressed tablets can be produced by tableting the compound in free-flowing form such as, for example, a powder or granules, where appropriate mixed with a binder, glidant, inert diluent and/or one (or more) surface-active/dispersing agent(s) in a suitable machine. Molded tablets can be produced by molding the compound, which is in powder form and is moistened with an inert liquid diluent, in a suitable machine.
[0062] Pharmaceutical compositions which are suitable for peroral (sublingual) administration comprise suckable tablets which contain a compound of formula I with a flavoring, normally sucrose and gum arabic or tragacanth, and pastilles which comprise the compound in an inert base such as gelatin and glycerol or sucrose and gum arabic.
[0063] Pharmaceutical compositions suitable for parenteral administration comprise preferably sterile aqueous preparations of a compound of formula I, which are preferably isotonic with the blood of the intended recipient. These preparations are preferably administered intravenously, although administration may also take place by subcutaneous, intramuscular or intradermal injection. These preparations can preferably be produced by mixing the compound with water and making the resulting solution sterile and isotonic with blood. Injectable compositions of the invention generally contain from 0.1 to 5% by weight of the active compound.
[0064] Pharmaceutical compositions suitable for rectal administration are preferably in the form of single-dose suppositories. These can be produced by mixing a compound of the formula I with one or more conventional solid carriers, for example cocoa butter, and shaping the resulting mixture.
[0065] Pharmaceutical compositions suitable for topical use on the skin are preferably in the form of ointment, cream, lotion, paste, spray, aerosol or oil. Carriers which can be used are petrolatum, lanolin, polyethylene glycols, alcohols and combinations of two or more of these substances. The active ingredient is generally present in a concentration of from 0.1 to 15% by weight of the composition, for example from 0.5 to 2%.
[0066] Transdermal administration is also possible. Pharmaceutical compositions suitable for transdermal uses can be in the form of single patches which are suitable for long-term close contact with the patient's epidermis. Such patches suitably contain the active ingredient in an aqueous solution which is buffered where appropriate, dissolved and/or dispersed in an adhesive or dispersed in a polymer. A suitable active ingredient concentration is about 1% to 35%, preferably about 3% to 15%. A particular possibility is for the active ingredient to be released by electrotransport or iontophoresis as described, for example, in Pharmaceutical Research, 2(6): 318 (1986).
[0067] The compounds of formula I exhibit favorable effects on glucose metabolism. They are particularly suitable for the prevention and treatment of type II diabetes.
[0068] The compounds of formula I may be administered on their own, but also in combination with further active ingredients. Further active ingredients suitable for combination products are: all antidiabetics mentioned in the Rote Liste 2004, chapter 12. They may be combined with the compounds of the formula I of the invention in particular for a synergistic improvement of the effect. Administration of the active ingredient combination may take place either by separate administration of the active ingredients to the patient or in the form of combination products in which a plurality of active ingredients are present in one pharmaceutical preparation. Most of the active ingredients listed below are disclosed in the USP Dictionary of USAN and International Drug Names, US Pharmacopeia, Rockville 2001.
[0069] Antidiabetics include insulin and insulin derivatives such as, for example, Lantus® (see www.lantus.com) or Apidra®, fast-acting insulins (see U.S. Pat. No. 6,221,633), GLP-1 derivatives such as, for example, those disclosed in WO 98/08871 of Novo Nordisk A/S, and orally effective hypoglycemic active ingredients.
[0070] The orally effective hypoglycemic active ingredients include, preferably, sulfonylureas, biguanidines, meglitinides, oxadiazolidinediones, thiazolidinediones, glucosidase inhibitors, glucagon antagonists, GLP-1 agonists, potassium channel openers such as, for example, those disclosed in WO 97/26265 and WO 99/03861 of Novo Nordisk A/S, insulin sensitizers, inhibitors of liver enzymes involved in the stimulation of gluconeogenesis and/or glycogenolysis, modulators of glucose uptake, compounds which alter lipid metabolism, such as antihyperlipidemic active ingredients and antilipidemic active ingredients, compounds which reduce food intake, PPAR and PXR agonists and active ingredients which act on the ATP-dependent potassium channel of the beta cells (PPAR=peroxisome proliferator activated receptor, PXR=pregnane X receptor, ATP=adenosine triphosphate).
[0071] In one embodiment of the invention, the compounds of the formula I are administered in combination with an HMGCoA reductase inhibitor such as simvastatin, fluvastatin, pravastatin, lovastatin, atorvastatin, cerivastatin, rosuvastatin (HMGCoA=3-hydroxy-3-methylglutaryl coenzyme A).
[0072] In one embodiment of the invention, the compounds of the formula I are administered in combination with a cholesterol absorption inhibitor such as, for example, ezetimibe, tiqueside, pamaqueside, or with a compound as described in PCT/EP 2004/00269, WO 2004/000804, WO 2004/000803, WO 2004/000805, EP 0114531, U.S. Pat. No. 6,498,156.
[0073] In one embodiment of the invention, the compounds of the formula I are administered in combination with a PPAR gamma agonist, such as, for example, rosiglitazone, pioglitazone, JTT-501, GI 262570.
[0074] In one embodiment of the invention, the compounds of the formula I are administered in combination with a PPAR alpha agonist, such as, for example, GW 9578, GW 7647.
[0075] In one embodiment of the invention, the compounds of the formula I are administered in combination with a mixed PPAR alpha/gamma agonist, such as, for example, GW 1536, AVE 8042, AVE 8134, AVE 0847, or as described in WO 00/64888, WO 00/64876, DE10142734.4.
[0076] In one embodiment of the invention, the compounds of the formula I are administered in combination with a fibrate such as, for example, fenofibrate, clofibrate, bezafibrate.
[0077] In one embodiment of the invention, the compounds of the formula I are administered in combination with an MTP inhibitor such as, for example, implitapide, BMS-201038, R-103757 (MTP=microsomal triglyceride transfer protein).
[0078] In one embodiment of the invention, the compounds of the formula I are administered in combination with bile acid absorption inhibitor (see, for example, U.S. Pat. No. 6,245,744 or U.S. Pat. No. 6,221,897), such as, for example, HMR 1741.
[0079] In one embodiment of the invention, the compounds of the formula I are administered in combination with a CETP inhibitor, such as, for example, JTT-705 (CETP=cholesteryl ester transfer protein).
[0080] In one embodiment of the invention, the compounds of the formula I are administered in combination with a polymeric bile acid adsorbent such as, for example, cholestyramine, colesevelam.
[0081] In one embodiment of the invention, the compounds of the formula I are administered in combination with an LDL receptor inducer (see U.S. Pat. No. 6,342,512), such as, for example, HMR1171, HMR1586 (LDL=low density lipids).
[0082] In one embodiment of the invention, the compounds of the formula I are administered in combination with an ACAT inhibitor, such as, for example, avasimibe (ACAT=acyl-co-enzyme A:cholesterol acyltransferase).
[0083] In one embodiment of the invention, the compounds of the formula I are administered in combination with an antioxidant, such as, for example, OPC-14117.
[0084] In one embodiment of the invention, the compounds of the formula I are administered in combination with a lipoprotein lipase inhibitor, such as, for example, NO-1886.
[0085] In one embodiment of the invention, the compounds of the formula I are administered in combination with an ATP-citrate lyase inhibitor, such as, for example, SB-204990.
[0086] In one embodiment of the invention, the compounds of the formula I are administered in combination with a squalene synthetase inhibitor, such as, for example, BMS-188494.
[0087] In one embodiment of the invention, the compounds of the formula I are administered in combination with a lipoprotein(a) antagonist, such as, for example, CI-1027 or nicotinic acid. In one embodiment of the invention, the compounds of the formula I are administered in combination with a lipase inhibitor, such as, for example, orlistat.
[0088] In one embodiment of the invention, the compounds of the formula I are administered in combination with insulin.
[0089] In one embodiment, the compounds of the formula I are administered in combination with a sulfonylurea such as, for example, tolbutamide, glibenclamide, glipizide or glimepiride.
[0090] In one embodiment, the compounds of the formula I are administered in combination with a biguanide, such as, for example, metformin.
[0091] In one further embodiment, the compounds of the formula I are administered in combination with a meglitinide, such as, for example, repaglinide.
[0092] In one embodiment, the compounds of the formula I are administered in combination with a thiazolidinedione, such as, for example, troglitazone, ciglitazone, pioglitazone, rosiglitazone or the compounds disclosed in WO 97/41097 of Dr. Reddy's Research Foundation, in particular 5-[[4-[(3,4-dihydro-3-methyl-4-oxo-2-quinazolinylmethoxy]phenyl]methyl]-2,4-thiazolidinedione.
[0093] In one embodiment, the compounds of the formula I are administered in combination with an α-glucosidase inhibitor, such as, for example, miglitol or acarbose.
[0094] In one embodiment, the compounds of the formula I are administered in combination with an adenosine A1 agonist such as, for example, those described in WO 2004/003002.
[0095] In one embodiment, the compounds of the formula I are administered in combination with an active ingredient which acts on the ATP-dependent potassium channel of the beta cells, such as, for example, tolbutamide, glibenclamide, glipizide, glimepiride or repaglinide.
[0096] In one embodiment, the compounds of the formula I are administered in combination with more than one of the aforementioned compounds, e.g. in combination with a sulfonylurea and metformin, with a sulfonylurea and acarbose, repaglinide and metformin, insulin and a sulfonylurea, insulin and metformin, insulin and troglitazone, insulin and lovastatin, etc. In a further embodiment, the compounds of the formula I are administered in combination with CART modulators (see “Cocaine-amphetamine-regulated transcript influences energy metabolism, anxiety and gastric emptying in mice” Asakawa, A, et al., M.: Hormone and Metabolic Research (2001), 33(9), 554-558), NPY antagonists, (NPY=neuropeptide Y, e.g. naphthalene-1-sulfonic acid {4-[(4-aminoquinazolin-2-ylamino)methyl]cyclohexyl-methyl}amide, hydrochloride (CGP 71683A)), MC4 agonists (MC4=melanocortin 4 receptor, e.g. 1-amino-1,2,3,4-tetrahydronaphthalene-2-carboxylic acid [2-(3a-benzyl-2-methyl-3-oxo-2,3,3a,4,6,7-hexahydropyrazolo[4,3-c]pyridin-5-yl)-1-(4-chlorophenyl)-2-oxoethyl]amide; (WO 01/91752)), orexin antagonists (e.g. 1-(2-methylbenzoxazol-6-yl)-3-[1,5]naphthyridin-4-ylurea, hydrochloride (SB-334867-A)), H3 agonists (H3=histamine receptor, e.g. 3-cyclohexyl-1-(4,4-dimethyl-1,4,6,7-tetrahydro-imidazo[4,5-c]pyridin-5-yl)-propan-1-one oxalic acid salt (WO 00/63208)); TNF agonists (TNF=tumor necrosis factor), CRF antagonists (CRF=corticotropin releasing factor, e.g. [2-methyl-9-(2,4,6-trimethylphenyl)-9H-1,3,9-triazafluoren-4-yl]dipropylamine (WO 00/66585)), CRF BP antagonists (CRF-BP=corticotropin releasing factor-binding protein, e.g. urocortin), urocortin agonists, β3 agonists (e.g. 1-(4-chloro-3-methanesulfonylmethylphenyl)-2-[2-(2,3-dimethyl-1H-indol-6-yloxy)ethylamino]ethanol hydrochloride (WO 01/83451)), CB1 (cannabinoid receptor 1) receptor antagonists (e.g. rimonabant or the active ingredients mentioned in WO 02/28346, MSH (melanocyte-stimulating hormone) agonists, CCK-A (CCK-A=cholecystokinin-A) agonists (e.g. {2-[4-(4-chloro-2,5-dimethoxyphenyl)-5-(2-cyclohexylethyl)thiazol-2-ylcarbamoyl]-5,7-dimethylindol-1-yl}acetic acid trifluoroacetic acid salt (WO 99/15525)), serotonin reuptake inhibitors (e.g. dexfenfluramine), mixed sertoninergic and noradrenergic compounds (e.g. WO 00/71549), 5HT agonists (serotonin mimetics), e.g. 1-(3-ethylbenzofuran-7-yl)piperazine oxalic acid salt (WO 01/09111), bombesin agonists, galanin antagonists, growth hormone (e.g. human growth hormone), growth hormone-releasing compounds (6-benzyloxy-1-(2-diisopropylaminoethylcarbamoyl)-3,4-dihydro-1H-isoquinoline-2-carboxylic acid tertiary butyl ester (WO 01/85695)), TRH agonists (TRH=TSH releasing hormone; TSH=thyroid-stimulating hormone; thyrotropin), see, for example, EP 0 462 884, uncoupling protein 2 or 3 modulators, leptin agonists (see, for example, Lee, Daniel W.; Leinung, Matthew C.; Rozhavskaya-Arena, Marina; Grasso, Patricia. Leptin agonists as a potential approach to the treatment of obesity. Drugs of the Future (2001), 26(9), 873-881), DA agonists (DA=dopamine autoreceptor, such as, for example, bromocriptine, Doprexin), lipase/amylase inhibitors (e.g. WO 00/40569), PPAR modulators (e.g. WO 00/78312), RXR (RXR=retinoid X receptor) modulators or TR-β agonists.
[0097] In one embodiment of the invention, the other active ingredient is leptin; see, for example, “Perspectives in the therapeutic use of leptin”, Salvador, Javier; Gomez-Ambrosi, Javier; Fruhbeck, Gema, Expert Opinion on Pharmacotherapy (2001), 2(10), 1615-1622.
[0098] In one embodiment, the other active ingredient is dexamphetamine or amphetamine.
[0099] In one embodiment, the other active ingredient is fenfluramine or dexfenfluramine.
[0100] In another embodiment, the other active ingredient is sibutramine.
[0101] In one embodiment, the other active ingredient is orlistat.
[0102] In one embodiment, the other active ingredient is mazindol or phentermine.
[0103] In a further embodiment, the other active ingredient is rimonabant.
[0104] In one embodiment, the compounds of the formula I are administered in combination with bulking agents, preferably insoluble bulking agents (see, for example, carob/Caromax® (Zunft H J; et al., Carob pulp preparation for treatment of hypercholesterolemia, ADVANCES IN THERAPY (September-October 2001), 18(5), 230-6.) Caromax is a carob-containing product from Nutrinova, Nutrition Specialties & Food Ingredients GmbH, Industriepark Hochst, 65926 Frankfurt/Main)). Combination with Caromax® is possible in one preparation or by separate administration of compounds of the formula I and Caromax®. Caromax® can in this connection also be administered in the form of food products such as, for example, in bakery products or muesli bars.
[0105] It will be appreciated that every suitable combination of the compounds of the invention with one or more of the aforementioned compounds and optionally one or more other pharmacologically active substances is regarded as falling within the protection conferred by the present invention.
[0106] The invention also relates to processes for preparing the compounds of formula I. Suitable processes are known in principle to the skilled worker and can be found in standard works of organic chemistry. A suitable process is shown for example in scheme 1.
[0107] The basic building block is formed by aldehyde of a protected hydroxybiphenylcarboxylic acid of the formula IV, which is prepared by reacting a bromide of the formula II with an aldehyde of the formula III. A radical R1, which has the meaning indicated above in formula I, is introduced by reacting the appropriate R1-amines with reductive amination of the CHO group. A radical R2, which has the meaning indicated above in formula I, is introduced by subsequent amidation with the acid chlorides R2COCl. Elimination of the protective groups results in a compound of the formula I.
[0108] The examples detailed below serve to illustrate the invention without, however, restricting it.
TABLE 1 I Ex. R1 R2 A 1 2-Methoxybenzyl- 4-Bromophenyl- Bond 2 4-Methoxybenzyl- 2-Benzodioxolyl- Bond 3 Benzyl- 2-Benzodioxolyl- Bond 4 2-Methoxybenzyl- 3-Methoxyphenyl- Bond 5 Cyclopropane-CH 2 — Cyclohexyl- Bond 6 2-Methoxybenzyl- Cyclohexyl- Bond 7 4-Methylbenzyl- 4-Bromophenyl Bond 8 Cyclopropane-CH 2 — n-Butyl- Bond 9 n-Butyl- Cyclohexyl- Bond 10 4-Methylbenzyl- Cyclohexyl- Bond 11 Phenyl-CH 2 —CH 2 — 2-Benzodioxolyl- Bond 12 Benzyl- 3-Methoxyphenyl Bond 13 4-Methylbenzyl- 3-Methoxyphenyl Bond 14 Cyclopropane-CH 2 — 2-Benzodioxolyl- Bond 15 n-Pentyl- 2-Benzodioxolyl- Bond 16 4-Fluorobenzyl- 2-Benzodioxolyl- Bond 17 4-Fluorobenzyl- 3-Methoxyphenyl Bond 18 4-Fluorobenzyl- Phenyl-CH═CH— Bond 19 4-Methylbenzyl- 2-Benzodioxolyl- Bond 20 Cyclopentyl- 2-Benzodioxolyl- Bond 21 Benzyl- 4-Bromophenyl- Bond 22 Benzyl- 2-Furanyl- Bond 23 4-Fluorobenzyl 4-Bromophenyl- Bond 24 4-Methoxybenzyl- n-Butyl- Bond
[0109] The preparation of some examples from table 1 is described in detail below, the other compounds of the formula I were obtained analogously:
4-(2,2-Dimethyl-4-oxo-4H-benzo[1,3]dioxin-6-yl)-benzaldehyde
[0110]
[0111] A mixture of 6-bromo-2,2-dimethyl-2,2-benzo[1,3]dioxin-4-one (1 g, 4.2 mmol) and potassium carbonate (4.5 g, 32.8 mmol, 8 eq) were diluted with THF (64 ml) and stirred at 25° C. for 15 min. The reaction vessel was flushed with N 2 and evacuated (5×). The mixture was stirred under an N 2 atmosphere for a further 15 min. In another reaction flask, 4-formyl-phenylboronic acid (0.6 g, 4 mmol) was dissolved in THF (34 ml) and degassed (×5). Pd(PPh 3 ) 4 (140 mg, 0.012 mol) was added to the first flask, and this solution was also degassed again (×1). The boronic acid (reaction vessel 2) was introduced in portions by a needle into the reaction mixture over a period of 2.5 h (30 min between each addition). The mixture was heated under reflux for 15 h, and the reaction was followed by thin-layer chromatography. The mixture was cooled, filtered through kieselguhr and washed with EtOAc. The filtrate was concentrated in vacuo, and the residue was purified by flash chromatography (1:9, ethyl acetate/hexane).
[0112] Yield: (519 mg, 46%).
[0113] General Method for the Reductive Amination
[0114] Biarylaldehyde ((56.4 mg, 0.2 mmol), the appropriate amine (0.24 mmol, 1.2 equiv) and THF/MeOH (1:2, 10 ml) was introduced into a carousel of reaction vessels. Glacial acetic acid (12 mg, 0.2 mmol) and polystyrene cyanoborohydride (120 mg, 2.5 mmol/g, 1.5 eq.) were added to the mixtures, and they were stirred at 50° C. for 24 h. They were then quenched with 4-alkoxybenzaldehyde scavenger resin (2.5 mmol/g, 4 equivalents), and the mixtures were stirred at 25° C. for 16 h. The reactions were followed by thin-layer chromatography (15:1 dichloromethane/methanol; 2 drops of triethylamine). The mixtures were filtered and washed with dichloromethane. The crude products were reacted further without further purification.
[0115] General Method for Parallel Amidation
[0116] The amines (crude products; ˜0.2 mmol, 1 eq) were dissolved in THF (2 ml), and Amberlite IRA 400-CO 3 2 (2.5 mmol/g, 1.5 eq) was added to the solutions. Solutions of the appropriate acid chlorides (0.24 mmol) in THF (2 ml) were added to these reaction mixtures, and the mixtures were shaken at 25° C. for 16 h. The resins were filtered off, and the solvent was distilled off in vacuo. The residues were taken up in EtOAc and washed with saturated NaHCO 3 solution. The organic phases were dried (Na 2 SO 4 ) and the solvent was distilled off in vacuo. The amides were reacted further without further purification.
[0117] General Method for Protective Group Elimination
[0118] The amides from the preceding stage are taken up in 4:1 trifluoroacetic acid/water (5 ml) and stirred at 25° C. for 15 h. The solvent is distilled off, and the crude products are purified by preparative HPLC.
[0119] Preparation of Amberlite IRA-400 Cyanoborohydride
[0120] 100 ml of an aqueous sodium cyanoborohydride solution (8% w/vol, slightly cloudy) is put onto 10 g of moist Amberlite IRA 100 resin (chloride form) in a frit. The resin is stirred and then filtered off with suction. The process is repeated 10×. The resin treated in this way is carefully washed with water until it is free of excess sodium cyanoborohydride (pH check) and is then dried by repeated washing with tetrahydrofuran. The average capacity is 2.5 mmol/g of dry resin.
[0121] Preparation of Amberlite IRA-400 Carbonate
[0122] Amberlite IRA 400 (Cl − ) resin is treated in analogy to the above method with a solution of sodium carbonate (10 g) in water (100 ml) and then washed with water until neutral.
[0123] The following examples were prepared by this method, and the identity was verified by mass spectrometry:
[0124] The activity of the compounds was tested as follows:
[0125] Enzymatic Test Systems for Detecting Inhibition of a Phosphatase
[0126] The compounds of the formula I were tested for their phosphatase-inhibiting effect in an in vitro assay. The enzyme preparation and the performance of the assay was carried out as follows.
[0127] Obtaining the Enzyme Preparation:
[0128] A) Cell Culture:
Sf9 cells (= Spodoptera frugiperda cell type; obtainable from invitrogen) are cultured in Grace's supplemented medium (Gibco-BRL) with 10% heat-inactivated fetal calf serum (Gibco-BRL) in spinner flasks at 28° C. in accordance with the protocol of Summers and Smith (A Manual for Methods for Baculovirus Vectors and Insect Culture Procedures [Bulletin No. 15555]. Texas A & M University, Texas Agricultural Experiment Station, College Station, Tex., 1987). Construction of recombinant Baculovirus transfer vectors: cDNA coding for the regulatory and catalytic domains of human PTP1B, but without the carboxy-terminal hydrophobic region (corresponding to 1-299 aa) was obtained by polymerase chain reaction via primers with attached cloning sites and suitable cDNA templates (obtainable for example from invitrogen) and then cloned into baculovirus expression vectors (Amersham Pharmacia Biotech.). The recombinant baculoviruses were prepared with the aid of the Bac-to-Bac baculovirus expression system (obtainable from Gibco-BRL). The gene was cloned into the pFASTBAC donor plasmid (obtainable from Life Technologies). The resulting plasmid was transformed into competent DH10BAC Escherichia coli cells (obtainable from Life Technologies). After transposition and antibiotic selection, the recombinant plasmid DNA was isolated from selected E. coli colonies and then used for the transfection of Sf9 insect cells. The virus particle in the supernatant medium was amplified three times up to a viral stock volume of 500 ml.
[0131] B) Production of Recombinant Protein:
Baculovirus infection of a 500 ml spinner culture of Sf9 cells was essentially carried out as described by Summers and Smith (see above). Sf9 cells at a density of 1-3×10 6 cells/ml were pelleted by centrifugation at 300 g for 5 min, the supernatant was removed, and the cells were resuspended in a density of 1×10 7 cells/ml in a suitable recombinant viral stock (MOI 10). After careful shaking at room temperature for 1.5 h, fresh medium was added in order to achieve a cell density of 1×10 6 cells/ml. The cells were then cultured in the suspension at 28° C. for suitable periods after postinfection.
[0133] C) Cellular Fractionation and Complete Cell Extracts of Infected Sf9 Cells:
After the postinfection, aliquots were subjected to an analysis of protein expression by SDS-PAGE and Western blot analysis. The cellular fractionation was carried out as described (Cromlish, W. and Kennedy, B. Biochem. Pharmacol. 52: 1777-1785, 1996). Complete cell extracts were obtained from 1 ml aliquots of the infected Sf9 cells after certain times postinfection. The pelleted cells (300×g, 5 min) were washed once in phosphate-buffered saline (4° C.), resuspended in 50 μl of water and disrupted by repeated freezing/thawing. Protein concentrations were determined with the aid of the Bradford method and bovine serum albumin as standard.
[0135] Assay Procedure:
[0136] A) Dephosphorylation of a Phosphopeptide:
This assay is based on the release of phosphate from a consensus substrate peptide which is detected in the nanomolar concentration range by the malachite green/ammonium molybdate method (Lanzetta, P. A., Alvarez, L. J., Reinach, P. S., Candia, O. A. Anal Biochem. 100: 95-97, 1979) adapted for the microtiter plate format. The dodecatrisphosphopeptide TRDIYETDYYRK (Biotrend, Cologne) corresponds to amino acids 1142-1153 of the catalytic domain of the insulin receptor and is (auto)phosphorylated on tyrosine residues 1146, 1150 and 1151. The recombinant hPTP1B was diluted with assay buffer (40 mM Tris/HCl, pH 7.4, 1 mM EDTA, 20 mM DTT), equivalent to an activity of 1000-1500 nmol/min/mg of protein and (a 20 μl portion) then preincubated (15 min, 30° C.) in the absence or presence of test substance (5 μl) in the desired concentration (final concentration of DMSO 2% max.) in a total volume of 90 μl (assay buffer). To start the dephosphorylation reaction, the peptide substrate (10 μl, prewarmed to 30° C.) was added to the preincubated enzyme preparation with or without test substance (final concentration 0.2-200 μM) and the incubation was continued for 1 h. The reaction was stopped by adding 100 μl of malachite green hydrochloride (0.45%, 3 parts), ammoniummolybdatetetrahydrate (4.2% in 4 N HCl, 1 part) and 0.5% Tween 20 as stop solution. After incubation at 22° C. for 30 min to develop the color, the absorption at 650 nm was determined using a microtiter plate reader (molecular devices). Samples and blanks were measured in triplicate. The PTP1B activity was calculated as nanomoles of liberated phosphate per min and mg of protein with potassium phosphate as standard. The inhibition of the recombinant hPTP1B by test substances was calculated as a percentage of the phosphatase control. The IC 50 values show significant agreement with a four-parameter non-linear logistic regression curve.
[0138] B) Cleavage of P-Nitrophenyl Phosphate:
[0139] This assay is based on the change in absorption of the non-physiological substrate p-nitrophenyl phosphate during cleavage to give nitrophenol under standard conditions (Tonks, N. K., Diltz, C. D:, Fischer, E. H. J. Biol. Chem. 263: 6731-6737, 1988; Burke T. R., Ye, B., Yan, X. J., Wang, S. M., Jia, Z. C., Chen, L., Zhang, Z. Y., Barford, D. Biochemistry 35: 15989-15996, 1996). The inhibitors are pipetted in suitable dilution into the reaction mixtures which contain 0.5-5 mM p-nitrophenyl phosphate. The following buffers were used (total volume 100 μl): (a) 100 mM sodium acetate (pH 5.5), 50 mM NaCl, 0.1% (w/v) bovine serum albumin, 5 mM glutathione, 5 mM DTT, 0.4 mM EGTA and 1 mM EDTA; (b) 50 mM Hepes/KOH (pH 7.4), 100 mM NaCl, 0.1% (w/v) bovine serum albumin, 5 mM glutathione, 5 mM DTT and 1 mM EDTA. The reaction was started by adding enzyme and carried out in microtiter plates at 25° C. for 1 h. The reaction was stopped by adding 100 μl of 0.2 N NaOH. The enzyme activity was determined by measuring the absorption at 405 nm with suitable corrections for absorption of the test substances and of p-nitrophenyl phosphate. The results were expressed as percentage of the control by comparing the amount of p-nitrophenol formed in the test substance-treated samples (nmol/min/mg of protein) with the amount in the untreated samples. The average and the standard deviation were calculated, and the IC50 values were determined by regression analysis of the linear portion of the inhibition curves.
TABLE 3 Biological activity Ex. IC-50 (μM) 1 1.2 2 1.2 3 1.5 4 1.4 5 1.6 6 1.3 7 1 8 1.9 9 1.6 10 1.6 11 1.6 12 1.6 13 1.7 14 1.8 15 1.5 16 1.9 17 1.6 18 1.45 19 1.28 20 1.8 21 0.6 22 1.3 23 0.5 24 0.6
[0140] It is evident from the table that the compounds of the formula I inhibit the activity of phosphotyrosine phosphatase 1B (PTP1B) and thus are very suitable for lowering the blood glucose level. They are therefore suitable in particular for the treatment of type I and II diabetes, of insulin resistance, of dyslipidemias, of the metabolic syndrome/syndrome X, of pathological obesity and for weight reduction in mammals.
[0141] Compounds of the formula I are also suitable, because of their inhibition of PTP1B, for the treatment of hyperglycerimia, high blood pressure, atherosclerosis, dysfunctions of the immune system, autoimmune diseases, allergic diseases such as, for example, asthma, arthritis, osteoarthritis, osteoporosis, proliferation disorders such as cancer and psoriasis, diseases with reduced or increased production of growth factors, hormones or cytokines, which induce the release of growth hormones.
[0142] The compounds are also suitable for the treatment of disorders of the nervous system such as, for example, Alzheimer's or multiple sclerosis.
[0143] The compounds are also suitable for the treatment of disturbances of wellbeing and other psychiatric indications such as, for example, depressions, anxiety states, anxiety neuroses, schizophrenia, for the treatment of disorders associated with the circadian rhythm and for the treatment of drug abuse.
[0144] They are additionally suitable for treatment of sleep disorders, sleep apnea, female and male sexual disorders, inflammations, acne, pigmentation of the skin, disorders of steroid metabolism, skin diseases and mycoses. | Disclosed are novel compound of formula I,
As defined herein and their use as pharmaceutically active compounds for reducing blood glucose, and/or treating one or more of type II diabetes, disturbances of lipid and carbohydrate metabolism, arteriosclerotic manifestations, and insulin resistance. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2008-238004, filed on Sep. 17, 2008; the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a semiconductor device manufacturing method.
[0004] 2. Description of the Related Art
[0005] With the progress of area reduction and downsizing of a semiconductor device, a highly-integrated static random access memory (SRAM) has a shortened length between gate electrodes adjacent in a longitudinal direction of the gate electrode. Recently, the demanded length has exceeded the resolution limit of a photolithography technique. Even so, as disclosed in Japanese Patent Application Laid-open No. 2004-356469, for example, a further shortened length between gate electrodes to achieve area reduction and downsizing of semiconductor devices has been required.
[0006] A contact is formed between gate electrodes adjacent in a lateral direction of the gate electrode. In this case, in order that the gate electrode and the contact are not short-circuited, positions of contact holes at the time of forming the contact need to be accurately aligned between the gate electrodes. However, to achieve further area reduction and downsizing of semiconductor devices, also in a lateral direction of the gate electrode, shortening of the length between the adjacent gate electrodes has been required. This further shortens a length between the gate electrode and the contact, and it makes alignment of the contact hole more difficult.
[0007] Shortening of the length between arrangement patterns described above has been required not only in gate electrodes but also required in wiring layers. Moreover, further shortening of the length between the arrangement patterns has been required.
BRIEF SUMMARY OF THE INVENTION
[0008] One aspect of this invention is to provide a manufacturing method of a semiconductor device including a semiconductor substrate that is formed thereon with: a first constituent member; a second constituent member that is extended to be separated from the first constituent member on an extension of a longitudinal direction of the first constituent member; and a third constituent member that is separated from the first constituent member and the second constituent member in a lateral direction of the first and second constituent members and that is opposed in one portion to the first and second constituent members, the manufacturing method comprising: transferring simultaneously by lithography, a first region from a position opposed between the first and second constituent members in the longitudinal direction to an end of a side of the first constituent member in the longitudinal direction in the third constituent member, and a first mask pattern for forming the first constituent member, onto a semiconductor substrate; transferring simultaneously by lithography a second region including regions other than the first region in the third constituent member and a second mask pattern for forming the second constituent member, onto the semiconductor substrate; and forming the first constituent member, the second constituent member, and the third constituent member on the semiconductor substrate by using the first mask pattern and the second mask pattern.
[0009] Another aspect of this invention is to provide a manufacturing method of a semiconductor device including a semiconductor substrate that is formed thereon with: a first constituent member; a second constituent member that is extended to be separated from the first constituent member on an extension of a longitudinal direction of the first constituent member; a third constituent member that is separated from the first constituent member and the second constituent member in a lateral direction of the first and second constituent members and that is opposed in one portion to the first and second constituent members; a first contact arranged to be separated from both the first constituent member and the third constituent member in a region between the first and third constituent members; and a second contact arranged to be separated from both the second constituent member and the third constituent member in a region between the second and third constituent members, the manufacturing method comprising: transferring simultaneously by lithography, a first region from a position opposed between the first and second constituent members in the longitudinal direction to an end of a side of the first constituent member in the longitudinal direction in the third constituent member, and a first mask pattern for forming the first constituent member, onto a semiconductor substrate; transferring simultaneously by lithography a second region including regions other than the first region in the third constituent member and a second mask pattern for forming the second constituent member, onto the semiconductor substrate; forming the first constituent member, the second constituent member, and the third constituent member on the semiconductor substrate by using the first mask pattern and the second mask pattern; forming by lithography a third mask pattern for forming the first contact on the semiconductor substrate by being aligned to the first constituent member and third constituent member; forming by lithography a fourth mask pattern for forming the second contact on the semiconductor substrate by being aligned to the second constituent member and third constituent member; and forming a contact hole for forming the first contact and a contact hole for forming the second contact on the semiconductor substrate by using the third mask pattern and the fourth mask pattern.
[0010] Another aspect of this invention is to provide a manufacturing method of a semiconductor device including a semiconductor substrate that is formed thereon with: a first constituent member; a second constituent member that is extended to be separated from the first constituent member on an extension of a longitudinal direction of the first constituent member; and a third constituent member that is separated from the first constituent member and the second constituent member in a lateral direction of the first and second constituent members and that is opposed in one portion to the first and second constituent members, the manufacturing method comprising: transferring simultaneously by lithography, a first region from a position opposed between the first and second constituent members in the longitudinal direction to an end of a side of the second constituent member in the longitudinal direction in the third constituent member, and a first mask pattern for forming the first constituent member, onto a semiconductor substrate; transferring simultaneously by lithography a second region including regions other than the first region in the third constituent member and a second mask pattern for forming the second constituent member, onto the semiconductor substrate; and forming the first constituent member, the second constituent member, and the third constituent member on the semiconductor substrate by using the first mask pattern and the second mask pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1A and 1B are schematic diagrams for explaining a configuration of a semiconductor device according to a first embodiment of the present invention;
[0012] FIG. 2 is a schematic diagram for explaining a semiconductor device manufacturing method according to the first embodiment;
[0013] FIG. 3 is a schematic diagram for explaining the semiconductor device manufacturing method according to the first embodiment;
[0014] FIG. 4 is a schematic diagram for explaining the semiconductor device manufacturing method according to the first embodiment;
[0015] FIG. 5 is a schematic diagram for explaining the semiconductor device manufacturing method according to the first embodiment;
[0016] FIGS. 6A and 6B are schematic diagrams for explaining the semiconductor device manufacturing method according to the first embodiment;
[0017] FIGS. 7A and 7B are schematic diagrams for explaining the semiconductor device manufacturing method according to the first embodiment;
[0018] FIGS. 8A and 8B are schematic diagrams for explaining the semiconductor device manufacturing method according to the first embodiment;
[0019] FIGS. 9A and 9B are schematic diagrams for explaining the semiconductor device manufacturing method according to the first embodiment;
[0020] FIGS. 10A and 10B are schematic diagrams for explaining the semiconductor device manufacturing method according to the first embodiment;
[0021] FIGS. 11A and 11B are schematic diagrams for explaining the semiconductor device manufacturing method according to the first embodiment;
[0022] FIGS. 12A and 12B are schematic diagrams for explaining a semiconductor device manufacturing method according to a second embodiment of the present invention;
[0023] FIGS. 13A and 13B are schematic diagrams for explaining the semiconductor device manufacturing method according to the second embodiment;
[0024] FIGS. 14A and 14B are schematic diagrams for explaining the semiconductor device manufacturing method according to the second embodiment;
[0025] FIGS. 15A and 15B are schematic diagrams for explaining the semiconductor device manufacturing method according to the second embodiment;
[0026] FIGS. 16A and 16B are schematic diagrams for explaining the semiconductor device manufacturing method according to the second embodiment;
[0027] FIGS. 17A and 17B are schematic diagrams for explaining a gate electrode in a semiconductor device according to a third embodiment of the present invention;
[0028] FIG. 18 is a schematic diagram for explaining a manufacturing method of a gate electrode in the semiconductor device according to the third embodiment;
[0029] FIG. 19 is a schematic diagram for explaining the manufacturing method of a gate electrode in the semiconductor device according to the third embodiment;
[0030] FIGS. 20A and 20B are schematic diagrams for explaining the manufacturing method of a gate electrode in the semiconductor device according to the third embodiment;
[0031] FIGS. 21A and 21B are schematic diagrams for explaining the manufacturing method of a gate electrode in the semiconductor device according to the third embodiment;
[0032] FIGS. 22A and 22B are schematic diagrams for explaining the manufacturing method of a gate electrode in the semiconductor device according to the third embodiment;
[0033] FIGS. 23A and 23B are schematic diagrams for explaining a wire layer in a semiconductor device according to a fourth embodiment of the present invention; and
[0034] FIG. 24 is a schematic diagram for explaining a manufacturing method of a wire layer in the semiconductor device according to the fourth embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Exemplary embodiments of a semiconductor device manufacturing method according to the present invention will be explained below in detail with reference to the accompanying drawings. The present invention is not limited to the descriptions of the following embodiments and various modifications can be appropriately made without departing from the scope of the invention. In the drawings explained below, scales of respective members may be shown differently from those in practice to facilitate understanding, and the same applies to the relationships between drawings. In addition, explanations and illustrations of constituent members not directly relevant to the present invention will be omitted.
First Embodiment
[0036] FIGS. 1A and 1B are schematic diagrams for explaining a part of the configuration of a semiconductor device according to a first embodiment of the present invention, that is, a highly-integrated SRAM in which six transistors are point-symmetrically laid out. FIG. 1A is a plan view and FIG. 1B is a cross-sectional view. In the semiconductor device, on a semiconductor substrate, a plurality of transistors (not shown) are arranged in device forming regions (active regions) 111 . The device forming region 111 is defined by being surrounded by device isolating regions 112 . Within the semiconductor substrate in each device forming region 111 , two impurity diffusion layers, which serve as a source and a drain of a transistor, are arranged (not shown).
[0037] On the semiconductor substrate between the two impurity diffusion layers, a plurality of substantially rectangular gate electrodes 121 made of polysilicon are arranged substantially parallel via a gate insulating film (not shown) made of a silicon oxide film, and interlayer insulating films 122 are arranged over the entire surface of the semiconductor substrate so that the gate electrodes 121 are covered. Within each interlayer insulating film 122 , a plurality of contact holes A 113 and contact holes B 114 each of which conducts to the impurity diffusion layer or the gate electrode 121 are arranged. FIGS. 1A and 1B depict a state that the contact holes A 113 and the contact holes B 114 are formed in the interlayer insulating film 122 . FIG. 1A depicts a state that the interlayer insulating film 122 is provided in a transparent manner.
[0038] In the first embodiment, the gate electrodes 121 adjacent in a longitudinal direction of each gate electrodes 121 (an X direction in FIG. 1A . Hereinafter, “longitudinal direction”) are arranged on the substantially same line. A length LX 1 between the gate electrodes 121 adjacent in the longitudinal direction (the X direction in FIG. 1A ) is set to a very short length that exceeds a resolution limit of a photolithography technique, making it very difficult to form its configuration.
[0039] Between the gate electrodes 121 adjacent in a lateral direction of each gate electrode 121 (a Y direction in FIG. 1A . Hereinafter, “lateral direction”), the contact hole A 113 or the contact hole B 114 is formed. A length between the gate electrode 121 and the contact hole A 113 , and a length LX 1 between the gate electrode 121 and the contact hole B 114 are set to a very short length that exceeds a resolution limit of a photolithography technique. This makes it very difficult to configure to form the contact hole A 113 and the contact hole B 114 at predetermined positions so that the contact formed by using the contact hole A 113 or the contact hole B 114 and the gate electrodes 121 are not short-circuited. When a length between members in an in-plane direction of a semiconductor substrate is thus set to a short length that exceeds a resolution limit of a photolithography technique, the SRAM according to the first embodiment leads to high integration of transistors, thereby realizing an SRAM with a reduced area.
[0040] A highly-integrated SRAM manufacturing method according to the first embodiment is explained below with reference to FIGS. 2 to 11B . FIG. 2 to FIG. 11B are schematic diagrams for explaining the highly-integrated SRAM manufacturing method according to the first embodiment, where each drawing denoted with A is a plan view, and each drawing denoted with B is a cross-sectional view along a line A-A in each corresponding drawing denoted with A. Explanations of the formation of the gate insulating film will be omitted. First, as shown in FIG. 2 , a design layout of an SRAM unit is extracted from a design layout of a semiconductor device, and rectangular patterns 121 p of the gate electrodes 121 are extracted from the extracted design layout.
[0041] Next, the rectangular pattern 121 p of each of the extracted gate electrodes 121 is divided into two substantially rectangular patterns, that is, a substantially rectangular gate pattern A (hereinafter, “gate A”) 11 and gate pattern B (hereinafter, “gate B”) 12 . These patterns A and B are divided along a borderline or certain intermediate position of the longitudinal direction (an X direction in FIG. 3 ) of each rectangular pattern, as shown in FIG. 3 . In this way, the design layout of the gate electrode 121 is divided into two, that is, the gate A 11 and the gate B 12 . In this case, each rectangular pattern is divided into two patterns along the borderline or certain intermediate position of the longitudinal direction of each rectangular pattern, and the borderline, however, can be any position as long as it is between the other two gate electrodes 121 opposed in the lateral direction.
[0042] Thereafter, in order that in each of the divided layouts, a pattern according to a design value is formed on the semiconductor substrate, there is manufactured a photomask that is formed with a gate electrode pattern corrected by using optical proximity correction (OPC). That is, two photomasks (a photomask for the gate A and a photomask for the gate B) are manufactured. At this time, the patterns for the gate A and the gate B in the photomasks are so formed that the gate A 11 and the gate B 12 are overlapped each other by several tens of nanometers in the longitudinal direction of the rectangular pattern, as shown in FIG. 4 .
[0043] Next, from the design layout of the SRAM unit, a design layout of the contact hole is extracted. In the design layout, as shown in FIG. 5 , a square-shaped contact hole flanked between the two gates A 11 adjacent in the lateral direction (a Y direction in FIG. 5 ) is set as a contact hole pattern A 13 . A square-shaped contact hole pattern flanked between the two gates B 12 adjacent in the lateral direction (the Y direction in FIG. 5 ) is set as a contact hole pattern B 14 , as shown in FIG. 5 . Thereby, the design layout of the contact hole is divided into two, that is, the contact hole pattern A 13 and the contact hole pattern B 14 .
[0044] Other contact hole patterns are classified into either the contact hole pattern A 13 or the contact hole pattern B 14 depending on a process margin. Thereafter, in order that in each of the divided layouts, a pattern according to a design value is formed on the semiconductor substrate, there is manufactured a photomask that is formed with a contact hole pattern corrected by using OPC or a contact hole pattern added with an unresolved assisting pattern. That is, two photomasks (a photomask for the contact hole pattern A and a photomask for the contact hole pattern B) are manufactured.
[0045] Next, as shown in FIGS. 6A and 6B , on a main surface of the semiconductor substrate formed with the device forming regions 111 defined by being surrounded by the device isolating regions 112 , a polysilicon film 121 a for forming gate electrodes is formed, and on top of the polysilicon film 121 a , a silicon nitride film, for example, is formed as a first hard mask film 131 a . By employing photolithography using the photomask for the gate A, a first resist patterns 132 are formed on the first hard mask film 131 a , as shown in FIGS. 6A and 6B . Thereby, the first resist patterns 132 are formed at a position corresponding to the gate A 11 on the main surface of the semiconductor substrate. Thereafter, according to need, a process of slimming the first resist pattern 132 is performed by etching.
[0046] Next, the first resist patterns 132 are used as a mask to etch the first hard mask film 131 a , and as shown FIGS. 7A and 7B , the first hard mask patterns 131 are formed on the polysilicon film 121 a . Thereby, the first hard mask patterns 131 are formed at a position corresponding to the gates A 11 .
[0047] Next, by employing photolithography using the photomask for the gates B, second resist patterns 133 are formed at a position corresponding to the gates B 12 , as shown in FIGS. 8A and 8B . The patterns of the photomask for the gates A and the patterns of the photomask for the gates B are so formed that the both patterns are overlapped each other in the longitudinal direction of the rectangular pattern by several tens of nanometers as shown in FIG. 4 , and thus the second resist pattern 133 is so formed that one portion thereof is overlapped with the first hard mask pattern 131 . The second resist pattern 133 is formed in a region of the rectangular pattern 121 p (over the entire region other than a region of at least the first hard mask pattern 131 ). Thereafter, according to need, a process of slimming the second resist patterns 133 are performed by etching.
[0048] Next, the first hard mask patterns 131 and the second resist patterns 133 are used as a mask to etch the polysilicon film 121 a , thereby removing the first hard mask patterns 131 and the second resist patterns 133 . As a result, the gate electrodes 121 are formed as shown in FIGS. 9A and 9B .
[0049] Next, formation of the interlayer insulating film 122 and a second hard mask film 134 a on the semiconductor substrate in this order is formed out, as shown in FIGS. 10A and 10B . A third resist film (not shown) is further formed on the semiconductor substrate. By employing photolithography using a photomask for the contact hole patterns A, a third resist patterns 135 are formed as shown in FIGS. 10A and 10B , thereby forming the contact hole patterns A 13 .
[0050] At this time, the contact hole patterns A 13 , which are aligned to the gates A 11 , is exposed. That is, the contact hole pattern A 13 is so aligned that one portion thereof is precisely overlapped over the gate A 11 of an underlayer, and the contact hole pattern A 13 are so aligned that another portion thereof is not overlapped in the gate A 11 in a region between the gates A 11 adjacent in the lateral direction. The exposure is performed in this state. Thereafter, as shown in FIGS. 10A and 10B , the third resist patterns 135 are used as a mask to etch the second hard mask film 134 a.
[0051] Next, the third resist patterns 135 are removed, and a fourth resist film (not shown) is formed on the semiconductor substrate. By employing photolithography using a photomask for the contact hole patterns B, a fourth resist patterns 136 are formed as shown in FIGS. 11A and 11B , thereby forming the contact hole patterns B 14 .
[0052] At this time, the contact hole patterns B 14 , which are aligned to the gates B 12 , is exposed. That is, the contact hole pattern B 14 is so aligned that one portion thereof is precisely overlapped over the gate B 12 of an underlayer, and the contact hole pattern B 14 is so aligned that another portion thereof is not overlapped with the gate B 12 in a region between the gates B 12 adjacent in the lateral direction. In this state, the exposure is performed. Thereafter, as shown in FIGS. 11A and 11B , the fourth resist patterns 136 are used as a mask to etch the second hard mask film 134 a , thereby forming second hard mask patterns 134 .
[0053] The fourth resist patterns 136 are then removed, and the second hard mask patterns 134 are used as a mask to etch the interlayer insulating film 122 , thereby forming the contact holes A 113 and the contact holes B 114 . As a result, the highly-integrated SRAM according to the first embodiment shown in FIGS. 1A and 1B is formed.
[0054] As described above, in the highly-integrated SRAM manufacturing method according to the first embodiment, at the time of forming the etching mask for forming the gate electrodes 121 by using the lithography, the pattern for the gate electrodes 121 are divided into two patterns, that is, the pattern for the gates A 11 and that for the gates B 12 , so that the patterns of the same type are not faced to each other at a line end of the pattern. Thereafter, the divided patterns are arranged on two respectively different photomasks, and transferred to the etching mask over two exposing steps. That is, pattern ends of the gate electrodes 121 adjacent in the longitudinal direction are arranged, one pattern after the other, on the different photomasks, and transferred to the etching mask over two exposing steps. Thereby, even when the length LX 1 between the gate electrodes 121 adjacent in the longitudinal direction exceeds the resolution limit of a photolithography technique, it is possible to prevent deterioration in the dimensional accuracy which is caused due to the length LX 1 at the time of forming the etching mask and which is found in the exposure at a photolithography step, and possible to form a plurality of gate electrodes 121 with a favorable positioning accuracy at a desired position in the longitudinal direction. In the first embodiment, a case that the divided patterns are arranged on the two respectively different photomasks and transferred to the etching mask over the two exposing steps has been described. However, the divided patterns can be separately arranged on a single photomask and transferred to the etching mask over the two exposing steps.
[0055] Further, in another highly-integrated SRAM manufacturing method according to the first embodiment, the pattern for the gate electrodes 121 in the regions overlapped in the longitudinal direction are divided, as patterns of the same type, into two, that is, the gate A 11 and the gate B 12 . The divided patterns are arranged on the two respectively different photomasks and transferred to the etching mask over the two exposing steps. The contact hole patterns A 13 arranged in a region between the gates A 11 in the lateral direction, which are directly aligned to the gates A 11 in the gate electrodes 121 , are exposed. The contact hole patterns B 14 arranged in a region between the gates B 12 in the lateral direction, which are directly aligned to the gates B 12 in the gate electrode 121 , are exposed.
[0056] Accordingly, the patterns for the contact holes are directly aligned only to the pattern for the adjacent gate electrodes 121 , and thus even when the length LY 1 between the contact hole and the gate electrode 121 adjacent in the lateral direction exceeds the resolution limit of a photolithography technique, a plurality of contact holes 113 and 114 can be formed at a desired position with a favorable positioning accuracy rather than deteriorating the accuracy of precisely overlapping the gate electrode 121 on the contact hole pattern. Moreover, the patterns for the contact holes are directly aligned only to the patterns for the adjacent gate electrodes 121 , and thus, even when the length LY 1 between the contact hole and the gate electrode 121 adjacent in the lateral direction or the position of the gate electrodes 121 adjacent in the lateral direction exceeds the accuracy limit of indirect aligning, the contact holes 113 and 114 can be formed at a desired position with a favorable positioning accuracy rather than deteriorating the accuracy of precisely overlapping the gate electrode 121 on the contact hole pattern. The indirect aligning accuracy is an accuracy of aligning the pattern for a first contact hole and the pattern for a first gate electrode in a case that the pattern for the first contact hole is not individually aligned directly to the pattern for the first gate electrode adjacent in the lateral direction and the position of the pattern for the first contact hole is determined according to the alignment between a pattern for the other second contact hole and the pattern for the second gate electrode adjacent to the second contact hole in the lateral direction, for example.
[0057] Therefore, in the highly-integrated SRAM manufacturing method according to the first embodiment, the length between the gate electrodes adjacent in the longitudinal direction and the length between the gate electrode and the contact hole are shortened, and at the same time, these members can be formed at a desired position with a favorable positioning accuracy. Thus, area reduction of a semiconductor device can be achieved.
Second Embodiment
[0058] In a second embodiment of the present invention, another manufacturing method of the highly-integrated SRAM of the first embodiment shown in FIG. 1 is described with reference to FIGS. 12A to 16B . FIGS. 12A to 16B are schematic diagrams for explaining a highly-integrated SRAM manufacturing method according to the second embodiment, where each drawing denoted with A is a plan view, and each drawing denoted with B is a cross-sectional view along a line A-A in each corresponding drawing denoted with A. Explanations of the formation of the gate insulating film will be omitted.
[0059] First, according to the steps described in the first embodiment with reference to FIGS. 2 to 5 , the photomask for the gates A, the photomask for the gates B, the photomask for the contact hole patterns A, and the photomask for the contact hole patterns B are manufactured.
[0060] Next, as show in FIGS. 12A and 12B , on a main surface of the semiconductor substrate formed with the device forming regions 111 defined by being surrounded by the device isolating regions 112 , the polysilicon film 121 a for forming gate electrodes is formed, and on top of the polysilicon film 121 a , a silicon nitride film, for example, is formed as a first hard mask film 141 a . On top of the first hard mask film 141 a , a silicon oxide film, for example, is formed as a second hard mask film 142 a . By employing photolithography using the photomask for the gates A, first resist patterns 143 are formed on the second hard mask film 142 a , as shown in FIGS. 12A and 12B . Thereby, the first resist patterns 143 are formed at a position corresponding to the gates A 11 on the main surface of the semiconductor substrate. Thereafter, according to need, a process of slimming the first resist patterns 143 are performed by etching.
[0061] Next, the first resist patterns 143 are used as a mask to etch the second hard mask film 142 a , and as shown in FIGS. 13A and 13B , second hard mask patterns 142 are formed on the first hard mask film 141 a . Thereby, the second hard mask patterns 142 are formed at a position corresponding to the gates A 11 on the main surface of the semiconductor substrate.
[0062] Next, by employing photolithography using the photomask for the gates B, second resist patterns 144 are formed at a position corresponding to the gates B 12 on the main surface of the semiconductor substrate, as shown in FIGS. 14A and 14B . The pattern of the photomask for the gates A and the pattern of the photomask for the gates B are so formed that the both patterns are overlapped each other in the longitudinal direction of the rectangular pattern by several tens of nanometers as shown in FIG. 4 , and thus the second resist pattern 144 is so formed that one portion thereof is overlapped with the second hard mask pattern 142 . Thereafter, according to need, a process of slimming the second resist patterns 144 are performed by etching.
[0063] Next, the second hard mask patterns 142 and the second resist patterns 144 are used as a mask to etch the first hard mask film 141 a , thereby forming a first hard mask patterns 141 , as shown in FIGS. 15A and 15B . Thereby, the first hard mask patterns 141 are formed at a position corresponding to the gates A 11 and the gates B 12 on the main surface of the semiconductor substrate.
[0064] Next, the first hard mask patterns 141 are used as a mask to etch the polysilicon film 121 a , thereby forming the gate electrodes 121 , as shown in FIGS. 16A and 16B . Thereafter, steps after the formation of the interlayer insulating film 122 ( FIGS. 10A and 10B ) in the first embodiment are implemented. As a result, the highly-integrated SRAM shown in FIG. 1 can be formed.
[0065] Also in the highly-integrated SRAM manufacturing method according to the second embodiment, the same effect as that in the first embodiment can be obtained. That is, the length between the gate electrodes adjacent in the longitudinal direction and the length between the gate electrode and the contact hole can be shortened, and at the same time, these members can be formed at a desired position with a favorable positioning accuracy. Thus, area reduction of a semiconductor device can be achieved.
Third Embodiment
[0066] A third embodiment of the present invention describes a manufacturing method of a gate electrode in a semiconductor device. FIGS. 17A and 17B are schematic diagrams for explaining arrangement of a gate electrode 152 in the semiconductor device according to the third embodiment, where FIG. 17A is a plan view thereof, and FIG. 17B is a cross-sectional view thereof. In FIGS. 17A and 17B , a plurality of substantially rectangular gate electrodes 152 (a gate electrode 152 A, a gate electrode 152 B, and a gate electrode 152 C) made of polysilicon are formed substantially parallel on a semiconductor substrate 151 .
[0067] The gate electrode 152 A and the gate electrode 152 B are arranged on the substantially same line to be separated by a length LX 2 in a longitudinal direction (an X direction in FIG. 17A . Hereinafter, “longitudinal direction”) of the gate electrode 152 . The length LX 2 is a length between the gate electrode 152 A and the gate electrode 152 B adjacent in the longitudinal direction (the X direction in FIG. 17A ). The gate electrode 152 C is arranged to be separated by a length LY 2 in a lateral direction (a Y direction in FIG. 17A . Hereinafter, “lateral direction”) of the gate electrode 152 relative to the gate electrode 152 A and the gate electrode 152 B and also to be overlapped with each portion of the both gate electrode 152 A and gate electrode 152 B in the longitudinal direction (the X direction in FIG. 17A ), for example, by the substantially same length. The length LY 2 is a length between the gate electrode 152 A and the gate electrode 152 C and between the gate electrode 152 B and the gate electrode 152 C, adjacent in the lateral direction (the Y direction in FIG. 17A ). Specifically, a gate insulating films are formed beneath the gate electrodes 152 , and device forming regions and device isolating regions are formed on the semiconductor substrate 151 . However, explanations of these constituent elements will be omitted.
[0068] In the third embodiment, the length LX 2 is set to a very short length that exceeds the resolution limit of a photolithography technique, making it very difficult to form its configuration. Moreover, the length LY 2 is set to a very short length that exceeds the resolution limit of a photolithography technique, making it very difficult to form its configuration. By having such a layout, the semiconductor device according to the third embodiment achieves high integration of transistors, thereby realizing a semiconductor device with a reduced area.
[0069] The manufacturing method of a gate electrode in the semiconductor device according to the third embodiment is described below with reference to FIGS. 18 to 22B . FIGS. 18 to 22B are schematic diagrams for explaining the manufacturing method of a gate electrode in the semiconductor device according to the third embodiment, where each drawing denoted with A is a plan view, and each drawing denoted with B is a cross-sectional view along a line A-A in each corresponding drawing denoted with A. Explanations of the formation of the gate insulating film will be omitted. First, as shown in FIG. 18 , rectangular patterns 152 p of the gate electrodes 152 are extracted from a design layout of the semiconductor device.
[0070] Next, in the extracted rectangular patterns 152 p of the gate electrodes 152 , the rectangular pattern 152 p of the gate electrode 152 A is used as a gate pattern A (hereinafter, “gate A”) 153 and the rectangular pattern 152 p of the gate electrode 152 B is used as a gate pattern B (hereinafter, “gate B”) 154 . In this way, the design layout of the gate electrodes 152 is divided into two, that is, the gate A 153 and the gate B 154 .
[0071] The gate electrode 152 C is divided into two substantially rectangular patterns along a borderline of position that neither overlaps (opposes) the rectangular pattern 152 p (gate A) of the gate electrode 152 A nor the rectangular pattern 152 p (gate B) of the gate electrode 152 B in the longitudinal direction (an X direction in FIG. 18 ), and the two divided patterns are classified into the gate A 153 and the gate B 154 so that the patterns adjacent in the lateral direction (a Y direction in FIG. 18 ) are differed. That is, in the two divided patterns, in the lateral direction (the Y direction in FIG. 18 ), the rectangular pattern 152 p of the gate electrode 152 C at a position adjacent to the rectangular pattern 152 p (gate A) of the gate electrode 152 A is the gate B 154 , and the rectangular pattern 152 p of the gate electrode 152 C at a position adjacent to the rectangular pattern 152 p (gate B) of the gate electrode 152 B is the gate A 153 .
[0072] In order that in each of the classified layouts, the pattern according to the design value is formed on the semiconductor substrate, there is manufactured a photomask that is formed with a gate electrode pattern corrected by using OPC. That is, two photomasks (the photomask for the gate A and the photomask for the gate B) are manufactured. At this time, the patterns for the gate A and the gate B in the photomasks are so formed that the gate A 153 and the gate B 154 are overlapped each other by several tens of nanometers in the longitudinal direction, as shown in FIG. 19 .
[0073] Next, as shown in FIGS. 20A and 20B , on the main surface of the semiconductor substrate 151 , a polysilicon film 152 a for forming a gate electrode is formed, and on top of it, a silicon nitride film, for example, is formed as a hard mask film 161 a.
[0074] By employing photolithography using the photomask for the gate B, first resist patterns 162 is formed on the hard mask film 161 a , as shown in FIGS. 20A and 20B . Thereby, the first resist patterns 162 is formed at a position corresponding to the gates B 154 on the main surface of the semiconductor substrate 151 . Thereafter, according to need, a process of slimming the first resist patterns 162 are performed by etching.
[0075] Next, the first resist patterns 162 are used as a mask to etch the hard mask film 161 a , and as shown in FIGS. 21A and 21B , a hard mask pattern 161 is formed on the polysilicon film 152 a . Thereby, the hard mask patterns 161 are formed at a position corresponding to the gate B 154 on the main surface of the semiconductor substrate 151 .
[0076] Next, by employing photolithography using the photomask for the gate A, second resist patterns 163 are formed at a position corresponding to the gate A 153 , as shown in FIGS. 22A and 22B . The pattern of the photomask for the gate A and the pattern of photomask for the gate B are so formed that the both patterns are overlapped each other in the longitudinal direction by several tens of nanometers, as shown in FIG. 19 , and thus the second resist pattern 163 is so formed that one portion thereof is overlapped with the hard mask pattern 161 . Thereafter, according to need, a process of slimming the second resist patterns 163 are performed by etching.
[0077] Next, the hard mask patterns 161 and the second resist patterns 163 are used as a mask to etch the polysilicon film 152 a , thereby removing the hard mask patterns 161 and the second resist patterns 163 . As a result, the gate electrode 152 can be formed as shown in FIGS. 17A and 17B .
[0078] As described above, in the manufacturing method of a gate electrode in the semiconductor device according to the third embodiment, at the time of forming the second resist patterns 163 for etching mask for forming the gate electrodes 152 A and the hard mask patterns 161 for etching mask for forming the gate electrode 152 B at a lithography step, the etching masks adjacent in the longitudinal direction are formed at different lithography steps. That is, the patterns of the gate electrodes 152 adjacent in the longitudinal direction are arranged, one pattern after the other, on the different photomasks, and transferred to the etching mask over two exposing steps. Thereby, even when the length LX 2 between the gate electrodes 152 adjacent in the longitudinal direction exceeds the resolution limit of a photolithography technique, it is possible to prevent deterioration in the dimensional accuracy which is caused due to the length LX 2 at the time of forming the etching mask and which is found in the exposure at a photolithography step, and possible to form a plurality of gate electrodes 152 with a favorable positioning accuracy at a desired position in the longitudinal direction. In the third embodiment, a case that the patterns for the gate electrodes 152 adjacent in the longitudinal direction are arranged, one pattern after the other, on the two respectively different photomasks, and transferred to the etching mask over the two exposing steps has been described. However, the patterns for the adjacent gate electrodes 152 can be separately arranged on a single photomask and transferred to the etching mask over the two exposing steps.
[0079] In another manufacturing method of a gate electrode in the semiconductor device according to the third embodiment, the etching mask for forming the gate electrode 152 C is manufactured by being divided into the hard mask pattern 161 and the second resist pattern 163 . At the time of forming the hard mask pattern 161 and the second resist pattern 163 , a region in which the etching masks are overlapped in the longitudinal direction is formed at different lithography steps. Thereby, even when the length LY 2 between the gate electrodes 152 adjacent in the lateral direction exceeds the resolution limit of a photolithography technique, it is possible to prevent deterioration in the dimensional accuracy which is caused due to the length LY 2 and which is found in the exposure at a photolithography step, and possible to form a plurality of gate electrodes 152 with a favorable positioning accuracy at a desired position in the lateral direction.
[0080] In the third embodiment, in the photomask for the gates A and the photomask for the gates B, the patterns for the gate A and for the gate B are formed to be overlapped each other by several tens of nanometers in the longitudinal direction, and thus the second resist pattern 163 is so formed that one portion thereof is overlapped with the hard mask pattern 161 . Thereby, at the time of forming the hard mask pattern 161 by using the photomask for the gates A, or at the time of forming the second resist pattern 163 by using the photomask for the gates B, even when slight positional deviation occurs in the longitudinal direction, the hard mask pattern 161 and the second resist pattern 163 are prevented from being separated from each other. That is, the separation of the mask pattern for forming the gate electrode 152 C, which is caused due to the formation of the photomask for forming the gate electrode 152 at two different lithography steps, can be prevented, thereby forming the gate electrode 152 C with a desired shape.
[0081] Accordingly, in the method of manufacturing a gate electrode in the semiconductor device according to the third embodiment, the length between the gate electrodes adjacent in the longitudinal direction and the lateral direction is shortened, and at the same time, these members can be formed at a desired position with a favorable positioning accuracy. Thus, area reduction of a semiconductor device can be achieved.
Fourth Embodiment
[0082] According to a fourth embodiment of the present invention, a manufacturing method of a wire layer in a semiconductor device will be described. FIGS. 23A and 23B are schematic diagrams for explaining arrangement of a wire layer in a semiconductor device according to the fourth embodiment, where FIG. 23A is a plan view thereof, and FIG. 23B is a cross-sectional view thereof. In FIGS. 23A and 23B , a plurality of substantially rectangular copper (Cu) wires 172 (a Cu wire 172 A, a Cu wire 172 B, and a Cu wire 172 C) made of copper (Cu) are formed substantially parallel on an interlayer insulating film 171 .
[0083] The Cu wire 172 A and the Cu wire 172 B are arranged on the substantially same line to be separated by a length LX 3 in a longitudinal direction (an X direction in FIG. 23A . Hereinafter, “longitudinal direction”) of the Cu wire 172 . The length LX 3 is a length between the Cu wire 172 A and the Cu wire 172 B adjacent in the longitudinal direction (the X direction in FIG. 23A ). The Cu wire 172 C is so positioned that it is separated by a length LY 3 in a lateral direction (a Y direction in FIG. 23A . Hereinafter, “lateral direction”) of the Cu wire 172 relative to the Cu wire 172 A and the Cu wire 172 B and that it is overlapped by the substantially same length only with respect to the Cu wire 172 A and Cu wire 172 B in the longitudinal direction (the X direction in FIG. 23A ). The length LX 3 is a length between the Cu wire 172 A and the Cu wire 172 C, and between the Cu wire 172 B and the Cu wire 172 C, adjacent in the lateral direction (the Y direction in FIG. 23A ).
[0084] In the fourth embodiment, the length LX 3 is set to a very short length that exceeds the resolution limit of a photolithography technique, making it very difficult to form its configuration. Moreover, the length LY 3 is set to a very short length that exceeds the resolution limit of a photolithography technique, making it very difficult to form its configuration. By having such a layout, the semiconductor device according to the fourth embodiment enables high integration of transistors and area reduction.
[0085] A manufacturing method of the Cu wire 172 in a semiconductor device according to the fourth embodiment is described next. First, from the design layout of the semiconductor device, rectangular patterns for the Cu wires 172 are extracted. Subsequently, in the extracted rectangular pattern for the Cu wire 172 , a rectangular pattern for the Cu wire 172 A is a wire pattern A (Hereinafter, “wire A”) 173 and a rectangular pattern for the Cu wire 172 B is a wire pattern B (Hereinafter, “wire B”) 174 , as shown in FIG. 24 . In this way, the design layout of the Cu wire 172 is classified into two, that is, the wire A 173 and the wire B 174 .
[0086] Thereafter, when the same steps as those after FIG. 20 in the third embodiment are implemented, the (Cu) wires 172 (the Cu wire 172 A, the Cu wire 172 B, and the Cu wire 172 C) can be formed. In this case, the wire A corresponds to the gate A and the wire B corresponds to the gate B. In the fourth embodiment, instead of the polysilicon film 152 a , a Cu film is formed.
[0087] In the manufacturing method of a wire layer in the semiconductor device according to the fourth embodiment, at the time of forming the etching mask for forming the Cu wire 172 A at a lithography step, the etching masks adjacent in the longitudinal direction are formed at different lithography steps. That is, the patterns for the Cu wires 172 adjacent in the longitudinal direction are arranged, one pattern after the other, on the different photomasks, and transferred to the etching mask over two exposing steps. Thereby, even when the length LX 3 between the Cu wires 172 adjacent in the longitudinal direction exceeds the resolution limit of a photolithography technique, it is possible to prevent deterioration in the dimensional accuracy which is caused due to the length LY 3 at the time of forming the etching mask and which is found in the exposure at a photolithography step, and possible to form a plurality of Cu wires 172 with a favorable positioning accuracy at a desired position in the longitudinal direction. In the fourth embodiment, a case that the patterns for the Cu wires 172 adjacent in the longitudinal direction are arranged, one pattern after the other, on the respectively different photomasks, and transferred to the etching mask over the two exposing steps has been described. However, the patterns for the adjacent Cu wires 172 can be separately arranged on a single photomask and transferred to the etching mask over the two exposing steps.
[0088] In another semiconductor device manufacturing method according to the fourth embodiment, the etching mask for forming the Cu wire 172 C is manufactured in a divided manner. At the time of forming the etching mask, a region in which the etching masks are overlapped in the longitudinal direction is formed at different lithography steps. Thereby, even when the length LY 3 between the Cu wires 172 adjacent in the lateral direction exceeds the resolution limit of a photolithography technique, it is possible to prevent deterioration in the dimensional accuracy which is caused due to the length LY 3 and which is found in the exposure at a photolithography step, and possible to form a plurality of Cu wires 172 with a favorable positioning accuracy at a desired position in the lateral direction.
[0089] In the fourth embodiment, in the photomask for the wires A and the photomask for the wires B, the patterns for the wires A and for the wire B are formed to be overlapped each other by several tens of nanometers in the longitudinal direction. Thereby, the separation of the mask pattern for forming the Cu wire 172 , which is caused due to the formation of the photomask for forming the Cu wires 172 at two different lithography steps, can be prevented, thereby forming Cu wire 172 C with a desired shape.
[0090] Accordingly, in the method of manufacturing a wire layer in the semiconductor device according to the fourth embodiment, the length between wires adjacent in the longitudinal direction and the lateral direction is shortened, and at the same time, these members can be formed at a desired position with a favorable positioning accuracy. Thus, area reduction of a semiconductor device can be achieved.
[0091] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | To include transferring simultaneously by lithography a first region from a position opposed between a first constituent member and a second constituent member in a longitudinal direction of a third constituent member to the end of a side of the first constituent member and a first mask pattern for forming the first constituent member, onto a semiconductor substrate, transferring simultaneously by lithography a second region including regions other than the first region out of the third constituent member and a second mask pattern for forming the second constituent member, onto the semiconductor substrate, and forming the first constituent member, the second constituent member, and the third constituent member on the semiconductor substrate by using the first and second mask patterns. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrically writable and erasable non-volatile semiconductor memory device (flash memory) operable on power from a single power supply.
2. Description of the Related Art
There is an electrically writable and erasable non-volatile semiconductor memory device (hereinafter called "flash memory").
FIG. 1 shows an example of the structure of this flash memory. In FIG. 1 an address signal is supplied via address buffers 1 to row decoders 2.
A voltage switching circuit 11 is supplied with a power supply voltage Vcc, a first high voltage Vpp for data writing and control signals PG and PGVER and outputs a voltage Vpp2. At the time of writing data in memory cells 4, the voltage switching circuit 11 outputs a first high voltage (e.g., 12 V) higher than the power supply voltage Vcc as the voltage Vpp2. At the time of write verifying, the voltage switching circuit 11 outputs a second high voltage lower than the first high voltage Vpp but higher than the supply voltage Vcc as the voltage Vpp2. The write verify is a process to check whether or not the threshold voltage of a data-written memory cell transistor has risen to a sufficient level.
Each row decoder 2 decodes the received address signal, and selects a word line connected to the gates of those memory cells 4 in the selected row to apply the voltage from the voltage switching circuit 11 to the word line. That is, in writing data, each row decoder 2 applies the first high voltage Vpp to the Gate of the selected memory cell 4. The threshold voltage of the memory cell transistor 4 where data has been written rises higher than those of unwritten memory cell transistors 4, and this memory cell transistor 4 becomes non-conductive at the time of normal data reading. When write verify is to be executed, the row decoder 2 applies the second high voltage to the gate of the selected memory cell transistor 4 to read data therefrom, and checks if this memory cell transistor 4 is non-conductive.
FIG. 2 illustrates the arrangement of the essential portions of the voltage switching circuit 11. With the illustrated structure, at the time of normal data reading, a control circuit (not shown) sets PG=0 V, PGVER=0 V and PG+PGVER=Vcc. This renders N type MOS transistors M1 and M2 non-conductive and an N type depletion transistor M3 conductive, so that read voltage (power supply voltage) Vcc is output as an output voltage Vpp2.
At the time of data writing, the control circuit sets PG=Vpp, PGVER=0 V and PG+PGVER=0 V. Consequently, the N type MOS transistor M1 becomes conductive, causing the first high voltage Vpp to be output as the output voltage Vpp2.
At the time of write verify, the control circuit sets PG and PG+PGVER to 0 V, and PGVER to Vpp. As a result, the N type MOS transistor M2 becomes conductive, causing the second high voltage (R2/(R1+R2))Vpp to be output as the output voltage Vpp2. The proper gate voltage of a target memory cell transistor at the write verify time can be set by properly determining the resistances R1 and R2.
If a flash memory is of a type that is externally supplied with only the supply voltage Vcc, the mentioned voltage Vpp should be produced from the supply voltage Vcc within the chip using a booster circuit. Generally, such a booster circuit has a small current drive capacity, which lowers the speed of switching the gate of each memory cell transistor 4 and thus slowing the operation speed of the whole memory device.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a flash memory operable with a single power supply voltage and capable of switching the gates of memory cell transistors at high speed.
To achieve this object, a flash memory according to the present invention comprises:
memory cells for storing data;
an internal booster circuit for generating a first voltage for data writing, higher than a supply voltage upon reception thereof; and
supply means, connected to the memory cells and the internal booster circuit, for receiving an address signal, supplying the first voltage to a gate of that memory cell which is specified by the address signal at a time of data writing, and dropping the first voltage to a second voltage lower than the first voltage but higher than the supply voltage and supplying the second voltage to the gate of the memory cell at a write verifying time.
With the above structure, the first voltage acquired by boosting the supply voltage is supplied to the gate of that memory cell which is specified by an address signal at the time of data writing, and the second voltage acquiring by dropping the first voltage is supplied to the gate of the memory cell at the write verifying time. In other words, the gate voltage of the memory cell at the write verify time is acquired by dropping the voltage that is applied to this gate at the data writing time. This design can make the speed of switching the gate of a target memory cell transistor faster than the scheme that uses a booster circuit to control the gate voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the structure of a conventional semiconductor memory device;
FIG. 2 is a circuit diagram of a voltage switching circuit shown in FIG. 1;
FIG. 3 is a block diagram illustrating the structure of a semiconductor memory device according to a first embodiment of the present invention;
FIG. 4 is a circuit diagram illustrating a row decoder and a row-line clamp circuit, shown in FIG. 3;
FIGS. 5A through 5C are timing charts illustrating the operation of the circuits shown in FIGS. 3 and 4;
FIG. 6 is a block diagram illustrating the structure of a semiconductor memory device according to a second embodiment of the present invention; and
FIGS. 7A through 7C are timing charts illustrating the operation of the circuit shown in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described referring to the accompanying drawings.
FIG. 3 presents a circuit block diagram illustrating the structure of an electrically writable and erasable non-volatile semiconductor memory device (flash memory) according to a first embodiment of the present invention.
Address buffers 1 receive an n-bit external address signal and outputs an internal address signal. The address buffers 1 latch the internal address signal in response to an address latch signal ADL at the times of data writing and write verify, and holds it during the data writing period and write verify period.
A booster circuit 12 receives a power supply voltage Vcc and supplies an internally boosted voltage Vpp2 to individual row decoders 2.
Each row decoder 2 is supplied with the internal address signal. In accordance with the internal address signal, each row decoder 2 supplies the power supply voltage Vcc via an associated word line to the gates of associated memory cell transistors 4 at the time of data reading, and supplies the boosted voltage Vpp2 from the booster circuit 12 to those gates at the time of data writing. At the time of write verify, the row decoder 2 supplies a voltage acquired by dropping the boosted voltage Vpp2 to the gate of the target memory cell transistor 4 in accordance with the internal address signal in cooperation with an associated row-line clamp circuit 3 (to be described later).
Each row-line clamp circuit 3 is supplied with a row-line clamp control signal PGVER. In accordance with the control signal PGVER, the row-line clamp circuit 3 pulls down the voltage Vpp2, supplied to the gate of the memory cell transistor 4, to V PGV +|V TP | (V PGV : verify reference voltage; V TP : threshold voltage of a P type MOS transistor) at the write verify time.
A control circuit 15 produces a control signal BXD (to be described later) as well as the aforementioned address latch signal ADL and row-line clamp control signal PGVER.
FIG. 4 illustrates the essential portions of each row decoder 2 and row-line clamp circuit 3 according to this embodiment.
Referring to FIG. 4, the internal address signal given from the address buffer 1 is supplied to a NAND gate 5. The NAND gate 5 outputs a low-level signal when the internal address signal satisfies a predetermined relationship. The output of the NAND gate 5 is connected via an invertor 6 to one end of a current path of an N type depletion transistor M4. The gate of the N type depletion transistor M4 is supplied with the control signal BXD, while the other end of the current path is connected to the gates of the associated memory cell transistors 4 through a word line.
This word line is connected to the gates of an N type MOS transistor M5 and a P type MOS transistor M6. One end of the current path of the N type MOS transistor M5 is grounded while the other end is connected to one end of the current path of the P type MOS transistor M6. The other end of the current path of the MOS transistor M6 is supplied with the internally boosted voltage Vpp2 from the booster circuit 12.
The word line is further connected to P type MOS transistors M7 and M8. The boosted voltage Vpp2 is applied to one end of the P type MOS transistor M7, which has its gate connected to a connection node between the transistors M5 and M6. The other end of the current path of the transistor M7 is connected to the word line.
One end of the current path of the P type MOS transistor M8 is grounded, while the other end is connected to the word line. The transistor M8 has its gate applied with the control signal PGVER.
In FIG. 4, the NAND gate 5, the invertor 6 and the transistors M4-M7 constitute the row decoder 2. And, the transistor M8 constitutes the row-line clamp circuit 3.
In FIG. 4, the control signal BXD is set to 0 V at the times of data writing and write verify or to Vcc at other operational times.
The operation of the flash memory shown in FIGS. 3 and 4 will now be described referring to FIGS. 5A through 5C.
At the beginning of data writing, the control circuit 15 outputs the address latch signal ADL. In response to the address latch signal ADL, the address buffer 1 holds the internal address signal during the data writing period and the write verify period.
At the data writing time, the potential of a node A (output of the invertor 6) of the row selected by the internal address signal becomes Vcc, as shown in FIG. 5A. As the control signal BXD is 0 V, the N type depletion transistor M4 becomes a resistance, gradually raising the voltage on the word line. Consequently, the MOS transistors M5 and M6 start functioning to supply a low-level voltage to the gate of the MOS transistor M7, rendering the transistor M7 conductive. Meanwhile, as shown in FIG. 5C, the control circuit 15 outputs the boosted voltage Vpp2 supplied from the booster circuit as the signal PGVER. This renders the P type MOS transistor M8 non-conductive.
The word line is charged (pulled up) by the P type MOS transistor M7, so that the voltage on the word line rises to the boosted voltage Vpp2 as shown in FIG. 5B. This voltage is applied to the gate of the memory cell transistor 4.
When the writing is complete and the write verify operation starts, the control circuit 15 sets the voltage level of the signal PGVER to the verify reference voltage V PGV (Vcc<V PGV <Vpp2), as shown in FIG. 5C. As a result, the P type MOS transistor M8 becomes conductive, discharging (pulling down) the charges on the word line. Since the current supply performance of the internal booster circuit 12 is smaller than the current drive performance of the P type MOS transistor M8, the gate voltage of the memory cell transistor 4 drops to V PGV +|V TP | (V TP : threshold voltage of the P type MOS transistor M8) from Vpp2, as shown in FIG. 5B.
In short, the boosted voltage Vpp2 is applied to the gate of the memory cell transistor 4 at the data writing time, and the voltage V PGV +|V TP | acquired by dropping the boosted voltage Vpp2 is applied to this gate at the write verify time.
According to this embodiment, as described above, the gate voltage of the memory cell transistor 4 at the write verify time is acquired by dropping the gate voltage at the data writing time (the voltage on the word line). This scheme can thus make the action of switching the gate of the memory cell transistor 4 faster than the design which causes the booster circuit 12 to produce the voltage at the write verify time as separate from the data writing voltage and then supplies it to the memory cell transistor 4.
A second embodiment of this invention will be described below referring to FIGS. 6 and 7.
FIG. 6 presents a block diagram of a flash memory according to this embodiment. The fundamental structure of the flash memory shown in FIG. 6 is basically the same as that shown in FIG. 3. The difference however lies in that a parallel circuit of an N type depletion transistor M9 and a resistor R3 having a sufficiently large resistance (several mega-ohms) is inserted between the internally boosted voltage Vpp2 and the row decoders 2. Further, the control circuit supplies a control signal PGVER2 to the gate of the transistor M9.
As shown in FIG. 7B, at the time data is written into this flash memory, the control circuit 15 sets PGVER2=Vpp2 to render the N type depletion transistor M9 conductive, supplying the voltage Vpp2 to the row decoders 2. Further, the control circuit 15 sets the signal PGVER to the supply voltage Vcc as shown in FIG. 7C, rendering the N type depletion transistor M8 non-conductive. As a result, the voltage on the word line becomes Vpp2 as shown in FIG. 7A.
At the time of write verify, the control circuit 15 sets the signal PGVER2 to 0 V to render the N type depletion transistor M9 non-conductive, supplying the voltage Vpp2 to the row decoders 2 via the resistor R3 with a high resistance. Further, the control circuit 15 sets the signal PGVER to 0 V to render the transistor M8 conductive. Accordingly, the voltage on the word line drops. Because the output current of the booster circuit 12 is restricted by the resistor R3, it is possible to prevent the boosted voltage Vpp2 from dropping more than necessary at the write verify time.
The present invention is not limited to the above-described embodiments, but it should be apparent to those skilled in the art that this may be embodied in many other specific forms without departing from the spirit or scope of the invention. For instance, although the control circuit 15 supplies the signal PGVER to each row decoder 2, the voltages Vpp2 and V PGV may be supplied to the row decoder 2 so that the row decoder 2 produces this signal itself. | A flash memory is operable using a single power supply voltage. In this flash memory, an internal booster circuit boosts the supply voltage to generate a write voltage higher than the supply voltage. A row decoder is connected to word lines, which are connected to memory cells. Upon reception of an address signal, the row decoder selects a word line specified by this address signal. A row-line clamp circuit, which is connected to the internal booster circuit and the word lines, supplies the write voltage to a word line selected at the time of data writing, and drops the write voltage and supplies it to the selected word line at the time of write verify. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to commonly assigned, U.S. patent application Kodak Docket No. ______ filed concurrently herewith, entitled “CONTINUOUS INKJET PRINTER HAVING ADJUSTABLE DROP PLACEMENT, in the name of Gilbert A. Hawkins, et al., the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to digitally controlled printing devices and more particularly relates to suppression of image artifacts of a continuous ink jet printhead that integrates multiple nozzles on a single substrate and in which the breakup of a liquid ink stream into printing droplets is caused by a periodic disturbance of the liquid ink stream.
BACKGROUND OF THE INVENTION
[0003] Ink jet printing has become recognized as a prominent contender in the digitally controlled, electronic printing arena because, e.g., of its non-impact, low-noise characteristics, its use of plain paper and its avoidance of toner transfers and fixing. Ink jet printing mechanisms can be categorized by technology as either drop on demand ink jet or continuous ink jet.
[0004] The first technology, drop-on-demand technology, provides ink droplets which impact upon a recording surface by using a pressurization actuator (thermal, piezoelectric, etc.). Selective activation of the actuator causes the formation and ejection of a flying ink droplet that crosses the space between the print head and the print media and strikes the print media. The formation of printed images is achieved by controlling the individual formation of ink droplets, as is required to create the desired image. Commonly practiced drop-on-demand technologies use thermal actuation to eject ink droplets from a nozzle. With thermal actuators, a heater, located at near the nozzle, heats the ink causing a quantity of ink to phase change into a gaseous steam bubble, increasing the internal ink pressure sufficiently for an ink droplet to be expelled. As is well known in the art, alternative methods of drop-on-demand droplet ejection use piezoelectric actuators, such as that disclosed in U.S. Pat. No. 5,224,843, issued to vanLintel, on Jul. 6, 1993, bimetallic actuators, such as those disclosed by Lebens et al, U.S. Pat. No. 6,460,972, and electrostatic actuators, as practiced by Seiko Epson, Inc., disclosed in U.S. Pat. No. 6,474,784.
[0005] The second technology, commonly referred to as “continuous stream” or “continuous” ink jet printing, uses a pressurized ink source that produces a continuous stream of ink droplets. Conventional continuous ink jet printers utilize electrostatic charging devices that are placed close to the point where a filament of ink breaks into individual ink droplets. The ink droplets are electrically charged and then directed to an appropriate location by deflection electrodes. When no print is desired, the ink droplets are directed into an ink-capturing mechanism (often referred to as catcher, interceptor, or gutter). When a print is desired, the ink droplets are directed to strike a print medium. U.S. Pat. No. 1,941,001, issued to Hansell on Dec. 26, 1933, and U.S. Pat. No. 3,373,437 issued to Sweet et al. on Mar. 12, 1968, each disclose an array of continuous ink jet nozzles wherein ink droplets to be printed are selectively charged and deflected towards the recording medium. This early technique is known as binary deflection continuous ink jet. U.S. Pat. No. 4,636,808, issued to Herron et al., U.S. Pat. No. 4,620,196 issued to Hertz et al. and U.S. Pat. No. 4,613,871 issued to Katerberg disclose techniques for improving image quality in electrostatic continuous ink jet printing including printing with a variable number of drops within pixel areas on a recording medium.
[0006] Today's commercialized inkjet printers, whether of the drop-on-demand or continuous inkjet type, are generally not capable of precisely steering droplets to control the placement of droplets precisely within pixels areas of the printed image. In both drop-on-demand and continuous inkjet technologies, failure to accurately control print droplet placement within printed pixel areas reduces the image quality that could be achieved if such control were available. Thus it would be desirable to enable control of the placement of droplets precisely within pixels areas. In some cases, control of drop placement can be used to directly compensate nozzle manufacturing defects which result in drop placement errors, for example by using a lookup table in which manufacturing defects were quantified; in other cases, control of drop placement can be used to directly improve image quality even in the absence of drop placement errors. For example, improvements in image quality can be achieved by deliberately altering the positions of drops within printed pixel areas in an imagewise fashion when printing text. Such alterations can better replicate the intended positions of sharply defined image features such as curved portions of script fonts. Control of drop placement is useful in producing halftone images for graphic arts proofing.
[0007] As controlling drop placement has proven difficult, related technologies have been developed to improve image quality that do not require precise control of the positions of drops within printed pixel areas to improve the visual appearance of images. For example, the use of “multiple passes” or “banding passes” in inkjet printers averages out errors in print drop placement that may be inherent in any one nozzle by employing many different nozzles during multiple passes, as will be described. Also, software algorithms can be employed to improve image quality. However, these methods suffer from disadvantages of cost and complexity and the degree to which they improve image quality.
[0008] For example, in a printhead with an array of ink nozzles, individual nozzles, differing slightly in fabrication, cause errors in drop placement, either in the direction in which the print head is scanned (fast scan direction) or in the direction in which the receiving medium is periodically stepped (slow scan direction, usually orthogonal to the fast scan direction). For the most part, these minor differences result in placement errors no larger than some fraction of a pixel dimension. Nonetheless, under some conditions, small placement errors within this sub-pixel range of dimensions cause undesirable image artifacts known as banding, most noticeable in areas of text or areas of uniform color. To suppress banding, drop-on-demand inkjet printers in particular use multiple passes (so-called banding passes) in printing images, each banding pass using a different subset of nozzles on the printhead to eject drops. Nozzles are selected dependent on particular algorithms or are selected at random. Repetitive errors in drop placement can thereby be distributed spatially. For example, drops printed in two adjacent lines parallel to the scanning direction of the printhead (fast scan direction) would be printed by many nozzles, each subject to its own slight misdirection and consequent drop misplacement, so as to reduce repetitive misplacements. This technique introduces pseudo random spatial variations in drop position. Such positional “noise” in the printed drop, while itself an image artifact, is generally agreed to be preferred to the case of repetitive misdirection, which is more easily detected by the eye. The use of banding passes is effective even in cases in which misplacements of printed drops change unpredictably with time and/or do not arise from nozzle imperfections. For example, distortion of the media due to wet loading, can result in image artifacts due to misplacement of drops one to another and environmental factors such as mechanical vibrations in the printer or fluctuating air currents near the printhead can also result in image artifacts due to misplacement of drops. While multiple banding passes enable a printhead to correct for known banding errors, a more complex printing pattern is required as well as a more complex medium transport mechanism. The use of banding passes necessarily requires more time to print an image, since not all nozzles are used all the time. Under worst-case conditions, correction for band effects can result in significant loss of productivity, even as high as 10× by some estimates. It should be noted that most continuous inkjet printers do not have scanned printheads and hence cannot easily adapt approaches such as the use of banding passes common in drop-on-demand printers.
[0009] Conventional software methods, which do not necessarily reduce productivity, can also be applied to improve image quality. These well-known techniques include dither matrices, blue noise masking, FM screening, and error diffusion. For example, U.S. Pat. No. 5,726,772 entitled “Method and Apparatus for Halftone Rendering of a Gray Scale Image Using a Blue Noise Mask” to Parker et al. discloses the use of ordered dither algorithms using fixed-size threshold screen patterns. U.S. Pat. No. 5,875,287 entitled “Banding Noise Reduction for Clustered-Dot Dither” to Li et al. discloses an improved method for minimizing banding artifacts using offset dither matrices. U.S. Pat. No. 6,443,549 entitled “Continuous Tone Reproduction Using Improved Ink Jet Droplet Dispersion Techniques” to Bitticker et al. discloses a hybrid dot placement scheme using different types of dot dispersion, such as error diffusion and dither matrices, based on the overall density of an area of the image. As yet another approach, U.S. Pat. No. 5,937,145 entitled “Method and Apparatus for Improving Ink-Jet Print Quality Using a Jittered Print Mode” to Garboden et al. discloses the employment of “jittering” algorithms to vary droplet timing in a scanning inkjet printer of the drop-on-demand type. While the software solutions of these prior art methods are able to provide some measure of help for reducing banding and other image artifacts, there are limitations to these solutions and some room for improvement. Specifically, limitations of the print hardware constrain the level of adjustability to one or more full pixel-to-pixel distances, rather than allowing movement over a fraction of a pixel. Dither matrices, blue noise, and other techniques are limited by hardware-imposed constraints, such as the inability to control individual nozzles in a row or matrix. Therefore, these existing methods manipulate the image data before sending it to the printer in order to compensate for characteristics of the imaging system. Improvement of printer hardware performance itself, including methods to control drop placement within pixel areas could alleviate at least some of the need to implement these software solutions in many types of imaging applications.
[0010] It can be seen from the above discussion that the ability to accurately control print droplet placement within printed pixel areas could provide valuable alternatives to techniques currently used to improve image quality or to supplement those techniques when used in combination with them.
[0011] Some progress has been made in this regard in the case of continuous inkjet printing. For example, although early continuous ink jet printing technologies were not capable of steering droplets ejected from individual nozzles so as to accurately position printed drops within printed pixel areas, later continuous inkjet technologies were disclosed which provided methods for controlling the placement of droplets in both the slow scan and fast scan directions precisely within pixels areas of the printed image:
[0012] U.S. Pat. No. 4,347,521 (Teumer) discloses a print head employing a complex set of electrodes for droplet deflection in a continuous ink jet apparatus so that a plurality of inkjet nozzles are able to print in the same pixel area;
[0013] U.S. Pat. No. 4,384,296 (Torpey) similarly discloses a continuous ink jet print head having a complex arrangement of electrodes about each individual print nozzle for providing multiple print droplets from each individual ink jet nozzle;
[0014] U.S. Pat. No. 6,367,909 (Lean) discloses a continuous ink jet printing apparatus employing an arrangement of counter electrodes within a printing drum for correcting drop placement;
[0015] U.S. Pat. No. 6,517,197 (Hawkins et al.) discloses an apparatus and method for corrective drop steering in the slow scan direction for a continuous ink jet apparatus using a slow-scan droplet steering mechanism that employs a split heater element;
[0016] U.S. Pat. No. 6,079,821 (Chwalek et al.) discloses a continuous ink jet printer that uses actuation of asymmetric heaters to create individual ink droplets from a filament of working fluid and to deflect those ink droplets. A print head includes a pressurized ink source and an asymmetric heater operable to form printed ink droplets whose trajectories can be controlled and non-printed ink droplets; and
[0017] U.S. Pat. No. 6,588,888 (Jeanmaire et al.) discloses a continuous ink jet printer capable of forming droplets of different size and with a droplet deflector system for providing a variable droplet deflection for printing and non-printing droplets.
[0018] While the above cited patents disclose methods for placing droplets precisely within pixel areas of the printed image in both the slow scan and fast scan directions, they require special nozzle designs and/or hardware which adds cost and complexity. Thus despite the cited improvements, technology for precisely controlling drop placement within pixel areas has not been commercialized due to cost and complexity. The capability of cost effectively providing precise control of drop placement in the fast scan direction, as described in commonly assigned copending U.S. application Ser. No. entitled “Continuous Inkjet Printer Having Adjustable Drop Placement” cost effectively affords partial control of droplet placement within pixel areas for continuous inkjet printers but provides only one-dimensional correction of droplet placement thereby allowing only a partial set of solutions for improving image quality.
[0019] Additionally, not all prior art solutions can be applied to a continuous ink jet printing apparatus, particularly for corrections in placement less than the center to center spacing of drops printed in succession and particularly where such an apparatus does not employ electrostatic forces for droplet deflection. Taken by themselves, none of these solutions meet all of the perceived requirements for robustness, sub-pixel placement accuracy, and cost. In particular, there remains significant room for improvement in controlling droplet placement in both orthogonal fast and slow scan directions. Specifically, there are advantages to a solution that would allow, at any position within a pixel area:
[0020] (a) control of the centroid of the printed drop anywhere within its associated pixel area;
[0021] (b) control of the number of droplets used to form a printed drop; and
[0022] (c) control of the spread of each printed drop.
[0023] Thus it can be appreciated that there is a continuing need for cost effective control capabilities for improved dot positioning for each ink jet nozzle in a continuous ink jet print head, particularly where these added capabilities can be used to suppress imaging artifacts.
SUMMARY OF THE INVENTION
[0024] According to a feature of the present invention, a method of printing comprises providing a travel path comprising a direction of motion of a printhead relative to a recording medium, the printhead having a linear array of nozzles positioned at a nonzero angle relative to the travel path; associating a pixel area of the recording medium with each nozzle of the linear array and a time interval during which a drop ejected from each nozzle can impinge the pixel area of the recording medium; dividing the time interval into a plurality of subintervals; grouping some of the plurality of subintervals into blocks; associating one of two labels with each block, the first label defining a printing drop, the second label defining non-printing drops; associating a drop forming pulse between consecutive selected subintervals of each block having the first label; associating a drop forming pulse between each subinterval of each block having the second label; associating a drop forming pulse between other subintervals, the drop forming pulse being between each pair of consecutive blocks; and causing drops to be ejected from each nozzle based on the associated drop forming pulses.
[0025] The current invention discloses a novel solution that provides a low cost means to control drop placement in both slow and fast scan directions. This capability, hitherto unavailable cost effectively, enables compensation for tolerance and alignment faults of individual print head nozzles and for the improvement in image quality even for printers with printheads having no faults. In addition to allowing sub-pixel positional control in both the slow scan direction and the fast scan direction, the ink jet print head apparatus and methods disclosed enable image processing algorithms to be employed for correcting various types of imaging artifacts.
[0026] The present invention provides a subdivided interval for droplet formation, allowing a number of flexible timing arrangements for droplet delivery from each individual inkjet nozzle and enabling a compact means of representing and controlling such timing arrangements.
[0027] It is an advantage of the present invention that it provides positional control for each individual nozzle of a print head upon each printing operation to within sub-pixel dimensions. It is another advantage of the present invention that it provides a method for suppressing imaging artifacts even for printers in which the printhead is not scanned. It is a further advantage of the present invention that it allows randomized print droplet placement to within sub-pixel dimensions.
[0028] These and other objects, features, and advantages of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings wherein there is shown and described an illustrative embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] In the detailed description of the preferred embodiments of the invention presented below, reference is made to the accompanying drawings, in which:
[0030] FIG. 1 a shows a simplified block schematic diagram of one exemplary printing apparatus according to the present invention;
[0031] FIG. 1 b shows a cross-section of a prior art printhead shown as part of FIG. 1 a;
[0032] FIG. 2 is a plane view showing a portion of an array of printed droplets relative to the position and motion of the print head;
[0033] FIG. 3 a is a timing diagram showing subdivision of time interval I into subintervals with an enlargement of the left portion of interval I for clarity;
[0034] FIG. 3 c is a timing diagram showing subdivision of time interval I into subintervals having drop forming pulses between adjacent subintervals resulting in a series of non-printing droplets (filled circles) traveling in air;
[0035] FIG. 3 c is a timing diagram showing an arrangement of the subdivisions of FIG. 3 a, grouped into blocks;
[0036] FIGS. 4 a - 4 b are timing diagrams illustrating different arrangements of droplet formation where two printing droplets form a printed drop on a recording media;
[0037] FIGS. 5 a - 5 b are plan views showing printed drops in pixel areas of a recording medium corresponding to the timing diagrams of FIGS. 4 a - 4 b;
[0038] FIG. 6 is a plane view showing one arrangement for tilting the print head with respect to the fast scan direction;
[0039] FIGS. 7 a - g are timing diagrams illustrating different arrangements of droplet formation where two printing droplets are formed having different volumes;
[0040] FIGS. 8 a - 8 g are plan views showing printed drops on pixel areas of a recording medium corresponding to the timing diagrams of FIGS. 7 a - 7 d, with the print head tilted as in FIG. 6 ;
[0041] FIG. 9 is a plan view showing a portion of an array of printed drops relative to the position and motion of the print head; two adjacent rows of printed drops inadvertently having a greater than average spacing in the slow scan direction;
[0042] FIG. 10 is a plan view showing a portion of the array of printed drops as in FIG. 9 relative to the position and motion of the print head in which the positions of the printed drops are controlled so as to make the printed drops uniformly spaced apart;
[0043] FIG. 11 is a plan view showing a portion of an array of printed drops relative to the position and motion of the print head; the printed drops inadvertently being misplaced in both the slow and fast scan directions;
[0044] FIG. 12 is a plan view showing a portion of the array of printed drop as in FIG. 11 relative to the position and motion of the print head in which the positions of the printed drops are controlled so as to make the printed drops uniformly spaced apart;
[0045] FIG. 13 is a plan view showing a portion of an array of printed droplets; the printed drops inadvertently being misplaced in both the slow and fast scan directions. Additionally, one row of printed drops is irregularly sized;
[0046] FIG. 14 is a plan view showing a portion of the array of printed droplets as in FIG. 13 now having a randomized arrangement using the method of the present invention;
[0047] FIG. 15 is a plan view showing side-by-side portions of an array of printed droplets uniformly spaced within pixel areas printed to form a portion of text; and
[0048] FIG. 16 is a plan view showing side-by-side portions of the array of printed droplets of FIG. 15 but with the position of drops deliberately altered to increase image quality.
DETAILED DESCRIPTION OF THE INVENTION
[0049] The present description is directed in particular to elements forming part of, or cooperating more directly with, apparatus in accordance with the invention. It is to be understood that elements not specifically shown or described may take various forms well known to those skilled in the art.
[0050] Referring to FIG. 1 a - 1 b, there is shown an imaging apparatus 10 capable of controlling the trajectory of fluid droplets according to the present invention. Imaging apparatus 10 accepts image data from an image source 50 and processes this data for a print head 16 in an image processor 60 . Image processor 60 , typically a Raster Image Processor (RIP) or other type of processor, converts the image data to a pixel-mapped page image for printing. During printing operation, a recording medium 18 is moved relative to print head 16 by means of a plurality of transport rollers 100 , which are electronically controlled by a transport control system 110 . A logic controller 120 provides control signals for cooperation of transport control system 110 with an ink pressure regulator 26 . Droplet controller 90 provides the drive signals for ejecting individual ink droplets from print head 16 to recording medium 18 according to the image data obtained from image memory 80 . Image data may include raw image data, additional image data generated from image processing algorithms to improve the quality of printed images, and data for drop placement corrections, which can be generated from many sources, for example, from measurements of the steering errors of each nozzle 21 in printhead 16 , as is well known to one skilled in the art of printhead characterization and image processing. Image memory 80 can therefore be viewed as a general source of data for drop ejection, such as the desired volume of ink drops to be printed, the exact location of printed drops, and shape of printed drops, as will we described.
[0051] Ink pressure regulator 26 , if present, regulates pressure in an ink reservoir 28 that is connected to print head 16 by means of a conduit 150 . It may be appreciated that different mechanical configurations for receiver transport control may be used. For example, in the case of page-width print heads, it is convenient to move recording medium 18 past a stationary print head 16 . On the other hand, in the case of scanning-type printing systems, it is more convenient to move print head 16 along one axis (i.e., a sub-scanning direction usually referred to as the fast scan direction) and recording medium 18 along an orthogonal axis (i.e., a main scanning direction usually referred to as the slow scan direction), in relative raster motion.
[0052] For an understanding of the method of the present invention, it is important to observe that there is a close relationship between the timing of droplet formation and release at print head 16 ( FIGS. 1 a, 1 b ) and the positional placement of that droplet to form a printed drop 32 ( FIG. 2 ) on recording medium 18 . This timing and related factors such as the volume of printing droplet 38 ( FIG. 1 b ), deflective forces acting upon printing droplet 38 when it is formed and during its flight time, speed of printing droplet 38 , and distance between print head 16 and recording medium 18 all play a part in effecting the desired positioning of printing droplet 38 onto recording medium 18 . The basic computations used for calculating the effects of each of these factors are relatively straightforward and are well known to those skilled in the inkjet printing arts.
[0053] It is also important to recognize that there is a close relationship between the signals provided to each nozzle of the printhead, for example signals in the form of voltage pulses carried on one or more wires connecting an image data source to the printhead or signals in the form of optical pulses carried by a fiber optic cable connecting the image data source to the printhead, and the timing of droplet formation and release at print head 16 . The signals are typically represented as pulses in a timing diagram, as described later, and the timing diagram for signals arriving at a particular nozzle is thus closely related to the spatial pattern of droplets ejected from the nozzle and thus to the positional placement of the droplets on the recording medium.
[0054] Referring to FIG. 2 , there is shown a plane view of a small number of printed drops 32 printed by print head 16 within pixel areas 44 on recording medium 18 . Ideally, in the example of FIG. 2 , each printed drop 32 is centered within its corresponding pixel area 44 . However, as is represented in FIG. 2 , not all printed drops 32 in any sampling meet this ideal condition, due to manufacturing imperfections, for example. Of particular interest with respect to the present invention is printed drop 32 positioning with respect to fast scan direction F of print head 16 , slow scan direction S, and the directions of a deflecting air flow A (U.S. patent application Publication No. 2003/0202054).
[0055] As is described in the above-cited disclosures of '595 Anagnostopoulos et al. and '362 Jeanmaire patents, printhead 16 provides a continuous stream of ink droplets. The continuous flow ink jet printer directs printing droplets to the surface of recording medium 18 and deflects non-printing droplets to a catcher, gutter, or similar device using the deflecting air flow which flows in the direction A. The apparatus and method of the present invention uses the same basic droplet formation and deflection methods of these earlier patents, and also provides improved droplet timing techniques and improved techniques for quantifying image data in order to position and shape droplets with in pixel areas on a recording medium.
[0056] Referring now to FIG. 3 a, there is shown a timing diagram corresponding to a time interval I which has been divided into a plurality of subintervals 34 , shown of equal duration in FIG. 3 a and in the enlargement of FIG. 3 a included for clarity. During a particular time interval I, drop forming pulses 42 (or pulses 42 ) can be provided between adjacent subintervals 34 . Such drop forming pulses are represented schematically in FIG. 3 b, which illustrates the case of drop forming pulses 42 placed between all adjacent subintervals. In FIG. 3 a and 3 b and in subsequently shown timing diagrams, time increases left to right. Certain patterns of drop forming pulses can cause printing drops to form at particular nozzles on printhead 16 of FIG. 1 a - 1 b, as a result of the drop forming pulses being sent to printhead 16 . Other patterns of drop forming pulses can cause non-printing drops to form at nozzles on printhead 16 . Drop forming pulses 42 are provided by droplet controller 90 of FIG. 1 a and are typically voltage pulses sent to printhead 16 through electrical connectors, as is well known in the art of signal transmission. However, other types of pulses, such as optical pulses, may also be sent to printhead 16 , to cause printing and non-printing droplets to be formed at particular nozzles, as is well known in inkjet printing. Once formed, printing drops travel through the air to a recording medium and later impinge on a particular pixel area of the recording medium which is thereby associated with interval I.
[0057] FIG. 3 b shows the case in which drop forming pulses 42 are placed between all adjacent subintervals in time interval I, which results in the formation of a series of non-printing droplets 40 , represented by small filled circles in FIG. 3 b, such non-printing droplets being ejected from a particular nozzle on printhead 16 . Each non-printing droplet 40 in FIG. 3 b can be said to have been produced by drop forming pulses at the beginning and end of the particular subinterval 34 shown above the non-printing droplet 40 , the drop forming pulse at the beginning of the subinterval being a leading pulse for the subinterval 34 and a the drop forming pulse at the end of the subinterval 34 being a trailing pulse for subinterval 34 . As described in U.S. Pat. Nos. 6,491,362 and 6,079,821, the non-printing droplet is formed some time after the leading and trailing pulses have been transmitted to printhead 16 . Thus the small solid dots shown below the timing diagram of pulses in FIG. 3 c are drawn to represent schematically the correspondingly formed ink droplets ejected from a particular nozzle and later moving as a stream of drops through the air.
[0058] Printing droplets 38 and non-printing droplets 40 are formed as a result of drop forming pulses acting on the fluid column ejected from the printhead, as disclosed in the above-referenced '821 Chwalek et al. and '197 Hawkins et al. patents describing the formation of droplets at print head. In those cases, the drop forming pulses are typically voltage pulses which produce heat pulses at the printhead nozzles, thereby forming droplets.
[0059] FIG. 3 c illustrates the way imaging data from image memory 80 ( FIG. 1 ) containing information on a printed drop desired to be printed on a particular pixel area 44 is used by droplet controller 90 ( FIG. 1 ) to send patterns of drop forming pulses to printhead 16 , whereupon any printing droplets once formed will travel through the air and impinge on a pixel area 44 corresponding to interval I on recording medium 18 . Of course printing an image on a portion of recording medium 18 comprising many pixel areas requires many repetitions of this process over many time intervals and many nozzles, as is well known in the art of inkjet printing. Referring to FIG. 3 c, there is represented a time interval I corresponding to the time available for providing pulses for forming a printed drop 32 comprising one or more printing droplets 38 ( FIG. 2 ) ejected from a particular nozzle of printhead 16 in response to patterns of drop forming pulses represented by vertical marks in interval I. Subintervals 34 in interval I are grouped into a plurality of blocks 36 . In this particular case, each block 36 comprises five subintervals 34 . For this example, then, interval I has a total of 40 subintervals 34 , grouped in eight blocks 36 . As is shown in FIG. 3 c, each block 36 contains four drop forming pulses 42 and there is a single drop forming pulse labeled 43 between each block 36 . The function of drop forming pulses labeled 43 lying between blocks is described subsequently. In the case shown in FIG. 3 c and all cases subsequently discussed, drop forming pulses 42 within blocks 36 and drop forming pulses 43 between blocks 36 occur between adjacent subintervals 34 . Typically, drop forming pulses 42 and 43 are the same, although this is not required, except for their location within or between blocks 36 . For example, it is within the scope of the present invention that pulses 43 are of higher voltage than pulses 42 , in order to more perfectly form printing drops.
[0060] It is to be understood that although FIG. 3 a and subsequent similar figures showing an interval I show blocks 36 beginning and ending within a subinterval 34 for clarity, it is also within the scope of the present invention that the time between the end of a block and the end of the last subinterval contained at least partially within the block can be arbitrarily small. Likewise, although the time between the end of one subinterval 34 and the beginning of the next is shown for clarity in FIG. 3 a and 3 c as a substantial fraction of the subinterval, it can be arbitrarily small. Similarly, the time between blocks is shown for clarity to be about the same as the duration of a subinterval but can in fact be arbitrarily small.
[0061] The grouping of subintervals 34 into blocks 36 is employed in the present invention to efficiently use image data to produce desired drop forming pulse arrangements in interval I which can cause one or more printing droplets 38 to be placed within a corresponding pixel area 44 , corresponding, for example, to the a pixel of information, a plurality of which generally comprise digital images.
[0062] In FIG. 3 c, the drop forming pulses 42 are present between all subintervals in all blocks and drop forming pulses 43 are present between all blocks. In this case, printhead 16 , in response to drop forming pulses, typically voltage pulses carried by connecting wires, produces a continuous series of non-printing droplets, as described in the above-referenced '821 Chwalek et al. and '197 Hawkins et al. patents describing the formation of droplets at print head.
[0063] Referring now to FIG. 4 a, there is shown a timing diagram with a more complex droplet arrangement in interval I. This case differs from that of FIG. 3 c in that the first two blocks 36 contain no drop forming pulses 42 between subintervals lying entirely within each block. Here, two printing droplets 38 are formed early during interval I, followed by a succession of non-printing droplets 40 , the mechanism of formation of the printing drops being described in the above-referenced '821 Chwalek et al. The two printing droplets 38 are said to form a printed drop 32 in the associate pixel area 44 .
[0064] As the annotation of FIG. 4 a indicates, in accordance with the present invention blocks 36 that form printing droplets 38 are represented as a binary “1.” Blocks 36 containing non-printing droplets 40 are represented as binary “0.” Thus, the data string “11000000,” a single 8-bit byte of data, can be used to represent the droplet arrangement of FIG. 4 a. Referring to the corresponding printed drop placement diagram of FIG. 5 a, there is shown the position of printed drop 32 within pixel area 44 for the droplet arrangement of FIG. 4 a, comprising two printing droplets 38 . When printed, printing droplets 38 tend to coalesce and form a single printed drop 32 having a center position or centroid of ink density shown as C in FIG. 5 a, on recording medium 18 , as is well known in the art of inkjet printing. Centroid C on recording medium 18 measures the average spatial location of the deposited ink. The centroid of the printed ink drops can be defined as that location at which the density of deposited ink weighted by its distance from the centroid is equal in all directions from C. Likewise, in terms of the timing diagram of FIG. 4 a, a centroid for the pulse sequence for forming printing drops in time can be said to correspond to the point in time midway between the two blocks 36 labeled “1” of interval I, that is the point in time midway between the time at which the first and second printing droplets are formed. Similarly, in terms of the drops shown as filled circles in FIG. 4 a, corresponding to printing droplets 38 traveling along a trajectory through the air, a centroid C of the traveling printing drops can be said to be the spatial location midway between the printing droplets 38 as they travel through the air; or, in general, as the location at which the density of ink weighted by its distance from the centroid is equal along both directions of the droplet trajectories. Other related definitions of a centroid are possible, as can be appreciated by one skilled in the art of inkjet printing; but in general the concept of a centroid is useful in discussing the dependence of the location of drops printed on a recording medium on the sequence of drop forming pulses. As can be appreciated by one skilled in the art of ink droplet printing, knowledge of the centroid of printing drops, the velocity of the drops, the motion of the recording medium, and the way the ink and media interact allows calculation of the spatial centroid of ink density on the recording medium.
[0065] In the arrangement of FIG. 4 a, drop forming pulses 43 act as leading and trailing drop forming pulses for printing droplets 38 , indicated schematically by the solid dots in FIG. 4 a. In other words, printing droplets 38 were formed as a result of those drop forming pulses acting on the fluid column ejected from the printhead, as disclosed in the above-referenced '821 Chwalek et al. In FIG. 5 a, spatial centroid C is dependent upon the timing centroid C of FIG. 4 a, allowing the position of spatial centroid C to be adjusted by manipulating this timing arrangement for forming printing droplets 38 . Spatial centroids C of printed drops 32 can thereby be flexibly and accurately moved in the fast scan direction F of FIG. 2 as described below.
[0066] For example, FIG. 4 b and its corresponding printed drop placement diagram 5 b show an alternate arrangement of two printing droplets 38 within interval I and show how this timing impacts their relative placement in forming printed drop 32 . As with FIGS. 4 a and 5 a, centroid C is also indicated. Binary data strings differ between these sequences, as shown. Spatial centroid C of the printed drops 32 is seen to be moved in its associated pixel area in the fast scan direction F in FIG. 5 b compared to its position in FIG. 5 a, in accordance with the binary representation of 1's and 0's in FIGS. 4 a - 4 b, due to the fact that the blocks 36 corresponding to printing droplets 38 occur at different times and to the fact that the receiving medium moves relative to the print head in direction F. A more detailed discussion of controlling the positioning of the centroid of printed drops in accordance with timing diagrams similar to FIGS. 4 a - 4 b is given in copending U.S. application Ser. No. ______ the teachings of which are incorporated herein. Alteration of the sequence of drop forming pulses does not change the position of the centroid of printed drops in the direction perpendicular to the fast scan direction, which is generally the slow scan direction S shown in FIG. 5 a and 5 b.
[0067] As discussed in copending U.S. application Ser. No. ______, the position of the centroid of printed drops within pixel areas may also be controlled in the fast scan direction by providing that the printing droplets are differently sized, and the teachings of this technique are incorporated in the present application. Alteration of the sizes of printing drops does not change the position of the centroid of printed drops in the direction perpendicular to the fast scan direction, i.e. in the slow scan direction S shown in copending U.S. application Ser. No. ______ because the direction of airflow A is aligned with the fast scan direction F. Differently sized drops are deflected by different amounts in the direction A by the airflow.
[0068] We next describe how the present invention allows control of the position of printed drops not only in the fast scan direction F but also in the direction perpendicular to F, that is in the slow scan direction S, thus allowing printed drops to be positioned anywhere within their respective pixel areas. Referring to FIG. 6 , there is shown a plan view of a small number of printed drops 32 printed by print head 16 (shown in phantom lines) within pixel areas 44 on recording medium 18 , the printhead being oriented in accordance with the present invention a an angle with respect to the fast scan direction F. Each ink jet nozzle of print head 16 prints a row 56 of printed drops 32 . Ideally, each printed drop 32 is centered within its corresponding pixel area 44 . Of particular interest with respect to the present invention is the positioning of printed drops 32 in two directions within corresponding pixel areas 44 , the fast scan direction F and the slow scan direction S in FIG. 6 . The fast scan direction F is the direction of scanning of print head 16 . As is described above and in commonly assigned copending U.S. application Ser. No. ______, positioning relative to fast scan direction F is a function of the timing of printing droplet release and scanning speed. The slow scan direction S is in the direction of the line of ink jet nozzles on print head 16 . In accordance with the present invention, the continuous inkjet printhead is angled with respect to the fast scan direction as shown in FIG. 6 , preferably by an amount of about 45 degrees. When the head is angled such that the direction of airflow A is no longer in the fast scan direction F, the timing methods discussed above allow printed drop 32 positioning in both the fast and slow scan directions. It should be noted that an additional effect, related to the current invention, of adjustment of the angle of print head 16 relative to fast scan direction F is that higher printing resolution is provided in the slow scan direction, since the nozzle to nozzle distance of print head 16 in the slow scan direction is decreased by a factor of the cosine of the angle of head rotation, as is known in the art of inkjet printing.
[0069] Referring to FIG. 6 , the direction of deflecting air flow A for angled print head 16 is no longer in the fast scan direction. Angling print head 16 relative to fast scan direction F, as shown in FIG. 6 , and also changing the volume of printing droplets 38 , as shown in FIGS. 7 a - 7 d, are now combined in accordance with the present invention to provide further positioning options for printing droplets 38 within their associated pixel areas, specifically to provide for altering the position of the centroid of printed drops with pixel areas in both the fast and slow scan directions. Referring now to the timing diagrams of FIGS. 7 a - 7 d and the corresponding spatial position diagrams of FIGS. 8 a - 8 d, the relative effects of orienting print head 16 at an angle to the fast scan direction while altering the sequences of drop forming pulses are illustrated. In a manner similar to the pulse timing sequences discussed in association with FIGS. 9 a - 9 d and FIGS. 10 a - 10 d of copending U.S. application Ser. No. ______, the timing diagrams of FIGS. 7 a - 7 d generate printing droplets 38 having different volumes due to the fact that for certain of the blocks 36 , a specific number of consecutive subintervals have no drop forming pulses 42 between them. Specifically, in the cases corresponding to FIGS. 7 a - 7 d, there are 5, 6, 7 and 8 subintervals respectively have no drop forming pulses between them. Possible representations of these sequences are indicated as “00044,” “00033,” “00022,” and “00011” above the blocks. Other mathematical ways of representing the pulse sequences are of course possible and within the intent of the present invention, including representations using data compression. Deflecting air flow A at print head 16 ( FIG. 6 ) has a different impact on the relative trajectories of these printing droplets 38 , depending on their volumes, as described by the Jeanmaire et al. '566 patent. In particular, printing droplets 38 of a larger volume, for example those formed by the pulse sequences of FIG. 7 d, are deflected less in direction A of FIG. 6 in comparison with printing droplets 38 of smaller volumes, for example those formed by the pulse sequences of FIG. 7 a, and thereby printed drops 32 are altered in their positions within their associated pixel areas in the direction A, which is substantially orthogonal to fast scan direction F. It should be noted that in FIGS. 7 a - 7 c , the printing drops formed during a specific number of consecutive subintervals having no pulses could equally well have been formed at the end of the associated block, rather than at the beginning, since the printing drops are formed whenever a sufficient number of consecutive subintervals contain no pulses.
[0070] It is important to note that orienting print head 16 at an angle to the fast scan direction does not change the direction of alteration of placement of printed drops within their associated pixel areas when the alteration is due to timing of the drop forming rather than due to changes in the volumes of printing drops. The effects of controlling the timing of the formation of printing drops, for example as illustrated by the difference between FIG. 4 a and 4 b, still controls the position of the printed drops within their associated pixel areas only in the fast scan direction, since the direction of scanning of each nozzle with respect to the recording medium is unchanged and since the change in direction of airflow A, while affecting all drops, does not affect them based on the time of their formation. By way of illustration, the effect of advanced timing, that is the formation of printing drops at an earlier time rather than at a later time, is shown for the angled printhead in the comparison of FIGS. 8 d and 8 e; the position of the printed drop being moved in the direction of page travel P, substantially in the fast scan direction. Thus, in accordance with the present invention, by controlling the timing of the formation of printing droplets as previously described as well as by controlling the volume of printing droplets, the location of printed drops 32 in their associated pixel areas may be arbitrarily controlled in both fast and slow scan directions on the recording media.
[0071] Also by way of illustration, as shown by a comparison of the timing diagrams of FIG. 7 a with those of FIG. 7 f and the print plan views of FIG. 8 a with those of FIG. 8 f, the elongation of printed drops 38 printed onto recording medium 18 can be changed so that not only the centroid of the printed drop can be caused to lie at any location within its associated pixel area but so that the printed drop may be elongated in the fast scan direction.
[0072] Again by way of illustration, as shown by a comparison of the timing diagrams of FIG. 7 a with those of FIG. 7 g and the print plan views of FIG. 8 a with those of FIG. 8 g, the printed drop 38 printed onto recording medium 18 can be changed so the printed drop is elongated in an arbitrary direction. As shown in FIG. 8 g, the elongated drop is slightly pear shaped due to the use of two printing drops of different sizes produced by the pulse sequence of FIG. 7 g. In some cases, this effect may be beneficial in rendering images; in other cases, the effect is not beneficial and may be compensated by standard diffusion algorithms which maintain the correct ink density averaged over several pixels, as is well known in the art of image processing. With reference to FIG. 1 , the timing control exercised for providing the sequences shown in FIGS. 7 a - 7 d can be provided by image processor 60 and droplet controller 90 using data stored in memory 80 .
[0073] Thus in general, because the present invention allows positioning of the printing drops 38 comprising printed drops 32 in both the slow and fast scan directions within pixel areas 44 , the exemplary sequence FIGS. 7 a - 7 g when combined with an altered print head 16 angle is particularly advantaged. This advantage may be exploited in various ways to improve image quality. As noted previously, this ability may be used to correct placement errors of printed drops caused by nozzles that produce angular deviations, for example with respect to the printhead surface, in the direction of ejected drops, caused for example by manufacturing defects or debris in or near the nozzle. Alternatively, even for printheads in which nozzles eject drops with no angular deviations, it may be advantageous for image quality to deliberately offset the positions of certain printed drops within their associated pixel areas in order that the pattern of deposited ink more closely resemble the intended image pattern. Thereby the apparent resolution of the printer can be increased, in an imagewise fashion if so desired. The information on what offsets are desired for specific pixels could for example be calculated from very high resolution scans of the image to be printed using the knowledge of the actual number of pixels which will constitute the final printed image, this information being stored in image memory 80 of FIG. 1 a, as can be appreciated by one skilled in the art of halftone image processing.
[0074] The ability to adjust the position of printed drops in both the fast and slow scan directions in accordance with the present invention is shown in FIGS. 9 and 10 to provide a method for correcting for differences in nozzle to nozzle performance by changing only the algorithms that image processor 60 ( FIG. 1 a ) implements to send data to droplet controller 90 , as shown in FIGS. 9 and 10 , which illustrate correction of a banding artifact using the methods of the current invention.
[0075] In FIG. 9 , rows of printed drops in their associated pixel areas (each member of the grid of rectangles in FIG. 9 ) are shown in relation to the angled printed 16 which is moving relative to recording medium 18 in the direction F, to the right in FIG. 9 . The airflow which separates printing and non-printing droplets is shown to be in the direction A in FIG. 9 . It can be appreciated that the airflow could equally lie in the direction opposite A in FIG. 9 , depending on which side of the row of nozzles the gutter of printhead 16 is located. It is also understood that the vertical distance between pixel areas relative to the spacing between nozzles in printhead 16 is given by the cosine of the angle between A and F, as has been described. The rows 56 marked with G indicate rows in which the printed drops lies higher (top dotted line) or lower (bottom dotted line) than would regularly spaced drops. In this example, the spacing of these rows (G) is larger than the vertical distance between pixel areas, here assumed to be square, due, for example, to defects in the manufacture of the nozzles printing printed drops in the rows demarcated G. In this example, the desired pattern of printed drops comprises drops of a constant size, each printed in the center of its respective pixel area. The presence of gap G produces a readily visible artifact, as can be appreciated by one skilled in the art of image processing.
[0076] In FIG. 10 , the methods in accordance with the present invention have been employed to provide substantial correction to the artifacts of FIG. 9 . In particular, altered rows 56 a and 56 b now comprise printed drops whose centroids lie in the center of their associated pixel areas. This has been accomplished, as can be appreciated from the discussion of FIGS. 7 and 8 , by, in the case of altered row 56 a, by decreasing the size of printing droplets 32 in altered rows 56 a, causing displacement of the centroid of printed drops 32 in altered rows 56 a in the direction A of FIGS. 9 and 10 due to the increased deflection of smaller drops in the direction of airflow A, as discussed in association with FIGS. 7 a - 7 d, while simultaneously altering the timing of the release of the printed drops so as to occur at earlier times, as discussed in association with FIG. 7 e. In the case of altered row 56 b, the change in the position of the centroid of printing drops 32 is accomplished by increasing the size of printing droplets 32 in altered row 56 b, causing displacement of the centroid of printed drops 32 in altered rows 56 b in the direction opposite A in FIGS. 9 and 10 due to the decreased deflection of larger drops in the direction of airflow A, as discussed in association with FIGS. 7 a - 7 d, while simultaneously altering the timing of the release of the printed drops so as to occur at later times, as discussed in association with FIG. 7 f.
[0077] Thus the ability to adjust the position of printed droplets in both the fast and slow scan directions provides a method for correcting for differences in nozzle to nozzle performance using a calibration procedure following these basic steps for each nozzle:
[0078] (i) releasing printing drop 38 onto a calibration print with a standard, predetermined timing;
[0079] (ii) measuring the error between the ideal and actual positioning of printing drops 38 for this nozzle, based on this standard timing; and,
[0080] (iii) calculating and storing a calibration correction factor, for example in droplet controller 90 , that adjusts nozzle timing for each nozzle to correct for any measured error.
[0081] Then, when printing using this nozzle, the calculated calibration correction factor is applied accordingly for the printing of all images. Such a calibration correction factor would typically be stored in a Look-Up Table, here assumed by way of example to reside in image processor 60 ( FIG. 1 a ), as is familiar to those skilled in the imaging arts. Following the calibration using the calibration procedure above, the image quality of images other than the calibration print, for example images containing text or photoquality pictures, could be improved by including, for each printed drop, the steps of
[0082] (iv) calculating, for each pixel area in that image, an additional image dependent drop position correction factor, for example by using any of many well known image processing algorithms designed to hide image artifacts in pictures and/or to smooth the edges of printed text,
[0083] (v) using the additional image dependent drop position correction factors to additionally adjust droplet timing for droplets printed at each pixel area in order that corrections be made not only to correct for misdirection in either the fast or slow scan directions or timing variations of individual nozzles but also to improve image quality by incorporating image processing algorithms to adjust the position of printed droplets in either the fast or slow scan directions.
[0084] It is important to recognize that the use of droplets of slightly varying sizes to adjust drop positions may result in unintended variations of ink density unless measures are taken to determine any lack or excess of ink laydown and compensate for such lack or excess. As is well known in the art of image processing, algorithms such as dithering enable correction in ink laydown over a group or groups of pixels, and the application of such algorithms is within the spirit and intent of the present invention. For example, the printed drops 32 a and 32 b in FIG. 10 are shown to have respectively an increased and decreased size, due to incorporation of one more and one less, respectively, printing drop in the respective printed drops. In these cases, the timing of the release of printing drops is respectively advanced and retarded so as to position the printed drop to be centered in the associated pixel in the fast scan direction. In this and other examples discussed, it is assumed that for a nozzle without manufacturing defects, that is a nozzle that does not misplace drops, the center of the associated pixel area for the ejection of a drop is chosen to correspond to a time of drop release approximately in the middle of interval I in FIGS. 3 c, that is in between the extremes shown respectively by FIGS. 4 a and 4 b, corresponding for example to a binary representation designated (000110000) and to have a size corresponding to a value lying between the extremes of FIGS. 7 a and 7 d, for example corresponding to FIGS. 7 b or 7 c, in order that there be a range of adjustment available for advancing or retarding the timing of release and for increasing or decreasing the drop size to alter placement of the centroid of the printed drop in any direction within its pixel area.
[0085] In FIG. 11 , rows of printed drops in their associated pixel areas are shown as in FIG. 9 but for the case of multiple nozzles being misdirected. In this example, the desired pattern of printed comprises drops of a constant size, each printed in the center of its respective pixel area. The presence of gap G as in FIG. 9 and of a periodic misplacement of drops in the direction F in each column of pixel areas produces readily visible artifacts, as can be appreciated by one skilled in the art of image processing. The misplacement of drops in the direction F could arise from either steering inaccuracies associated with the nozzles or from variations in the delay between the time a drop ejection signal is sent to a nozzle and the time drops are ejected.
[0086] In FIG. 12 , the methods in accordance with the present invention have been employed to provide substantial correction to the artifacts of FIG. 11 . In particular, the printed drops all have centroids lying in the center of their associated pixel areas. This has been accomplished, as can be appreciated from the discussion of FIGS. 7 and 8 , by, in the case of the nozzle printing in the first row from the top of FIG. 11 , by delaying the time of ejection of printing drops 38 . This could be accomplished, by way of example, by changing a binary representation designated (000110000) to one designated (000011000) for ejecting printing drops printed in the first row. Similarly, in the case of the nozzle printing in the second row from the top of FIG. 11 , the time of ejection of printing drops 38 is shown to be advanced in FIG. 12 , which could be accomplished, by way of example, by changing and from a binary representation designated (000110000) to one designated (001100000) in the second row. In the case of the third row, the size of the printing drops have been increased and the time of ejection of printing drops has been delayed, etc. Since, in the case of the third row, the printed drops are larger, it may be desirable to compensate this effect by deliberately decreasing the size of printed drops in neighboring regions, either periodically or randomly, as is well known in the art of image processing. This is readily accomplished in accordance with the present invention by reducing the number of printing drops which form a printed drop. Thus the ability to adjust the position of printed droplets in both the fast and slow scan directions provides a method for correcting for differences in nozzle to nozzle performance using a calibration procedure following the basic steps discussed previously.
[0087] In FIG. 13 , rows of printed drops in their associated pixel areas are shown as in FIG. 9 but for the case of a subset of nozzles being misdirected and one nozzle (that printing drops in the third row from the to of FIG. 13 ) that exceed the expected drop volume. In this example, the desired pattern of printed comprises drops of a constant size, each printed in the center of its respective pixel area. The combination of misdirected nozzles and drop volume variation produces readily visible artifact, as can be appreciated by one skilled in the art of image processing. The misplacement of the large drops in the third row could arise from either steering inaccuracies associated with the nozzles or from variations in the delay between the time a drop ejection signal is sent to a nozzle and the time drops are ejected.
[0088] In FIG. 14 , the methods in accordance with the present invention have been employed to hide at least a portion of the artifacts of FIG. 12 . In particular, the printed drops have been altered randomly as to both the value of their timing (either retardation or advancement) and their volume (either increased or decreased volume). This can be accomplished, as can be appreciated from the discussion of FIGS. 7 and 8 , by randomly delaying or advancing the time of ejection of printing drops 38 and by randomly incrementing or decrementing the volume size. As is well known in the art of image processing, while the resulting image is not exactly the desired pattern, the presence of random noise reduces the objectionablility of the artifacts. Significantly, using the method of the present invention, the capability for precision placement of printed drop 32 is available at each individual nozzle of print head 16 and with the formation of each individual printed drop 32 from each nozzle. This means that, unlike previous print head designs, print head 16 of the present invention can perform dithering or add random spatial noise to its printing pattern. It is of course understood that algorithms other that those introducing random choices for timing and volume “noise” may be used to further decrease the appearance of objectionable artifacts, as is well known in the art of image processing, the precise nature of which is not the topic of the current invention. For example, in FIG. 14 the first printed drop in the third row from the top is substantially larger than the desired printed drop size, as a result of a random choice for is volume, and may itself represent a visible artifact. It is within the intended scope and purpose of the present invention that further algorithms, not of a random nature, might have alternatively been applied to recognize such potential image artifacts and mitigate them, for example by reducing the number of printing drops comprising printed drop 32 in FIG. 14 , particularly, as is well known in the art of error diffusion, in which the probability of such an alteration preserves to a maximum extent the average desired volume of printed drops in the neighborhood of printed drop 32 a.
[0089] Thus the ability to adjust the position of printed droplets in both the fast and slow scan directions again is shown to provide a method for correcting for differences in nozzle to nozzle performance. A calibration procedure following the basic steps discussed previously in combination with image processing algorithms stored and executed in image processor 60 ( FIG. 1 a ) thus enables a simple and cost effective means of improving image quality. Alteration or improvement of such means is within the scope of the present invention, particularly to be noted is the opportunity for such improvements enabled by eh present invention that require only changes in the programming of image processor 60 .
[0090] In FIG. 15 , rows of printed drops in their associated pixel areas are shown as in FIG. 9 but for the case of printing of text or other graphic figure. In this example, as opposed to the previously discussed preferred embodiments, it is assumed that no nozzles are misdirected and that there are no drop volume variations amongst nozzles. However, the portion of the text as render in FIG. 15 is not ideal, because of limitations of resolution and drop position, as is well known in the graphic reproduction arts. The dotted line in FIG. 15 traces the desired figure line of the centroid of printed drops for the portion of text desired to be printed. The departure of the drop centers from the dotted line represents an image artifact from the point of view of graphic printing.
[0091] In FIG. 16 , the methods in accordance with the present invention have been employed to hide at least a portion of the artifacts of FIG. 15 . In particular, the printed drops have been altered in the position of their centroid locations so that the centroid positions more closely follow the desired figure line. Thereby, the quality of the printed text is improved. The information as to how the centroid locations are to be altered can be calculated by algorithms incorporated, for example, in the function of image processor 60 , FIG. 1 a or stored in memory 80 .
[0092] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the scope of the invention as described above, and as noted in the appended claims, by a person of ordinary skill in the art without departing from the scope of the invention. For example, while the examples shown in FIGS. 9 a - 9 c subdivide printed drop interval I into 40 subintervals, some other arrangement of subintervals could be used. Other methods of ink stream deflection could alternately be employed, including the use of electrostatic force. It should be noted that while a diagonal angular orientation of about 45 degrees of print head 16 relative to fast scan is shown in FIG. 6 , other angles could be used. For example, angles over a range from about 10 degrees to about 80 degrees could be advantaged for rotation of print head 16 relative to fast scan direction F. It can be thus appreciated that the angle of print head 16 relative to fast scan direction F, can be simply changed in order to optimize the principals taught in the present invention, as can the number of intervals I, subintervals 34 , and blocks 36 within interval I. It should also be noted the while the present invention is described in terms of the shaping and positioning of printed drops within their associated pixel areas, it is understood that drops may be positioned on or slightly over the boundaries between pixel areas. It is also within the scope and intent of the present invention that the centers of the pixel areas associated with printing drops ejected from particular nozzles can be defined in a variety of substantially equivalent ways, as can be appreciated by one skilled in printing images. For example, the center of a pixel area might be taken to correspond to the location of a single printing drop of a particular size released at the timing midpoint during interval I in FIG. 3 a.
[0093] Thus, what is provided is an apparatus and method for improved control of printed drop placement on the recording medium in a continuous inkjet printer, allowing a print head to compensate for mechanical and dimensional artifacts by exercising timing and deflection control at each individual print head nozzle.
[0094] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
[0000]
10 . Printer system
14 . Heater control circuits
15 . Substrate
16 . Printhead
17 . Ink gutter
18 . Recording medium
19 . Ink
20 . Medium transport system
21 . Nozzles
22 . Heater
24 . Micro controller
26 . Ink pressure regulator
28 . Reservoir
30 . Ink channel
32 . Printed drop
32 a. Altered printed drop
32 b. Altered printed drop
34 . Subinterval
36 . Block
38 . Printing droplet
40 . Non-printing droplet
42 . Drop forming pulse or pulse
43 . Drop forming pulse or pulse
44 . Pixel areas
48 . Deflection means
50 . Image source
56 . Row
56 a. Altered row
56 b. Altered row
60 . Image processor
80 . Image memory
90 . Droplet controller
100 . Recording medium transport roller
110 . Transport control system
120 . Logic controller
150 . Ink conduit
A. Deflecting air flow C. Centroid I. Printed drop interval F. Fast scan direction S. Slow scan direction T.G. Gap | A method of printing is provided. The method includes providing a travel path comprising a direction of motion of a printhead relative to a recording medium, the printhead having a linear array of nozzles positioned at a nonzero angle relative to the travel path; associating a pixel area of the recording medium with each nozzle of the linear array and a time interval during which a drop ejected from each nozzle can impinge the pixel area of the recording medium; dividing the time interval into a plurality of subintervals; grouping some of the plurality of subintervals into blocks; associating one of two labels with each block, the first label defining a printing drop, the second label defining non-printing drops; associating a drop forming pulse between consecutive selected subintervals of each block having the first label; associating a drop forming pulse between each subinterval of each block having the second label; associating a drop forming pulse between other subintervals, the drop forming pulse being between each pair of consecutive blocks; and causing drops to be ejected from each nozzle based on the associated drop forming pulses. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Application No. 2005-20935, filed Mar. 14, 2005, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] An aspect of the present invention relates to an optical recording device, and, more particularly to a technique capable of reducing a deviation of an Optimum Power Calibration (Optimum Power Calibration) operation and of improving speed.
[0004] 2. Description of the Related Art
[0005] In an optical recording/reproducing device, using an irradiated beam with accurate power to record information on an optical recording medium is important. Due to environments of combinations of all recording media and recording devices and also deviation between devices, such an accurate power may not be provided substantially all the time (e.g., by recording on a disk in advance).
[0006] Thus, in order to find out an optimum optical power for a recording operation, an optical recording/reproducing device generally conducts an OPC (Optimum Power Calibration) operation in a test area of the optical disk inserted therein to detect an optimum optical power (Popt), and uses the detected optimum recording optical power in a recording operation.
[0007] The test area is particularly reserved for recording test patterns. Such a reserved area is, for example, known as a Disk Test Zone or an OPC Test Zone. Such a test area may be configured as one successive region or as a plurality of sub regions.
[0008] That is to say, an optical disk drive system controls a laser power (or, recording power) level required to record data on a corresponding optical disk through a Power Calibration Area (PCA), when conducting a recording mode for a once recordable optical disk such as CD-R and DVD-R. This is called Optimum Power Control (OPC).
[0009] However, though an optimum recording power is obtained via an OPC operation, if an environment for recording is changed by the time an actual recording operation is conducted, producing an accurate recording characteristic may be impossible. For example, the optimum recording power determined by an OPC operation may be changed, and, thus, a Beta (or, an asymmetry) of recorded signals may also be changed to produce inaccurate recording characteristics. This could occur in the following exemplary cases: where a power sensitivity is generated at each position on the optical disk, where a wavelength of LD is shifted due to high temperatures, and a deviation is generated on beam spot due to a disk skew phenomenon, varying thicknesses of disks or a resulting defocus of the beam spot on the disks, and/or where disk and/or optical conditions are changed due to a fact that an actual recording may not be conducted until a long time after the OPC.
[0010] In order to solve these problems, there has been proposed a method for β compensation by repeatedly recording and measuring test data while changing a recording optical power little by little.
[0011] Hereinafter, the recording optical power compensation method of the related art as discussed above is described with reference to FIG. 1 .
[0012] As shown in FIG. 1 , an optical disk is inserted into the apparatus, a recording operation is requested ( 21 ), and an OPC operation is conducted in the Power Calibration Area (PCA) of the optical disk before the recording operation to determine an optimum recording power ( 22 ). That is to say, an optimum optical power corresponding to an optimum beta value given to each MID is detected.
[0013] According to the related art, generally, a test recording is made in a certain area of the optical disk using the optimum recording power detected by the OPC. Then, a Radio Frequency (RF) level of the recording signal in the area is measured to set a target beta.
[0014] The detected recording power is recorded as a user data of the disk ( 24 ). Then, whether a recording medium is a DVD-R ( 26 ) is determined. If the recording medium is determined to be a DVD-R (or a CD-R, where appropriate) in operation 26 , a beta β compensation operation is conducted.
[0015] In order to conduct the β compensation operation, a mode is switched to a read mode, namely a loader is switched into a standby mode ( 30 ), and a finally recorded area is found ( 31 ).
[0016] Based on the RF level measured at the recorded area in operation 31 , a beta β value is calculated through an OPC operation ( 32 ). At this time, the RF level is calculated by measuring Top/Center/Bottom levels.
[0017] In a common OPC (Optical Power Calibration) operation, a controller of the system applies a control signal to an optical drive and simultaneously varies a recording optical power little-by-little based on a target recording optical power (e.g., 8 mW) that is detected from the optical disk. Meanwhile, the optical drive outputs a recording signal for test data with an optical power corresponding to the applied control signal, and an optical pickup records a certain amount of test data in a test area of the PCA.
[0018] If the test data is completely recorded, the system controller controls the optical pickup to read out the read test data in order, and then detects a β value from a regenerated RF signal that is output from an R/F unit.
[0019] In addition, the system controller checks on how many measurements of the detected β value have been conducted (which is set to 5 times in the example of FIG. 1 ) ( 33 ), stores the measured β value in an internal memory if the measurements have been conducted less than 5 times ( 40 ), and calculates an average of the measured β values if the measurements have been conducted over 5 times ( 34 ).
[0020] The average value calculated in operation 34 is compared with the β value (or, the target β value) of the optical disk that is detected in operation 22 ( 35 ). If an absolute value of the difference between the measured β value and the target β value is found to be greater than a predetermined level (or, an allowable range: a), the recording power is decreased as much as 0.1 mW ( 39 ). In contrast, if the absolute value of the difference between the measured β value and the target β value is less than a predetermined level, the recording power is increased as much as 0.1 mW ( 37 ). Then, the β compensation operation is completed ( 38 ).
[0021] If the recording medium is found to not be a DVD-R in operation 26 or after the β compensation operation is conducted, the loader progresses in a standby state until the next recording ( 28 ) operation, and then the process is ended ( 29 ). Otherwise, the process proceeds to operation 24 to record data in a user data area of the disk with the optimum optical power detected in the above operation.
[0022] However, a problem exists in that the detected optimum optical power may generate a jitter due to a serious deviation of the recording optical power (commonly, not smaller than 0.4 mV) after a full DC erasing for the recording optical power the reserved PCA found first by an OPC operation in a non-recorded area of a new disk. Thus, the OPC operation may not be applicable to a Blu-ray set.
[0023] In addition, the Blu-ray set requires a relatively large amount of time to search an area that is required for an OPC operation in comparison to a common optical disk.
[0024] That is to say, referring to FIG. 2 , if a Blu-ray disk is inserted and a recording operation is requested ( 50 ), the system controller searches a Bland area for an OPC operation in an OPC test zone of the Blu-ray disk (hereinafter, referred to as a Physical ADIP (Address in Pre-groove) Address (PAA) area) ( 52 ), before the recording operation. In addition, if a blank area is not found, all of the PAA area is erased using an erase DC power ( 54 ) operation.
[0025] Thereafter, user data is recorded in the PAA area through a power swing operation and an optimum recording optical power is detected by measurement and a Kappa Curve ( 56 ). Then, a recording signal is recorded via an optical driving current corresponding to the optimum recording optical power ( 58 ).
[0026] A common Blu-ray set requires 5 seconds on an average to conduct operation 52 in the above procedure, and about 30 seconds to execute operation s 54 .
[0027] Thus, since at least 5 seconds and up to 35 seconds are required to set the PAA area, an entire recording time may be reduced by decreasing the area searching time.
SUMMARY OF THE INVENTION
[0028] The present invention is designed to solve the above and/or other problems of the related art, and, therefore, an aspect of the present invention provides a method and apparatus capable of reducing a deviation of an optimum recording optical power in a Blu-ray disk and of reducing a recording time.
[0029] In order to accomplish the above and/or other aspects of the invention, the present invention provides a method of setting an optimum recording optical power of a recording medium, which includes setting a test data recording area for measuring the optimum recording optical power of the recording medium; recording the test data after erasing the set recording area with erase power; and detecting the recorded data and then setting the optimal recording optical power.
[0030] Preferably, the test data recording area is set using target address and length to which the test data is to be recorded, and the length is set to 5 tracks.
[0031] The test data may be recorded in front of a middle tract of the set recording area so as to decrease crosstalk.
[0032] The recording medium may be an optical disk, a Blu-ray disk, or a similar type of disk.
[0033] In addition, the setting of the test data recording area preferably includes reading finally recorded address and length; generating a new address by adding the length to the read address; and generating a new length by allocating a predetermined track to the new address.
[0034] The finally recorded address and length may be stored in and then read from a non-volatile memory or a user data area of the recording medium.
[0035] In addition, the method of setting an optimum recording optical power according to the present invention may further include recording data in the recording medium with the set optimum recording optical power so that data may be recorded using the optimum recording optical power.
[0036] In another aspect of the invention, there is also provided an apparatus for setting an optimum recording optical power of a recording medium, which includes an optical drive for outputting an intensity drive signal according to an input signal; an optical pickup for recording signals in the recording medium according to the intensity drive signal of the optical drive and also detecting a recording signal from a recording surface; and a controller for setting an area on which a test data for measuring the optimum recording optical power of the recording medium is to be recorded, controlling the optical drive to record the test data in the set recording area after erasing the set recording area with erase power, and detecting the recorded data to set the optimum recording optical power.
[0037] Preferably, the test data recording area is set using target address and length to which the test data is to be recorded, and the length is set to 5 tracks, and the test data is recorded in front of a middle tract of the set recording area.
[0038] In addition, the recording medium may be an optical disk.
[0039] The controller generates a new address by reading finally recorded address and length and then adding the length to the read address, and at the same time sets the test data recording area by generating a new length by allocating a predetermined track to the new address.
[0040] In addition, the finally recorded address and length are preferably stored in a non-volatile memory or a user data area of the recording medium.
[0041] Additional and/or other aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0043] FIG. 1 is a flowchart illustrating a conventional recording optical power compensation method;
[0044] FIG. 2 is a flowchart illustrating an OPC test zone searching process of a conventional Blu-ray set;
[0045] FIG. 3 shows an optical disk device to which an improved method for reducing deviation and recording time according to an embodiment of the present invention is applied; and
[0046] FIG. 4 is a flowchart illustrating an OPC test zone of a Blu-ray set of according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0047] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0048] FIG. 3 shows an optical disk device to which an improved method to reduce a deviation of an OPC operation and a recording time, according to an embodiment of the present invention, is applied. As shown in FIG. 3 , the optical disk device 100 includes a digital recording signal processor (DSP RECORD) 150 a to add an error correction code (ECC) to input digital data so as to convert the input digital data into a recording format, a channel bit encoder 160 to re-convert the data that is converted into the recording format into a bit stream, an optical drive 170 to output an intensity drive signal according to an input signal, an optical pickup 190 to record signals on an optical disk 110 according to the intensity drive signal and to detect a recording signal from a recording surface, an R/F unit 180 to filter and shape the signal detected by the optical pickup 190 to output the signal as a binary code, a drive unit 120 to drive a spindle motor M that rotates the optical pickup 190 and the optical disk 110 , a servo unit 130 to receive a tracking error signal (TE) and a focus error signal (FE) of the optical pickup 190 and a rotating speed of the optical disk 110 and to control an operation of the drive unit 120 , and a digital regenerated signal processor (DSP REGENERATE) 150 b to restore the binary signal into an original data with its own clock synchronized to the binary signal output from the R/F unit 180 .
[0049] A controller 140 optimally controls a recording optical power via a β value detected from a regenerated RF signal of recorded data and a power increase level that is set for each recording speed in consideration of the characteristic changes of the inserted optical disk 110 or the optical pickup 190 during the recording operation. The controller 140 calculates the β value by measuring Top/Bottom levels of the RF level in the recording area using commonly understood methods.
[0050] In addition, the controller 140 includes a memory 142 that stores a Physical ADIP Addresses (PAA) area and lengths of data finally recorded in the PAA area. Thus, if the optical disk is inserted and a recording operation is requested, the controller 140 reads the PAAs and lengths that are stored in the memory 142 , selects a target PAA and length, and then controls the optical drive 170 to unconditionally erase the selected PAA and length using an Erasing Power.
[0051] Though the controller 140 has been described as including the internal memory 142 , a use of a non-volatile memory such as NVRAM is also possible.
[0052] Hereinafter, a process of searching an OPC test zone in a Blu-ray disc, according to an embodiment of the present invention, is described with reference to FIG. 4 . As shown in FIG. 4 , if an optical disk is inserted and a recording operation is requested ( 210 ), the controller 140 reads the last recorded area stored in the memory 142 so as to prepare to conduct a new OPC operation ( 220 ). That is to say, in operation 220 , the controller 140 reads a PAA area and a length of an area that is stored in the memory 142 at which the last OPC operation was carried out.
[0053] The controller 140 then designates a new PAA area and length, in which a new OPC operation is conducted, in contrast to the PAA area and length read in operation 220 ( 230 ). Generally, the length is set to 5 tracks, and a test data record to actually execute the OPC operation is, according to an embodiment of the invention, recorded in a front of a middle tract of the set length in order to decrease crosstalk that may occur.
[0054] Thereafter, the controller 140 unconditionally erases the area required to conduct the OPC operation by using an erase power with reference to the set PAA area and length ( 240 ). That is to say, the controller 140 operates the optical drive 170 regardless of the fact that the corresponding area may have been used in a recording operation or not. As a result, the optical pickup 190 forcibly erases the corresponding area once. According to the test results, an OPC recording deviation of the same set or the same disks is less than 0.1%, and a recording power was measured in the range of ±5%. Thus, the OPC operation discussed above may be applicable for the Blu-ray set.
[0055] In addition, about 0.5 seconds are taken to forcibly erase the corresponding area. Thus, while the OPC area is set in about 0.5 seconds, the conventional methods required 5 to 35 seconds since approximately 5 seconds were required to search a Bland APP area and approximately 30 seconds were required to forcibly erase all of the PAA areas when there was no Blank PAA area. Thus, the present invention enables a reduction in operating time by at least 4.5 seconds and up to 34.5 seconds.
[0056] Test data is recorded in the erased PM area through a power swing and then an optimum recording optical power is detected using measurement and an application of a Kappa Curve ( 250 ). Then, a recording signal is recorded using an optical drive power corresponding to the detected optimum recording optical power ( 260 ). Operations 250 and 260 are executed to record test data and to search an optimum recording optical power as in the conventional method. As such these operations are not described in detail here.
[0057] In addition, though the finally recorded PM area was described as being stored in a memory, it is also possible that the finally recorded PM is recorded in a user area of the disk and that the relevant data is read in the user area before conducting the OPC operation. Thus, where the data is stored in a non-volatile memory, the data may not be used in another disk device. However, if the data is recorded in the user area as in the above, the data may be used though a disk device is changed, effectively. The controller 140 previously sets target PM area and length and erases data once with an erase power and then records the test data so as to measure an optimum optical power. Since, the process of recording the target PM area and length is well known in the art the process is not described in detail here.
[0058] As is mentioned above, the controller 140 previously sets a PM area to conduct an OPC operation and then erases the area with an erase power in the process of searching for an optimum recording optical power, which may shorten time and reduce power deviation since the same processor is applied.
[0059] According to the method and apparatus to improve deviation of an optimum recording optical power of the present invention, an OPC recording power deviation may be improved and then applied to a Blu-ray set, and a Lead-in time may be reduced by at least 4.5 seconds up to 34.5 seconds, which allows faster recording operation.
[0060] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A method of improving a problem of a deviation of an optimum recording optical power, which is capable of reducing deviation of OPC (Optical Power Calibration) power and shortening a Lead-in time by previously setting an area in which an OPC operation may be conducted and erasing the area with an erase power. | 6 |
BACKGROUND OF THE INVENTION
[0001] A typical reciprocating compressor will have a valve plate with one, or more, suction ports and discharge ports formed therein. Normally the suction and discharge valves will be of the same general type. Each valve would be normally closed and would open due to a pressure differential across the valve in the direction of opening. Since suction valves open into the compression chamber/cylinder they generally do not have valve backers in order to minimize the clearance volume and thus deflection of the valve is not physically limited. When a suction valve opens, the valve tip(s) engage recess(es) in the crankcase after a small amount of opening movement with further opening being due to flexure of the valve away from the valve seat and into the cylinder.
[0002] The resilience of the suction valves and adherence of the valve to the valve seat due to an oil film (“stiction”) resists the opening of the suction valve. The opening movement of the suction valve before the tip(s) engage the recess(es) would only permit a restricted flow into the cylinder. So, the valve tip slams into the recess and flexes into the cylinder for every cycle. The greatest degree of flexure occurs, nominally, at the mid-point of the valve between the tip support and the pin support. Because the valve tips are located near the suction ports and because the valve tips are in a nominal line contact with the crankcase, the valve tips tend to be stressed which can result in valve failure by permitting the valve to be drawn into the cylinder.
SUMMARY OF THE INVENTION
[0003] For multi-port suction valves, each valve tip and the associated tip recess are located along lines extending from the axis of the cylinder through the axis of the associated suction port. This arrangement minimizes the distance between the axis of each suction port and the tip recess and places the load due to flow through the suction ports as close as possible to the cylinder wall tip support thereby minimizing the effects of transverse bending while shortening the span from the pins to the tips. This combination yields the valve with the lowest maximum stress.
[0004] It is an object of this invention to reduce maximum operating stress on suction valves.
[0005] It is another object of this invention to optimize valve tip and valve tip recess locations. These objects, and others as will become apparent hereinafter, are accomplished by the present invention.
[0006] Basically, a valve tip and its associated recess are provided along each line from the center of the cylinder through the center, or axis, of a suction port.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a fuller understanding of the present invention, reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings wherein:
[0008] [0008]FIG. 1 is a cylinder side view of a valve plate showing one of two suction valves in place;
[0009] [0009]FIG. 2 is a sectional view taken along line 2 - 2 of FIG. 1; and
[0010] [0010]FIG. 3 is a view taken along line 3 - 3 of FIG. 2 and with the second suction valve in place.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] In FIGS. 1 and 2, the numeral 30 generally designates a valve plate associated with two cylinders of a reciprocating compressor. Two, or more, suction passages 30 - 1 and 30 - 2 having axes A and B, respectively, and at least one discharge passage 30 - 3 having an axis C are associated with each cylinder. The point D corresponds to the axis of a cylinder. The point E corresponds to the axis of the bore 30 - 4 and pin/bolt 60 holding valve plate 30 , and discharge valve 50 in place when a single bolt 60 is used. If more than one bolt 60 is used, axis E would be at a mid-point of a line going through their centers. Pins 22 are received in bores 30 - 5 and secure suction valve 20 in place. Axis F is the mid-point between the axes of pins 22 and their bores 30 - 5 for each suction valve 20 . The axes A, B, C, D, E and F are illustrated as points or lines, even in the absence of the related structure, because of their relationships relative to the present invention. Referring specifically to FIG. 1, suction passages 30 - 1 and 30 - 2 are symmetrically located relative to a plane defined by axes C, D, E and F. It will be noted that the plane defined by axes C, D, E and F divides suction valve 20 into two symmetrical portions but that only two of the axes are necessary to define the plane. If there were two discharge passages associated with a cylinder, the plane of symmetry would be defined by axis D and E together with a mid-point of the axes of the two discharge passages. It will be noted that suction passages 30 - 1 and 30 - 2 are also symmetrically located as to suction valve 20 when it is in place. Discharge valve 50 is only visible through discharge passage 30 - 3 . Suction valve 20 has two arms or projections, 20 - 1 and 20 - 2 , respectively, which, as noted, are symmetrical with respect to suction valve 20 . The first arm 20 - 1 extends in the direction of a plane defined by axes A and D and terminates in a tip 20 - 1 a which is symmetrical relative to the plane defined by axes A and D. The second arm 20 - 2 extends in the direction of a plane defined by axes B and D and terminates in a tip 20 - 2 a which is symmetrical relative to the plane defined by axes B and D.
[0012] In FIGS. 2 and 3, the numeral 10 generally designates a reciprocating compressor with two cylinders being illustrated. As is conventional, each cylinder of compressor 10 has a suction valve 20 and a discharge valve 50 , which are illustrated as reed valves, as well as a piston 42 which is located in bore a 40 - 3 of crankcase 40 . Valves 20 and 50 coact with valve plate 30 in their valving action. Discharge valve 50 has a backer 51 which limits the movement of valve 50 and is normally configured to dissipate the opening force applied to valve 50 via discharge passage 30 - 3 over its entire opening movement. When the valve 20 is in the open position which is shown in phantom in FIG. 2, tips 20 - 1 a and 20 - 2 a engage ledges 40 - 1 a and 40 - 2 a in recesses 40 - 1 and 40 - 2 , respectively, in crankcase 40 which act as valve stops. Ledges 40 - 1 a and 40 - 2 a are engaged after an opening movement of suction valve 20 on the order of 0.1 inches, in order to minimize the clearance volume, with further opening movement occurring by flexure of valve 20 as shown in phantom. Specifically, movement of valve 20 is as a cantilevered beam until tips 20 - 1 a and 20 - 2 a engage ledges 40 - 1 a and 40 - 2 a , respectively. At this point there are three locations of support. The first is at the secured end of valve 20 and is in the nature of a line or thin band contact with crankcase 40 symmetrically located with respect to a plane defined by axes C, D, E and F and tending to produce the flexure shown in phantom in FIG. 2. This flexure is essentially about an axis perpendicular to the plane defined by axes C, D, E and F. At one level tips 20 - 1 a and 20 - 2 a effectively support the free end of the valve 20 to produce the flexure illustrated in phantom. This, however, is the result of the individual coaction of tips 20 - 1 a and 20 - 2 a with ledges 40 - 1 a and 40 - 2 a , respectively. As best shown in FIG. 3, the portions of tips 20 - 1 a and 20 - 2 a overlying ledges 40 - 1 a and 40 - 2 a , respectively, are the narrowest portions of valve 20 and are symmetrical about the planes defined by axes A and D and axes B and D, respectively. Being narrow, tips 20 - 1 a and 20 - 2 a are prone to being flexed. Due to the symmetry, tips 20 - 1 a tends to flex about an axis transverse to the plane defined by axes A and D and tips 20 - 2 a tends to flex about an axis transverse to the plane defined by axes B and D.
[0013] Because flexure relative to tips 20 - 1 a and 20 - 2 a is about axes transverse to planes defined by axis A and D and axes B and D, respectively, the greatest amount of movement of tips 20 - 1 a and 20 - 2 a due to flexure is required to draw valve 20 into bore 40 - 3 . Because of the symmetry of tips 20 - 1 a and 20 - 2 a relative to the planes defined by axis A and D and axes B and D, the forces due to the gas flow through the suction ports 30 - 1 and 30 - 2 also act symmetrically. Stress is minimized by minimizing the effects of transverse bending by minimizing the distance between the applied load on the valve due to gas flow and the valve tip support by ledges 40 - 1 a and 40 - 2 a.
[0014] In operation, suction valves 20 are unseated during the suction stroke when the pressure differential across valves 20 is sufficient to overcome the inherent spring force of the valve 20 , adhesion forces, etc. Upon the unseating of a valve 20 , impingement by the suction flow through suction passages 30 - 1 and 30 - 2 flexes valve 20 relative to the fixed end of valve 20 until tips 20 - 1 a and 20 - 2 a engage ledges 40 - 1 a and 40 - 2 a of recesses 40 - 1 and 40 - 2 , respectively. At this point there is no longer flexure solely relative to a single fixed end. The major flexure is at a, nominal, mid-point between the fixed end and the tips 20 - 1 a and 20 - 2 a which engage ledges 40 - 1 a and 40 - 2 a about an axis transverse to a plane defined by axes C and D. Additionally, there is flexure by each of the tips 20 - 1 a and 20 - 2 a and/or by their respective arms and 20 - 1 and 20 - 2 . Tip 20 - 1 a flexes about an axis transverse to a plane defined by axes A and D and tip 20 - 2 a flexes about an axis transverse to a plane defined by axes B and D. The flexure of tips 20 - 1 a and 20 - 2 a causes their movement relative to ledges 40 - 1 a and 40 - 2 a , respectively, to be directly towards axes A and B, respectively, which are at a minimum distance such that the maximum stress produced is reduced.
[0015] It will be noted that movement of tips 20 - 1 a and 20 - 2 a , to permit flexure, is along planes A-D and B-D, respectively, which is also along a radius of bore 40 - 3 . This results in movement along planes which results in the tips 20 - 1 a and 20 - 2 a being centered relative to recesses 40 - 1 and 40 - 2 . Accordingly, clearances around the tips 20 - 1 a and 20 - 2 a can be minimized thereby reducing the clearance volume and forces are balanced on the tips 20 - 1 a and 20 - 2 a in their engagement with recesses 40 - 1 a and 40 - 2 a , respectively.
[0016] Although a preferred embodiment of the present invention has been described and illustrated, other changes will occur to those skilled in the art. For example, three, or more, suction ports may be used. It is therefore intended that the scope of the present invention is to be limited only by the scope of the appended claims. | A valve tip and its associated recess are provided along each line from the center of the cylinder through the center, or axis, of a suction port. | 5 |
FIELD OF THE INVENTION
The invention relates to the oil industry and can be used to increase oil recovery from an oil-bearing formation in the course of its exploitation using any known method.
BACKGROUND OF THE INVENTION
Seismic or elastic wave stimulation is a known technique for enhancing oil recovery from an oil-bearing bed, as described in "Elastic-Wave Stimulation of Oil Production: A Review of Methods and Results," Geophysics Vol. 59, No. 6 (June 1994). One method of generating seismic stimulation is shown in Russian Federation Patent No. 2,001,254, in which two rotating imbalanced weights cause vibration of a platform on the surface. The weight, energy and resonance frequency of the vibration generator are calculated in accordance with the physical and mechanical properties of the ground above the oil bed, and harmonic waves are induced and propagated to the oil bearing level. The main disadvantage of this method is its low efficiency; loss of energy during wave passage from the surface to the oil bed may be as high as 98% and more.
Another known method is shown in Russian Federation Patent No. 1,710,709, in which an anvil plate is dropped to the bottom of the well and a heavy weight (water-filled tubing) is repeatedly lifted and dropped onto the anvil plate, imparting vibrations into the oil bed. Although this method avoids the energy loss associated with vibration generated at the surface, it is inefficient because the force of the falling weight is directed vertically, thus limiting the energy of the elastic vibrations imparted lateral to the well. Additionally, the repeated striking of the well bottom eventually destroys that surface.
The object of the present invention is to increase the effectiveness of the wave generation wells by increasing intensity of the elastic oscillations in the oil-bearing formation and optimization of their number. Another objective of the invention is to reduce additional expenditures for setting and drilling out of cement bridges in wave generation wells and to minimize the cost of installing and maintaining the equipment required for wave stimulation of oil-bearing formations.
SUMMARY OF THE INVENTION
The posed objectives are achieved by a method of wave stimulation of the oil accumulation, involving the generation of elastic oscillations in the producing formation by inflicting periodic impacts on the bottom of the wave generation well with a force not to exceed the maximum value for elastic deformation of the hard cement behind the casing. Shocks to the bottom hole zone in response wells are delivered by waves with a pressure drop at the wave front corresponding to the compression limiting strength of the perforated zone capped with a cement plug in the wave generation wells. The shock wave is generated by means of compression and subsequent release of fluid in the wave generating wells.
The number of wave generating wells is calculated by dividing the surface area of the whole oil accumulation by the effective area for one well. Candidates for wave generating wells are depleted or newly drilled artificial lift wells equipped with pumping jacks and wells which are recompleted from a lower horizon to an upper one. In the case of wells to be recompleted from a lower horizon to an upper one, a cement plug is installed at or below the base of the upper producing interval. Newly drilled wells are left unperforated during service as wave generation wells.
The device for wave stimulation of the oil accumulation includes a lifting mechanism in the form of a pumping unit installed at the wellhead and a tubing string suspended in the production casing of the well having a cylinder and seating ring installed on the bottom end of the tubing string. A plunger connected to the pumping unit by means of sucker rods and a polish rod is installed in the cylinder so that the plunger exits from the cylinder at the top of the upstroke. One or more centralizers are installed in the tubing string above the cylinder.
In operation, the well casing and tubing string are filled with a liquid such as water and sealed tight. The motion of the pumping unit causes the plunger to move up and down in the cylinder at the end of the tubing string. On the upstroke, the liquid in the tubing string above the plunger is compressed, while the liquid below the plunger is subject to negative pressure. At the top of the stroke, the plunger is pulled out of the cylinder, suddenly releasing the compressed liquid and causing a compression shock wave to travel downward until it strikes the floor of the well. On the downstroke, the plunger is reinserted into the cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the general view of the device installed on the well.
FIG. 2 shows a cross-section along the lower portion of the plunger, upper portion of the cylinder, and the centralizer.
FIG. 3 shows a cross-section of the supply device.
FIG. 4 shows a cross-section of the centralizer bushing.
FIG. 5 shows a theoretical graph for changes in wellhead pressure in the process of operating the device.
DETAILED DESCRIPTION OF THE INVENTION
As seen in FIG. 1, the pressure wave generating device includes a lifting mechanism in the form of a pumping unit 1, a tubing string 2 run into the production casing 3 of the well, suspended in the wellhead from the Christmas tree consisting of casing valve 4, tubing valve 5, bypass valve 6, and stuffing box 7. A cylinder 8 with a seating ring 9 is installed at the end of tubing string 2. Plunger 10 is run in cylinder 8 to allow for axial displacement and withdrawal from cylinder 8 at the top of the upstroke of the pumping unit 1. Plunger 10 is connected to pumping unit 1 via sucker rods 11 and polish rod 12. One or more centralizers 13 are installed in the lower portion of tubing string 2 to keep plunger 10 aligned with cylinder 8 when it is withdrawn from cylinder 8.
Plunger 10 (FIG. 2) is constructed in the form of a flow-through cylinder 16, in the lower part of which, bushing 17 and two threaded retainers 18 and 19 are installed coaxially. Between threaded retainers 18 and 19 are located the seating ring 20 and sealing ball 21. Centralizer 13 is made in the form of bushings with a conical taper 22 and flow channels 51 (FIG. 4) fixed in the production tubing 2.
The supply device 14, (FIG. 3), is made in the form of a housing 23 having a chamber 24. Housing 23 is attached to a pressure gauge 25, gauge line bleed valve 26, pressure tube 27, pressure tube bleed valve 28, and a supply hose 29. The pressure tube 27 is coupled to the wellhead 30, while the supply hose 29 is connected to chamber 15. Inside chamber 24, sealing ring 32 with sealing ball 33 are installed on threaded retainer 31 so as to separate the pressure tube 27 and supply hose 29.
Operating the device is achieved in the following manner. Into each well selected for wave generation, the described device is mounted and the well is filled with fluid 34 (FIG. 1). In most cases, water is the selected fluid. To perform this operation, a pump 35 is connected with an elbow 36 to the flange of casing valve 4, while surge chamber 37 is connected by elbows 38 to the flanges of production valve 5 and bypass valve 6. Opening valves 4, 5 and 6, fluid 34 is pumped into the well by means of pump 35 until stable circulation is achieved, filling the well and the device with fluid 34.
In the process of stable circulation of liquid 34, chamber 15 is also filled. To achieve this, the body 23 of the supply device 14 is turned 180° with respect to axis "a" (FIG. 3). In the process, the sealing ball 33 comes off its seat 32 and liquid 34 from the wellhead 30 enters chamber 15 through pressure tube 27 and supply hose 29. After filling chamber 15, body 23 of the supply device 14 is returned to its original position.
Valves 4, 5, 6, and bleed valve 28 are then closed, and stuffing box 7 is disconnected from the wellhead. The upper portion of the wellhead is filled with liquid 39, which has a lower density and higher viscosity than liquid 40. Liquid 39, which may be a light lubricating oil, remains at the top of the wellhead and lubricates and seals the stuffing box as the polish rod passes through it.
Stuffing box 7 is then reinstalled, valve 4 is opened and the pressure in the well is increased using pump 35 until all of the air in the liquid is dissolved to 1-2 MPa. Valve 4 is then closed and bleed valve 28 is opened. Pump 35, elbow 36, surge chamber 37, and elbow 38 are disconnected from the wellhead by closing their respective valves.
Pumping unit 1 is then turned on. As the plunger 10 moves down; liquid 34 raises sealing ball 21 and flows from below to above plunger 10. As the plunger 10 moves up, sealing ball 21 isolates liquid 40 from liquids 34 and 41. Liquids 34, 40 and 41 are all the same fluid (e.g., water) that was pumped into the device originally. As a result, compression of liquid 40 and expansion of liquids 34 and 41 occur. The degree of compression of liquid 40 is recorded on pressure gauge 25; the degree of expansion of liquids 34 and 41 is recorded on pressure gauge 42. Sealing ball 33 (FIG. 3) prevents liquid cross-flow from the wellhead 30 into chamber 15. As the pumping unit 1 approaches the uppermost position, plunger 10 pulls out of cylinder 8. At the moment that plunger 10 pulls out of cylinder 8, liquid 40 is vented into liquid 41. A compression shock wave is generated in liquid 41 and it moves along casing 3 and delivers a shock to the bottom of the well 43, then is reflected upward.
The reflected shock wave, on reaching the wellhead, once again changes its direction and delivers a repeat impact on the bottom of the well 43. Thus, the well fluid experiences a wave oscillation process with a frequency of pressure oscillations, f, numerically equal to C/2L, where C is the velocity of the shock wave front, and L is the length of production casing in the well. To increase the frequency of impacts "f" on the bottom of the well 43, a reflector (not shown) can be installed in production casing 3 to reduce the travel path "L," thereby achieving the desired objective.
Through one stroke of pumping unit 1 at a speed of 5 strokes per minute and well depth of the order of 2,000 meters, the wellhead pressure recorded on manometer 25 undergoes the changes shown in FIG. 5. As the plunger 10 travels upward, it gradually increases from a static pressure P y to liquid pressure P c . On approaching the uppermost position of pumping unit 1 the pressure drops to below the zero point. Inasmuch as at this time there is some pressure drop between the hydrostatic liquid pressure in chamber 15 and well pressure, liquid cross-flow occurs from chamber 15 into the wellhead 30 through supply hose 29 and pressure tube 27. As plunger 10 travels downward, pressure gauge 25 registers two reflected waves. The first reflected wave returns to the wellhead with some pressure P 1 which is lower than pressure P c . The second reflected wave returns to the wellhead with some pressure P 2 which is less than pressure P 1 . At the moment when pumping unit 1 approaches the lowest point of travel, the pressure at the wellhead becomes equal to static pressure P y . The described cycle of pressure changes then repeats itself.
In the process, the slug of liquid flowing from chamber 15 into the wellhead 30 in each cycle depends on the position of drain valve 28 and the height of chamber 15 at the surface. With greater leakage through stuffing box 7 and greater loss of liquid down the well, valve 28 is opened wider while chamber 15 is raised higher above the surface. With low rates of leakage through stuffing box 7 and lesser liquid losses to the well valve 28 is pinched back and chamber 15 is raised less above the surface. The required opening of valve 28 and elevation of chamber 15 above the surface are determined experimentally or by calculations based on the operating conditions for the installation with minimal static wellhead pressure P y and maximum venting pressure P c . After selecting the optimum operating conditions for the device, the valve 26 is pinched back and pressure gauge 25 is shut off, since it would not withstand prolonged operation under the conditions of changing pressures described above.
In the process of operating the system, fluid is added to chamber 15 and stuffing box 7 is serviced as required. The impact force at the bottom of the well 43 will be a function of the length of the tubing string and the travel of the plunger. This force should not exceed the limiting value for the elastic deformation of cement in the casing annulus 44. The optimum operating condition for the device is achieved by setting the speed of the pumping unit to correspond to the frequency of well fluid oscillation of the reflected compression wave.
Implementing the inventive method and device for an entire oil field is achieved in the following manner. First, the effective zone for a single well in the wave generating group is determined. Toward this end, the inventive device is put in operation and the performance of surrounding wells is observed. The boundary for the effect of one wave generating well is a line passing through the bottom hole locations of the furthest wells responding to the stimulation. In the first approximation the zone effected by a single wave generating well can be estimated as a circle with a radius of 2,500 to 3,000 meters. The number of wave generating wells is determined by dividing the surface area of the entire oil accumulation by the area effected by one well, and the entire accumulation is then broken up into that number of equal zones. Within each zone a wave generating well is selected out of those being recompleted from a lower to an upper horizon, a newly drilled well or a well designed for artificial lift. To save expense, candidate wells should already be equipped or intended to be equipped with a pumping unit.
Because the compression wave works as a sealed system, there should be no perforations in the well casings; otherwise the operating fluid will be injected into the accumulation zone. In the case of using wells being recompleted from a lower to an upper interval, a cement plug is generally installed at or below the base of the upper producing interval. In the case of a well designated for artificial lift, a cement plug is installed above the perforated interval. Finally, in the case of using newly drilled wells, they are left unperforated.
Utilizing this method for wells recompleted in an upper horizon from a lower, newly drilled wells and artificial lift wells equipped or designated to be equipped with pumping units, makes it possible to eliminate additional expenditures for setting cement plugs, since plugs are installed in these wells in accord with the general plan of development, regardless of whether the wells are used for shock wave stimulation. On the other hand, setting cement plugs in wells recompleted from a lower horizon to an upper and leaving unperforated newly drilled wells serves to eliminate the additional cost for drilling up cement plugs, inasmuch as it would not be required in subsequent conversion of wells from wave generating to producing status. Finally, making use of the described device makes it possible to reduce the expenditures for its manufacture and servicing since all of the basic components can be made from standard oil field equipment.
Although the present invention has been described in considerable detail with reference to a preferred version thereof, other versions are possible. For example, operating fluids other than water may be used, and other designs for the plunger, the fill system or the lift mechanism may be employed. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred version contained herein. | Disclosed is a method and apparatus for increasing the effectiveness of shock wave stimulation of oil-bearing formations by increasing the intensity of elastic oscillations in the oil accumulation. The device includes a pumping unit and a tubing string run in the production casing of the well, hung in a wellhead. A cylinder is installed on the end of the tubing string. A plunger works in the cylinder, traveling coaxially and coming out of the cylinder at the top of the pumping unit upstroke. The plunger is connected to the pumping unit by sucker rods and a polish rod. On the plunger upstroke the fluid in the tubing string is compressed. At the top of the pumping unit upstroke the fluid in the production tubing is discharged into the production casing generating a shock wave. | 4 |
PRIORITY
This application is a Continuation Application of U.S. application Ser. No. 12/246,104, filed in the U.S. Patent and Trademark Office on Oct. 6, 2008, which claims priority under 35 U.S.C. §19(a) to a Korean Patent Application filed in the Korean Intellectual Property Office on Oct. 4, 2007 and assigned Ser. No. 10-2007-0100053, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a remote control method for remote-controlling a target apparatus using a mobile communication terminal, and a remote control system thereof.
2. Description of the Related Art
Recently, as the Liquid Crystal Display (LCD) equipped with electronics devices becomes bigger, the size of the monitor of a Personal Computer (PC) and the like also increases in size. In addition, it is possible to display hologram or lifelike broadcasting in a three-dimensional (3D) manner using the monitor of the PC.
Meanwhile, a technology has been developed that uses a mobile communication terminal as an input device, in place of a mouse which is an input device of the PC. A conventional mobile communication terminal which remote-controls the PC, merely performs an On/Off or Hot-key function of the PC, or moves a pointer displayed on a display screen using a 4-way key. Particularly, since the technology of controlling the PC using the mobile communication terminal has restrictions on the number of functions, it was difficult to fully control the PC without the mouse separately connected thereto.
SUMMARY OF THE INVENTION
An aspect of the present invention is to address at least the problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide a remote control method for remote-controlling a target apparatus that displays a 3D display screen, using a mobile communication terminal, and a remote control system thereof.
According to an aspect of the present invention, a mobile communication terminal is provided that includes a motion sensor, and a transceiver configured for communication with a target apparatus including a display screen. The mobile communication terminal also includes a processing unit configured to establish, via the transceiver, a communication link with the target apparatus having the display screen adapted to visualize an object, detect an amount of displacement of the mobile communication terminal, via the motion sensor, generate motion information using the amount of displacement of the mobile communication terminal, and transmit the motion information to the target apparatus. The motion information corresponds to movement data of the object and the amount of displacement is detected based on at least one of current position information, acceleration information and angular velocity information of the mobile communication terminal.
According to another aspect of the present invention, a remote control method is provided for remote-controlling a target apparatus using a mobile communication terminal. A communication link is established with the target apparatus having a display screen adapted to visualize an object. An amount of displacement of the mobile communication terminal is detected. Motion information is generated using the amount of displacement of the mobile communication terminal. The motion information is transmitted to the target apparatus. The motion information corresponds to movement data of the object and the amount of displacement is detected based on at least one of current position information, acceleration information and angular velocity information of the mobile communication terminal.
According to another aspect of the present invention, a target apparatus is provided that is remote-controlled by a mobile communication terminal. The target apparatus includes a transceiver configured for communication with the mobile communication terminal. The target apparatus also includes a display to visualize an object. The target apparatus further includes a processing unit configured to establish, via the transceiver, a communication link with the mobile communication terminal, receive data corresponding to an amount of displacement of the mobile communication terminal, generate motion information using the amount of displacement of the mobile communication terminal, and move the object according to the motion information. The motion information corresponds to movement data of the object, and the amount of displacement is detected based on at least one of current position information, acceleration information and angular velocity information of the mobile communication terminal.
According to another aspect of the present invention, a remote control method is provided for remote-controlling a target apparatus using a mobile communication terminal. A communication link is established with the mobile communication terminal. Data is received corresponding to an amount of displacement of the mobile communication terminal. Motion information generated using the amount of displacement of the mobile communication terminal is generated. An object displayed on a display of the target apparatus is moved according to the motion information. The motion information corresponds to movement data of the object, and the amount of displacement is detected based on at least one of current position information, acceleration information and angular velocity information of the mobile communication terminal
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram illustrating a schematic structure of a remote control system according to an embodiment of the present invention;
FIG. 2 is a diagram illustrating a mobile communication terminal according to an embodiment of the present invention;
FIG. 3 is a flowchart illustrating a method for determining a reference point between a mobile communication terminal and a PC in a remote control system according to an embodiment of the present invention;
FIG. 4 is a diagram illustrating a mobile communication terminal and a PC, for determining reference point coordinates in a remote control system according to an embodiment of the present invention;
FIG. 5 is a flowchart illustrating a method in which a mobile communication terminal remote-controls a PC in a remote control system according to an embodiment of the present invention;
FIG. 6 is a flowchart illustrating a method in which a mobile communication terminal remote-controls a PC in a remote control system according to an embodiment of the present invention;
FIGS. 7A and 7B are diagrams illustrating shifting of a pointer of a PC in a remote control system according to an embodiment of the present invention;
FIGS. 8A and 8B are diagrams illustrating games realized in a remote control system according to an embodiment of the present invention; and
FIG. 9 is a flowchart illustrating a method in which a mobile communication terminal remote-controls a PC in a remote control system according to an embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Preferred embodiments of the present invention will now be described in detail with reference to the annexed drawings. In the drawings, the same or similar elements are denoted by the same reference numerals even though they may be depicted in different drawings. In the following description, a detailed description of known functions and configurations incorporated herein has been omitted for clarity and conciseness.
In the following description, the target apparatus is assumed to be a Personal Computer (PC). However, the target apparatus may include any device having a two-dimensional (2D) or three-dimensional (3D) display screen, as well as a PC.
FIG. 1 is a block diagram illustrating a schematic structure of a remote control system according to a preferred embodiment of the present invention.
The remote control system includes a mobile communication terminal 10 and a PC 40 , and the mobile communication terminal 10 and the PC 40 are wire/wireless-connected to each other to exchange data.
The mobile communication terminal 10 includes a Radio Frequency (RF) unit (not shown), a transceiver 12 , a key input unit 14 , a first display 16 , a first memory 18 , a motion information generator 20 , and a first controller 30 .
The RF unit performs a wireless communication function of the mobile communication terminal 10 . The RF unit includes an RF transmitter (not shown) for frequency up-converting and amplifying a transmission signal, and an RF receiver (not shown) for low-noise-amplifying and frequency down-converting a received signal.
The transceiver 12 transmits a signal generated in a signal generator 22 to the PC 40 , and receives a radio signal generated in the PC 40 . The transceiver 12 transmits, to the PC 40 , an initialization signal, a motion signal, and pointer motion information, generated in the signal generator 22 . The transceiver 12 receives an initialization response signal and a motion response signal, generated in the PC 40 .
The key input unit 14 includes alphanumeric keys capable of receiving numerals, characters and function keys for setting various functions, and receives inputs from a user.
According to a preferred embodiment of the present invention, the key input unit 14 can receive from the user a key input for carrying out a remote control mode of the mobile communication terminal 10 . In the remote control mode, the key input unit 14 can receive a key input for performing an operation corresponding to a position pointed by a pointer of the PC 40 . A Hot-key function can be set in the key input unit 14 . In this case, if a numeric/character key input is received through the key input unit 14 , a particular function of the PC 40 , which is set in the corresponding numeric/character key, can be immediately performed.
The first display 16 , which can be an LCD, outputs various display data generated by the mobile communication terminal 10 . When the LCD is a touch screen, the first display 16 can also serve as an input means.
The first memory 18 can be composed of a program memory and a data memory. Various information necessary for controlling an operation of the mobile communication terminal 10 is stored in the first memory 18 .
According to a preferred embodiment of the present invention, data is generated and stored in the first memory 18 when the mobile communication terminal 10 executes the remote control mode, such as: (i) reference point coordinates of the PC 40 , (ii) a position value of the mobile communication terminal 10 corresponding to the reference point coordinates, (iii) display information of the PC 40 , (iv) an angular velocity of the mobile communication terminal 10 calculated by a gyro sensor, (v) an acceleration of the mobile communication terminal 10 calculated by an acceleration sensor, (vi) a current position value of the mobile communication terminal 10 calculated by a position sensor, and (vii) motion point coordinates of the PC 40 corresponding to the current position value.
The motion information generator 20 generates motion information, which is information indicating how the pointer of the PC 40 will move on the display screen of the PC 40 in response to movement of the mobile communication terminal 10 . For this, the motion information generator 20 includes the signal generator 22 and a pointer motion information generator 24 .
The signal generator 22 generates the signals necessary when the mobile communication terminal 10 carries out the remote control mode. When the mobile communication terminal 10 executes the remote control mode by the controller 30 or upon receipt of a user input, the signal generator 22 generates an initialization signal to set reference point coordinates of the PC 40 . The term “reference point coordinates” refers to coordinates of the point where a communication interface 42 of the PC 40 has received the initialization signal. The signal generator 22 generates an initialization signal that includes data indicating the execution of the remote control mode, and data for requesting coordinates of the reference point which is a point where the initialization signal has arrived.
According to a preferred embodiment of the present invention, if the position of the mobile communication terminal 10 is changed by the user while executing the remote control mode, the signal generator 22 generates a motion signal for moving the pointer of the PC 40 according to the movement of the mobile communication terminal 10 . The signal generator 22 generates the motion signal that includes (i) data for requesting coordinates of the motion point which is the point where the initialization signal has arrived at the PC 40 , (ii) a current position value based on the movement of the mobile communication terminal 10 , and (iii) acceleration and angular velocity of the mobile communication terminal 10 obtained when it moves from the previous position to the current position.
In addition, according to another preferred embodiment of the present invention, the signal generator 22 can generate a periodic signal. As the signal generator 22 generates the periodic signal, the first controller 30 can measure the time required when the initialization signal or the motion signal, transmitted from the signal generator 22 to the PC 40 , comes back to the mobile communication terminal 10 after being processed into an initialization response signal or a motion response signal by the PC 40 . The first controller 30 measures a round-trip time of the initialization signal, and stores it in the first memory 18 . Thereafter, the first controller 30 measures a round-trip time of the motion signal based on the movement of the mobile communication terminal 10 , and compares it with the round-trip time of the initialization signal. As a result, the first controller 30 can determine if the distance from the PC 40 is shorter or longer than as compared with when the mobile communication terminal 10 , which has generated the motion signal, transmitted the initialization signal.
The pointer motion information generator 24 generates pointer motion information which is the information for moving the pointer of the PC 40 according to the movement of the mobile communication terminal 10 . The pointer motion information generator 24 , under the control of the controller 30 , calculates distance, velocity and angle at which the pointer of the PC 40 should move on the display screen of the PC 40 according to the movement of the mobile communication terminal 10 .
According to the present invention, the motion information generator 20 , which includes an acceleration sensor, a gyro sensor and a position sensor, can sense acceleration, angular velocity, and position of the mobile communication terminal 10 due to the movement of the mobile communication terminal 10 by the user. The acceleration sensor is a sensor for measuring an acceleration of an object by sensing dynamic power of acceleration, vibration, impact, etc. The gyro sensor is a sensor for sensing an angular velocity that acts in the inertial system. The position sensor, which can be, for example, a Global Positioning System (GPS), senses a correct position every time the mobile communication terminal 10 moves by the user.
The first controller 30 controls the overall operation of the mobile communication terminal 10 . According to a preferred embodiment of the present invention, when a user input for the remote control mode is received through the key input unit 14 , the first controller 30 switches the mode of the mobile communication terminal 10 to the remote control mode. In addition, when a user input for switching from the remote control mode to another operation mode is received through the key input unit 14 during the remote control mode, the first controller 30 switches to the other operation mode after ending the remote control mode.
When the remote control mode is executed, the first controller 30 transmits an initialization signal to the PC 40 , receives an initialization response signal therefrom, and controls the motion information generator 20 to calculate a distance between the mobile communication terminal 10 and the PC 40 . The first controller 30 stores reference point coordinates received from the PC 40 in the first memory 18 .
When movement by the user is sensed, the first controller 30 controls the motion information generator 20 to generate a motion signal according to the movement. When a motion response signal is received from the PC 40 in response to the motion signal, the first controller 30 stores the motion point coordinates included in the motion response signal in the first memory 18 .
The first controller 30 controls the pointer motion information generator 24 to generate pointer motion information using the motion point coordinates included in the motion response signal.
The PC 40 in the remote control system includes the communication interface 42 , a second memory 44 , a second display 46 , a coordinate determiner 48 , and a second controller 50 .
The communication interface 42 performs a wire/wireless communication function of the PC 40 . According to a preferred embodiment of the present invention, the communication interface 42 receives the initialization signal, motion signal and pointer motion information, transmitted from the mobile communication terminal 10 , and transmits to the mobile communication terminal 10 the initialization response signal and motion response signal generated in the coordinate determiner 48 of the PC 40 .
According to a preferred embodiment of the present invention, the communication interface 42 can be, for example, a display screen. When the communication interface 42 is a display screen, the initialization signal or motion signal transmitted from the mobile communication terminal 10 is received at a certain point on the display screen, converted into an initialization response signal or a motion response signal, and then transmitted back to the mobile communication terminal 10 .
The second memory 44 , like the first memory 18 , can be composed of a program memory and a data memory. Various information necessary for controlling an operation of the PC 40 is stored in the second memory 44 .
According to a preferred embodiment of the present invention, the second memory 44 receives an initialization signal from the mobile communication terminal 10 , and stores the current position value of the mobile communication terminal 10 based on the initialization signal, and coordinates of a reference point which is the point where the initialization signal has arrived at the PC 40 . When the PC 40 receives a motion signal, the second memory 44 stores the current position value, acceleration and angular velocity of the mobile communication terminal 10 based on the motion signal. When coordinates of the motion point are determined by the coordinate determiner 48 , the second memory 44 stores the determined motion point coordinates.
In addition, the second memory 44 can store pointer motion information transmitted from the mobile communication terminal 10 . The pointer motion information includes motion point coordinates, moving distance, and moving velocity of the pointer, which are the information needed for moving the pointer of PC 40 on the display screen.
Like the first display 16 , the second display 46 , which can be composed of an LCD, outputs various display data generated in the PC 40 . When the LCD is a touch screen, the second display 46 can also serve as an input means.
According to a preferred embodiment of the present invention, when the mobile communication terminal 10 executes the remote control mode, the second display 46 moves the displayed pointer according to the pointer motion information received from the mobile communication terminal 10 . The second display 46 can serve as the communication interface 42 that receives the initialization signal and the motion signal. When the second display 46 serves as the communication interface 42 , coordinates of the point where the initialization signal or motion signal received from the mobile communication terminal 10 has arrived, become reference point coordinates or motion point coordinates corresponding to the current position value of the mobile communication terminal 10 .
The coordinate determiner 48 , under the control of the second controller 50 , generates an initialization response signal and a motion response signal corresponding to the initialization signal and the motion signal received from the mobile communication terminal 10 . Further, the coordinate determiner 48 determines coordinates of a reference point which is the point where the initialization signal is received, and coordinates of a motion point which is the point where the motion signal is received.
When the initialization signal is received, the coordinate determiner 48 determines a reference point corresponding thereto, and generates an initialization response signal including coordinates of the reference point. Since the reference point is a point based on which the pointer of the PC 40 is later displayed according to the movement of the mobile communication terminal 10 , the coordinate determiner 48 can determine the coordinates as, for example, (0, 0, 0) corresponding to the coordinates of the reference point on the X, Y and Z axes of a 3D coordinate system, respectively. The coordinate determiner 48 can generate an initialization response signal including display information of the PC 40 . The display information is information on the display device of the PC 40 such as resolution information of the PC 40 .
When a motion signal is received from the mobile communication terminal 10 , the coordinate determiner 48 determines coordinates of the motion point which is the point where the motion signal is received. The coordinate determiner 48 generates a motion response signal including the motion point coordinates, and transmits the motion response signal to the mobile communication terminal 10 . According to another preferred embodiment of the present invention, the coordinate determiner 48 can calculate a distance from the reference point to the motion point. The coordinate determiner 48 then generates a motion response signal including the distance from the reference point to the motion point.
The second controller 50 controls the overall operation of the PC 40 . According to a preferred embodiment of the present invention, when an initialization signal is received from the mobile communication terminal 10 , the second controller 50 perceives that the mobile communication terminal 10 executes the remote control mode. When the initialization signal is received, the second controller 50 controls the coordinate determiner 48 to determine reference point coordinates for the initialization signal, and when the motion signal is received, the second controller 50 controls the coordinate determiner 48 to determine the motion point coordinates for the motion signal.
When the pointer motion information is received from the mobile communication terminal 10 , the second controller 50 controls the second display 46 to display the pointer according to the received pointer motion information.
FIG. 2 is a diagram illustrating a mobile communication terminal according to a preferred embodiment of the present invention.
As shown in FIG. 2 , the mobile communication terminal 10 has three axes: an X axis, a Y axis, and a Z axis. Accordingly, the mobile communication terminal 10 can receive an input not only from the 2D X/Y-axis plane but also from the 3D screen. Referring to FIG. 2 , when the mobile communication terminal 10 moves along the X axis, the pointer of the PC 40 moves left and right on the display screen. When the mobile communication terminal 10 moves along the Y axis, the pointer of the PC 40 moves up and down on the display screen. When the mobile communication terminal 10 moves along the Z axis, the pointer of the PC 40 moves in and out to/from the display screen, with the distance between the mobile communication terminal 10 and the PC 40 getting shorter and longer.
FIG. 3 is a flowchart illustrating a method for determining a reference point between a mobile communication terminal and a PC in a remote control system according to a preferred embodiment of the present invention.
The key input unit 14 of the mobile communication terminal 10 receives a key input for execution of the remote control mode from the user, and the controller 30 executes remote control mode in Step S 62 . The controller 30 controls the pointer motion information generator 24 of the motion information generator 20 to calculate a current position value of the mobile communication terminal 10 in Step S 64 .
The current position value of the mobile communication terminal 10 , calculated in Step S 64 , is a value based on which the position value of the mobile communication terminal 10 can be determined when the mobile communication terminal 10 is moved by the user after initialization for execution of the remote control mode. Therefore, if it is assumed in Step S 64 that the current position value of the mobile communication terminal 10 is indicated by X/Y/Z-axis 3D coordinates, it is preferable that the current position value is designated as the origin of (0, 0, 0). In this case, it is assumed that the X axis, the Y axis and the Z axis in the mobile communication terminal 10 are different from the X axis, the Y axis and the Z axis in the PC 40 .
The signal generator 22 generates an initialization signal in Step S 66 . The initialization signal is a signal generated to determine particular coordinates on the display screen of the PC 40 , which correspond to the current position value calculated in Step S 64 , in order to map each position to which mobile communication terminal 10 moves, to the position on the display screen of the PC 40 .
The PC 40 receives the initialization signal from the mobile communication terminal 10 in Step S 68 , and determines reference point coordinates corresponding to the current position value in Step S 70 . The initialization signal transmitted from the mobile communication terminal 10 is received at the PC 40 in such a manner that it arrives at a certain point on the display screen, and the PC 40 determines the point where the initialization signal has arrived, as a reference point, and transmits the coordinates to the mobile communication terminal 10 . In this case, the reference point coordinates can be, for example, any one of the multiple pixels distributed on the display screen of the PC 40 .
According to a preferred embodiment of the present invention, the PC 40 can determine coordinates of the point where the initialization signal of the mobile communication terminal 10 is received as (0, 0, 0), and recalculate coordinates for each point where the pointer is located, using the reference point.
The PC 40 transmits an initialization response signal including the reference point coordinates to the mobile communication terminal 10 in Step S 72 . According to a preferred embodiment of the present invention, the PC 40 transmits the initialization response signal including the display information. The display information can include screen resolution of the PC 40 , and driver information for the display device of the PC 40 .
The mobile communication terminal 10 receives the initialization response signal from the PC 40 in Step S 72 . The mobile communication terminal 10 calculates the distance from the PC 40 , and stores reference point coordinates in Step S 74 .
The pointer motion information generator 24 , under the control of the first controller 30 , measures the time from the transmission time of the initialization signal to the reception time of the initialization response signal, and calculates the distance between the mobile communication terminal 10 and the PC 40 using the measured time.
When the initialization signal generated in the signal generator 22 arrives at the PC 40 , it is processed into an initialization response signal and then transmitted back to the mobile communication terminal 10 . The time for which the initialization signal is processed into the initialization response signal is negligibly shorter than the time for which the initialization signal or the initialization response signal is delivered. According to a preferred embodiment of the present invention, the time for which the initialization signal arrives at the PC 40 from the mobile communication terminal 10 is equal to the time for which the initialization response signal arrives at the mobile communication terminal 10 from the PC 40 . Therefore, the time for which the initialization signal is transmitted to the PC 40 and then its associated initialization response signal is received at the mobile communication terminal 10 , can be regarded as the round-trip time between the mobile communication terminal 10 and the PC 40 for the initialization signal.
Since the pointer motion information generator 24 knows the time required when the initialization signal makes a round trip between the mobile communication terminal 10 and the PC 40 , it can find the distance between the mobile communication terminal 10 and the PC 40 . Here, a velocity of the initialization signal is previously stored in the first memory 18 , and the initialization signal can be, for example, infrared rays and ultrasonic waves.
FIG. 4 is a diagram illustrating a mobile communication terminal and a PC, for determining reference point coordinates in a remote control system according to a preferred embodiment of the present invention.
In the drawing, the mobile communication terminal 10 and the PC 40 both use the X/Y/Z-axis 3D coordinate system.
The mobile communication terminal 10 transmits an initialization signal, and the PC 40 receives the initialization signal. The PC 40 determines the point where the initialization signal is received, as a reference point, and then determines the coordinates of the reference point. Preferably, the coordinate determiner 48 determines the reference point coordinates as (0, 0, 0). The mobile communication terminal 10 then receives an initialization response signal including the reference point coordinates, transmitted from the PC 40 . Preferably, the mobile communication terminal 10 receives the initialization response signal in the position where it transmitted the initialization signal.
Shown in FIG. 4 is a diagram for the case when the communication interface 42 of the PC 40 that received the initialization signal from the mobile communication terminal 10 is a display screen. Therefore, the coordinate determiner 48 determines the point where the initialization signal has arrived on the display screen of the PC 40 as a reference point, and transmits coordinates of the determined reference point to the mobile communication terminal 10 .
The mobile communication terminal 10 receives the initialization response signal transmitted from the PC 40 in the position where it transmitted the initialization signal, and measures the time for which the initialization signal is transmitted from the mobile communication terminal 10 to the PC 40 , and the time for which the initialization response signal is transmitted from the PC 40 to the mobile communication terminal 10 . The mobile communication terminal 10 then calculates the distance between the mobile communication terminal 10 and the PC 40 using the measured time, and stores it in the first memory 18 .
The distance between the mobile communication terminal 10 and the PC 40 in the process of determining a reference point using the initialization signal becomes an origin point based on which the first controller 30 can later determine whether the mobile communication terminal 10 has become closer to or further away from the PC 40 when the mobile communication terminal 10 is moved by the user. The distance between the mobile communication terminal 10 and the PC 40 in the process of determining the reference point coordinates using the initialization signal will be referred to herein as a “reference distance”.
According to the present invention, when the distance between the mobile communication terminal 10 and the PC 40 is further than the reference distance, the mobile communication terminal 10 generates pointer motion information that displays the pointer of the PC 40 as if it moves in the opposite direction (e.g., +Z axis) of the direction of the mobile communication terminal 10 . On the contrary, when the distance between the mobile communication terminal 10 and the PC 40 is closer than the reference distance, the mobile communication terminal 10 generates pointer motion information that displays the pointer of the PC 40 as if it moves toward the direction (e.g., −Z axis) of the position where the mobile communication terminal 10 is located.
FIG. 5 is a flowchart illustrating a method in which a mobile communication terminal remote-controls a PC in a remote control system according to a preferred embodiment of the present invention.
It is assumed in FIG. 5 that the mobile communication terminal 10 is now executing the remote control mode, and reference point coordinates of the PC 40 and a position value of the mobile communication terminal 10 , which corresponds to the reference point coordinates, are previously stored in the first memory 18 and the second memory 44 .
The first controller 30 senses a movement of the mobile communication terminal 10 in Step S 82 . The movement of the mobile communication terminal 10 indicates a change in position of the mobile communication terminal 10 from a first position to a second position by the user, or a change in the angle of the mobile communication terminal 10 with respect to the PC 40 from a first angle to a second angle. In the remote control mode, the movement of the mobile communication terminal 10 is sensed through at least one of a position sensor, an acceleration sensor and a gyro sensor.
The signal generator 22 generates a motion signal under the control of the first controller 30 in Step S 84 . The motion signal is a signal generated to move the pointer of the PC 40 according to the movement of the mobile communication terminal 10 . The signal generator 22 can generate a motion signal including the acceleration, the angular velocity and the current position value of the mobile communication terminal 10 .
The mobile communication terminal 10 transmits the generated motion signal to the PC 40 in Step S 86 . The PC 40 receives the motion signal, and generates its associated motion response signal in Step S 88 . The coordinate determiner 48 of the PC 40 can generate a motion response signal including pointer motion point coordinates.
The PC 40 transmits the motion response signal to the mobile communication terminal 10 in Step S 90 , and the mobile communication terminal 10 receives the motion response signal and generates pointer motion information depending thereon in Step S 92 . The pointer motion information is information indicating how the pointer of the PC 40 should move in reply to the movement of the mobile communication terminal 10 . The PC 40 receives pointer motion information from the mobile communication terminal 10 in Step S 94 , and moves the displayed pointer according to the received pointer motion information in Step S 96 .
FIG. 6 is a flowchart illustrating a method in which a mobile communication terminal remote-controls a PC in a remote control system according to a preferred embodiment of the present invention.
The mobile communication terminal 10 senses a movement for shifting a pointer of the PC 40 in Step S 102 . Using the sensors, the mobile communication terminal 10 calculates a its current position value, and the acceleration and the angular velocity obtained when it moves from the previous position to the current position in Step S 104 . The first controller 30 controls the position sensor to sense the current position of the mobile communication terminal 10 , and senses a moving velocity and an acceleration based on the moving velocity when the mobile communication terminal 10 moves from the previous position to the current position, using the acceleration sensor. Using the gyro sensor, the first controller 30 can sense whether a body of the mobile communication terminal 10 is inclined as compared with the previous position.
The signal generator 22 generates a motion signal including the current position value, the acceleration and the angular velocity of the mobile communication terminal 10 , and the first controller 30 transmits the generated motion signal to the PC 40 via the transceiver 12 in Step S 106 .
Upon receipt of the motion signal from the mobile communication terminal 10 , the PC 40 determines pointer motion point coordinates according to the current position value of the mobile communication terminal 10 , and generates a motion response signal including the pointer motion point coordinates. The PC 40 transmits the generated motion response signal to the mobile communication terminal 10 through the communication interface 42 .
The transceiver 12 in the mobile communication terminal 10 receives from the PC 40 the motion response signal including the motion point coordinates of the pointer, which correspond to the current position value in Step S 108 .
The pointer motion information generator 24 calculates a distance from the PC 40 by measuring the time from the transmission time of the motion signal to the reception time of the motion response signal in Step S 110 . By calculating the distance from the PC 40 , the mobile communication terminal 10 can determine if the distance from the PC 40 in its current position is longer or shorter than the distance from the PC 40 in its previous position. In addition, if the time from the transmission time of the motion signal to the reception time of the motion response signal in the current position is equal to that in the previous position, it is obvious that the distance between the mobile communication terminal 10 and the PC 40 is not changed.
The pointer motion information generator 24 generates pointer motion information using acceleration, angular velocity, motion point coordinates of the pointer, and distance from the PC 40 in Step S 112 . The pointer motion information generator 24 determines a velocity of the mobile communication terminal 10 using the acceleration of the mobile communication terminal 10 when the pointer of the PC 40 has moved. In addition, the pointer motion information generator 24 determines an angle of the mobile communication terminal 10 using the angular velocity when the pointer moves on the display screen. Using the distance from the PC 40 , the pointer motion information generator 24 determines whether it will shift the pointer forward or backward on the display screen when the pointer has moved to the motion point coordinates corresponding to the current position value from the motion point coordinates corresponding to the previous position value of the mobile communication terminal 10 . For example, when the distance between the mobile communication terminal 10 and the PC 40 becomes shorter, the pointer motion information generator 24 determines to display the motion point as if it moves back on the display screen; and when the distance between the mobile communication terminal 10 and the PC 40 becomes longer, the pointer motion information generator 24 determines to display the pointer as if it pops out.
The mobile communication terminal 10 transmits the pointer motion information to the PC 40 in Step S 114 . Upon receipt of the pointer motion information, the PC 40 can determine how it will move the displayed pointer according to the movement of the mobile communication terminal 10 . The PC 40 controls the second display 46 to display the pointer according to the pointer motion signal.
According to another preferred embodiment of the present invention, the PC 40 can generate in Step S 106 the pointer motion information using the current position value, the acceleration and the angular velocity received from the mobile communication terminal 10 and the motion point coordinates determined according to the current position value.
FIGS. 7A and 7B are diagrams illustrating shifting of a pointer of a PC in a remote control system according to a preferred embodiment of the present invention.
FIG. 7A illustrates pointer shifting when the PC 40 has a 2D display screen, and FIG. 7B illustrates pointer shifting when the PC 40 has a 3D display screen.
It is assumed in FIG. 7A that an angle of the mobile communication terminal 10 is 0° when coordinates of the point where the motion signal transmitted from the mobile communication terminal 10 has arrived at the PC 40 are (x 0 , y 0 , z 0 ), and an angle of the mobile communication terminal 10 is A° when coordinates of the point where the motion signal has arrived are (x 1 , y 1 , z 1 ).
Even though only the angle of the mobile communication terminal 10 is changed, the remote control system according to the present invention considers that the mobile communication terminal 10 has moved. Therefore, in FIG. 7A , the PC 40 shifts the displayed pointer according to the movement of the mobile communication terminal 10 , considering that the mobile communication terminal 10 has been moved by the user.
The distance between the mobile communication terminal 10 and the PC 40 for the angle 0° is different from the distance between the mobile communication terminal 10 and the PC 40 for the angle A°. Since the mobile communication terminal 10 is inclined by A°, its distance from the PC 40 gets longer as compared with when the mobile communication terminal 10 is inclined by 0°. Therefore, although not shown in FIG. 7A , the PC 40 should incline the displayed pointer toward the +Z axis. Since the PC 40 has a 2D display screen, the PC 40 displays the pointer as if it pops out toward the mobile communication terminal 10 at the point where it is inclined by A° toward the +Z axis at the coordinates of (x 0 , y 0 , z 0 ). In this manner, the coordinates of the pointer, which are calculated as the mobile communication terminal 10 moves, are (x 1 , y 1 , z 1 ).
Likewise, it is also assumed in FIG. 7B that an angle of the mobile communication terminal 10 is 0° when coordinates of the point where the motion signal transmitted from the mobile communication terminal 10 has arrived at the PC 40 are (x 0 , y 0 , z 0 ), and an angle of the mobile communication terminal 10 is B° when coordinates of the point where the motion signal has arrived are (x 2 , y 2 , z 2 ).
Even in FIG. 7B , since the acceleration, the angular velocity and the current position value are changed as the angle of the mobile communication terminal 10 is inclined by B°, the PC 40 shifts the displayed pointer according thereto. Since the PC 40 has a 3D display screen, the pointer having coordinates of (x 2 , y 2 , z 2 ) is displayed at the point where it is inclined by B° toward the +Z axis with respect to the pointer having coordinates of (x 0 , y 0 , z 0 ).
FIGS. 8A and 8B are diagrams illustrating games realized in a remote control system according to a preferred embodiment of the present invention.
FIG. 8A illustrates a display screen of the PC 40 , on which a 3D game is played, and FIG. 8B illustrates a display screen of the PC 40 , on which a 2D game is played.
Referring to FIGS. 8A and 8B , the user can shift the pointer of the PC 40 to his/her desired position by applying a motion to the mobile communication terminal 10 . The user not only can shift the pointer to the desired position, but also adjust a moving velocity of the pointer, while viewing the 3D display screen of FIG. 8A or the 2D display screen of FIG. 8B . The user can move the mobile communication terminal 10 fast or slow, so the pointer can shift at the velocity corresponding thereto.
According to a preferred embodiment of the present invention, a predetermined command for the corresponding point where the pointer is positioned can be sent from the PC 40 to the mobile communication terminal 10 to be executed in the mobile communication terminal 10 . For example, when the pointer of the PC 40 arrives at a predetermined point, the mobile communication terminal 10 can generate a vibration, or the voice data stored in the first memory 18 can be played back.
FIG. 9 is a flowchart illustrating a method in which a mobile communication terminal remote-controls a PC in a remote control system according to a preferred embodiment of the present invention.
The first controller 30 of the mobile communication terminal 10 executes the remote control mode in Step S 122 , and receives a user input through the key input unit 14 in Step S 124 .
The first controller 30 determines if the user input received in Step S 124 is for shifting the pointer of the PC 40 in Step S 126 . If the user input is for shifting the pointer of the PC 40 , the first controller 30 controls the mobile communication terminal 10 to generate pointer motion information for the user input and to transmit it to the PC 40 in Step S 128 .
However, if the user input is not for shifting the pointer of the PC 40 , the first controller 30 performs an operation corresponding to the user input in Step S 130 . The operation can include performing an operation corresponding to the point where the pointer is positioned on the display screen of the PC 40 . According to a preferred embodiment of the present invention, the first controller 30 can control the signal generator 22 to generate a command for performing an operation corresponding to the point where the pointer is positioned, and send the generated command to the PC 40 .
As is apparent from the foregoing description, the present invention provides a remote control method for remote-controlling a target apparatus that displays a 3D display screen, using a mobile communication terminal, and a remote control system thereof.
While the invention has been shown and described with reference to a certain preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | Methods and apparatuses are provided for remote-controlling a target apparatus using a mobile communication terminal. A communication link is established with the target apparatus having a display screen adapted to visualize an object. An amount of displacement of the mobile communication terminal is detected. Motion information is generated using the amount of displacement of the mobile communication terminal. The motion information is transmitted to the target apparatus. The motion information corresponds to movement data of the object and the amount of displacement is detected based on at least one of current position information, acceleration information and angular velocity information of the mobile communication terminal. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to a biosensor and more particularly to an electrochemical biosensor for determining the concentration of an analyte in a carrier. The invention is particularly useful for determining the concentration of glucose in blood and is described herein with reference to that use but it should be understood that the invention is applicable to other analytic determinations.
BACKGROUND OF THE INVENTION
[0002] Electrochemical biosensors generally comprise a cell having a working electrode, a counter electrode and a reference electrode. Sometimes the function of the counter and reference electrodes are combined in a single electrode called a “counter/reference” electrode or “pseudo reference electrode”. As herein used the term “counter electrode” includes a counter/reference electrode where the context so admits.
[0003] The sample containing the analyte is brought into contact with a reagent containing an enzyme and a redox mediator in the cell. Either the mediator is reduced (receives at least one electron) while the analyte is oxidised (donates at least one electron) or visa versa. Usually it is the analyte which is oxidised and the mediator which is reduced. The invention will be herein described principally with reference to that system but it is also applicable to systems in which the analyte is reduced and the mediator oxidised.
[0004] Electrochemical glucose analysers such as those used by diabetics to monitor blood glucose levels or such as are used in clinics and hospitals are commonly based upon the use of an enzyme such as glucose oxidase dehydrogenase (GOD) and a redox mediator such as a ferricyanide or ferrocyanide. In such prior art system, the sample (e.g. blood) containing the analyte (e.g. glucose) is brought into contact with the reagents in the cell. Glucose is oxidised to gluconic acid and the glucose oxidase is thereby reduced. The mediator then re-oxidizes the glucose oxidase and is reduced in the process. The reduced mediator is then re-oxidized when it transfers electrons to the working electrode. After allowing passage of a predetermined time, sufficient to obtain an accurate estimate of the Faraday current, the concentration of glucose is estimated from the magnitude of the current or voltage signal then measured.
[0005] Prior art electrochemical cells consist of two (or three) adjacent electrodes spaced apart on one side of an insulator and adapted for connection to a measuring device. A target area on which the blood sample is placed is defined on or between the electrodes. Co-pending Application PCT/AU95/00207 describes a cell in which electrodes are disposed on opposite sides of a porous membrane, one of the electrodes having a liquid permeable target area.
[0006] In the prior art there is a need to separate the working electrode from the counter (or counter/reference) electrode by a sufficient distance to avoid products of electrochemical reaction at one electrode from interfering with those at the other. In practice a separation of the electrodes of more than 500 μm is required to achieve acceptable accuracy.
[0007] Each batch of cells is required to have been previously calibrated and leads to inaccuracies during use because of variations within the batch, in sample composition, and in ambient conditions.
[0008] It is desired to improve the accuracy and reliability of such biosensors. Achievement of these objectives is made difficult in the case of sensors intended to determine the concentration of analytes in blood because blood contains dissolved gases, ions, colloids, complex micelles, small scale cellular debris, and living cellular components in a predominantly aqueous medium. Any of these may interfere in the determination. Existing sensors are also susceptible to influence from other interfering substances that may be present in the sample and which may be oxidised at the working electrode and mistakenly identified as the analyte of interest. Alternatively, the interfering substances may reduce the oxidised form of the redox mediator. These effects will give artificially elevated estimates of the analyte concentration. Additionally there is always some reduced redox mediator present before the analyte is added and its concentration needs to be known and subtracted from the measured value of reduced mediator to give an accurate concentration of the analyte. Moreover, oxygen in the blood may act as a redox mediator for glucose oxidase dehydrogenase (GOD) in competition with ferrocyanide. Thus high oxygen concentrations can lead to low estimates of glucose concentration. In addition the measurements are sensitive to factors such as changes in humidity, temperature, solution viscosity and haematocrit content.
OBJECT OF THE INVENTION
[0009] It is an object of the present invention to provide a method of analysis and apparatus for use in the method which avoid or ameliorate at least some of the disadvantages of the prior art. It is an object of preferred forms of the invention to provide a biosensor of improved accuracy, and/or reliability and/or speed and a method for its use.
DISCLOSURE OF THE INVENTION
[0010] According to one aspect the invention consists in a method for determining the concentration of a reduced (or oxidised) form of a redox species in an electrochemical cell of the kind comprising a working electrode and a counter electrode spaced from the working electrode by a predetermined distance, said method comprising the steps of:
(1) applying an electric potential difference between the electrodes, (2) selecting the potential of the working electrode such that the rate of electro-oxidation of the reduced form (or electro-reduction of the oxidised form) of the species is diffusion controlled, (3) selecting the spacing between the working electrode and the counter electrode so that reaction products from the counter electrode arrive at the working electrode, (4) determining current as a function of time after application of the potential and prior to achievement of a steady state, (5) estimating the magnitude of the steady state current, and (6) obtaining from the change in current with time and the magnitude of the steady state current, a value indicative of the diffusion coefficient and/or of the concentration of the reduced form (or the oxidised form) of the species.
[0017] The concentration measured in this way is substantially independent of variation if any in the diffusion coefficient of the reduced form, and therefore is compensated for variations in temperature and viscosity. The concentration so measured is independent of variations in haematocrit and other substances which affect the diffusion coefficient of the reduced form of the redox species.
[0018] It will be appreciated that the method of the invention is equally applicable for determining the concentration of a reduced form of a redox species or an oxidized form of a redox species in the cell. In the case that the concentration of the reduced form is to be determined the potential of the working electrode must be maintained such that the rate of electro oxidation of the reduced form is diffusion controlled in step ( 2 ) and it is the concentration of the reduced form that is obtained in step ( 5 ). In the case that the concentration of oxidized form is to be determined, the potential of the working electrode must be maintained such that the rate of electro reduction of the oxidized form is diffusion controlled in step ( 2 ) and it is the concentration of the oxidized form that is obtained in step ( 5 ).
[0019] The redox species may be an analyte or may be a redox mediator.
[0020] In preferred embodiments of the method a mediator is used and the concentration of the reduced (or oxidized) form of the mediator is in turn indicative of the concentration of an analyte and a measure of the diffusion coefficient of the reduced (or oxidized) form of the mediator is determined as a precursor to the determination of the concentration of the analyte.
[0021] For preference the cell comprises a working electrode and counter/reference electrode. If a reference electrode separate from a counter electrode is used, then the reference electrode may be in any convenient location in which it is in contact with the sample in the sensor.
[0022] In contrast to prior art, when conducting the method of the invention, the electrodes are sufficiently close that the products of electrochemical reaction at the counter electrode migrate to the working electrode during the period of the test. For example, in an enzyme ferricyanide system, the ferrocyanide produced at the counter electrode diffuses to the working electrode.
[0023] This allows a steady state concentration profile to be achieved between the electrodes leading to a steady state current. This in turn allows the diffusion coefficient and concentration of the redox species (mediator) to be measured independently of sample variations and therefore greatly improves accuracy and reliability.
[0024] The method also permits the haematocrit concentration of blood to be determined from the diffusion coefficient by use of look-up tables (or by separation of red cells from plasma and measurement of the diffusion coefficient of the red cell fraction) and the plasma fraction, and comparing the two.
[0025] According to a second aspect, the invention consists in apparatus for determining the concentration of a redox species in an electrochemical cell comprising:
an electrochemical cell having a working electrode and a counter (or counter/reference) electrode, means for applying an electric potential difference between said electrodes, means for measuring the change in current with time, and characterised in that the working electrode is spaced from the counter electrode by less than 500 μm.
[0029] In preferred embodiments the cell has an effective volume of 1.5 microlitres or less. Apparatus for use in the invention may comprise a porous membrane, a working electrode on one side of the membrane, a counter/reference electrode on the other side, said electrodes together with a zone of the membrane therebetween defining an electrochemical cell, and wherein the membrane extends laterally from the cell to a sample deposition area spaced apart from the cell zone by a distance greater than the thickness of the membrane.
[0030] Preferably the porous membrane, the distance of the target area from the cell portion, and the membrane thickness are so selected in combination that when blood (comprising plasma and red cells) is placed on the target area a plasma front diffuses laterally towards the electrochemical cell zone in advance of the red cells.
[0031] It is thus possible to fill a thin layer electrochemical cell with plasma substantially free of haematocrit which would cause a variation in the diffusion coefficient of the redox mediator and which would affect the accuracy of the test as hereinafter explained.
[0032] In preferred embodiments of the biosensor according to the invention a second electrochemical cell zone of the membrane is defined by a second working electrode and a second counter/reference electrode on the opposite side of the membrane from the second working electrode. The second electrochemical cell zone is situated intermediate the first cell zone and the sample deposition or “target” area, or is situated on the side of the target area remote from the first electrochemical zone. In these embodiments the plasma comes into contact with enzyme in, or on route to, the first electrochemical cell while plasma reaching the second cell does not. The first cell thus in use measures the concentration of reduced mediator in the presence of plasma (including electrochemically interfering substances), and enzyme while the second electrochemical cell measures it in the presence of plasma (including electrochemically interfering substances) and in the absence of enzyme. This allows determination of the concentration of the reduced interfering substances in the second cell and the concentration of reduced interfering substances plus analyte in the first cell. Subtraction of the one value from the other gives the absolute concentration of analyte.
[0033] In a highly preferred embodiment of the invention a hollow cell is employed wherein the working and reference (or counter/reference) electrodes are spaced apart by less than 500 μm and preferably by from 20-200 μm.
DESCRIPTION OF THE DRAWINGS
[0034] The invention will now be more particularly described by way of example only with reference to the accompanying drawings wherein:
[0035] FIG. 1 is a schematic drawing (not to scale) of a first embodiment according to the invention shown in side elevation.
[0036] FIG. 2 shows the embodiment of FIG. 1 in plan, viewed from above.
[0037] FIG. 3 shows the embodiment of FIG. 1 in plan, viewed from below.
[0038] FIG. 4 shows the embodiment of FIG. 1 viewed in end elevation.
[0039] FIG. 5 is a schematic drawing (not to scale) of a second embodiment according to the invention in side elevation.
[0040] FIG. 6 shows the embodiment of FIG. 5 in plan, viewed from above.
[0041] FIG. 7 is a schematic drawing (not to scale) of a third embodiment according to the invention, in side elevation.
[0042] FIG. 8 shows the embodiment of FIG. 7 in plan, viewed from above.
[0043] FIG. 9 is a schematic drawing (not to scale) according to the invention in plan view, viewed from above.
[0044] FIG. 10 shows the embodiment of FIG. 9 in end elevation.
[0045] FIG. 11 shows the embodiment of FIG. 9 in side elevation.
[0046] FIG. 12 shows a schematic drawing (not to scale) of a hollow cell embodiment according to the invention, viewed in cross section.
[0047] FIG. 13 is a graph showing a plot of current (ordinate axis) versus time (co-ordinate axis) during conduct of a method according to the invention.
[0048] FIG. 14 is a further graph of use in explaining the method of the invention.
[0049] In FIGS. 5 to 12 , components corresponding in function to components of the embodiment of FIGS. 1 to 4 are identified by identical numerals or indicia.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0050] With reference to FIGS. 1 to 4 there is shown a first embodiment of apparatus of the invention, in this case a biosensor for determining glucose in blood. The embodiment comprises a thin strip membrane 1 having upper and lower surfaces 2 , 3 and having a cell zone 4 defined between a working electrode 5 disposed on upper surface 2 and a counter electrode 6 disposed on lower surface 3 . The membrane thickness is selected so that the electrodes are separated by a distance “1” which is sufficiently close that the products of electrochemical reaction at the counter electrode migrate to the working electrode during the time of the test and a steady state diffusion profile is substantially achieved. Typically, “1” will be less than 500 μm. A sample deposition or “target” area 7 defined on upper surface 2 of membrane 1 is spaced at a distance greater than the membrane thickness from cell zone 4 . Membrane 1 has a diffusion zone 8 extending between target area 7 and cell zone 4 . A suitable reagent including a redox mediator “M”, an enzyme “E” and a pH buffer “B” are contained within cell zone 4 of the membrane and/or between cell zone 4 and target area 7 . The reagent may also include stabilisers and the like.
[0051] In some cases it is preferable to locate the enzyme and mediator and/or the buffer in different zones of the membrane. For example the mediator may be initially located within electrochemical cell zone 4 while the enzyme may be situated below target area 7 or in diffusion zone 8 .
[0052] Haemoglobin releases oxygen at low pH's, but at higher pH's it binds oxygen very firmly. Oxygen acts as a redox mediator for glucose oxidase dehydrogenase (GOD). In a glucose sensor this competes with the redox mediator leading to low estimates of glucose concentration. Therefore if desired a first pH buffer can be contained in the vicinity of target area 7 to raise the pH to such a level that all the oxygen is bound to haemoglobin. Such a pH would be non-optimal for GOD/glucose kinetics and would consequently be detrimental to the speed and sensitivity of the test. In a preferred embodiment of the invention a second pH buffer is contained as a reagent in the vicinity of the working electrode to restore the pH to kinetically optimal levels. The use of a second buffer does not cause oxygen to be released from the haemoglobin as the haemoglobin is contained within the blood cells which are retained near blood target area 7 or are retarded in diffusion in comparison with the plasma and therefore not influenced by the second buffer. In this manner oxygen interference may be greatly reduced or eliminated.
[0053] In use of the sensor a drop of blood containing a concentration of glucose to be determined is placed on target zone 7 . The blood components wick towards cell zone 4 , the plasma component diffusing more rapidly than red blood cells so that a plasma front reaches cell zone 4 in advance of blood cells.
[0054] When the plasma wicks into contact with the reagent, the reagent is dissolved and a reaction occurs that oxidises the analyte and reduces the mediator. After allowing a predetermined time to complete this reaction an electric potential difference is applied between the working electrode and the counter electrode. The potential of the working electrode is kept sufficiently anodic such that the rate of electro oxidation of the reduced form of the mediator at the working electrode is determined by the rate of diffusion of the reduced form of the mediator to the working electrode, and not by the rate of electron transfer across the electrode/solution interface.
[0055] In addition the concentration of the oxidised form of the mediator at the counter electrode is maintained at a level sufficient to ensure that when a current flows in the electrochemical cell the potential of the counter electrode, and thus also the potential of the working electrode, is not shifted so far in the cathodic direction that the potential of the working electrode is no longer in the diffusion controlled region. That is to say, the concentration of the oxidized form at the counter electrode must be sufficient to maintain diffusion controlled electro oxidation of the reduced form of the mediator at the working electrode.
[0056] The behaviour of a thin layer cell is such that if both oxidised and reduced forms of the redox couple are present, eventually a steady state concentration profile is established across the cell. This results in a steady state current. It has been found that by comparing a measure of the steady state current with the rate at which the current varies in the current transient before the steady state is achieved, the diffusion coefficient of the redox mediator can be measured as well as its concentration. This is in contrast to the Cottrell current that is measured in the prior art. By measuring the Cottrell current at known times after application of a potential to the sensor electrodes it is only possible to determine the product concentration times square root of the diffusion coefficient and therefore it is not possible to determine the concentration of the mediator independent of its diffusion coefficient.
[0057] In a cell according to the current invention, by solving the appropriate diffusion equations it can be shown that over a restricted time range a plot of In(i/i ∞ −1) vs time (measured in seconds) is linear and has a slope (denoted by S) which is equal to −4π 2 D/1 2 where “i” is the current at time “t”, “i ∞ ” is the steady state current, “D” is the diffusion coefficient in cm 2 /sec, “1” is the distance between the electrodes in cm and “π” is approximately 3.14159. The concentration of reduced mediator present when the potential was applied between the electrodes is given by 2π 2 i ∞ /FAIS, where “F” is Faraday's constant, A is the working electrode area and the other symbols are as given above As this later formula uses S it includes the measured value of the diffusion coefficient.
[0058] Since 1 is a constant for a given cell, measurement of i as a function of time and i ∞ enable the value of the diffusion coefficient of the redox mediator to be calculated and the concentration of the analyte to be determined.
[0059] Moreover the determination of analyte concentration compensates for any variation to the diffusion coefficient of the species which is electro oxidised or electro reduced at the working electrode. Changes in the value of the diffusion coefficient may occur as a result of changes in the temperature and viscosity of the solution or variation of the membrane permeability. Other adjustments to the measured value of the concentration may be necessary to account for other factors such as changes to the cell geometry, changes to the enzyme chemistry or other factors which may effect the measured concentration. If the measurement is made on plasma substantially free of haematocrit (which if present causes variation in the diffusion coefficient of the redox mediator) the accuracy of the method is further improved.
[0060] Each of electrodes 5 , 6 has a predefined area. In the embodiments of FIGS. 1 to 4 cell zone 4 is defined by edges 9 , 10 , 11 of the membrane which correspond with edges of electrodes 5 , 6 and by leading (with respect to target area 7 ) edges 12 , 13 of the electrodes. In the present example the electrodes are about 600 angstrom thick and are from 1 to 5 mm wide.
[0061] Optionally, both sides of the membrane are covered with the exception of the target area 7 by laminating layers 14 (omitted from plan views) which serves to prevent evaporation of water from the sample and to provide mechanical robustness to the apparatus. Evaporation of water is undesirable as it concentrates the sample, allows the electrodes to dry out, and allows the solution to cool, affecting the diffusion coefficient and slowing the enzyme kinetics, although diffusion coefficient can be estimated as above.
[0062] A second embodiment according to the invention, shown in FIGS. 5 and 6 , differs from the first embodiment by inclusion of a second working electrode 25 and counter/reference electrode 26 defining a second cell zone 24 therebetween. These electrodes are also spaced apart by less than 500 μm in the present example. Second electrodes 25 , 26 are situated intermediate cell zone 4 and target area 7 . In this embodiment the redox mediator is contained in the membrane below or adjacent to target area 7 or intermediate target area 7 and first cell zone 4 . The enzyme is contained in the membrane in the first cell zone 4 and second cell zone 24 . The enzyme does not extend into second cell 24 . In this case when blood is added to the target area, it dissolves the redox mediator. This wicks along the membrane so that second electrochemical cell 24 contains redox mediator analyte and serum including electrochemically interfering substances. First electrochemical cell receives mediator, analyte, serum containing electrochemically interfering substances, and enzyme. Potential is now applied between both working electrodes and the counter electrode or electrodes but the change in current with time is measured separately for each pair. This allows the determination of the concentration of reduced mediator in the absence of analyte plus the concentration of electrochemically interfering substances in the second electrochemical cell and the concentration of these plus analyte in the first electrochemical cell. Subtraction of the one value from the other gives the absolute concentration of analyte.
[0063] The same benefit is achieved by a different geometry in the embodiment of FIGS. 7 and 8 in which the second working electrode and second counter/reference electrode define the second cell 24 on the side of target area 7 remote from first electrochemical cell 4 . In this case the enzyme may be contained in the membrane strip between the target area and cell 1 . The redox mediator may be in the vicinity of the target area or between the target area and each cell. The diffusion coefficient of mediator is lowered by undissolved enzyme and the arrangement of FIGS. 7 and 8 has the advantage of keeping enzyme out of the thin layer cells and allowing a faster test (as the steady state current is reached more quickly). Furthermore the diffusion constant of redox mediator is then the same in both thin layer cells allowing more accurate subtraction of interference.
[0064] Although the embodiments of FIGS. 1 to 8 are unitary sensors, it will be understood that a plurality of sensors may be formed on a single membrane as shown in the embodiment of FIGS. 9 to 11 . In this case the electrodes of one sensor are conductively connected to those of an adjacent sensor. Sensors may be used successively and severed from the strip after use.
[0065] In the embodiment of FIGS. 9 to 11 electrode dimensions are defined in the diffusion direction (indicated by arrow) by the width of the electrode in that direction. The effective dimension of the electrode in a direction transverse to diffusion direction is defined between compressed volumes 16 of the membrane in a manner more fully described in co-pending Application PCT/AU96/00210, the disclosure of which is incorporated herein by reference in its entirety. For clarity optional laminated layer 14 of FIG. 1 has been omitted from FIGS. 9 to 11 .
[0066] In the embodiment of FIG. 12 there is shown a hollow cell according to the invention wherein the electrodes 5 , 6 are supported by spaced apart polymer walls 30 to define a hollow cell. An opening 31 is provided on one side of the cell whereby a sample can be admitted into cavity 32 . In this embodiment a membrane is not used. As in previous embodiments, the electrodes are spaced apart by less than 500 μm, preferably 20-400 μm and more preferably 20-200 μm. Desirably the effective cell volume is 1.5 microlitres or less.
[0067] It will be understood that the method of the invention may be performed with a cell constructed in accord with co-pending application PCT/AU95/00207 or cells of other known design, provided these are modified to provide a sufficiently small distance between electrode faces.
[0068] The method of the invention will now be further exemplified with reference to FIGS. 13 and 14 .
EXAMPLE 1
[0069] A membrane 130 microns thick was coated on both sides with a layer of Platinum 60 nanometers thick. An area of 12.6 sq. mm was defined by compressing the membrane. 1.5 microlitres of a solution containing 0.2 Molar potassium ferricyanide and 1% by weight glucose oxidase dehydrogenase was added to the defined area of the membrane and the water allowed to evaporate.
[0070] The platinum layers were then connected to a potentiostat to be used as the working and counter/reference electrodes. 3.0 microlitres of an aqueous solution is containing 5 millimolar D-glucose and 0.9 wt % NaCl was dropped on to the defined area of the membrane. After an elapse of 20 seconds a voltage of 300 millivolts was applied between the working and counter/reference electrodes and the current recorded for a further 30 seconds at intervals of 0.1 seconds.
[0071] FIG. 13 is a graph of current versus time based on the above measurements.
[0072] Using a value of the steady state current of 26.9 microamps the function In(i/26.9−1) was computed and plotted versus time. The slope of the graph ( FIG. 14 ) is −0.342 which corresponds to a diffusion coefficient of 1.5×10 −6 cm 2 per second and a corrected glucose concentration (subtracting background ferrocyanide) of 5.0 millimolar.
[0073] The steady state current is one in which no further significant current change occurs during the test As will be understood by those skilled in the art, a minimum current may be reached after which there may be a drift due to factors such as lateral diffusion, evaporation, interfering electrochemical reactions or the like. However, in practice it is not difficult to estimate the “steady state” current (i ∞ ). One method for doing so involves approximating an initial value for i ∞ . Using the fit of the i versus t data to the theoretical curve a better estimate of i ∞ is then obtained. This is repeated reiteratively until the measured value and approximated value converge to within an acceptable difference, thus yielding an estimated i ∞ .
[0074] In practice, the measurements of current i at time t are made between a minimum time t min and a maximum time t max after the potential is applied. The minimum and maximum time are determined by the applicability of the equations and can readily be determined by experiment of a routine nature. If desired the test may be repeated by switching off the voltage and allowing the concentration profiles of the redox species to return towards their initial states.
[0075] It is to be understood that the analysis of the current v. time curve to obtain values of the Diffusion Co-efficient and/or concentration is not limited to the method given above but could also be achieved by other methods.
[0076] For instance, the early part of the current v. time curve could be analysed by the Cottrell equation to obtain a value of D 1/2 ×Co (Co=Concentration of analyte) and the steady state current analysed to obtain a value of D×Co. These 2 values can then be compared to obtain D and C separately.
[0077] It will be understood that in practice of the invention an electrical signal is issued by the apparatus which is indicative of change in current with time. The signal may be an analogue or digital signal or may be a series of signals issued at predetermined time intervals These signals may be processed by means of a microprocessor or other conventional circuit to perform the required calculations in accordance with stored algorithms to yield an output signal indicative of the diffusion coefficient, analyte concentration, haematocrit concentration or the like respectively. One or more such output signals may be displayed by means of an analogue or digital display.
[0078] It is also possible by suitable cell design to operate the cell as a depletion cell measuring the current required to deplete the mediator. For example in the embodiment of FIG. 5 the method of the invention may be performed using electrodes 5 , 6 , which are spaced apart by less than 500 μm. An amperometric or voltametric depletion measurement may be made using electrodes 5 and 26 which are spaced apart more than 500 μm and such that there is no interference between the redox species being amperometrically determined at electrodes 5 , 26 .
[0079] The depiction measurement may be made prior to, during or subsequent to, the measurement of diffusion coefficient by the method of the invention. This enables a substantial improvement in accuracy and reproducibility to be obtained.
[0080] In the embodiments described the membrane is preferably an asymmetric porous membrane of the kind described in U.S. Pat. No. 4,629,563 and U.S. Pat. No. 4,774,039 both of which are incorporated herein in their entirety by reference. However symmetrical porous membranes may be employed. The membrane may be in the form of a sheet, tube, hollow fibre or other suitable form.
[0081] If the membrane is asymmetric the target area is preferably on the more open side of the asymmetric membrane. The uncompressed membrane desirably has a thickness of from 20 to 500 μm. The minimum thickness is selected having regard to speed, sensitivity, accuracy and cost. If desired a gel may be employed to separate haematocrit from GOD. The gel may be present between the electrodes and/or in the space between the sample application area and the electrodes.
[0082] The working electrode is of any suitable metal for example gold, silver, platinum, palladium, iridium, lead, a suitable alloy. The working electrode may be preformed or formed in situ by any suitable method for example sputtering, evaporation under partial vacuum, by electrodeless plating, electroplating, or the like. Suitable non-metal conductors may also be used for electrode construction. For example, conducting polymers such as poly(pyrrole), poly(aniline), porphyrin “wires”, poly(isoprene) and poly (cis-butadiene) doped with iodine and “ladder polymers”. Other non-metal electrodes may be graphite or carbon mixed with a binder, or a carbon filled plastic. Inorganic electrodes such as In 2 O 3 or SnO 2 may also be used. The counter/reference electrode may for example be of similar construction to the working electrode. Nickel hydroxide or a silver halide may also be used to form the counter/reference electrode. Silver chloride may be employed but it will be understood that chloridisation may not be necessary and silver may be used if sufficient chloride ions are present in the blood sample. Although in the embodiments described the working electrode is shown on the upper surface of the biosensor and the counter/reference electrode is on the lower surface, these may be reversed.
[0083] It is preferable that the working electrode and counter (or counter/reference) electrodes are of substantially the same effective geometric area.
[0084] If a separate reference and counter electrode are employed, they may be of similar construction. The reference electrode can be in any suitable location.
[0085] It will be understood that the features of one embodiment hereindescribed may be combined with those of another. The invention is not limited to use with any particular combination of enzyme and mediator and combinations such as are described in EP 0351892 or elsewhere may be employed. The system may be used to determine analytes other than glucose (for example, cholesterol) by suitable adaptation of reagents and by appropriate membrane selection. The system may also be adapted for use with media other than blood. For example the method may be employed to determine the concentration of contaminants such as chlorine, iron, lead, cadmium, copper, etc., in water.
[0086] Although the cells herein described have generally planar and parallel electrodes it will be understood that other configurations may be employed, for example one electrode could be a rod or needle and the other a concentric sleeve.
[0087] It will be apparent to those skilled in the art from the disclosure hereof the invention may be embodied in other forms without departing from the inventive concept herein disclosed. | This invention relates to a biosensor and more particularly to an electrochemical biosensor for determining the concentration of an analyte in a carrier. The invention is particularly useful for determining the concentration of glucose in blood and is described herein with reference to that use but it should be understood that the invention is applicable to other analytic determinations. | 8 |
This application is a CIP of Ser. No. 09/478,743 filed Jan. 6, 2000 now abandoned.
FIELD OF THE INVENTION
The present invention relates to novel compounds, pharmaceutical compositions containing them, to processes for their preparation and to the uses thereof. More particularly, this invention relates to compounds that exhibit agonist activity to peroxisome proliferator-activated receptor gamma enabeling them to be useful in modulation of blood glucose and the increase of insulin sensitivity in mammals
BACKGROUND OF THE INVENTION
Type II or Non-Insulin Dependent Diabetes Mellitus (NIDDM) involves abnormal glucose metabolism characterized by defects in three organ systems, namely, liver (increased glucose production by the liver due to increased levels of glucagon and free fatty acids as well as recycling of gluconeogenic precursors lactate and pyruvate), pancreas (impaired glucose-induced insulin secretion leading to fasting hyperglycemia) and peripheral target tissues such as the skeletal muscle (resistance to the action of insulin due to insulin receptor or post receptor defects).
The sulfonyl urea class of drugs exert their anti-hyperglycemic effects by stimulating the release of insulin from the β cells of the pancreas. These however have undesirable toxic effects such as fatigue of β cells with long term use, obesity and incidence of hypoglycemia. The biguanides act on insulin resistance by reduced glucose absorption, decreased glucuneogenesis, increased anorexia, enhance insulin binding to its receptor and increased glucose transport in fat and muscle. Thus the treatment of insulin resistance and/or suppression of increased hepatic glucose production in type II diabetes is an attractive area of drug development.
The thiazolidinedione class of drugs (troglitazone), was developed for its potent lipid-peroxide-lowering activity which improved hyperglycemia, hyperinsulinemia and hypertriglceridemia in the diabetic KK mice (a genetically insulin resistance model of type II diabetes). Troglitazone also increased glucose uptake in adipocytes thus increasing insulin sensitivity and responsiveness.
Three cell lines have been used to assess the effects of thiazolidinediones: NIH 3T3 mouse fibroblast that differentiates into insulin responsive adipocytes (fat cell model), HepG2, a human hepatoma cell line (liver cell model) and L6 rat myocytes (muscle cell model). In the first model the “glitazones” increase the differentiation into adipocytes and increase the expression of fat cell-specific genes like lipoprotein lipase, aP2, acyl CoA synthase and adipsin thereby contributing to the stimulation of triglyceride clearance. In the latter model and in fat cells the thiazolidinediones increase the expression of glucose transporter, GLUT4, thereby exerting an insulin-sensitizing effect by stimulating basal and insulin-stimulated glucose uptake. Recently, it has been demonstrated that the thiazolidinediones and prostanoids of the J2 series are ligands for the Peroxisome Proliferator Activated Receptors (members of the steroid/thyroid hormone receptor super family). Members of this family include the alpha, gamma and delta, of which the PPARg receptor has been shown to be preferentially expressed in preadipocytes and immune system. A general model for activation of PPARgamma by thiazolidinediones include a ligand induced conformational change leading to the displacement of a “corepressor” or allowing the binding of a coactivator thereby facilitating heterodimerization with another nuclear receptor RXR. The activated heterodimer interacts with specific DNA sequences “TGACCT-N-TGACCT” or PPREs (the Peroxisome Proliferator Response Elements) to activate transcription of thiazolidinedione responsive genes (such as lipoprotein lipase), either directly or by interacting with sites that overlap insulin responsive sequences (IRS) (such as in the glucokinase promoter). The PPREs have been identified in the promoters of a number of genes for proteins involved in the regulation of lipid metabolism suggesting that PPARgamma is an attractive therapeutic target for obesity and NIDDM.
SUMMARY OF THE INVENTION
The present invention relates to heterocycle derivatives which are peroxisome proliferator-activated receptor-gamma (PPAR-gamma) selective agonists and such are useful in the modulation of blood glucose and the increase of insulin sensitivity in mammals. This activity of the piperazine derivatives of the invention make them particularly useful in the treatment of those conditions selected from the group consisting of diabetes, atherosclerosis, hyperglycemia, hyperlipidemia, obesity, syndrome X, insulin resistance, hypertension, heart failure and cardiovascular disease in mammals.
DESCRIPTION OF THE INVENTION
The present invention relates to the compounds of formula (I) below and its derivatives, pharmaceutically acceptable salts thereof, which are non-thiazolidinedione PPARgamma agonists so that they might surmount the problems associated with the known thiazolidinediones and thus offer an advantage as a therapeutic agent in treating diseases described above.
The present invention provides novel compounds of Formula (I) or pharmaceutical
acceptable salts thereof, wherein the broken line represents an optional double bond;
X is H, O, S;
A is —C(O)—, —S(O)m—;
B is O, S, NR 6 , wherein R 6 is H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl and C 2 -C 6 alkynyl and C 3 -C 6 cycloalkyl;
n is 0 or 1;
m is 1 or 2;
G is C 3 -C 10 cycloalkyl, C 4 -C 10 cycloalkenyl, saturated C 3 -C 10 heterocyclyl, C 3 -C 10 cycloalkyl-C 1 -C 3 alkyl, C 4 -C 10 cycloalkenyl-C 1 -C 3 alkyl, saturated C 3 -C 10 heterocyclyl-C 1 -C 3 alkyl, said cycloalkyl, cycloalkenyl, heterocyclyl and alkyl optionally substituted with 1 to 3 groups of R s , wherein heterocyclyl contains 1 to 4 heteroatoms which may be nitrogen, sulfur or oxygen atom;
R 1 is hydrogen, hydroxy, thio, nitro, cyano, azido, amino, trifluoromethyl, trifluoromethoxy, C 1 -C 6 alkyl, C 1 -C 6 alkyloxy, C 1 -C 6 alkylthio, C 1 -C 6 alkylamino, C 1 -C 6 alkenyl, C 1 -C 6 alkenyloxy, C 1 -C 6 alkenylamino, C 3 -C 8 cycloalkyl, C 3 -C 8 cycloalkyloxy, C 3 -C 8 cycloalkylamino, C 3 -C 8 cycloalkylthio, C 1 -C 6 alkylcarbonylamino, C 3 -C 8 cycloalkylcarbonylamino, C 5 -C 10 aryl, C 5 -C 10 heteroaryl or C 5 -C 10 saturated heteroaryl; said aryl, heteroaryl, alkyl, alkenyl, and cycloalkyl optionally substituted with 1 to 3 groups of R s ;
R 2 , R 3 , R 4 and R 5 independently are H, trifluoromethyl, C 5 -C 10 aryl, C 5 -C 10 heteroaryl, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, saturated C 5 -C 10 heteroaryl, C 5 -C 10 aryl-C 1 -C 10 alkyl, C 5 -C 10 heteroaryl-C 1 -C 10 alkyl, COR 7 , CO 2 R 7 , CONR 7 R 8 , SO 2 NR 7 R 8 , said aryl, heteroaryl, alkyl, alkenyl, and cycloalkyl optionally substituted with 1 to 3 groups of R s ;
R 7 and R 8 independently are H, hydroxy, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 5 -C 10 aryl, C 5 -C 10 heteroaryl, said aryl, heteroaryl, alkyl, alkenyl, and cycloalkyl optionally substituted with 1 to 3 groups of R s ;
R s represents a member selected from the group consisting of halo, cyano, nitro, trihalomethyl, carbamoyl, hydroxy, OCF 3 acyl, aryl, heteroaryl, S(O)R 8 , ═N(OR 8 ), SO 2 R 8 , COOR 8 , —CONR 7 R 8 , —C 1 -C 6 alkylCONR 7 R 8 , C 1 -C 6 alkyloxy, aryloxy, arylC 1 -C 6 alkyloxy, thio, C 1 -C 6 alkylthio, arylthio, arylC 1 -C 6 alkylthio, NR 7 R 8 , C 1 -C 6 alkylamino, arylamino, arylC 1 -C 6 alkylamino, di(arylC 1 -C 6 alkyl)amino, C 1 -C 6 alkylcarbonyl, arylC 1 -C 6 alkylcarbonyl, C 1 -C 6 alkylcarboxy, arylC 1 -C C 6 alkylcarboxy, —NR 7 CO 2 R 8 , —NR 7 CO 2 R 8 , —NR 7 SO 2 R 8 , —CONR 7 R 8 , —SO 2 NR 7 R 8 , —OCONR 7 R 8 , —C 1 -C 6 alkylaminoCONR 7 R 8 , arylC 1 -C 6 alkylcarbonylamino, tetrahydrofuryl, morpholinyl, piperazinyl, or a saturated or partial saturated cyclic 5,6 or 7 membered amine or lactam; said aryl, and heteroaryl optionally substituted with 1 to 3 groups of halo or C 1 -C 6 alkyl; wherein R 7 and R 8 are defined as above.
Definitions
As used herein, the “—” (e.g. —COR 7 which indicates the carbonyl attachment point to the scaffold) signifies a stable covalent bond, certain preferred points of attachment points being apparent to those skilled in the art.
The term “halogen” or “halo” include fluorine, chlorine, bromine, and iodine.
The term “alkyl” includes C 1 -C 12 saturated aliphatic hydrocarbon groups unless otherwise defined. It may be straight or branched alkyl groups. Branched means that one or more lower alkyl groups such as methyl, ethyl, or propyl are attached. The alkyl group may be substituted by one or more hydroxy, halo, cycloalkyl, cycloalkenyl or heterocyclyl. Examplary alkyl groups include methyl, ethyl, fluoromethyl, difluoromethyl, trifluoromethyl, cyclopropylmethyl, cyclopentylmethyl, n-propyl, i-propyl, n-butyl, t-butyl, n-pentyl, 3-pentyl, heptyl, octyl, nonyl, decyl, and the like.
When substituted alkyl is present, this refers to a straight, branched or cyclic alkyl group as defined above, substituted with 1-3 groups as defined with respect to each variable.
The term “alkenyl” includes C 2 -C 12 aliphatic hydrocarbon groups containing at least one carbon to carbon double bond and which may be straight or branched unless otherwise defined. Preferably one carbon to carbon double bond is present, up to four non-aromatic carbon to carbon double bond may present. Branched means one or more lower alkyl groups such as methyl, ethyl or propyl are attached to a linear alkenyl chain. “Lower alkenyl” means about 2 to about 4 carbon atoms in the chain which may be straight or branched. For example, this definition shall include but is not limited to ethenyl, propenyl, butenyl, and cyclohexylbutenyl, decenyl, and the like. As described above with respect to alkyl, the straight, branched and cyclic portion of the alkenyl group may contain double bonds and may be substituted when substituted alkenyl group is provided.
The term “alkynyl” includes C 2 -C 12 aliphatic hydrocarbon groups containing at least one carbon to carbon triple bond and which may be straight or branched unless otherwise defined. Preferably one carbon to carbon double bond is present, up to carbon to carbon triple bond may present. Branched means one or more lower alkyl groups such as methyl, ethyl or propyl are attached to a linear alkynyl chain. “Lower alkynyl” means about 2 to about 4 carbon atoms in the chain which may be straight or branched. For example, this definition shall include but is not limited to ethynyl, propynyl, butynyl, and the like. As described above with respect to alkyl, the straight, branched and cyclic portion of the alkynyl group may contain triple bonds and may be substituted when substituted alkynyl group is provided.
The term “cycloalkyl” means a non-aromatic mono- or multicyclic ring system of about 3 to about 10 atoms. Preferred monocyclic cycloalkyl rings include cyclopentyl, fluorocyclopentyl, cyclohexyl and halocyclohexyl and cycloheptyl; More preferred is cyclohexyl. The cycloalkyl group may be substituted by one or more halo, methylene (CH 2 ═), alkyl, fused aryl and fused heteroaryl.
The term “cycloalkenyl” means a non-aromatic mono- or multicyclic ring system containing a carbon-carbon double bond and having about 3 to about 10 atoms. Preferred monocyclic cycloalkyl rings include cyclopentenyl, cyclohexenyl and halocyclohexenyl and cycloheptenyl; More preferred is cyclohexenyl. The cycloalkyl group may be substituted by one or more halo, methylene (CH 2 ═), alkyl, fused aryl and fused heteroaryl.
The term “heterocyclyl” means an about 4 to about 10 member monocyclic or multicyclic ring system wherein one or more of the atoms in the ring system is an element other than carbon chosen amongst nitrogen, oxygen or sulfur. The heterocyclyl may be optionally substituted by one or more alkyl group substituents. Examplary heterocyclyl moieties include quinuclidine, pentamethylenesulfide, tetrahedropyranyl, tetrahydrothiophenyl, pyrrolidinyl or tetrahydrofuranyl.
The term “alkyloxy” (e.g. methoxy, ethoxy, propyloxy, allyloxy, cyclohexyloxy) represents an “alkyl” group as defined above having the indicated number of carbon atoms attached through an oxygen bridge. The term “alkyloxyalkyl” represents an “alkyloxy” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “aryloxy” (e.g. phenoxy, naphthyloxy and the like) represents an aryl group as defined below attached through an oxygen bridge.
The term “arylalkyloxy” (e.g. phenethyloxy, naphthylmethyloxy and the like) represents an “arylalkyl” group as defined below attached through an oxygen bridge.
The term “arylalkyloxyalkyl” represents an “arylalkyloxy” group as defined above attached through an “alkyl” group defined above having the indicated number of carbon atoms.
The term “arylthio” (e.g. phenylthio, naphthylthio and the like) represents an “aryl” group as defined below attached through a sulfur bridge.
The term “alkyloxycarbonyl” (e.g. methylformate, ethylformiat and the like) represents and “alkyloxy” group as defined above attached through a carbonyl group.
The term “aryloxycarbonyl” (e.g. phenylformate, 2-thiazolylformiat and the like) represents an “aryloxy” group as defined above attached through a carbonyl group.
The term “arylalkyloxycarbonyl” (e.g. benzylformate, phenylethylformiat and the like) represents an “arylalkyloxy” group as defined above attached through a carbonyl group.
The term “alkyloxycarbonylalkyl” represents an “alkyloxycarbonyl” group as defined above attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “arylalkyloxycarbonylalkyl” represents an “arylalkyloxycarbonyl” group as defined above attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “alkylthio” (e.g. methylthio, ethylthio, propylthio, cyclohexylthio and the like) represents an “alkyl” group as defined above having the indicated number of carbon atoms attached through a sulfur bridge.
The term “arylalkylthio” (e.g. phenylmethylthio, phenylethylthio, and the like) represents an “arylalkyl” group as defined above having the indicated number of carbon atoms attached through a sulfur bridge.
The term “alkylthioalkyl” represents an “alkylthio” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “arylalkylthioalkyl” represents an “arylalkylthio” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylamino” (e.g. methylamino, diethylamino, butylamino, N-propyl-N-hexylamino, (2-cyclopentyl)propylamino, pyrrolidinyl, piperidinyl, and the like) represents one or two “alkyl” groups as defined above having the indicated number of carbon atoms attached through an amine bridge. The two alkyl groups may be taken together with the nitrogen to which they are attached forming a cyclic or bicyclic system containing 3 to 11 carbon atoms and 0 to 2 additional heteroatoms selected from nitrogen, oxygen or sulfur, the ring system can optionally be substituted with at least one C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, hydroxy, C 1 -C 6 alkyloxy, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, NRR 8 , C 1 -C 6 alkylaminoC 1 -C 6 alkyl substituent wherein the alkyl and aryl groups are optionally substituted as defined in the definition section and R and R 8 are defined as above.
The term “arylalkylamino” (e.g. benzylamino, diphenylethylamino and the like) represents one or two “arylalkyl” groups as defined above having the indicated number of carbon atoms attached through an amine bridge. The two “arylalkyl” groups may be taken together with the nitrogen to which they are attached forming a cyclic or bicyclic system containing 3 to 11 carbon atoms and 0 to 2 additional heteroatoms selected from nitrogen, oxygen or sulfur, the ring system can optionally be substituted with at least one C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, hydroxy, C 1 -C 6 alkyloxy, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, NRR 8 , C 1 -C 6 alkylaminoC 1 -C 6 alkyl substituent wherein the alkyl and aryl groups are optionally substituted as defined in the definition section and R 7 and R 8 are defined as above.
The term “alkylaminoalkyl” represents an “alkylamino” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “arylalkylaminoalkyl” represents an “arylalkylamino” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “arylalkyl” (e.g. benzyl, phenylethyl) represents an “aryl” group as defined below attached through an alkyl having the indicated number of carbon atoms or substituted alkyl group as defined above.
The term “alkylcarbonyl” (e.g. cyclooctylcarbonyl, pentylcarbonyl) represents an “alkyl” group as defined above having the indicated number of carbon atoms attached through a carbonyl group.
The term “arylalkylcarbonyl” (e.g. phenylcyclopropylcarbonyl, phenylethylcarbonyl and the like) represents an “arylalkyl” group as defined above having the indicated number of carbon atoms attached through a carbonyl group.
The term “alkylcarbonylalkyl” represents an “alkylcarbonyl” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “arylalkylcarbonylalkyl” represents an “arylalkylcarbonyl” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylcarboxy” (e.g. heptylcarboxy, cyclopropylcarboxy, 3-pentenylcarboxy) represents an “alkylcarbonyl” group as defined above wherein the carbonyl is in turn attached through an oxygen bridge.
The term “arylalkylcarboxy” (e.g. benzylcarboxy, phenylcyclopropylcarboxy and the like) represents an “arylalkylcarbonyl” group as defined above wherein the carbonyl is in turn attached through an oxygen bridge.
The term “alkylcarboxyalkyl” represents an “alkylcarboxy” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “arylalkylcarboxyalkyl” represents an “arylalkylcarboxy” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “alkylcarbonylamino” (e.g. hexylcarbonylamino, cyclopentylcarbonylaminomethyl, methylcarbonylaminophenyl) represents an “alkylcarbonyl” group as defined above wherein the carbonyl is in turn attached through the nitrogen atom of an amino group. The nitrogen atom may itself be substituted with an alkyl or aryl group.
The term “arylalkylcarbonylamino” (e.g. benzylcarbonylamino and the like) represents an “arylalkylcarbonyl” group as defined above wherein the carbonyl is in turn attached through the nitrogen atom of an amino group. The nitrogen atom may itself be substituted with an alkyl or aryl group.
The term “alkylcarbonylaminoalkyl” represents an “alkylcarbonylamino” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms. The nitrogen atom may itself be substituted with an alkyl or aryl group.
The term “arylalkylcarbonylaminoalkyl” represents an “arylalkylcarbonylamino” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms. The nitrogen atom may itself be substituted with an alkyl or aryl group.
The term “alkylcarbonylaminoalkylcarbonyl” represents an “alkylcarbonylaminoalkyl” group attached through a carbonyl group. The nitrogen atom may be further substituted with an “alkyl” or “aryl” group.
The term “aryl” represents an unsubstituted, mono-, di- or trisubstituted monocyclic, polycyclic, biaryl aromatic groups covalently attached at any ring position capable of forming a stable covalent bond, certain preferred points of attachment being apparent to those skilled in the art. Aryl thus contains at least one ring having at least 5 atoms, with up to two such rings being present, containing up to 10 atoms therein, with alternating (resonating) double bonds between adjacent carbon atoms. Aryl groups may likewise be substituted with 0-3 groups selected from R s . The definition of aryl includes but is not limited to phenyl, biphenyl, indenyl, fluorenyl, naphthyl (1-naphtyl, 2-naphthyl).
Heteroaryl is a group containing from 5 to 10 atoms, 1-4 of which are heteroatoms, 0-4 of which heteroatoms are nitrogen, and 0-1 of which are oxygen or sulfur, said heteroaryl groups being substituted with 0-3 groups selected from R s . The definition of heteroaryl includes but is not limited to pyrrolyl (2-pyrrolyl), pyrazolyl (3-pyrazolyl), imidazolyl (1-imidazolyl, 2-imidazolyl, 4-imidazolyl, 5-imidazolyl), triazolyl (1,2,3-triazol-1-yl, 1,2,3-triazol-2-yl, 1,2,3-triazol-4-yl, 1,2,4-triazol-3-yl), oxazolyl (2-oxazolyl, 4-oxazolyl, 5-oxazolyl), isoxazolyl (3-isoxazolyl, 4-isoxazolyl, 5-isoxazolyl), thiazolyl (2-thiazolyl, 4-thiazolyl, 5-thiazolyl), thiophenyl (2-thiophenyl, 3-thiophenyl), pyridyl (2-pyridyl, 3-pyridyl, 4-pyridyl), pyrimidinyl (2-pyrimidinyl, 4-pyrimidinyl, 5-pyrimidinyl, 6-pyrimidinyl), pyrazinyl, pyridazinyl (3-pyridazinyl, 4-pyridazinyl, 5-pyridazinyl), quinolyl (2-quinolyl, 3-quinolyl, 4-quinolyl, 5-quinolyl, 6-quinolyl, 7-quinolyl, 8-quinolyl), isoquinolyl (1-isopuinolyl, 3-isoquinolyl, 4-isoquinolyl, 5-isoquinolyl, 6-isoquinolyl, 7-isoquinolyl, 8-isoquinolyl), benzo[b]furanyl (2-benzo[b]furanyl, 3-benzo[b]furanyl, 4-benzo[b]furanyl, 5-benzo[b]furanyl, 6-benzo[b]furanyl, 7-benzo[b]furanyl), 2,3-dihydrobenzo[b]furanyl (2-(2,3-dihydrobenzo[b]furanyl), 3-(2,3-dihydrobenzo[b]furanyl), 4-(2,3-dihydrobenzo[b]furanyl), 5-(2,3-dihydrobenzo [b]furanyl), 6-(2,3-dihydrobenzo[b]furanyl), 7-(2,3-dihydro-benzo[b]furanyl)), benzo[b]thiophenyl (2-benzo[b]thiophenyl, 3-benzo[b]thiophenyl, 4-benzo[b]thiophenyl, 5-benzo[b]thiophenyl, 6-benzo[b]thiophenyl, 7-benzo[b]thiophenyl), 2,3-dihydrobenzo[b]thiophenyl (2-(2,3-dihydrobenzo [b]thiophenyl), 3-(2,3-dihydrobenzo[b]thiophenyl), 4-(2,3-dihydrobenzo[b]thiophenyl), 5-(2,3-dihydrobenzo[b]-thiophenyl), 6-(2,3-dihydrobenzo[b]thiophenyl), 7-(2,3-dihydrobenzo[b]thiophenyl)), indolyl (1-indolyl, 2-indolyl, 3-indolyl, 4-indolyl, 5-indolyl, 6-indolyl, 7-indolyl), indazolyl (1-indazolyl, 3-indazolyl, 4-indazolyl, 5-indazolyl, 6-indazolyl, 7-indazolyl), benzimidazolyl (1-benzimidazolyl, 2-benzimidazolyl, 4-benzimidazolyl, 5-benzimidazolyl, 6-benzimidazolyl, 7-benzimidazolyl, 8-benzimidazolyl), benzoxazolyl (1-benzoxazolyl, 2-benzoxazolyl), benzothiazolyl (1-benzothiazolyl, 2-benzothiazolyl, 4-benzothiazolyl, 5-benzothiazolyl, 6-benzothiazolyl, 7-benzothiazolyl), carbazolyl (1-carbazolyl, 2-carbazolyl, 3-carbazolyl, 4-carbazolyl), 5H-dibenz[b,f]azepinyl (5H-dibenz[b,f]azepin-1-yl, 5H-dibenz[b,f]azepin-2-yl, 5H-dibenz[b,f]azepin-3-yl, 5H-dibenz[b,f]azepin-4-yl, 5H-dibenz[b,f]azepie-5-yl), 10,11-dihydro-5H-dibenz[b,f]azepinyl (10,11-dihydro-5H-dibenz[b,f]azepin-1-yl, 10,11-dihydro-5H-dibenz[b,f]azepin-2-yl, 10,11-dihydro-5H-dibenz[b,f]azepin-3-yl, 10,11-dihydro-5H-dibenz[b,f]azepin-4-yl, 10,11-dihydro-5H-dibenz[b,f]azepin-5-yl), piperidinyl (2-piperidinyl, 3-piperidinyl, 4-piperidinyl), pyrrolidinyl (1-pyrrolidinyl, 2-pyrrolidinyl, 3-pyrrolidinyl), phenylpyridyl (2-phenylpyridyl, 3-phenylpyridyl, 4-phenylpyridyl), phenylpyrimidinyl (2-phenylpyrimidinyl, 4-phenylpyrimidinyl, 5-phenylpyrimidinyl, 6-phenylpyrimidinyl), phenylpyrazinyl, phenylpyridazinyl (3-phenylpyridazinyl, 4-phenylpyridazinyl, 5-phenylpyridazinyl).
The tern “arylcarbonyl” (e.g. 2-thiophenylcarbonyl, 3-methoxyanthrylcarbonyl, oxazolylcarbonyl) represents an “aryl” group as defined above attached through a carbonyl group.
The term “arylalkylcarbonyl” (e.g. (2,3-dimethoxyphenyl)propylcarbonyl, (2-chloronaphthyl)pentenylcarbonyl, imidazolylcyclopentylcarbonyl) represents an “arylalkyl” group as defined above wherein the “alkyl” group is in turn attached through a carbonyl.
The compounds of the present invention have asymmetric centers and may occur as racemates, racemic mixtures, and as individual enantiomers or diastereoisomers, with all isomeric forms being included in the present invention as well as mixtures thereof.
Pharmaceutically acceptable salts of the compounds of formula 1, where a basic or acidic group is present in the structure, are also included within the scope of this invention. When an acidic substituent is present, such as —COOH or —P(O)(OH) 2 , there can be formed the ammonium, morpholinium, sodium, potassium, barium, calcium salt, and the like, for use as the dosage form. When a basic group is present, such as amino or a basic heteroaryl radical, such as pyridyl, an acidic salt, such as hydrochloride, hydrobromide, acetate, oxalate, maleate, fumarate, citrate, palmoate, methanesulfonate, p-toluenesulfonate, and the like, can be used as the dosage form.
Also, in the case of the —COOH or —P(O)(OH) 2 being present, pharmaceutically acceptable esters can be employed (e.g. methyl, tert-butyl, pivaloyloxymethyl, and the like), and those esters known in the art for modifying solubility or hydrolysis characteristics for use as sustained release or prodrug formulations.
In addition, some of the compounds of the instant invention may form solvates with water or common organic solvents. Such solvates are encompassed within the scope of the invention.
The term “therapeutically effective amount” shall mean that amount of drug or pharmaceutical agent that will elicit the biological or medical response of a tissue, system, animal, or human that is being sought by a researcher, veterinarian, medical doctor or other.
Prefered compounds for use according to the invention are selected from the following species:
Methyl[1-cyclohexylcarbamoyl-4-benzyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetate;
[1-Cyclohexylcarbamoyl-4-benzyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetic acid;
N-Tetrahydrofurfuryl[1-cyclohexylcarbamoyl-4-benzyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-piperazin-2-yl]-acetamide;
[1-Cyclohexylcarbamoyl-4-benzyl-6-(S)-benzyl-5-oxo-piperazin-2-yl]-acetic acid;
N-Methyl[1-cyclohexylcarbamoyl-4-benzyl-6-(S)-benzyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl[1-cyclohexylcarbamoyl-4-(4-methoxybenzyl)-6-(S)-methylcarbamoyl-3-oxo-piperazin-2-yl]-acetamide;
N-Tetrahydrofurfuryl(R)-[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Tetrahydrofurfuryl(S)-[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Tetrahydrofurfuryl(R)-[1-cyclohexylcarbamoyl-4-cyclohexylmethyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Tetrahydrofurfuryl(S)-[1-cyclohexylcarbamoyl-4-cyclohexylmethyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl(R)-[1-cyclohexylcarbamoyl-4-(3-pyridylmethyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl(S)-[1-cyclohexylcarbamoyl-4-(3-pyridylmethyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl(R)-[1-cyclohexylcarbamoyl-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl(S)-[1-cyclohexylcarbamoyl-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
[1-cyclohexylcarbamoyl-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetic acid;
(R)-[1-cyclohexylcarbamoyl-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetic acid;
(S)-[1-cyclohexylcarbamoyl-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetic acid;
N-Methyl(R)-[1-(1-piperidylcarbamoyl)-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl(S)-[1-(1-piperidylcarbamoyl)-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Tetrahydrofurfuryl(R)-[1-cyclohexylcarbamoyl-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Tetrahydrofurfuryl(S)-[1-cyclohexylcarbamoyl-4-(3,4-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Tetrahydrofurfuryl(R)-[1-cyclohexylcarbamoyl-4-(4-dimethylminobenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Tetrahydrofurfuryl(S)-[1-cyclohexylcarbamoyl-4-(4-dimethylminobenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
Methyl[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetate;
N-Methyl(R)-[1-cyclohexylmethylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl(S)-[1-cyclohexylmethylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl(R)-[1-cyclohexylcarbamoyl-4-benzyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl(S)-[1-cyclohexylcarbamoyl-4-benzyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl(R)-[1-cyclopentylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl(S)-[1-cyclopentylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl(R)-[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl(S)-[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl(R)-[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl(S)-[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl(R)-[1-cyclohexylcarbamoyl-4-cyclohexylmethyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Butyl(S)-[1-cyclohexylcarbamoyl-4-cyclohexylmethyl6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl[1-cyclohexylcarbamoyl-4-cyclohexylmethyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-Methyl[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-butyl-5-oxo-piperazin-2-yl]-acetamide;
N-Ethyl[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
N-(2-Hydroxyethyl)[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide;
Preparation of Compounds
Compounds of formula 1 may be prepared by the application or adaptation of known methods, by which is meant methods used heretofore or described in the literature. General methods for preparing compounds according to the invention may also be prepared as described in the schemes that follows.
Scheme 1 illustrated below, refers to the preparation of compounds of the formula (1), wherein n=1, and R 3 is introduced from the corresponding amine used in the first step. The compound of formula 1-2 is prepared from a compound of formula 1-1, a 4-bromocrotonate derivative which can be reacted with an amine in an appropriate solvent (such as dichloromethane, DMF, THF, etc.). The subsequent coupling with an Fmoc amino acids or a Boc
amino acid in the presence of DIC or EDC in a solvent, such as DMF, THF or dichloromethane, under the standard conditions gives an acylated product of formula 1-3. Removal of Fmoc protecting group can be achieved by the treatment with piperidine in DMF. A simultaneous cyclization occurs under the basic conditions to give the cyclic compounds, formula 1-4. Alternatively, Boc protecting group can be removed under the standard condition (TFA/DCM) gives a free amine derivative which then undergoes an intramolecular Michael addition in the presence of base, such as triethylamine or DIEA. Compounds of formula 1-6 are obtained by the treatment with various isocyanates in the presence of a base (DIEA, triethylamine, DMAP or pyridine).
Alternatively, the preparation of a compound of formula 1-6 from 1-4 is also achieved via an intermediate of formula 1-5 which is formed by the treatment with excess of phosgene, triphosgene, sulfonyl chloride, or their equivalents, such as carbonyldiimidazole and sulfonyldiimidazole. The subsequent formation of a urea or a sulfonamide is achieved by the treatment with an amine.
The compound of formula 1-6 is then converted to a carboxylic acid of formula 1-8 under various cleavage conditions, preferably in the presence of LiOH/THF/H 2 O at room temperature for 15-24 h. A compound of formula 1-9 is prepared from the compound of formula 1-8 in the presence of an appropriate alcohol and a coupling reagent (DCC/DMAP, BOP-Cl/Et 3 N) in an aprotic solvent at 20-30° C., preferably at room temperature. An amide of formula 1-7 is prepared from the compound of formula 1-6 in the presence of an excess of amine. The compound of formula 1-8 can also be converted to the amide of formula 1-7 under various coupling conditions in the presence of the amine. Preferable coupling reagents are DIC and EDC in DCM or DMF.
Scheme 2 shows an alternative means for the preparation of a key intermediate of formula 1-2. A Boc-α-amino aldehyde undergoes Wittig reaction by using an alkyl dialkylphosphonoacetate under standard conditions to give an α,β-unsaturated ester.
Removal of the Boc protecting group gives the intermediate 1-2.
Scheme 3 shows a sequence for preparation of the corresponding piperazine analogs described as formula 3-5, 3-6, and 3-7. A reductive amination of Boc-α-amino aldehyde gives a 1,2-diamine of formula 3-2. The unprotected amino group is alkylated with a 4-bromocrotonate to give a precursor 3-3. An intramolecular cyclization under the same conditions as described in
Scheme 1 gives a piperazine intermediate. The same precedure can be followed for the preparation of ureas and sulfonamides.
An alternative means for the preparation of these compounds according to the invention is the use of solid phase synthesis method. As shown in Scheme 4, a bromocrotonate moiety can be linked to a solid support, e.g, Wang resin, Merrifield resin, etc. Compared to the Scheme 1, the solid support can be considered as an alternative protecting group. However, a unique advantage of this approach is the intermediate from each step is not to be purified, the reaction can be pushed to completion by using the excess of the reagents (usually 5-10 equiv.). A final compound is released under an appropriate cleavage condition.
Scheme 5 shows a sequence for the preparation of a class of compounds described as formula 5-6. By the solid phase approach, An orthogonally protected Boc-Fmoc-diaminopropionate resin is selectively de-protected to release β-amino group. A reductive alkylation followed by acylation with fumaric acid monoester give a compound of formula 5-3.
Removal of the Boc group followed by cyclization give a polymer-bound piperazinone intermediate of formula 5-4. The further functional groups, such as urea and sulfonamide, can be introduced under the same conditions described above.
EXAMPLES
The following examples are by way of illustration of various aspects of the present invention and are not intended to be limiting thereof.
General Procedures—Reagent Systems and Test Methods
Anhydrous solvents were purchased from Aldrich Chemical Company and used directly. Resins were purchased from Advanced ChemTech, Louisville, Ky., and used directly. The loading level ranged from 0.35 to 1.1 mmol/g. Unless otherwise noted, reagents were obtained from commercial suppliers and used without further purification. Preparative thin layer chromatography was preformed on silica gel pre-coated glass plates (Whatman PK5F, 150 Å, 1000 μm) and visualized with UV light, and/or ninhydrin, p-anisaldehyde, ammonium molybdate, or ferric chloride. NMR spectra were obtained on a Varian Mercury 300 MHz spectrometer. Chemical shifts are reported in ppm. Unless otherwise noted, spectra were obtained in CDCl 3 with residual CHCl 3 as an internal standard at 7.26 ppm. IR spectra were obtained on a Midac M1700 and absorbencies are listed in inverse centimeters. HPLC/MS analysis were performed on a Hewlett Packard 1100 with a photodiode array detector coupled to a Micros Platform II electrospray mass spectrometer. An evaporative light scattering detector (Sedex 55) was also incorporated for more accurate evaluation of sample purity. Reverse phase columns were purchased from YMC, Inc. (ODS-A, 3 μm, 120 Å, 4.0×50 mm).
Solvent system A consisted of 97.5% MeOH, 2.5% H 2 O, and 0.05% TFA. Solvent system B consisted of 97.5% H 2 O, 2.5% MeOH, and 0.05% TFA. Samples were typically acquired at a mobile phase flow rate of 2 ml/min involving a 2 minute gradient from solvent B to solvent A with 5 minute run times. Resins were washed with appropriate solvents (100 mg of resin/1 ml of solvent). Technical grade solvents were used for resin washing.
Examples 1-3
Preparation of methyl[1-cyclohexylcarbamoyl-4-benzyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetate, [1-cyclohexylcarbamoyl-4-benzyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acelic acid, and N-tetrahydrofurfuryl[1-cyclohexylcarbamoyl-4-benzyl-6-(S)-isobutyl-5-oxo-piperazin-2-yl]-acetamide
Substitution with Amine
To a solution cooled at 0 C. containing methyl 4-bromocrotonate (2 mL, 17 mmol) and DCM (25 mL) were added benzyl amine (2.2 mL, 20.4 mmol) and DIEA (5.9 mL, 34 mmol). The mixture was stirred at 0 C. for 10 min, then warmed to rt with continuing stirring for 2 h at which time TLC analysis indicated the starting material had been consumed. The mixture was then concentrated and the residue was treated with EtOAc. The solid was filtered and washed with EtOAc. The combined filtrates were concentrated to give the crude product.
Boc Protection
A half amount of the above crude product was treated with dioxane (10 mL), water (3 mL) and DIEA (2 mL). To this mixture was added (Boc) 2 O (1.8 g, 9 mmol). After vigorously stirring at rt for 2 h, TLC indicated the reaction was completed. The mixture was concentrated, diluted with EtOAc, washed with aqueous citric acid and with brine. The organic layer was dried over Na 2 SO 4 , filtered and concentrated to give a residue which was purified by flash chromatography on silica gel (1.6 g, 62% yield).
Acylation with an Amino Acid
Another half amount of the crude product obtained from the first step was added to a mixture of Fmoc-L-Leu-OH (3.5 g, 10 mmol) and DCM (20 mL). After the resulting mixture was cooled to 0 C., EDC (1.9 g, 10 mmol) was added. The mixture was stirred for 15 min, then warmed to room temperature with stirring for another 3 h. The mixture was diluted with EtOAc, washed with 1N HCl, water and brine. The organic layer was dried over Na 2 SO 4 . Filtration followed by concentration gave a residue which was purified by flash chromatography on silica gel (2.6 g, 56%). MS (ES) m/e: 541 (M+H + ).
Deprotection and Cyclization
The above Fmoc-Leu coupled product (1.08 g, 2 mmol) was treated with 5% piperidine in DCM for 30 min. The solution was concentrated, the residue was diluted with EtOAc, and then washed with H 2 0. The organic layer was dried over Na 2 SO 4 . Filtration and concentration gave the crude cyclic product which was then dissolved in DCM (10 mL). Cyclohexyl isocyanate (500 mg, 4 mmol) was added. The mixture was stirred at rt for 2 h. Water was then added, the product was extracted with EtOAc. The organic layer was dried over Na 2 SO 4 , filtered and concentrated to give a residue. Purification by flash chromatography on silica gel gave the title compound (700 mg, 79% yield). MS (ES) m/e: 444 (M+H + ).
Hydrolysis of Methyl Ester
The methyl ester obtained in the above step (150 mg) was treated with 1.2 equiv. of LiOH in a 1:1 mixture of dioxane and water (5 mL). The mixture was stirred at rt until the methyl ester had been consumed. The mixture was then concentrated and another equiv. of LiOH in 5 mL of water was added. The aqueous layer was washed with Et 2 O, then acidified by addition of a 1 N HCl solution. The product was extracted with EtOAc. The organic layer was washed with water, dried over Na 2 SO 4 . Filtration followed by concentration gave the pure product (100 mg). MS (ES) m/e: 430 (M+H + ).
Amide
The carboxylic acid obtained above (50 mg, 0.12 mmol) was dissolved in 1 mL of DCM. Tetrahydrofurfurylamine (20 mg, 0.2 mmol) and EDC (38.5 mg, 0.2 mmol) were added. The resulting mixture was stirred at rt for 12 h, then diluted with EtOAc, washed with 1 N HCl. The organic layer was then neutralized with sat. NaHCO 3 followed by washing with brine. Concentration under reduced pressure gave an oil which was purified by flash chromatography(hexane:EtOAc, 2:1-1:1) (45 mg, 89% yield). The product contains two diastereoisomers (cis and trans) which were separated on a preparative TLC plate. MS (ES) m/e: 513 (M+H + ).
Example 4
Preparation of N-methyl[1-cyclohexylcarbamoyl-4-(3,5-dimethoxybenzyl)-6-(S)-isobutyl-piperazin-2-yl]-acetamide
Reductive Amination
To a mixture of Boc-L-Leu-CHO (1.17 g, 5.5 mmol) in DCM (30 mL) were added trimethyl orthoformate (1.18 mL, 10.8 mmol), 3,5-dimethoxybenzylamine (1 g, 5.9 mmol) and a catalytic amount of HOAc (0.2 mL). The resulting mixture was stirred at rt for 4 h. The mixture was concentrated and dried in vacuo. The obtained imine was dissolved in 10 mL of MeOH. To this solution was added sodium cyanoborohydride (650 mg, 11 mmol). The resulting mixture was stirred at rt overnight, then poured into ice water with stirring for 5 min, extracted with EtOAc. The organic layer was washed with sat. NaHCO 3 and brine. Concentration gave the crude product which was purified by flash chromatography on silica gel (1.4 g, 70% yield).
N-alkylation with methyl 4-bromocrotonate
To a solution of the amine prepared above (366 mg, 1 mmol) and DIEA (258 mg, 2 mmol) in DCM (5 mL) cooled at 0 C. was added methyl 4-bromocrotonate (215 mg, 1.2 mmol). The mixture was stirred at 0 C. for 10 min, then warmed to rt. Stirring continued for 12 h at which time TLC analysis indicated the starting material had been consumed. The mixture was then concentrated and the residue was treated with EtOAc. The solid was filtered and washed with EtOAc. The combined filtrates were concentrated to give the crude product which was purified by flash chromatography on silica gel (250 mg, 54% yield). MS (ES) m/e: 465 (M+H + ).
De-protection and Cyclization
The obtained product from the previous step (100 mg) was treated with 20% TFA in DCM (0.5 mL) at rt for 15 min. The mixture was then evaporated to give a residue which was dissolved in DCM (5 mL). The solution was then washed with sat. NaHCO 3 . DIEA (5 mmol) was added. After stirring for 30 min, the mixture was concentrated to give the crude cyclic product which was directly used for the next step without further purification. MS (ES) m/e: 365 (M+H + ).
Urea Formation and Aminolysis
The above crude product was dissolved in 2 mL of DCE, cyclohexyl isocyanate (50 mg, 0.4 mmol) was then added. After stirring at rt for 2 h, it was treated with 1 mL of water. The organic layer was separated and concentrated to give a residue which was treated with a 1:1 mixture of 40% MeNH 2 (aq.) and THF (1 mL). The mixture was stirred at rt for 12 h. Concentration followed by purification on a preparative TLC plate gave the pure compound (70 mg, 66% yield). MS (ES) m/e: 489 (M+H + ).
Example 5
Preparation of [1-cyclohexylcarbamoyl-4-benzyl-6-(S)-benzyl-5-oxo-piperazin-2-yl]-acetic acid
Step 1: Displacement of Bromide
4-Bromocrotonate Wang Resin (300 mg, loading 0.9 mmol/g) was suspended in a solution of benzylamine [0.5M] in NMP (8 mL) and shaken for 45 min at room temperature. After filtration, the resulting mixture was washed by 2×10 mL of DMF, 3×10 mL of DCM/MeOH, 2×10 mL of DCM then dried under nitrogen. IR(KBr): 1718 cm −1 .
Step 2: Acylation
To the resin were added Fmoc-L-phenylalanine (10 eq), DIC (10 eq), and DMF (3 mL/100 mg of resin). The resulting mixture was shaken for 24 h at room temperature. After filtration, the resin was washed with 2×DMF (3 mL/100 mg of resin), 2×DCM/MeOH, 2×DCM then dried under nitrogen.
Step 3: Deprotection and Cyclization
The resin was suspended in a solution of piperidine (20%) in DMF (3 mL/100 mg of resin) and shaken for 30 min. After filtration, the resin was washed with 2×DMF (3 mL/100 mg of resin), 2×DCM/MeOH, 2×DCM then dried under nitrogen. IR (KBr): 1734 cm −1 .
Step 4: Formation of Urea
The resin was suspended in a solution of cyclohexyl isocyanate [0.5M] in DCE (3 mL/100 mg of resin) and shaken for 12 h at room temperature. The resin was filtered and washed by 2×DME, 2×DCM/MeOH, 2×DCM then dried under nitrogen.
Alternative Method for the Formation of Urea
The resin was suspended in a solution of 0.1 M DIEA in DCE (1 mL/100 mg resin). A solution of 0.1 M triphosgene (0.5 mL/100 mg resin) was then added. After shaking at rt for 4 h, a solution of 1 M cyclohexylamine in DMF (0.3 mL) was added. Shaking continued overnight. The resin was filtered and washed with 2×DMF, 3×DCM/MeOH, 3×DCM then dried under nitrogen.
Step 5: Cleavage of the Product
The resin was suspended in a mixture of TFA (25%) in DCM (3 mL/100 mg of resin) and shaked for 30 min. After filtration, the resin was washed by 2×DCM (3 mL/100 mg of resin). The volatils were removed under reduced pressure to lead to crude 50 mg. Purification via the ester (treatment of the crude by TMSCH 2 N 2 ) afforded 25 mg of pure desired compound as a mixture of two isomers with a 2:1 ratio (39%, based on 0.9 mmol/g loading). MS (ES) m/e (relative intensity): 478 (M+H + , 100), 353 (40).
1H NMR (a mixture of two isomers of the corresponding methyl esters, CDCl 3 ) δ7.40-7.02 (m, 10H), 4.90 (d, 1H), 4.76 (d, 1H), 4.71 (dd, 1H), 4.55 (dd, 1H), 4.50 (m, 1H), 4.32 (d, 1H), 4.31 (d, 1H), 4.08 (d, 1H), 4.02 (m, 1H), 3.73 (m, 2H), 3.62 (m, 1H), 3.57 (s, 3H), 3.54 (dd, 1H), 3.48 (s, 3H), 3.43 (dd, 1H), 3.40 (dd, 1H), 3.19 (dd, 1H), 3.09 (dd, 1H), 3.04 (dd, 1H), 2.87 (dd, 1H), 2.48 (dd, 1H), 2.20 (m, 1H), 2.17 (dd, 1H), 1.97 (dd, 1H), 1.95-1.80 (m, 2H), 1.71-1.57 (m, 3H), 1.41-1.25 (m, 2H), 1.10 (m, 1H).
Example 6
Preparation of N-methyl[1-cyclohexylcarbamoyl-4-benzyl-6-(S)-benzyl-5-oxo-piperazin-2-yl]-acetamide
Step 1-5
Starting from 4-bromocrotonate Merrifield Resin, the same procedure was followed as described for the preparation of Example 5.
Step 6: Cleavage of the Product
The resin was suspended in a 1:1 mixture of methylamine (40% in H 2 O)/THF (3 mL per 100 mg of resin) and shaken for 24 h. After filtration, the resin was washed by 2×DCM (3 mL/100 mg of resin). The volatiles were removed under reduced pressure to afford crude product (69 mg). After purification on a preparative TLC plate, 35 mg of the pure desired compound were isolated as a mixture of two isomers with a 2:1 ratio (55%, based on 0.9 mmol/g loading). MS (ES) m/e (relative intensity): 477 (M+H + , 70), 352 (100).
1H NMR (a mixture of two isomers, CDCl 3 ) δ7.40-7.05 (m, 10H), 5.24 (d, 1H), 5.15 (d, 1H), 4.98 (d, 1H), 4.90 (d, 1H), 4.79 (dd, 1H), 4.66 (dd, 1H), 4.58 (br, 1H), 4.35 (m, 1H), 4.22 (d, 1H), 3.77 (dd, 1H), 3.70 (d, 1H), 3.61 (m, 1H), 3.53 (dd, 1H), 3.43 (m, 1H), 3.37 (dd, 1H), 3.10 (dd, 1H), 3.02 (dd, 1H), 2.59 (d, 3H), 2.50 (d, 3H), 2.26 (d, 1H), 2.02 (d, 1H), 1.94 (d, 1H), 1.82-1.55 (m, 4H), 1.37-1.25 (m, 2H), 1.13 (m, 1H).
Example 7
Preparation of N-methyl[1-cyclohexylcarbamoyl-4-(4-methoxybenzyl)-6-(S)-methylcarbamoyl-3-oxo-piperazin-2-yl]-acetamide
Reductive N-alkylation
N α -Boc-N β -Fmoc-(S)-2,3-diaminopropionate Merrifield resin [Boc-(Fmoc)Dpr-Merrifield resin] (0.84 g, 0.6 mmol/g) was treated with 20% piperidine in DMF at room temperature for 30 min. The mixture was filtered and theresin was washed with DMF (3×), MeOH/DCM (5×) and DCM (3×). After drying in vacuo, the resin was mixed with anisaldehyde (0.62 mL, 10 equiv.), trimethyl orthoformate (TMOF) (3.5 mL) and DCM (3.5 mL). The resulting slurry was shaken at room temperature for 4 h. The resin was filtered, and washed with DMF (2×), MeOH/DCM (3×), and DMF (3×). The obtained resin was then mixed with 0.17 M NaBH 3 (CN) in MeOH (7.5 mL) and 1% AcOH in DMF (7.5 mL). The suspension was shaken at room temperature overnight. The resin was filtered, washed with DMF (3×), 1 M DIEA in DCM (1×), MeOH/DCM (3×), and DCM (3×), and dried in vacuo.
Acylation
The dried resin (250 mg, 0.16 mmol) was treated with fumaric acid ethyl monoester (10 equiv.), EDC (12 equiv.) and NMP (1.7 mL). The suspension was shaken overnight. The resin was filtered, washed with DMF (3×), MeOH/DCM (5×) and DCM (3×).
De-protection and Cyclization
The above resin was treated with 20% TFA in DCM (5 mL) for 30 min, then washed with DCM (6×) and 1 M DIEA in NMP (3.5 mL). An additional portion of 1 M DIEA in NMP was added and the resulting mixture was kept at room temperature for 1 h. Filtration followed by washing [DMF (2×), DCM/MeOH (3×) and DCM (3×)] gave the cyclic product.
Urea Formation and Cleavage
The above resin was mixed with 0.5 M cyclohexyl isocyanate in DCE (3 mL) overnight. Filtration followed by washing with DMF (3×), MeOH/DCM (3×) and DCM (3×), gave the resin which was then treated with a 1:1 mixture of 40% MeNH2 aqueous solution and THF for 20 h. The resin was filtered and washed with THF. The combined filtrates were concentrated to give a residue. Purification on a preparative TLC plate (MeOH/Hexane/EtOAc: 1:3:3) gave the desired product as a mixture of two diastereoisomers. MS (ES): 474 (M+1).
Examples 8-43
The following compounds are made using the methods described and examplified above.
Isomer/
Examples
Mixture
R3
R4
G
B
R5
8
A
NH
9
B
NH
10
A
NH
11
B
NH
12
A
NH
13
B
NH
14
A
NH
15
B
NH
16
M
O
H
17
A
O
H
18
B
O
H
19
A
NH
Me
20
B
NH
Me
21
A
NH
22
B
NH
23
A
NH
24
B
NH
25
M
O
Me
26
A
NH
Me
27
B
NH
Me
28
A
NH
Me
29
B
NH
Me
30
A
NH
Me
31
B
NH
Me
32
M
NH
Me
33
A
NH
Me
34
B
NH
Me
35
M
NH
36
A
NH
37
B
NH
38
A
NH
39
B
NH
40
M
NH
Me
41
M
NH
Me
42
M
NH
43
M
NH
Example 8
1 H NMR (CDCl 3 ): δ0.96 (d, J=6.6 Hz 6H), d 1.08-1.70 (m, 8H), d 1.78-2.06 (m, 7H), d 2.22-2.30 (m, 1H), d 2.56-2.65 (m, 1H), d 3.04-3.13 (m, 2H), d 3.46-3.57 (m, 3H), d 3.70-3.95 (m, 3H), d 3.75 (s, 6H), d 4.35 (dd, J=14.7, 5.7 Hz, 1H), d 4.45-4.50 (m, 1H), d 4.62 (dd, J=14.4, 5.1 Hz, 1H), d 4.83 (t, J=6.6 Hz, 1H), d 5.74 (br, 1H), d 6.13 (br, 1H), d 6.36 (s, 3H).
Example 9
1 H NMR (CDCl 3 ): d 0.89 (d, J=6.3 Hz, 3H), d 1.06 (d, J=6.3 Hz, 3H), d 1.07-1.17 (q, J=12.0 Hz, 2H), d 1.25-1.69 (m, 7H), d 2.30 (d, J=14.1 Hz, 1H), d 2.94-3.12 (m, 1H), d 3.23 (d, J=13.8 Hz, 1H), d 3.30-3.48 (m, 1H), d 3.57-3.64 (m, 2H), d 3.68-3.90 (m, 3H), d 3.74 (s, 6H), d 4.14 (br d, J=7.2 Hz, 1H), d 4.38 (br dd, J=10.8, 3.6 Hz, 1H), d 4.52 (s, 2H), d 5.05 (br dd, J=13.2, 10.5 Hz, 1H), d 5.76 (br d, J=5.7 Hz, 1H), d 6.37-6.41 (m, 3H).
Example 10
1 H NMR (CDCl 3 ): δ0.90-0.97 (m, 9H), δ1.15-2.06 (m, 23H), δ2.40 (dd, J=14.7, 4.8 Hz 1H), δ2.66 (dq, J=15.3, 4.5 Hz, 1H), δ3.07-3.30 (m, 4H), δ3.52-3.64 (m, 3H), δ6 3.73-3.97 (m, 5H), δ4.50 (t, J=6.0 Hz, 1H), δ4.62 (t, J=7.2 Hz, 1H), δ5.47 (t, J=7.2 Hz, 1H), δ6.22 (br, 1H).
Example 11
1 H NMR (CDCl 3 ): δ0.89 (d, J=6.6 Hz, 3H), d 1.05 (d, J=6.6 Hz, 3H), d 0.87-2.03 (m, 28H), d 2.28 (dd, J=14.1, 9.3 Hz, 1H), d 2.48 (d, J=13.5 Hz, 1H), d 2.74 (dd, J=13.8, 6.0 Hz, 1H), d 3.07-3.21 (m, 1H), d 3.43-3.95 (m, 8H), d 4.14 (t, J=6.3 Hz, 1H), d 4.30 (br d, J=7.2 Hz, 1H), d 4.63 (br t, J=9.0 Hz, 1H), d 6.29 (br, 1H).
Example 12
1 H NMR (CDCl 3 ): δ0.89-0.98 (m, 9H), d 1.10-1.91 (m, 17H), d 2.20 (dd, J=15.3, 5.1 Hz, 1H), d 2.58 (dd, J=15.3, 8.7 Hz, 1H), d 3.08-3.24 (m, 3H), d 3.53-3.62 (m, 2H), d 4.34 (d, J=14.7 Hz, 1H), d 4.52-4.57 (m, 1H), d 4.78-4.83 (m, 2H), d 5.76 (br d, J=6.3 Hz, 1H), d 6.07 (br, 1H), d 7.25-7.29 (m, 1H), d 7.60-7.63 (m, 1H), d 8.50-8.54 (m, 2H).
Example 13
1 H NMR (CDCl 3 ): d 0.90-0.94 (m, 6H), d 1.06-2.00 (m, 21H), d 2.36 (d, J=12.9 Hz, 1H), d 3.11-3.19 (m, 2H), d 3.43 (dd, J=13.5, 2.1 Hz, 1H), d 3.61-3.66 (m, 2H), d 4.21-4.29 (m, 2H), d 4.55 (d, J=14.7 Hz, 1H), d 4.73-4.80 (m, 2H), d 5.63 (br, 1H), d 7.29-7.30 (m, 1H), d 7.6-7.71 (m, 1H), d 8.57-8.58 (m, 2H).
Example 14
1 H NMR (CDCl 3 ): d 0.88-0.99 (m, 9H), d 1.10-1.19 (m, 3H), d 1.29-1.48 (m, 7H), d 1.55-1.67 (m, 6H), d 1.80-1.95 (m, 4H), d 1.21 (dd, J=15.0, 5.7 Hz, 1H), d 2.53 (dd, J=15.0, 8.1 Hz, 1H), d 3.10-3.29) m, 3H), d 3.48-3.54 (m, 2H), d 3.86 (s, 6H), d 4.35 (d, J=14.1 Hz, 1H), d 4.48 (br, 1H), d 4.63-4.70 (m, 2H), d 5.51 (br, 1H), d 5.80 (br, 1H), d 6.79 (s, 3H).
Example 15
1 H NMR (CDCl 3 ): δ0.87-0.98 (m, 6H), d 1.08 (d, J=6.3 Hz, 3H), d 1.06-1.19 (m, 3H), d 1.24-1.42 (m, 6H), d 1.48-1.68 (m, 5H), d 1.88-1.96 (m, 4H), d 2.25 (d, J=14.1 Hz, 1H), d 3.04-3.14 (m, 2H), d 3.27 (d, J=13.2 Hz, 1H), d 3.60 (br d, J=12.9 Hz, 2H), d 3.85 (s, 6H), d 4.10 (br d, J=8.4 Hz, 1H), d 4.34-4.39 (m, 2H), d 4.68 (br d, J=9.9 Hz, 1H), 4.93 (br, 1H), d 5.28 (br, 1H), d 6.69-6.87 (m, 3H).
Example 16
1H NMR (CDCl13): d 1.03-1.80 (m, 7H), d 1.11 (t, J=6.3 Hz, 6H), d 1.96-2.07 (m, 4H), d 2.42 (dd, J=15.9, 6.3 Hz, 1H), d 2.82 (dd, J=15.9, 6.9 Hz, 1H), d 3.26 (dd, J=13.2, 5.7 Hz, 1H), d 3.55-3.86 (m, 5H), d 3.88 (s, 6H), d 4.45 (d, J=14.4 Hz, 1H), d 4.57 (t, J=6.6 Hz, 1H), d 4.69 (t, J=6.0 Hz, 1H), d 4.80 (d, J=14.4 Hz, 1H), d 5.09 (br d, J=5.7 Hz, 1H), d 6.48 (s, 3H).
Example 17
1H NMR (CDCl3): d 1.04 (d, J=6.6 Hz, 3H), d 1.19 (d, J=6.3 Hz, 3H), d 1.18-1.28 (m, 5H), d 1.67-1.80 (m, 5H), d 1.99-2.08 (m, 3H), d 2.42 (dd, J=15.6, 8.7 Hz, 1H), d 2.59 (dd, J=15.6, 3.3 Hz, 1H), d 3.47 (d, J=13.5 Hz, 1H), d 3.71 (dd, J=14.1, 3.6 Hz, 1H), d 3.86 (s, 6H), d 4.23 (d, J=14.7 Hz, 1H), d 4.31 (dd, J=9.9, 4.8 Hz, 1H), d 4.49 (br, 1H), d 4.63 (br d, J=7.2 Hz, 1H), d 5.06 (d, J=14.4 Hz, 1H), d 6.60-6.40 (br, 1H), d 6.48 (s, 3H).
Example 18
1H NMR (CDCl3): d 1.09 (t, J=6.3 Hz, 6H), d 1.22 (d, J=6.9 Hz, 1H), d 1.60-2.21 (m, 8H), d 2.30 (s, 1H), d 2.34-2.37 (m, 2H), d 2.78 (t, J=5.7 Hz, 1H), d 2.91 (d, J=4.8 Hz, 3H), d 3.15-3.21 (m, 2H), d 3.40-3.50 (m, 1H), d 3.66 (dd, 9.9,3.3 Hz, 1H), d 3.89 (s, 6H), d 4.47 (d, J=14.4 Hz, 1H), d 4.77 (d, J=14.7 Hz, 1H), d 6.50 (s, 3H), d 6.70 (br, 1H).
Example 19
1H NMR (CDCl3): d 1.04 (d, J=6.3 Hz, 3H), d 1.21 (d, J=6.0 Hz, 3H), d 1.62-2.37 (m, 6H), d 2.77 (d, J=4.8 Hz, 3H), d 2.92 (d, J=4.5 Hz, 3H), d 3.30 (d, J=13.5 Hz, 1H), d 3.81 (d, J=12.9 Hz, 1H), d 3.87 (s, 6H), d 4.21 (br d, J=7.5 Hz, 1H), d 4.32 (d, J=14.4 Hz, 1H), 4.60 (br d, J=7.5 Hz, 1H), d 4.96 (d, J=13.8 Hz, 1H), d 5.31 (br, 2H), d 6.54 (s, 1H), d 6.60 (s, 2H).
Example 20
1 H NMR (CDCl 3 ): d 0.96 (d, J=6.3 Hz, 6H), d 1.06-1.21 (m, 3H), d 1.26-1.39 (m, 3H), d 1.44-1.66 (m, 4H), d 1.70, 1.98 (m, 8H), d 2.22 (dt, J=15.3, 4.8 Hz, 1H), d 2.57 (dq, J=15.3, 4.2 Hz, 1H), d 3.00-3.13 (m, 2H), d 3.46-3.57 (m, 3H), d 3.70-3.90 (m, 2H), d 3.85 (s, 6H), d 4.36 (dd, J=14.4, 4.8 Hz, 1H), d 4.44-4.49 (m, 1H), d 4.62 (dd, J=14.4, 4.2 Hz, 1H), d 4.80 (t, J=6.9 Hz, 1H), d 5.70 (br t, J=6.9 Hz, 1H), d 6.09 (br, 1H), d 6.75-6.81 (m, 3H).
Example 21
1 H NMR (CDCl 3 ): d 0.90 (d, J=6.6 Hz, 3H), d 1.08 (d, J=6.6 Hz, 3H), d 1.06-1.19 (m, 3H), d 1.22-1.38 (m, 2H), d 1.42-1.71 (m, 6H), d 1.78-1.98 (m, 7H), d 2.28 (d, J=14.1 Hz, 1H), d 2.94-3.06 (m, 1H), d 3.31 (d, J=12.9 Hz, 1H), d 3.38-3.48 (m, 1H), d 3.61 (d, J=10.5 Hz, 2H), d 3.70-3.92 (m, 3H), d 3.85 (d, J=6.2 Hz, 6H), d 4.13 (d, J=9.9 Hz, 1H), d 4.37 (dd, J=11.1, 4.2 Hz, 1H), d 4.48 (dd, J=14.1, 9.3 Hz, 1H), d 4.59 (dd, J=14.1, 6.9 Hz, 1H), d 4.99 (br t, J=9.0 Hz, 1H), d 5.68 (br, 1H), d 6.83 (s, 2H), d 6.88 (s, 1H).
Example 22
1H NMR (CDCl3): d 0.92-0.96 (m, 6H), d 1.07-1.25 (m, 3H), d 1.32-1.40 (m, 3H), d 1.45-1.70 (m, 5H), d 1.85-1.99 (m, 6H), d 2.19 (dd, J=16.1, 5.4 Hz, 1H), d 2.50-2.56 (m, 1H), d 2.95 (s, 6H), d 3.03-3.10 (m, 2H), d 3.44-3.60 (m, 3H), d 3.69-3.75 (m, 1H), d 3.79-3.88 (m, 2H), d 4.23 (d, J=14.1 Hz, 1H), d 4.44-4.49 (m, 1H), d 4.70 (d, J=14.4 Hz, 1H), d 4.78 (t, J=6.6 Hz, 1H), d 5.65 (br t, J=7.5 Hz, 1H), d 6.01 (br, 1H), d 6.66 (d, J=8.7 Hz, 2H), d 7.11 (d, J=8.7 Hz, 2H).
Example 23
1 H NMR (CDCl 3 ): d 0.91 (d, J=6.6 Hz, 3H), d 0.98 (d, J=6.6 Hz, 3H), d 0.99-1.21 (m, 2H), d 1.23-1.71 (m, 8H), d 1.78-1.96 (m, 7H), d 2.20 (d, J=14.7 Hz, 1H), d 2.84-3.10 (m, 1H), d 2.95 (s, 6H), d 3.18 (dd, J=12.3, 5.7 Hz, 1H), d 3.28-3.44 (m, 1H), d 3.62 (d, J=10.5 Hz, 2H), d 3.67-3.88 (m, 1H), d 4.05 (br d, J=4.8 Hz, 1H), d 4.11 (t, J=13.8 Hz, 1H), d 4.43 (br dd, 1H), d 4.87 (t, J=13.2 Hz, 1H), d 5.17 (br t, J=6.6 Hz, 1H), d 5.38 (br, 1H), d 6.69 (d, J=8.7 Hz, 2H), d 7.20 (d, J=6.6 Hz, 2H).
Example 24
1H NMR (CDCl3): d 1.03-2.06 (m, 28H), d 2.36 (dd, J=16.5,9.9 Hz, 2H), d 2.44 (dd, J=15.0, 5.7 Hz, 1H), d 2.66 (d, J=14.4 Hz, 2H), d 2.95 (dd, J=16.5,7.8 Hz, 1H), d 3.22 (dd, J=12.9, 4.2 Hz, 1H), d 3.49 (d, J=13.8 Hz, 2H), d 3.61-3.81 (m, 10H), d 3.88 (s, 12H), d 4.31-4.46 (m, 8H), d 4.56-4.68 (m, 6H), d 4.86-4.90 (m, 2H), d 5.22 (br d, J=7.5 Hz, 1H), d 6.44-6.51 (m, 6H).
Example 25
1 H NMR (CD 3 OD): d 1.08 (t, J=6.6 Hz, 6H), d 1.34-1.41 ((m, 4H), d 1.62-1.93 (m, 9H), d 2.50 (dd, J=15.3, 6.0 Hz, 1H), d 2.78 (dd, J=12.0, 8.1 Hz, 1H), d 2.81 (s, 3H), d 3.12 (t, J=6.2 Hz, 2H), d 3.39 (dd, J=13.2, 4.8 Hz, 1H), d 3.43 (s, 1H), d 3.68 (dd, J=13.2, 6.0 Hz, 1H), d 3.88 (s, 6H), d 4.03 (m, 1H), d 4.51 (d, J=14.7 Hz, 1H), d 4.58 (m, 1H), d 4.77 (d, J=14.7 Hz, 1H), d 5.10 (dd, J=9.0, 4.8 Hz, 1H), d 6.54 (d, J=2.2 Hz, 2H), d 7.02 (d, J=2.2 Hz, 1H).
Example 26
1 H NMR (CD 3 OD): d 0.98-1.10 (m, 2H), d 1.02 (d, J=6.3 Hz, 3H), d 1.15 (d, J=6.3 Hz, 3H), d 1.24-1.39 (m, 2H), d 1.50-1.65 (m, 1H), d 1.71-1.86 (m, 7H), d 2.31 (dd, J=15.3, 9.0 Hz, 1H), d 2.48 (dd, J=15.0, 3.1 Hz, 1H), d 2.78 (s, 3H), d 3.03-3.21 (m, 2H), d 3.52 (dd, J=13.8, 1.8 Hz, 1H), d 3.85 (dd, J=13.5, 2.4 Hz, 1H), d 3.88 (s, 6H), d 4.39 (br d, J=14.1 Hz, 2H), d 4.62 (q, J=4.8 Hz, 1H), d 4.91 (d, J=14.4 Hz, 1H), d 6.53-6.57 (m, 3H).
Example 27
1H NMR (CDCl3): d 1.10 (t, J=6.6 Hz, 6H), d 1.22-1.53 (m, 6H), d 1.68-2.01 (m, 7H), d 2.32 (dd, J=15.0, 6.0 Hz, 1H), d 2.68 (dt, J=15.0, 7.5 Hz, 1H), d 2.87 (d, J=4.8 Hz, 3H), d 3.23 (dd, J=12.6, 4.2 Hz, 1H), d 3.64 (dd, J=12.9, 5.1 Hz, 1H), d 3.64-3.77 (m, 1H), d 4.46 (d, J=14.2 Hz, 1H), d 4.61 (m, 1H), d 4.85 (dd, J=7.5, 6.6 Hz, 1H), d 4.93 (d, J=14.7 Hz, 1H), d 5.62 (br, d, J=7.8 Hz, 1H), d 5.92 (br, 1H), d 7.35-7.50 (m, 5H).
Example 28
1H NMR (CDCl3): d 1.04 (t, J=6.6 Hz, 3H), d 1.20 (t, J=6.6 Hz, 3H), d 1.23-1.32 (m, 3H), d 1.37-1.47 (m, 4H), d 1.66-1.81 (m, 4H), d 1.93-1.99 (m, 4H), d 2.34 (d, J=14.4 Hz, 1H), d 2.72 (d, J=4.8 Hz, 3H), d 3.32 (d, J=13.8 Hz, 1H), d 3.73-3.79 (m, 2H), d 4.21 (br d, J=8.1 Hz, 1H), d 4.44 (d, J=14.1 Hz, 1H0, d 4.52 (dd, 10.5, 4.2 Hz, 1H), d 5.04 (br d, J=13.8 Hz, 3H), d 7.45-7.50 (m, 5H).
Example 29
1 H NMR (CDCl 3 ): d 1.10 (t, J=6.3 Hz, 6H), d 1.44-1.57 (m, 3H), d 1.66-2.08 (m, 8H), d 2.37 (dd, J=15.0, 5.7 Hz, 1H), d 2.69 (dd, J=15.0, 7.8 Hz, 1H), d 2.89 (d, J=4.5 Hz, 3H), d 3.25 (dd, J=12.9, 5.1 Hz, 1H), d 3.63 (dd, J=12.9, 5.4 Hz, 1H), d 3.89 (s, 6H), d 4.11-4.18 (m, 1H), d 4.41 (d, J=14.1 Hz, 1H), d 4.60 (dd, J=7.5, 2.1 Hz, 1H), d 4.84 (d, J=14.1 Hz, 1H), d 4.87 (d, J=13.8 Hz, 1H), d 5.76 (br d, J=6.3 Hz, 1H), d 5.94 (br d, J=4.2 Hz, 1H), d 6.50 (s, 3H).
Example 30
1 H NMR (CDCl 3 ): d 1.04 (d, J=6.6 Hz, 3H), d 1.20 (d, J=6.3 Hz, 3H), d 1.44-1.5 (m, 2H), d 1.62-1.83 (m, 6H), d 1.91-2.16 (m, 4H), d 2.35 (d, J=14.1 Hz, 1H), d 2.78 (d, J=5.1 Hz, 3H), d 3.33 (dd, J=13.5, 1.5 Hz, 1H), d 3.78 (dd, J=13.8, 1.8 Hz, 1H), d 3.89 (s, 6H), d 4.20 (dd, J=13.5, 6.9 Hz, 2H), d 4.40 (d, J=14.4 Hz, 1H), d 4.53 (dd, J=10.2, 3.9 Hz, 1H), d 4.90 (d, J=14.1 Hz, 1H), d 5.18 (br d, J=6.3 Hz, 1H), d 5.39 (br, 1H), d 6.53 (t, J=2.1 Hz, 1H), d 6.59 (d, J=2.7 Hz, 2H).
Example 38
1H NMR (CDCl3): d 0.89-0.99 (m, 12H), d 1.05-1.93 (m, 26H), d 2.39 (dd, J=14.7, 6.0 Hz, 1H), d 2.67 (dd, J=15.0, 7.2 Hz, 1H), d 3.11-3.33 (m, 4H), d 3.61 (dd, J=12.9, 5.1 Hz, 2H), d 4.51 (t, J=6.3 Hz, 2H), d 2.36 (br, d, J=6.0 Hz, 1H), d 6.01 (br, 1H).
Biological Results
A reporter gene assay utilizing transfected human hepatoma (HepG2) cells is used to screen for compounds that transcriptionally activate a PPRE via a PPAR-gamma mediated pathway. Cells are exposed to experimental compounds dissolved in DMSO for 36-48 h prior to determination of reporter gene activity. 15dPGJ2 (2 μM) is used as positive control and vehicle (DMSO) is used as a negative control. The data is expressed in Table 1 below as μM to achieve EC50.
TABLE 1
EXAMPLES
EC5O (μM)
39
1.35
32
0.62
41
2.35
16
3.6
25
>10
42
0.25
43
>1
35
0.12
Animal Tests
Compounds prepare in accordance with Examples 8 and 36 were evaluated for their effect on serum glucose and serum insulin in db/db mice (C578BL/KsJ-db/db Jcl). The compounds were dissolved in a vehicle consisting of 2% Tween80 in distilled water and administered orally. Dosage volume was 10 ml/kg body weight. All aspects of the work including experimentation and disposal of the animals was performed in general accordance with the International Guiding Principles for Biomedical Research Involving Animals (CIOMS Publication No. ISBN 92 90360194, 1985). Glucose-HA Assay kits (Wako, Japan) were used for determination of serum glucose and ELISA Mouse Insulin Assay kits (SPI bio, France) were utilized for determination of insulin. The positive control was troglitazone (Helios Pharmaceutical, Louisville, Ky.).
The animals were divided into twenty groups of four animals each. The animals weighed 52±5 gms at age 8-10 weeks. During the experiment the animals were provided free access to laboratory chow (Fwusow Industry Co., Taiwan) and water
Prior to any treatment a blood sample (pretreatment blood) was taken from each animal. Four groups of animals, the vehicle groups, received only doses of the vehicle. Each of the vehicle groups received of 100, 30, 10 or 1 ml/kg body weight of the vehicle orally. A triglitazone solution (10 ml/kg body weight in tween 80/water) was administered orally to the four positive control groups in doses of 100, 30, 10 and 1 ml/kg body weight respectively. The compound of Example 8 was administered orally as a solution (10 ml/kg body weight in tween 80/water) to four groups of animals with each group receiving a different dose of the compound. The dosage rates were 100, 30, 10 and 1 ml/kg body weight with only one dosage rate administered to each group. The compound of Example 36 was likewise solubilized (10 ml/kg body weight in tween 80/water) and administered to four groups of animals in doses of 100, 30, 10 and 1 ml/kg body weight with each group receiving a different dose. The vehicle, positive control and test compound solutions were administered to the groups immediately, 24 hours and 48 hours after drawing the pretreatment blood. Blood was withdrawn (post treatment blood) 1.5 hours after administration of the last dose.
The serum glucose levels of the blood samples was determined enzymatically (Mutaratose-GOD) and the insulin levels by ELISA (mouse insulin assay kit). The mean±SEM of each group was calculated and the percent inhibition of serum glucose and insulin was obtained by comparison between pretreatment blood and post treatment blood. The percentage of reduction of the serum glucose and insulin levels in the post treatment blood relative to the pretreatment blood was determined and the Unpaired students t test was applied for the comparison between the control and test solution groups and the vehicle group. A significant difference was considered at P<0.05.
The positive control, troglitazone, showed a significant reduction of glucose level at 10 mg/kg body weight (25±2%). Test solutions containing the compound of Example 8 exhibited a significant reduction of serum glucose at a dosage rate of 100 mg/kg body weight (P<0.01) relative to the vehicle treated groups. Test solutions containing the compound of Example 36 exhibited a significant reduction of serum glucose at dosage rates of 30 mg/kg body weight (P<0.05) and 100 mg/kg body weight (P<0.01) relative to the vehicle treated groups. The results of the animal tests are setforth in Table 2 below.
TABLE 2
Dose
Serum Glucose
Serum Insulin
(mg/kg)
(% reduction)
(% reduction)
EXAMPLE 8
100
41 ± 6
6 ± 2.5
30
14 ± 2
5 ± 4
10
18 ± 6
1 ± 4
3
−1 ± 3
−7 ± 3
1
9 ± 8
3 ± 7
EXAMPLE 36
100
40 ± 7
2 ± 4
30
37 ± 8
1 ± 2
10
−4 ± 7
−9 ± 6
3
0 ± 2
−9 ± 2
1
−1 ± 2
8 ± 7
The PPAR-gamma agonist compounds of the present invention are useful in treatment conditions where modification of the effects of PPAR-gamma is of therapeutic benefit in treatment methods for mammals, including humans, involving the administration of therapeutically effective amounts of a compound of Formula 1 or a pharmaceutically acceptable salt or solvate thereof. The PPAR-gamma agonist activity of the compounds of the present invention make them particularly useful as medicaments in the treatment of PPAR-gamma mediated diseases. For example, diseases such as diabetes, both Type I and Type II, hyperglycemia, insulin resistance, obesity and certain vascular and cardiovascular diseases such as artherosclerosis and hypertension are associated with increased PPAR-gamma levels. It will be understood that the term treatment refers also to the use of the compounds of Formula 1 for the prophylaxis or prevention of PPAR-gamma mediated diseases.
The compounds of Formula 1 are provided in suitable topical, oral and parenteral pharmaceutical formulations for use in the treatment of PPAR-gamma mediated diseases. The compounds of the present invention may be administered orally as tablets or capsules, as oily or aqueous suspensions, lozenges, troches, powders, granules, emulsions, syrups or elixars. The compositions for oral use may include one or more agents for flavoring, sweetening, coloring and preserving in order to produce pharmaceutically elegant and palatable preparations. Tablets may contain pharmaceutically acceptable excipients as an aid in the manufacture of such tablets. As is conventional in the art these tablets may be coated with a pharmaceutically acceptable enteric coating, such as glyceryl monostearate or glyceryl distearate, to delay disintegration and absorption in the gastrointestinal tract to provide a sustained action over a longer period.
Formulations for oral use may be in the form of hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, such as peanut oil, liquid paraffin or olive oil.
Aqueous suspensions normally contain active ingredients in admixture with excipients suitable for the manufacture of an aqueous suspension. Such excipients may be a suspending agent, such as sodium carboxymethyl cellulose, methyl cellulose, hydroxypropylmethyl cellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; a dispersing or wetting agent that may be a naturally occuring phosphatide such as lecithin, a condensation product of ethylene oxide and a long chain fatty acid, for example polyoxyethylene stearate, a condensation product of ethylene oxide and a long chain aliphatic alcohol such as heptadecaethylenoxycetanol, a condensation product of ethylene oxide and a partial ester derived from a fatty acid and hexitol such as polyoxyethylene sorbitol monooleate or a fatty acid hexitol anhydrides such as polyoxyethylene sorbitan monooleate.
The pharmaceutical compositions may be in the form of a sterile injectable aqueous or oleagenous suspension. This suspension may be formulated according to know methods using those suitable dispersing or wetting agents and suspending agents that have been mentioned above. The sterile injectable preparation may also be formulated as a suspension in a non toxic perenterally-acceptable diluent or solvent, for example as a solution in 1,3-butanediol. Among the accetable vehicles and solvents that may be employed are water, Ringers solution and isotonic sodium chloride solution. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition fatty acids such as oleic acid find use in the preparation of injectables.
The compounds may also be administered in the form of suppositories for rectal administration of the drug. These compositions can be prepared by mixing the drug with a suitable non-irritating excipient that is solid at about room temperature but liquid at rectal temperature and will therefor melt in the rectum to release the drug. Such materials include cocoa butter and other glycerides.
For topical use preparations, for example, creams, ointments, jellies solutions, or suspensions, containing the compounds of the present invention are employed.
The compounds of the present invention may also be administered in the form of liposome delivery systems such as small unilamellar vesicles, large unilamellar vesicles and multimellar vesicles. Liposomes can be formed from a variety of phospholipides, such as cholesterol, stearylamine or phosphatidylcholines.
Dosage levels of the compounds of the present invention are of the order of about 0.5 mg/kg body weight to about 100 mg/kg body weight. A preferred dosage rate is between about 30 mg/kg body weight to about 100 mg/kg body weight. It will be understood, however, that the specific dose level for any particular patient will depend upon a number of factors including the activity of the particular compound being administered, the age, body weight, general health, sex, diet, time of administration, route of administration, rate of excretion, drug combination and the severity of the particular disease undergoing therapy. To enhance the therapeutic activity of the present compounds they may be administered concomitantly with other orally active antidiabetic compounds such as the sulfonylureas, for example, tolbutamide and the like.
As will be understood by those skilled in the art, various arrangements which lie within the spirit and scope of the invention other than those described in detail in the specification will occur to those persons skilled in the art. It is therefor to be understood that the invention is to be limited only by the claims appended hereto. | Compounds having the structure
are peroxisome proliferator-activated receptor-gamma (PPAR-gamma) selective agonists and as such are useful in the modulation of blood glucose and the increase of insulin sensitivity in mammals. This activity of the piperazine derivatives of the invention make them particularly useful in the treatment of those conditions selected from the group consisting of diabetes, atherosclerosis, hyperglycemia, hyperlipidemia, obesity, syndrome X, insulin resistance, hypertension, heart failure and cardiovascular disease in mammals. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods of manufacturing semiconductor wafers, particularly single crystal silicon wafers.
2. Description of the Prior Art
A prior art method of manufacturing semiconductor wafers comprises a slicing step for obtaining thin disc-shape wafers through slicing a single crystal ingot obtained through pulling by using a single crystal pulling apparatus, a chamfering step for chamfering an outer periphery edge of a wafer for preventing chips and cracks of said sliced wafer, a lapping step for flattening the chamfered wafer surfaces, a wet etching step for removing a process damage layers remaining on the chamfering and lapping, a single-side mirror-polishing step for mirror-polishing one side surface of the etched wafers and a washing step for improving the cleanliness thereof by removing an abrasive and foreign particles remaining on the polished wafers.
The individual steps in the above prior art method, however, have various problems. In the first slicing step, in which the ingot is sliced into the thin disc-shape wafers with a circular internal blade slicer or a wire saw, a slight difference between right and left side of cutting resistances offered to the slicing blade prevent straight advancement of the blade cutting. As a result, swelling or warp is generated on the cutting surface. Such swelling or warp is a cause of cumbersome and troublesome processes in the subsequent steps.
In the lapping step, the warp cannot be removed although the swelling can be removed.
In the etching step, mixed acid or alkali aqueous solution is used as etching solution to remove the process damage layers which are generated by the previous mechanical processing. However, the flatness of the wafer surface is influenced by the activity of the etching solution, and it is required to remove the process damage layers while maintaining the flatness.
The polishing step uses a mechanical/chemical polishing process consisting of a plurality of stages, and a highly accurate mirror finish is obtained highly efficiently with a composite geometric effect in the dynamic function of mechanical polishing and the chemically removing function of etching. These functions are influenced by the proportions of mechanical element and chemical element during the polishing.
Japanese Patent Application Heisei 6-227291, filed by the applicant and not publicly known, proposes means for reducing swelling of as-cut wafers right after the above slicing process and before lapping, particularly unevenness or swelling of long cycles of 0.5 to 30 mm, as shown in FIG. 10. To preclude the long cycle swelling noted above, instead of holding a wafer 1 such that the back surface 1b thereof is directly chucking on the surface of chucking base plate 2 as shown in (A), wax or like adhesive 3 is provided between the wafer 1 and the base plate 2 as shown in (B), for absorbing long cycle unevenness or swelling etc. on the back surface 1b. (This technique is hereinafter referred to as first grinding technique.)
In this technique, with the wafer back surface 1b secured to the upper surface of the base plate 2 via the intervening adhesive 3, the unevenness of the back wafer surface 1b is held absorbed in the adhesive 3. In the other words, the adhesive 3 serves as unevenness absorber, and the surface polishing of the wafer 1 thus can be done without elastic deformation thereof even with unevenness present on the wafer back surface 1b. It is thus possible to maintain the flatness of the ground front surface 1a even when the adhesion is released.
In this prior art technique (not well known), clearances formed by above "swelling" generated on them when a wafer or like thin work is set on the base plate 2, are filled to prevent their transfer to the front surface of the work. The adhesive 3 may be fused wax, hot-melt adhesive, gypsum, ice, etc.
In Japanese Patent Application Heisei 8-80719, not public known, the application proposes other means for reducing swelling of cycles of about 0.5 to 30 mm. This proposition uses a vertical in-feed surface grinding machine, which has a cup-shaped grindstone with a wafer setting turntable providing variable wafer chucking force. Hereupon, "the in-feeds grinding" is meant the method which feed the grindstone perpendicularly to its frictional rotation surface. In this case, in the final grinding stage, i.e., a spark-out time, the chucking pressure on the wafer is switched over to a low pressure to grind the work, thereby removing the swelling. (This technique is hereinafter referred to as ground as second grinding technique.)
Specifically, as shown in FIG. 11, in an initial stage of grinding the work 1 is held for grinding under a suction pressure close to the normal vacuum as shown in (A). However, in a final stage (or spark-out time, i.e., zero in-feed grinding time) in which the grindstone feed pressure is reduced or substantially zero, the suction pressure is reduced to a pressure, under which the holding pressure can be maintained, as shown in (B). By so doing, the surface grinding can be made in a state that the elastic deformation force of the wafer is substantially reduced while maintaining the holding force, and the flatness obtained by the surface grinding can be maintained even by releasing the chucking.
When the thin wafer as the work of the surface grinding process is as-cut wafer right after the slicing, the suction pressure close to vacuum is suitably -600 to -760 mm Hg, and the suction pressure in the state that the elastic deformation force of the wafer is substantially released is suitably -100 to -50 mm Hg.
As the etching means, "A System for Removing Material from Wafers" is proposed in Japanese Laid-Open Patent Publication Heisei 5-160074, and "A Method and an Apparatus for Noncontacting Plasma Polishing and Smoothing of Uniformly Thinned Substrates" is proposed in Japanese Laid-Open Patent Publication 6-5571. According to this proposal, shape data of wafer before etching is fed back to a local etching stock removal to improve the thickness accuracy and flatness accuracy of the wafer after the etching. This plasma etching system is capable of noncontacting control of the process by plasma-assisted chemical etching.
This system permits removal of process damage layers or the like without reducing the flatness of the wafer, and the feedback of the shape data permits fine flattening through control of high frequency power supplied reactivity plasma gas and variation of the speed of the wafer in an X-Y direction.
In the single-side mirror-finish polishing step, the front wafer surface having been etched in the preceding etching step is brought to the single-side mirror-finish polishing step and has no problem. However, on the back wafer surface in which the large surface roughness is left as it is, the sharp ends of unevenness are broken off by chipping, generating a large number of particles and reducing the yield.
To solve this problem, the applicant has earlier proposed a technique in Japanese Patent Application Heisei 7-207514, not well known (prior art).
According to this proposal, a double-side wafer polishing step is incorporated in a method of semiconductor manufacture to improve the flatness of polished wafer, and also dust particle generation due to chipping from the back wafer surface by polishing of double-side wafer is suppressed to improve the yield of the apparatus.
With recent high function diversification, performance improvement, super-miniaturization, light weightiness and integration density increase of semiconductor, the high quality and large size of a wafer as substrate have been improved, and it is difficult to obtain highly accurate flatness of wafers of 200 to 300 mm and above in size. As an up-to-date method of wafer manufacture on a coming age, a manufacturing technique permitting high flatness and quality improvement is desired particularly for wafers of increased sizes.
SUMMARY OF THE INVENTION
The invention seeks to provide a method of semiconductor wafer manufacture, which while reducing the process, permits high flatness and quality improvement particularly even though the diameter of those wafers might be increased to comply with the needs of the time. Particularly, the invention has an object of providing a method of semiconductor wafer manufacture suited for processing increased size wafers in a material processing for removing long cycle swelling generated on as-cut wafers and also removing a process damage layers, these removals having been impossible by conventional lapping, by combining the above various prior application techniques and prior art techniques, such that the process has no adverse effects on subsequent process stages, while further preventing generation of particles by single-side polishing.
A more specific object of the invention is to provide a method of semiconductor wafer manufacture, in which surface grinding means is used for a flattening step to remove warp of as-cut wafers, which has been difficult by lapping as problem of conventional process, while preventing particle generation in a double-side polishing.
Another object of the invention is to provide a method of semiconductor wafer manufacture, which permits effective removal of cutting particles and process damage layers due to mechanical processing up to the flattening step.
A further object of the invention is to provide a method of semiconductor wafer manufacture, in which first grinding means based on double-side grinding is introduced to remove wafer shape fluctuations due to batch processing of wafers while reforming warp or swelling of an as-cut wafer generated at the time of slicing an ingot, and subsequently the work is highly accurately flattened by using the second grinding means.
A still further object of the invention is to provide a method of semiconductor wafer manufacture, which permits effective removal of cutting particles and process damage layers from wafers while maintaining the flatness thereof.
A yet further object of the invention is to provide a method of semiconductor wafer manufacture, in which a plasma etching step is effectively introduced to effect flattening of and process damage layers removal from wafers at a time, while preventing particle generation.
A history until completion of the present invention will now be described.
Problems posed in the manufacture of large size wafers are flatness improvement and quality improvement such as removal of cutting particles and process damage layers. A technique for solving these problems is a basis of techniques for manufacturing future wafers. As such a technique, the applicant studied the double-side polishing technique shown in the Japanese Patent Application Heisei 7-207514 (prior application technique) noted above.
The double-side polishing technique will be briefly described.
The flatness of wafers obtainable in the prior art slicing step is 10 to 20 μm in terms of TTV (total thickness variation), i.e., the difference between the maximum and minimum wafer thicknesses. Besides, the wafer has process damage to a maximum depth of 30 μm on one side.
As described before, the long cycle swelling as mentioned before is generated in the slicing step.
In the instant prior application technique, after chamfering the wafers obtained by slicing, by double-side polishing the chamfered wafers using a hard polishing pad (with an Asker C hardness of 80 or above; JIS K6301), very satisfactory flatness (TTV) could be obtained with a single-side polishing stock removal of 30 μm or above. Also, it was found that process damage layer and swelling peculiar to the slicing can be removed.
However, although the double-side polishing system is for simultaneously polishing the two sides of a wafer with polishing pads applied to an upper and a lower plate, it is of batch type (of simultaneously polishing a plurality of wafers), and fluctuations of the thickness and flatness of the material supplied to the polishing step have great influence on the flatness of the polished wafers.
To be above to obtain highly accurate flatness with less polishing stock removal, it is necessary to supply as material the wafers having small thickness fluctuations and satisfactory flatness at a preceding process of the polishing step.
To solve this problem, the invention features flattening thin disc-shape wafers obtained right after slicing or after chamfering if desired, with predetermined surface grinding means, and grinding both-sided said flattened wafers by simultaneous double-side polishing, preferably using a hard polishing pad (with an Asker C hardness of 80 or above).
In this case, the surface grinding may be done on one wafer after another to maintain highly accurate flatness, while the double-side polishing may be done either by batch polishing or on a wafer after another.
In this case, prior to said double-side polishing, wafers may be processed one after another using a cup-shaped grindstone in-feed vertical surface grinding machine. By so doing, it is possible to supply wafers with stable thickness accuracy and flatness to the double-side polishing step.
The invention also features flattening thin disc-like wafers obtained right after slicing or after chamfering if desired, with predetermined surface grinding means, removing process damage layers from said flattened wafers while maintaining the flatness thereof by a predetermined etching process, and both-side polishing of said wafers after the process damage layer removal by simultaneous double-side polishing, suitably using hard polishing pad (with an Asker C hardness of 80 or above).
In this case, the etching process is suitably a wet etching process using an alkali solution as the etching solution.
By carrying out the etching process with an alkali solution after flattening with the surface grinding means, the surface roughness can be greatly improved, thus permitting great polishing stock removal reduction in the subsequent double-side polishing step.
Besides, the use of the alkali solution as the etching solution permits removal of cutting particles and process damage layers while reliably maintaining the flatness secured in the preceding step.
The surface grinding may be done with wax or like adhesive interposed between a wafer and a base plate surface supporting by suction the back surface of the wafer. Alternatively, the surface grinding may be done on the front surface of a wafer with the back surface thereof held chucked by a negative pressure, and the negative pressure for holding the thin work chucked (hereinafter referred to as chucking pressure) may be reduced in a final stage of grinding, preferably in a spark-out time when a grindstone feed pressure is reduced.
In either of the above techniques, it is possible to maintain the flatness of the wafer surface having a surface ground and obtain great removal of swelling on an as-cut wafer which has heretofore been impossible, thus permitting highly accurate material to be supplied to the double-side polishing step and contributing to the efficiency improvement.
The surface grinding step may be constituted by a first grinding step based on double-side grinding and a second grinding step based on cup-shaped grindstone in-feed surface grinding.
By introducing the double-side grinding step prior to the surface grinding, it is possible not only to get a wafer batch processing but also to form process damage layers on both wafer sides to impart both of these surfaces with balanced elastic distortions and prevent generation of the secondary warp. Particularly it is possible to reduce thickness fluctuations of the wafer. These effects can also be obtained when double-side polishing wafers by wafer batch processing.
Suitably, thin disc-like wafers obtained right after slicing or after chamfering if desired, are flattened with surface grinding means or lapping means, and after the removal of process damage layers from the flattened wafers and fine flattening thereof are done in a dry etching process using plasma, said wafers are both-side polished by simultaneous double-side polishing, preferably with hard polishing pad (with an Asker C hardness of 80 or above).
In this case, the flattening may be done in a dry etching process using plasma, so that it is possible to dispense with the flattening step by the surface grinding means or lapping means and flatten as-cut wafers obtained right after slicing, in a dry etching process using plasma directly, after the process damage layer removal and flattening, and both-side polish said flattened wafers by simultaneous double-side polishing, preferably using hard polishing pad (with an Asker C hardness of 80 or above).
It is further possible to flatten as-cut wafers obtained right after slicing with surface grinding means or lapping means and remove process damage layers from said flattened wafers while maintaining the flatness thereof in a predetermined etching process, further after the process damage layer removed by a dry etching process using plasma, both-side polish said flattened wafers by simultaneous double-side polishing, preferably using hard polishing pad (with an Asker C hardness of 80 or above).
In this case, the plasma etching means is suitably constructed such as to carry out chemical etching assisted by plasma.
Such a technique may be implemented by a system, in which wafer shape data before the etching is fed back to a local etching stock removal to improve the thickness accuracy and flatness accuracy of wafer after the etching. Such a system may employ a technique of PACE (plasma-assisted chemical etching) which is developed by Heuges Danbary Optical Systems Inc., according to the Japanese Laid-Open Patent Publication Heisei 6-5571.
By introducing such noncontact plasma-assisted chemical etching capable of feedback control to the material working step of double-side polishing particularly, it is possible to obtain mirror-finish polished wafers having highly accurate flatness.
Thus, according to the invention, by adopting a double-side polishing step for a polishing step in the prior art working process, which comprises the steps of wire saw slicing, lapping, etching and polishing, and adopting, in lieu of the lapping in the prior art process, a double-side grinding step and a surface grinding step with low pressure suction in a process of supplying the material to the polishing step, it is possible to greatly improve the flatness, suppress thickness fluctuations of material wafers and improve the production control in the double-side polishing.
The application of the plasma dry etching capable of the feedback control, permits finer flatness improvement and further production control improvement.
Thus, only according to the invention it is possible to improve the high flatness and quality while simplifying the process particularly on large size wafers of 200 to 300 mm and above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart illustrating a process of manufacturing semiconductor wafers in an embodiment of the invention;
FIG. 2 is a flow chart which shows a shape in a case of leading a plasma dry etching step P in a manufacturing process of FIG. 1, in which:
(A) illustrates a case of subjecting etched wafers obtained through steps E to H in FIG. 1 to the plasma dry etching process;
(B) illustrates a case of subjecting flattened wafers obtained through the steps E to G in FIG. 1 to the plasma dry etching process; and
(C) illustrates a case of subjecting as-cut wafer formed by chamfering sliced wafers to the plasma dry etching process;
FIG. 3 shows schematic views showing double-side grinding machines, (A) showing a one-by-one grinding machine, and (B) showing a batch type grinding machine;
FIG. 4 shows a low-pressure surface grinding machine, (A) being a sectional view, (B) being a perspective view;
FIG. 5 shows a double-side polishing machine, (A) showing a vertical sectional view, (B) showing a fragmentary sectional view;
FIG. 6 is a sectional view showing a plasma-assisted chemical etching machine;
FIG. 7 is a bar graph showing the double-side polished flatness of an alkali etched wafer according to the invention and that of a surface polished wafer;
FIG. 8 is a graph showing the surface roughness of a material wafer, which is obtained by lapping an as-cut wafer and then alkali etching the lapped wafer (Comparative Example 1), that of a material wafer, which is obtained by lapping an as-cut wafer and acid etching the lapped wafer (Comparative Example 2), and that of a product wafer, which is obtained by surface grinding an as-cut wafer and alkali etching the ground wafer (Embodiment 1);
FIG. 9 is a graph showing the flatness changing when a wafer obtained right after wire saw as-cut wafer is plasma etched and then double-side polished;
FIG. 10 shows functions of basic constructions for a well-known surface grinding technique in (A) and a first surface grinding technique adopted according to the invention in (B); and
FIG. 11 shows functions of a basic construction for a second surface grinding technique adopted according to the invention.
In the figures, designated at 1 is a wafer, at 11a an upper grindstone, at 12a a lower grindstone, at 14 a carrier, at 20 a base plate, at 21 a turntable, at 22 a cup-shaped grindstone, at 29A a high pressure vacuum source, at 29B a low pressure vacuum source, at 32 a two-dimensional moving unit, at 33 a holder, at 38 a plasma chamber space, at 39 a process gas supply tube, at 40a a high frequency drive electrode, at 41 vacuum reaction chamber, at 51 a lower polishing turn table, at 52 an upper polishing turn table, at 51a and 51a a polishing pad, at 53 a center gear, at 54 an internal gear, at 55 a geared carrier, at E a slicing step, at F a chamfering step, at G a flattening step, at H an etching step, at K a double-side polishing step, at P a plasma etching step.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the invention will now be described with reference to the drawings. Unless particularly described, the sizes, shapes, relative positions, etc. of components described in connection with the embodiment have no sense of limiting the scope of the invention, and are merely exemplary.
FIG. 1 is a flow chart illustrating an embodiment of the method of semiconductor wafer manufacture according to the invention. FIG. 2 illustrates flow charts in different cases of introducing a plasma dry etching step.
Referring to FIG. 1, a process of semiconductor wafer manufacture according to the invention comprises a slicing step E of slicing a semiconductor single crystal ingot into thin disc-shape wafers, a chamfering step F for chamfering sliced wafers, a flattening (or surface grinding) step G of flattening the chamfered wafers, a wet etching step H for removing cutting particles and process damage layers generated on the flattened wafer surfaces, and a double-side polishing step K for mirror-polishing the etched wafer surfaces. Material wafers to be supplied to the double-side polishing step K are obtained through the steps E to H.
The as-cut wafers right after the slicing of an ingot with a wire saw or a circular internal blade slicer in the slicing step E, have swelling with cycles of 0.5 to 30 mm as noted above and also unevenness of short cycles. In the prior art lapping process, it was difficult to remove the former swelling of long cycles, although the latter unevenness could be removed.
The flattening step G may be constituted by a first grinding step G-1 based on double-side grinding and a subsequent second grinding step G-2 for grinding the front and back wafer surfaces by single-side surface grinding. As alternatives, it may be constituted by the first grinding technique shown in (B) in FIG. 10 or by the second grinding technique shown in FIG. 11.
For improving the production efficiency and the grinding accuracy, suitably the first grinding step G-1 is carried out with a batch type grinding machine, and the second grinding machine G-2 is carried out with a single wafer type grinding machine.
As shown in (A) in FIG. 3, the double-side grinding is done on a vertical double-head double-disc grinding machine having a high rigidity structure as well-known.
Referring to the figure, the machine has an upper grindstone 11a driven at a high speed by a driving unit 12a and a lower grindstone 11b driven in the same direction and at a high speed by a driving unit 12b. A plurality of as-cut wafers 1 held by a carrier 14 which is driven in the opposite direction to the rotation of the grindstones and at a low speed, are successively fed for double-side grinding between the upper and lower grindstones 11a and 11b. The wafers are thus doubled-side ground one after another.
Shown in (B) in FIG. 3 is a batch type double-side grinding machine, which comprises an upper and a lower turn table 61 and 62 with respective grindstones 61a and 62a and rotated in opposite directions to each other. A center gear 63 is provided on the lower turn table 62 at the rotation center thereof, and an internal gear 64 is provided on the outer periphery of the lower turn table 62. A plurality of geared carriers 66, which each carry a plurality of wafers 1 each set in a wafer receiving hole 66b, are interposed between the upper and lower grindstones 61a and 62a such that they are in mesh with the center gear 63 and the internal gear 64, and undergo a planetary motion, i.e., rotation and revolution, with the rotation of the lower turn table 62 to effect simultaneous double-side grinding (i.e., batch grinding) of a plurality of wafers 1 under an adequate pressure applied by the upper turn table 61.
All the above grinding steps are for removing a major part of warp or swelling of the as-cut wafers. In any of these steps, a material free from thickness fluctuations can be formed, while forming process damage layers on both work surfaces due to the double-side grinding for preventing generation of distortion and secondary warp during grinding.
Referring back to FIG. 1, in the second grinding step G-2, the front and back surfaces of work are ground by single-side surface grinding with a vertical in-feed surface grinding machine using a cup-like grindstone.
In this embodiment, the grinding for flattening is done with the sole second grinding technique shown in FIG. 11.
As schematically shown in (A) and (B) in FIG. 4, wafers are processed one by one with a high rigidity vertical surface grinding machine. The machine comprises an upper structure, which includes a cup-like grindstone 22 driven for rotation in the direction of arrow 24 at a high speed by a driving unit 26 and vertically reciprocable in directions of arrows 26a, and a turntable 21 which is rotatable by a center shaft horizontally as shown by arrow 25 at a high speed. A base plate 20 made of a ceramic or like porous material is provided on the turntable 21. A high pressure vacuum source 29A and a low pressure vacuum source 29B are provided, to which the turntable 21 can be coupled to via a duct 28 and a switching valve 28a for chucking the base plate 20. A wafer 1 as a material is held chucked on said base plate 20, and toward the end of grinding the prevailing high pressure vacuum of -600 mm Hg is switched over to a low pressure vacuum of -50 to -100 mm Hg for spark-out to remove swelling of the wafer. Reference numeral 27 designates a drive motor for driving the turntable.
With this construction, the accuracy (i.e., fluctuations) of the feed of the vertical high-speed rotation grindstone directly constitutes the accuracy of the thickness of the wafer as material. The wafer thickness accuracy thus can be readily controlled, and wafers having stable and high flatness can be provided.
Instead of adopting the above grinding technique, the first grinding technique shown in (B) in FIG. 10 as described above, may be adopted, in which the adhesive 3 such as wax is interposed between the wafer 1 and the top surface of the base plate 2, to which the back wafer surface 1b is held, to absorb long cycle swelling or the like on said back wafer surface 1b side.
The wet etching step H shown in FIG. 1, is for removing process damage layers or the like, which have been formed on the material surfaces in the flattening step G, without spoiling the flatness obtained in the flattening step G. The flatness may be spoiled depending on the etching solution or the agitation thereof or progress of reaction during the etching. The best etching solution is an alkali solution (e.g., 45 to 50% NaOH or KOH solution).
The double-side polishing step K shown in FIG. 1, is constituted by a high efficiency, batch processing system step, in which material wafers having the thickness accuracy and flatness accuracy obtained in the previous steps E to H, are processed while preventing particle generation and suppressing processing damages as shown in the Japanese Patent Application Heisei 7-207514 noted above.
FIG. 5 shows the construction for carrying out the double-side polishing. A lower and an upper turn table 51 and 52 with respective polishing pads 51a and 52a are rotatable in opposite directions. A center gear 53 is provided on the lower turn table 51 at the rotation axis thereof. An internal gear 54 is provided on the outer periphery of the lower turn table 51. A plurality of geared carriers 55, which each carry a plurality of wafers 1 each fitted in a wafer receiving hole 55b, is provided between the lower and upper polishing pads 51a and 52a such that they mesh with the center gear 53 and the internal gear 54 for rotation in the direction of solid arrow B and revolution in the direction of dashed arrow C with the rotation of the lower plate in the direction of arrow A. A plurality of wafers 1 thus can be simultaneously polished under an adequate pressure applied by the upper turn table 52. Reference numeral 56 in the figure designates a polishing solution feeding port.
FIG. 2 shows three different forms of the method of semiconductor wafer manufacture as shown in FIG. 1 when a plasma etching step is introduced. The plasma etching step utilizes plasma-assisted chemical etching (PACE) developed by Heughes Danbary Optical Systems Inc. noted above. In this technique, thickness fluctuation data is fed back to an etching process.
In the form shown in (A) in FIG. 2, etched wafers obtained through the steps E to H shown in FIG. 1 are finely flattened as material wafers in the plasma etching step P before being fed to the double-side polishing step K.
The plasma etching step P permits removal of warp and swelling, and the conventional lapping step G-1`' can be added to the flattening step G without any problem.
In the form shown in (B) in FIG. 2, wafers formed through the steps E to G shown in FIG. 1 and after removal of minute unevenness in a lapping step G-1' and also, if necessary, flattening in a surface grinding step G-2' based on the first or second grinding step (G-1 or G-2 shown in FIG. 1), are subjected as material wafers to removal of cutting particles and process damage layers and also minute flattening in the plasma etching step P before being fed to the double-side polishing step K.
As an example, it is possible to provide the conventional lapping step G-1' in lieu of the first grinding step (G-1) and use the lapping step G-1' and the second grinding step G-2 in FIG. 1 (back/front surface single-side grinding step) for the flattening step G.
The plasma etching step P further permits flattening in addition to the removal of warp or swelling, so that it is possible to omit the flattening step G without any problem.
In the form shown in (C) in FIG. 2, chamfered as-cut wafers obtained through the steps E and F shown in FIG. 1 are subjected as material wafers to the removal of cutting particles and process damage layers and also to the flattening in the plasma etching step P before being fed to the double-side polishing step K.
The plasma-assisted chemical etching is disclosed in Japanese Laid-Open Patent Publication Heisei 6-5571, and is not described here in detail. Briefly, FIG. 6 shows an example of the construction to this end. The construction has a vacuum reaction chamber 41, which is defined by an upper, an intermediate and a lower horizontal frame 30a to 30c, cylindrical peripheral walls 31a and 31b provided between the horizontal fames 30a and 30b and between the horizontal frames 30b and 30c, respectively, and a central exhausting port 42 provided in the lower horizontal frame 30a. Cylindrical structures 30d to 30f are suspended from the upper horizontal frame 30c, and under their lower ends a plasma chamber space 38 is defined between dielectric members 36 and 37. The cylindrical structures 30d to 30f are screwed to one another to permit adjustment of their distance from and angle to the wafer 1. Reference numeral 35 designates a wafer support set on an electrically grounded holder 33.
A process gas supply tube 39 is disposed above the plasma chamber space 38, and at the ceiling thereof a high frequency drive electrode 40a and a high frequency input conductor 40 connected thereto are provided and form a central part of etching reaction.
The material wafer 1 is supported via the wafer support 35 on the electrically grounded holder 33, and a two-dimensional moving unit 32 is provided thereunder for appropriately adjusting the etching position. Although not shown, the present machine has mechanisms for adjusting high frequency power, gas pressure and temperature. Reaction gas is introduced into plasma, and high frequency power is applied thereto. The process is made controllable by controlling these operations. Selective local etching and also entire etching of the work is made possible by a noncontact operation as occasion demands.
Effects obtainable with the above steps will now be described.
1. In manufacture of material wafers ready for polishing from as-cut wafers by using the surface grinding step to the flattening step G shown in FIG. 1:
The graph in FIG. 7 shows the flatness level of material wafers, which were obtained from as-cut wafers through the conventional process alkali etching, and material wafers, which were obtained in the embodiment of the invention adopting the low pressure surface grinding step shown in FIG. 11 as the flattening step G shown in FIG. 1 for 20 μm double-side polishing the wafers obtained after flattening as-cut wafers as material using hard polishing pad (with Asker C hardness of 80 or above).
As is seen from the figure, the flatness level obtained after the double-side polishing of the surface ground wafers (embodiment) was improved by about 10% over the flatness level obtained after the double-side polishing of the alkali etched wafers (prior art).
Conversely, thickness sorting of prior art alkali etched wafers is necessary for obtaining an equal flatness level.
2. In manufacture of material wafers ready for polishing through surface grinding and etching of as-cut wafers:
FIG. 8 shows results of evaluation on surface roughness and necessary polishing stock removal so far as to get sufficiently mirror-finished surface of material wafers obtained with Comparative Examples 1 and 2 and Embodiment 1 of the invention.
With Comparative Example 1, the surface roughness (Rmax(μ)) was 2 to 2.5 μm and the polishing stock removal(μ) were 14 to 15 μm. With Comparative Example 2, the surface roughness (Rmax(μ)) was 0.8 to 1 μm and the polishing stock removal(μ) were 7 to 10 μm. With Embodiment 1, the surface roughness Rmax(μ) was 0.3 to 0.5 μm and the polishing stock removal(μ) were 3 to 5 μm.
That is, with Embodiment 1, the surface roughness Rmax(μ) and the polishing stock removal(μ) were improved to 1/3 to 1/2 compared to Comparative Examples 1 and 2.
Further, the mirror finish was also judged by observing scattered light from surface (with a usual light scattering type particle counter) and microscope examination.
a) Comparative Example 1
Wafers obtained through alkali etching by 30 μm after lapping with FO/#1200.
b) Comparative Example 2
Wafers obtained through acid etching by 30 μm after lapping with FO#1200.
c) Embodiment 1
Wafers through alkali etching by 20 μm after the low pressure surface grinding shown in FIG. 11 with #2000 diamond grindstone (resin bond).
3. In manufacture of material wafers in step shown in (C) in FIG. 2 using plasma dry etching:
FIG. 9 shows the effect obtained with the embodiment using plasma-assisted chemical etching (PACE). As shown in (c) in FIG. 2, the flatness of the material as wire saw as-cut wafer chamfered after slicing, which had been about 11 μm (TTV), was greatly improved up to about 1.5 μm through plasma etching based on the PACE. By carrying out subsequent double-side simultaneous polishing of the work, a flatness of 1 μm and below could be readily obtained.
With the processes shown in (A) and (B) in FIG. 2, in which the flattening step is carried out before the plasma-assisted chemical etching (PACE), further effects can be expected. | According to the invention, the flatness and quality can be improved while simplifying the process even when large size wafers of 200 to 300 mm or above are processed. Basic steps involved are a slicing step E for obtaining thin disc-shape wafers by slicing, a chamfering step F for chamfering the sliced wafers, a flattening step G for flattening the chamfered wafers, an alkali etching step H for removing process damage layers from the flattened wafers, and a double-side polishing step K of simultaneously polishing the two sides of the etched wafers. If necessary, a plasma etching step is used in lieu of the flattening and etching steps G and H respectively. | 7 |
OBJECT OF THE INVENTION
[0001] The object of the present invention is an end stop device for blind-rolling shafts that can be used in a wide range of blinds, regardless of their length.
[0002] In addition, it has a high breaking strength as it must engage a helical cylindrical pinion only with an endless gear, so that its lifetime measured in number of cycles with resistance to fatigue is very high.
[0003] This winding mechanism is also characterised by a special constitution of the helical cylindrical pinion, formed by two parts, as well as the assembly meant to determine the end of run, which also presents a counter for the number of revolutions of the blinds shaft.
BACKGROUND OF THE INVENTION
[0004] Mechanisms and devices are well known in the state of the art for stopping the blinds at their position of maximum winding, which consist of an endless gear, a central pinion and one or two satellite pinions about the aforementioned pinion.
[0005] Within systems with one satellite pinion is document ES2130875, in which the central and the satellite pinion have corresponding inserts which meet laterally to lock the system in one sense of rotation, so that it can only rotate in the opposite sense.
[0006] In said systems at least two pairs of contacts are established between the teeth of the endless gear and the pinions, the central pinion simultaneously contacting the endless gear and the satellite pinion, so that their teeth are subjected to greater loads a greater number of time, leading to breakage of the mechanisms due to fatigue of the teeth of said central pinion.
[0007] In addition, the path of the blinds handle is limited by the size and the number of teeth of both the central pinion and the satellite pinion.
[0008] The size of the pinions is determined by the space limitations, so that the only variable is the number of teeth which, for a given pinion size, depends on the loads it must withstand.
[0009] In this way, the height of the blinds cannot exceed a certain length, as otherwise the stop will be reached before the blinds are fully raised.
[0010] All of these drawbacks are overcome by the invention described below.
DESCRIPTION OF THE INVENTION
[0011] The present invention relates to an end stop device for blind-rolling shafts formed by a case which in turn consists of two essentially identical half-bodies provided with internal recesses and protrusions where the device elements are housed.
[0012] Among the device elements is the endless gear, which is driven from the outside by a handle, a cardan shaft or whichever drive means is available.
[0013] When the endless gear turns is actuates the helical cylindrical pinion, which rests on a circumferential seat of a coupling flange in which is inserted the blinds shaft, to which the pinion transmits its motion.
[0014] Placed outside the coupling flange and above the helical cylindrical pinion is a circular ring with a convex protrusion that together with another protrusion antagonistic of a toothed wheel will determine the end of run.
[0015] One of the case half-bodies is provided with a protrusion in the form of a circular crown, inside which a stud is inserted that crosses a housing body which is coupled to the external circumference of the circular crown-shaped protrusion.
[0016] The lower part of the housing body has tabs which are guided to close an upper part of said housing body.
[0017] The upper part of the housing body has an orifice that houses a ball and a spring, the ball having a diameter “d” slightly smaller than the diameter “D” of the orifice, so that it can pass through all its sections except through the upper section of the orifice, which has a diameter “D′”, where the diameters have the following relationship:
[0000] D′<d<D.
[0018] In this way, the spring compressed by the closing action of the bottom part of the housing body will push the ball against the end of the orifice, so that the ball juts out of the top of the housing body.
[0019] The portion of the ball that juts out will never be more than its radius, i.e. “d/2”, due to the section of the orifice with a diameter of “D′” smaller than the diameter of the ball, “d”, which acts as a stop.
[0020] Located above the housing body is the toothed wheel with pointed teeth, having a concave inter-tooth space with the exception of an area between two consecutive teeth, which is convex from the end of one tooth to the other and which is responsible for determining the end of run when it meets the convex protrusion of the circular ring placed above the helical cylindrical pinion.
[0021] The toothed wheel is provided on its lower part with a number of adjacent essentially hemispheric cut-outs, in a number identical to that of the teeth of the toothed wheel, these cut-outs located about a circumference of a certain radius.
[0022] These essentially hemispheric cut-outs allow housing the ball of the housing body when the toothed wheel revolves.
[0023] As the helical cylindrical pinion turns, it carries with it the circular ring with a convex protrusion so that when it is opposite the toothed wheel it will engage said wheel and make it turn by an amount determined by the number of teeth, so that the housing body ball will enter the next cut-out.
[0024] The convex protrusion of the circular ring will rotate another turn until it is opposite and engages another tooth of the toothed wheel.
[0025] The end of run will occur when the convex protrusion of the circular ring meets the convex area of the toothed wheel.
[0026] To ensure the invariability of the relative distance between the blinds shaft and the shaft of the toothed wheel, above the circular ring and the toothed wheel is placed a plate with two orifices that can be coupled to the outer shape of the coupling flange and the stud.
[0027] Lastly, it is necessary to known the gear ratios between each of the two gear pairs and the diameter of the blinds shaft; to know the essentially hemispherical cut-out that must be placed on the ball in the initial position, as well as the initial position of the helical cylindrical pinion that defines that of the circular ring and its convex protrusion, all of this according to the height of the blinds so that the end of run occurs when the blinds are in a fully raised position.
[0028] This construction provides a system that can be used for a wide range of blinds with very different lengths, while lengthening the lifetime cycles of the mechanism.
DESCRIPTION OF THE DRAWINGS
[0029] The present descriptive memory is completed by a set of drawings that illustrate the preferred and non-limiting example of the invention.
[0030] FIG. 1 shows an exploded perspective view of the end of run for winding shafts of blinds.
PREFERRED EMBODIMENT OF THE INVENTION
[0031] In view of the above, the present invention relates to an end stop device for blind-rolling shafts formed by a case that in turn consists of two essentially identical half-bodies ( 1 ) provided with recesses and internal protrusions in which the elements of the device are housed.
[0032] Each half-body ( 1 ) has a number of arc-shaped seats ( 1 . 1 ) meant to house the endless gear ( 2 ), as well as a central orifice ( 1 . 2 ) for housing the winding shaft of the blinds.
[0033] Above said central orifice ( 1 . 2 ) is placed a circumferential seat ( 3 . 1 ) of a coupling flange ( 3 ) of the shaft which has a number or ribs ( 3 . 2 ) to ensure the correct positioning of the grooves ( 4 . 1 ) of a helical cylindrical pinion ( 4 ).
[0034] This constitutes the engagement between the endless gear ( 2 ) and the helical cylindrical pinion ( 4 ), transmitting the motion of the actuation handle to the winding shaft of the blinds.
[0035] Outside the coupling flange and above the helical cylindrical pinion ( 4 ) is placed a circular ring ( 5 ) with a convex protrusion ( 5 . 1 ).
[0036] One of the case half-bodies ( 1 ) has a circular crown-shaped protrusion ( 1 . 3 ) inside which is inserted a stud ( 6 ) that crosses a housing body ( 7 ) that is coupled to the external circumference of the circular crown-shaped protrusion ( 1 . 3 ).
[0037] The housing body ( 7 ) is formed by a lower part ( 7 . 1 ) provided with tabs ( 7 . 1 . 2 ) which are guided to close against an upper part ( 7 . 2 ) of said housing body ( 7 ).
[0038] In turn, the upper part ( 7 . 2 ) of the housing body ( 7 ) has an orifice ( 7 . 3 ) which houses a rigid element ( 8 ), preferably a ball, and an elastic element ( 9 ), preferably a spring, wherein the elastic element ( 9 ) pushes the rigid element ( 8 ), which can pass through all the sections of the orifice ( 7 . 3 ) save the top one, so that the rigid element ( 8 ) juts out of the upper part ( 7 . 2 ) of the housing body ( 7 ).
[0039] Above the housing body ( 7 ) is a toothed wheel ( 10 ) having the stud ( 6 ) as its shaft, with pointed teeth and a concave inter-tooth space ( 10 . 1 ) antagonistic of the convex protrusion ( 5 . 1 ) of the circular ring ( 5 ).
[0040] One area ( 10 . 2 ) between two consecutive teeth is convex, covering the space from one end of a tooth to another, determining the end of run when it meets the convex protrusion ( 5 . 1 ) of the circular ring ( 5 ).
[0041] The toothed wheel ( 10 ) is provided on its bottom part with a number of adjacent cut-outs ( 10 . 3 ), preferably hemispherical, identical in number to the teeth of said toothed wheel ( 10 ). These cut-outs ( 10 . 3 ) are arranged about a circumference with a fixed radius in order to house the rigid element ( 8 ) of the housing body ( 7 ) when the toothed wheel ( 10 ) turns.
[0042] To ensure the invariability of the relative distance between the blinds shaft and the shaft of the toothed wheel ( 10 ), above the circular ring ( 5 ) and the toothed wheel ( 10 ) is placed a plate ( 11 ) with two orifices ( 11 . 1 , 11 . 2 ) that can be coupled to the outer shape of the coupling flange ( 3 ) and the stud ( 6 ).
[0043] Knowing the gear ratios between each of the two gear pairs and the diameter of the blinds shaft allows determining the initial position of the toothed wheel ( 10 ) above the rigid element ( 8 ), as well as the initial position of the helical cylindrical pinion ( 4 ) that defines that of the convex protrusion ( 5 . 1 ) of the circular ring ( 5 ), all of this according to the height of the blinds so that the end of run occurs when the blinds are in a fully raised position.
[0044] The essence of this invention is not affected by variations in the materials, shape and size of its component elements, described in a non-limiting manner that will allow its reproduction by an expert. | The object of the present invention is an end stop device for blind-rolling shafts that can be used for a wide range of blinds regardless of their length, as well as having a high breaking strength as a helical cylindrical pinion must only engage an endless gear, so that its lifetime measured in number of cycles resisting fatigue is very high, as well as having a special construction of the helical cylindrical pinion formed by two parts, as well as of the assembly meant to determine the end of run, which has a counter for the number of turns made by the blinds shaft. | 4 |
FIELD OF INVENTION
This invention relates to a pilot operated valve system that will detect the presence of a water leakage and turn off the associated valve in order to stop the flow of the water, thus avoiding significant property damage. More particularly the invention pertains to such applications as clothes washing machines, dishwashing machines, toilets, sinks, and refrigerators equipped with ice cube makers, which occasionally are the source of water leaks due to broken hoses, faulty water level detectors, and the like. Insurance companies have recently disclosed that water damage claims have exceeded fire damage claims. This emphasizes the need for preventive measures as would be provided by this invention. Since the invention does not require any electronics circuitry or complex mechanical devices to function, it provides a cost-effective and reliable means of turning off the source of water leakage.
DESCRIPTION OF PRIOR ART
There are numerous water leak detection systems, most of which involve the use of an electronic means for sensing the presence of fluids such as water. The sensor elements of such systems typically involve measuring the conductivity of the water and use such a detection means to energize a solenoid or other such device to turn off an associated water valve. Not only does the electronics circuitry add cost and reduced reliability, but also requires the presence of electrical power to function. If a water leak occurs coincidentally with an electrical power outage, the valve will fail to accomplish its purpose, unless auxiliary power is supplied.
There are several prior art patents that provide water shutoff protection utilizing a water sensor that changes physical properties when placed in contact with water, thereby activating a valve shutoff device. Upon review it will become evident that most of these patents are intended for use on water heaters. Installation of such shutoff devices requires plumbing skills such as cutting into the existing water source pipe and soldering the new valve device in place or installing the necessary threaded fittings to accommodate the new valve. In many locations it would involve hiring a licensed plumber to comply with local building codes. The cost and complexity of such an installation often is a deterrent to undertaking the project. As will be seen by the following disclosure the proposed water shutoff system of the present invention is intended for use on the indicated appliances such as clothes washing machines, etc. and can be easily installed. Since no knowledge of plumbing skills is required, this invention would lend itself to do-it-yourself installation.
One device described in U.S. Pat. No. 2,798,503, dated Jul. 9, 1957, issued to Carver et al, utilizes a water softenable link that dissolves when coming in contact with water leaking from a water heater into an associated drip pan. As described, the cable attaching the water softenable link to the shutoff valve must be positioned directly beneath the shutoff valve so that the softenable link can be anchored in the drip pan. While appropriate for this installation it would not provide the flexibility to be applicable on other applications.
Another device described in U.S. Pat. No. 3,920,031, dated Nov. 18, 1975, issued to Maxfield provides a water shutoff device associated with a water heater application. The water detection means involves the use of a water-soluble material held in compression by a spring. The water detection means is placed in a drip pan that surrounds base of the water heater such that, as water leaks from the faulty water heater, it will reach a level to dissolve the detection means which in turn releases a spring driven valve that is plumbed into the water supply line of the water heater.
There are numerous patents that describe the application of the pilot valve technology. One of the more prominent patents is U.S. Pat. No. 4,387,878 dated Jun. 14, 1983 and issued to Zuksusky. This patent describes the use of a flexible diaphragm, in conjunction with specifically sized apertures, to control the open or closed valve condition. The Zuksusky patent utilizes an electric solenoid to open or close the appropriate pilot aperture, thereby allowing fluid to flow or not flow through the valve assembly. The present invention utilizes a modification of the pilot valve configuration, without the solenoid requirement, and will be described in detail later.
U.S. Pat. No. 5,169,117 dated Dec. 8, 1992, issued to Huang shows applicable prior art to be cited in this application. This patent describes a means for opening and closing a pilot valve by moving magnets in such a manner to open or close the pilot aperture. The magnet movement is accomplished using a small drive motor and hence requires the use of electric power as opposed to the present invention that requires no electric power to operate.
Another device described in U.S. Pat. No. 5,632,302, dated May 27, 1997, and issued to Robert M. Lenoir, Jr. provides two different means of specifically dealing with water heater leakage. One means involves the use of an electrical sensor to detect the presence of water leakage specifically from a water heater in order to activate a solenoid to turn off an associated water valve located in the cold water input pipe of the water heater. A second described means involves the use of a thin, dissolvable strip, which is in tension, and dissolves in the presence of water thus releasing a spring mechanism which, in turn, activates a spring loaded valve specifically located in the cold water input pipe of a water heater. There are two basic drawbacks to this second means as described. First, the use of a standard ball valve in such an application requires the use of a spring-loaded valve with a very strong spring. Ball valves typically involve full contact seals such as O-rings on both the inlet and outlet sides of the rotating ball. These O-rings produce a great deal of pressure on the ball, thus requiring inordinate rotational torque to close the valve, making the valve reliability questionable. Second, the dissolvable strip as described in the invention is shown in tension. Most such materials, which might be used as described, are composed of a water soluble, crystalline structure that exhibits poor tensile strength, thus making it unreliable and subject to premature failure. As will be seen later, the present invention overcomes the above shortcomings and provides an easily installed system for water and, where applicable, non-water systems.
Yet another U.S. Pat. No. 6,024,116, dated Feb. 15, 2000, issued to Almberg et al, again deals specifically with water leak detection in water heater applications. It provides a water softenable latch that, when exposed to water, will release a valve mechanism from its open to closed state thus turning off the water supply. In addition the invention turns off the gas supply to the water heater.
U.S. Pat. No. 6,792,967, dated Sep. 21, 2004, issued to Franklin, the inventor herein, describes a water shutoff valve with leak detector that is designed to function primarily with such applications as clothes washing machines, dishwashing machines, toilets, sinks, and refrigerators equipped with ice cube makers. Although the valve described in the U.S. Pat. No. 6,792,967 patent accomplishes the objectives as described, it has two shortcomings that might be considered objectionable in certain operating situations. The first such shortcoming occurs after the valve has been set to a closed position as a result of a water leak being detected. After the leak has been repaired the valve must be reset to an open position to allow normal fluid flow to the applicable appliance. It has been found that in some situations pressing the main body of the valve in an axial direction to reset it to an open position causes what is commonly called a hydraulic lock. This hydraulic lock occurs as a result of trying to compress a liquid. In this case the liquid would be the water trapped between the water source valve and the shutoff valve to be reset. The simple solution to this problem is to turn off the water source valve and momentarily unthread the coupling between the water source valve and the shutoff valve thus relieving the hydraulic lock. It is believed that this may present a problem for those individuals who are not mechanically inclined. A second shortcoming was found in my original patent, namely, that the water shutoff valve required an ability to elongate in an axial direction when activated to a closed position. Thus the valve was restricted to use with flexible water lines that coupled the output of the shutoff valve to the applicable appliance. In most applications this would not be a problem, however in toilet installations, for esthetic reasons, it is often desirable to use a rigid, chrome-plated pipe to couple the output of an associated water source valve to the toilet tank. Obviously the shutoff valve described in U.S. Pat. No. 6,792,967 would not allow use in such an application. It is the goal the present invention to overcome the above shortcomings and to describe a valve system that utilizes a variation on proven pilot valve technology, in conjunction with the technology described in my earlier patent, to produce a more acceptable shutoff valve with leak detection capabilities.
Most prior art that was found addresses the subject of water leak conditions as they pertain to water heaters. The following described invention pertains more specifically for use with clothes washing machines, dishwashing machines, toilets, sinks, and refrigerators equipped with ice cube makers.
SUMMARY OF THE INVENTION
This invention provides a simple, reliable means of detecting and shutting off the source of most common water leaks involved with clothes washers, dishwashers, toilets, sinks, and refrigerators equipped with ice cube makers by utilizing a pilot operated shutoff valve in conjunction with a water sensor. Although the following invention description focuses primarily on those appliance applications listed above, which involve water leakage, it could likewise apply to other applications involving the use of other non-water fluids, where applicable. As will be seen later, the valve described in this invention utilizes a flexible diaphragm that allows water to flow from the valve's entry port to its exit port in normal operation but closes the water flow path when activated to its closed condition. The use of this pilot valve structure, in conjunction with a water sensor and activation mechanism, provides a compact, simple water shutoff device. The use of this valve does not preclude the use of other pilot valve configurations by those skilled in the art to accomplish the goals of this invention.
The water sensor described in this invention utilizes a water-soluble substance in a compression mode. Other methods for containing the water-soluble material, for example, in a bending, torsion, or tension mode, as devised by those skilled in the art, should not detract from the spirit of this invention. The water-soluble substance could be composed of such materials as sugar, salt, or the like. These materials exhibit relatively high strength in compression when dry and lose most if not all of that strength when exposed to a fluid such as water. As will be shown later with regard this invention, a spring maintains pressure against the water-soluble substance and will initiate a closure of the associated valve when the water-soluble substance dissolves.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a typical clothes washing machine installation with water sensors and shutoff valves located at the inlets to the hose lines.
FIG. 1A shows an enlargement of an area of FIG. 1 to provide a more detailed depiction of the shutoff valve installation.
FIG. 2 shows a typical toilet installation with a water sensor and shutoff valve located at the inlet to the rigid pipe that passes water to the toilet reservoir tank. The rigid pipe can be replaced by an appropriate flexible hose.
FIG. 3 shows a partial cutaway of a typical sink installation with a water sensor and shutoff valve located at the inlet to the flexible hose line.
FIG. 4 shows a partial cutaway of a typical refrigerator installation equipped with an automatic ice maker device, along with a water sensor and shutoff valve connected to a water source via a hose or tubing means.
FIG. 5 shows the external side view of the shutoff valve used with hose connections on typical dishwashing machine or clothes washing machine installations.
FIG. 6 shows the external side view of the shutoff valve with typical fittings for toilet, refrigerators equipped with ice makers, and sink installations.
FIG. 7 shows an external front view of the shutoff valve with typical fittings for toilet, refrigerators equipped with ice makers, and sink installations.
FIG. 8 shows a cross-sectional side view of the shutoff valve with an input adapter for use with a standard compression fitting arrangement and a typical, threaded output for use with a flexible hose or rigid tubing connection. The valve is shown in an open condition.
FIG. 9 shows a cross-sectional end view of the shutoff valve with the outlet pilot aperture in an open condition which allows fluid to flow through the valve.
FIG. 10 shows the same cross-sectional side view of the shutoff valve shown in FIG. 8 but with the valve in a closed condition.
FIG. 11 shows the same cross-sectional end view of the shutoff valve of FIG. 9 with the outlet pilot aperture shown in a closed condition.
FIG. 12 shows an internal view of the valve latch mechanism when the valve is in an open condition.
FIG. 13 shows an internal view of the valve latch mechanism when the valve is in a closed condition.
FIG. 14 shows an external, top view of the water sensor assembly.
FIG. 14A shows a partial isometric view of the water sensor cartridge.
FIG. 15 shows an external, side-elevation view of the water sensor assembly.
FIG. 16 shows a top, cutaway view of the water sensor assembly in a standby state.
FIG. 17 shows the top, cutaway view of the water sensor assembly in an activated state.
DETAILED DESCRIPTION
The following FIGS. 1 , 1 A, 2 , 3 , and 4 are provided to show typical installations in which the water shutoff valve of the present invention might be utilized. FIG. 1 shows a clothes washing machine 20 as it might be installed with its hot and cold water connections. Valves 21 and 21 a represent the hot and cold water valves respectively, normally found on such appliance installations, providing the supply water to the clothes washing machine 20 . Attached to these valves 21 and 21 a are the shutoff valves 22 and 22 a to be described herein. Hoses 23 and 23 a provide the water connections between the shutoff valves and the hot and cold water inputs to the clothes washing machine. Cable assemblies 24 and 24 a are used to couple the water sensor assemblies 25 and 25 a to the shutoff valves 22 and 22 a respectively. FIG. 1A is an enlargement of the above mentioned valve 21 , shutoff valve 22 , cable assembly 24 and hose 23 , and is provided to visually clarify the actual connections. A typical connection that might be used in a dish washer application is not shown since it closely resembles that used on the clothes washing machine with the exception that only one hose connection, namely the hot water line, is used.
FIG. 2 shows a toilet installation 26 with its reservoir tank 27 . A typical installation has a valve 28 that allows a means for turning on and off the source of water necessary for operation. Connected to the top outlet of valve 28 is shutoff valve 29 . Although the internal structure of valve 29 is the same as the previously mentioned shutoff valves 22 and 22 a , it differs in the fact that the hose connections of valves 22 and 22 a are replaced by smaller, threaded connections appropriate for that installation. Rigid pipe 30 provides the necessary coupling between the top of shutoff valve 29 and the bottom of the reservoir 27 . It should be understood rigid pipe 30 could be replaced by a flexible hose. Cable assembly 24 provides the necessary coupling between the shutoff valve 29 and the water sensor assembly 25 .
FIG. 3 shows a partial cutaway view of a typical sink installation in which a sink 31 is mounted in a cabinet 32 with the associated hot and cold faucets 33 . Although the side view shows only one faucet connection, it should be understood that the other faucet connection, either hot or cold, is identical to that shown in the foreground. Valve 28 , shutoff valve 29 , cable assembly 24 , and water sensor assembly 25 , are identical to that previously described in FIG. 2 and, hence, carry the same number designations. Hose 34 provides the necessary coupling between the top of the shutoff valve 29 and the faucet configuration 33 .
FIG. 4 shows a typical refrigerator 35 installation with a partial cutaway view of the ice cube maker 36 as it might be located within the freezer compartment. The tubing 37 connects the ice cube maker to the shutoff valve 29 that is in turn connected to the water valve 28 . Cable assembly 24 connects the shutoff valve to the water sensor 25 .
FIG. 5 shows the outside structure of the shutoff valve 22 shown in FIGS. 1 and 1 a . Coupling sleeve 38 is internally threaded, and independently rotatable as might be found on a standard water hose. It provides a means of fastening the shutoff valve to a standard water faucet or water pipe equipped with a hose thread. Cable assembly 24 , with its internal cable 90 and tubing 91 , is used to couple the shutoff valve to the associated water sensor assembly, to be described in detail later. Threaded outlet 39 for the shutoff valve 22 provides a means for connecting a hose to the shutoff valve. Such a hose is described in FIG. 1 as items 23 and 23 a.
FIG. 6 shows the outside structure of the shutoff valve 29 shown in FIGS. 2 through 4 . As previously mentioned, the only difference between this shutoff valve 29 and that of shutoff valves 22 and 22 a is the inlet and outlet connection means. A small, internally threaded and rotatable sleeve 41 provides a means of connecting the shutoff valve 29 to a water source often using a compression fitting or rubber grommet, not shown. The standard installation would typically attach the inlet of the shutoff valve 29 to the threaded outlet of a valve 28 . Threaded outlet 42 provides a means of attaching the flexible hose 34 to the appropriate appliances as shown in FIGS. 3 and 4 or to the rigid pipe 30 in FIG. 2 . In both FIGS. 5 and 6 item 40 represents the latching mechanism used to determine whether the shutoff valve is to be in an open or closed condition.
FIG. 7 shows the front view of shutoff valve 29 and displays the reset button 43 . This reset button is normally depressed and latched in that position when the shutoff valve 29 is open, allowing fluid flow through the valve body. If a water leak is detected and the shutoff valve is placed in a valve-closed condition the reset button 43 will extend outward from the valve body. This will provide an indication that the shutoff valve has been tripped to a closed position and, in addition, provide a means of resetting the valve to an open condition once the water leak has been repaired.
FIG. 8 is a cross sectional view of shutoff valve 29 shown in a valve open condition in which fluid is flowing through the shutoff valve. From this point on, for simplification, the word valve will be equivalent to shutoff valve unless stated otherwise. The fluid path is from left to right as shown by the flow arrow. Fluid enters the valve 29 at the input adapter 44 that is threaded into the valve body 45 . The threaded coupling 41 of FIGS. 6 and 7 is not shown, but if shown would appear over the input adapter 44 . The input adapter 44 allows different size tubing to be installed depending on the size of the valve 28 output ( FIGS. 1 through 4 ) to which the valve 29 is to be coupled. There are two paths for fluid flow through the valve 29 , namely, the main fluid flow and the restricted fluid flow. The main flow represents the majority of fluid that flows through the valve 29 . The restricted flow is a small portion of the total fluid flow through the valve 29 and has a primary purpose of controlling the opening and closing of the main flow using the pilot apertures to be described. As shown, the main fluid flow is up and over valve seat 46 , downward between the valve seat 46 and alignment probe 47 portion of insert 48 , and through valve output 59 . In addition there is a restricted fluid flow through filter holes 49 , that are part of the diaphragm 50 , and then into reservoir 67 . Channel 51 of insert 48 provides a common flow path that couples all the filter holes 49 , allowing them to have a fluid connection to the input pilot aperture 52 . Next, the restricted fluid flow passes through an input pilot aperture 52 , through hole 53 , channel 54 , hole 55 , then past the clearance between the valve body 45 and magnet 56 enclosure 80 , and finally through an output pilot aperture 57 of insert 58 to the valve output 59 . The above flow path comprises the fundamental part of a pilot valve that allows it to function as it does. Although the pilot valve technology is well known in the art and accomplished using variations on a basic theme, the fundamental principle involves controlling pressure differentials to open or close the diaphragm 50 portion of valve 29 . Returning to the valve 29 of FIG. 8 , the diaphragm 50 is normally composed of a rubber material that flexes at point 60 allowing it to move upward as shown or to move downward to close against the valve seat 46 as shown in FIG. 10 . The periphery of diaphragm 50 is captured between the valve body 45 and the insert 61 at point 62 . The key element in determining whether the diaphragm opens or closes against the valve seat 46 is whether outlet pilot aperture 57 is open or closed by magnet 56 moving downward to place the seal element 63 against outlet pilot aperture 57 . This situation will be discussed in detail later. As shown in FIG. 8 the restricted fluid passes through the open outlet pilot aperture 57 to join the main fluid flow. The aperture openings 52 and 57 are sized such that the input pilot aperture 52 is smaller than the output pilot aperture 57 . Because of this, a pressure differential is established between the lower side of diaphragm 50 a and the reservoir 67 , since more fluid can escape via output pilot aperture 57 than can be supplied via input pilot aperture 52 . In normal operation the diaphragm 50 and insert 48 will move up and down as water demand is varied at the valve output 59 . This water demand will depend on the appliance valve, such as a sink faucet, being on or off. As long as outlet pilot aperture 57 remains open diaphragm 50 will flex upward each time an appliance valve is opened, thus allowing fluid passage through the valve 29 . It will be noted that O-ring 65 provides a fluid seal between valve body 45 and insert 61 . Likewise, O-ring 68 provides a fluid seal between valve body 45 and plug 69 . Spring 70 provides a small force to aid in the closure of diaphragm 50 against valve seat 46 . Plate 71 is held in place by screws 72 and functions to retain insert 61 and plug 69 . Alignment probe 47 functions to ensure that the surface of diaphragm 50 is in proper alignment with the valve seat 46 during closure.
FIG. 9 shows a cross sectional end view of valve 29 in the same relative vertical position as shown in FIG. 8 . Magnet 56 and seal 63 are again shown in the upward position allowing fluid to flow through outlet pilot aperture 57 . The magnet 56 and seal 63 are encased in the enclosure 80 which has an opening 64 that allows the seal 63 to contact the tip of outlet pilot aperture 57 when magnet 56 is moved to its lower position. Magnets 78 and 79 are shown encased in the extensions 74 and 75 respectively of the reset button 43 forming a reset structure. Springs 76 and 77 provide a downward force against the magnets and thus against the reset extensions 74 and 75 . The reset button 43 and its extensions are locked in the position shown by pin 83 that is captured by latch arm 84 . Latch arm 84 is part of the latching mechanism 40 that will be explained in detail later. As shown, the polarity of magnets 78 and 79 are opposite to the polarity of magnet 56 . This arrangement allows the magnet fields of the three magnets to interact so as to cause magnet 56 to follow the position of magnets 78 and 79 . It would be possible to eliminate one magnet, say 78 , and still have the relative movement between magnets 56 and 79 . It was found, however, that by providing a second magnet 78 the reliability of the system was enhanced, largely because of the reduced friction of magnet 56 and its enclosure 80 rubbing against the adjacent wall in which they move up and down. Essentially magnet 56 could be considered as floating between the two outside magnets 78 and 79 . In addition, because the magnets 78 and 79 are encased in reset button 43 extensions 74 and 75 , the attractive force that would normally pull these magnets toward magnet 56 is restricted by the rigidity of the extensions. In this way the friction between the total reset button structure and the walls of the valve body is minimized. As will be seen later this lower friction reduces the force necessary to activate the latching mechanism 40 .
FIG. 10 shows a side, cross sectional view of the valve 29 in a closed condition. Fluid flow through the valve is now blocked by diaphragm 50 and insert 48 pressing against the valve seat 46 . The force necessary to hold these elements against the valve seat is a result of magnet 56 and its associated seal 63 closing the fluid flow path through output pilot aperture 57 . Since the pressure at the output 59 of valve 29 is lower than the input fluid pressure to the valve, the fluid that flows into the reservoir 67 via filter holes 49 and aperture 52 will cause an increase in pressure against the top of insert 48 , thereby pressing the diaphragm 50 firmly against the valve seat 46 .
FIG. 11 is once again a cross sectional, end view of valve 29 showing the position of magnet 56 and seal 63 now pressing against the output pilot aperture 57 thereby closing it to fluid flow. In this view it is assumed that a water leak has been detected by the detection means to be described later. As a result the latch arm 84 of latching mechanism 40 releases pin 83 , causing the reset extensions 74 and 75 , and the reset button 43 to move downward. Springs 76 and 77 produce the force necessary to cause this movement. Plate 73 provides a stop that limits the movement of reset button 43 . Since magnets 78 and 79 are now also positioned lower, their magnetic fields cause magnet 56 , seal 63 , and enclosure 80 to follow the downward movement. Thus it can be seen that by moving the reset structure up or down, magnets 78 and 79 will likewise move in a manner causing magnet 56 , seal 63 , and enclosure 80 to follow, thereby opening or closing the output pilot aperture 57 . This in turn, through the pilot valve action, causes valve 29 to open or close the fluid communication between its input and output. Although the opening and closing of the output pilot aperture 57 could be accomplished by means other than a magnetic arrangement, it would require a shaft with an O-ring seal that could provide a path for subsequent water leakage.
FIG. 12 is a top view of latching mechanism 40 with the top cover removed. Latch pin 83 has a force from springs 76 and 77 (FIG'S. 9 and 11 ) acting to try to move it to the left. Latch arm 84 holds latch pin 83 in place. Latch arm 84 pivots about pin 85 and is biased in a clockwise direction by a torsion wire spring 86 . Cable assembly 24 includes an internal cable 90 that passes through slot 89 and has a retainer ring 93 fastened to the end of internal cable 90 allowing the retainer ring 93 to apply a rotational force on latch arm 84 when internal cable 90 is pulled upward. Lock ring 92 holds the cable tubing 91 from moving axially relative to the latch mechanism yet allows one to rotate relative to the other. As shown, the latching mechanism 40 is in a standby condition with the valve 29 in an open condition.
FIG. 13 is again a top view of latching mechanism 40 but with the latch mechanism shown in a tripped condition, as would be the case when a water leak has been detected. As will be explained later, when the leak detector senses a water leak condition internal cable 90 will be pulled within the cable tubing 91 causing retainer ring 93 to move toward the lock ring 92 . When this happens latch arm 84 is rotated in a counter clockwise direction, thereby releasing latch pin 83 to move to the left within slot 87 . As previously described, this releases the reset structure composed of items 43 , 74 , and 75 to move in a manner that will cause closure of the outlet pilot aperture 57 , thereby causing the valve 29 to become closed to fluid flow. When the leak has been repaired, the leak detector can be reset by replacing the water sensor cartridge as will be described later. During the process of replacing the water sensor cartridge, the internal cable 90 will be forced to move within the cable tubing 91 allowing the latch arm 84 to rotate clockwise, back to its original position with the right most portion of latch arm 84 resting against ledge 88 . When the reset button 43 is pressed, the latch pin 83 will slide within slot 87 and will rotate latch arm 84 slightly in a counter clockwise direction as it moves up the incline portion 84 a of latch arm 84 until the latch pin 83 reaches a point where the latch pin 83 will be recaptured by latch arm 84 and latched in place. It should be noted that, although not shown, the latching mechanism 40 can be installed on valve 29 in the position shown or flipped over to allow the cable assembly 24 to be routed in the opposite direction. There is a comparable slot opposite slot 87 that allows latch pin 83 to enter the latching mechanism 40 housing. The purpose in providing this feature is to allow more convenient routing of the cable assembly 24 depending on whether the latching structure is installed in a water hose application, i.e. clothes washing machine, or an alternate application such as under a sink or toilet.
FIG. 14 is the top view of the water sensor assembly 25 . The upper section 94 , along with the lower section 95 as viewed in FIG. 15 , form the main enclosure of the water sensor assembly 25 . This main enclosure is connected to the water sensor cartridge 98 by a twist-lock coupling. FIG. 14A shows a partial isometric view of the water sensor cartridge 98 as would be seen at the interface 100 as indicated in FIG. 14 between the upper section 94 of water sensor assembly 25 and the water sensor cartridge 98 . Locking segments 96 and 96 a will interlock with comparable segments (not shown) that are part of the upper and lower sections 94 and 95 of water sensor assembly 25 . The lines 97 and 97 a denote the inner surfaces of the cartridge 98 that interlock with the corresponding locking surfaces (not shown) of the upper and lower sections 94 and 95 . This interlocking configuration can be better seen in FIG. 15 where segments 96 and 99 are shown mating at surface 97 . Thus it can be seen that replacement of the water sensor cartridge 98 is simply a matter of twisting and removing the water sensor cartridge 98 relative to the upper and lower sections 94 and 95 of water sensor assembly 25 . A replacement cartridge can be installed by reversing the process. With regard to the water sensor cartridge 98 , holes 101 allow fluid access to a water-soluble element 108 ( FIG. 16 ) contained within the sensor cartridge 98 . Item 102 is an end cap that captures the water-soluble element within the sensor cartridge 98 . Cable assembly 24 is routed to the latching mechanism 40 as previously described.
FIG. 15 is a side-view of the upper 94 and lower 95 sections of the leak detector assembly 25 . These sections are fastened together as an integral assembly. As previously mentioned, this view more clearly shows how the interlocking surfaces provide a means to couple the water sensor cartridge 98 to the upper and lower sections 94 and 95 of the water sensor assembly 25 .
FIG. 16 is a top, cutaway view of the water sensor assembly 25 . The internal cable 90 and tubing 91 enter the water sensor assembly 25 at the left end. Tubing 91 is held in axial position relative to the water sensor assembly 25 by lock ring 104 . Retainer ring 105 is fastened to the end of internal cable 90 and is located within a cavity 106 of plunger 107 . As shown, spring 110 exerts a rightward force against plunger 107 . The right end 107 a of plunger 107 presses against plate 109 that acts to more evenly distribute the existing force against the water-soluble element 108 . Since the water-soluble element 108 has considerable strength in compression the plunger 107 will be held in the position shown.
FIG. 17 is a cutaway view of the water sensor assembly 25 after a water leak has been detected. When the water-soluble element 108 was exposed to water, or other appropriate fluid, it dissolves allowing spring 110 to force plunger 107 and plate 109 in a rightward direction. In doing so, retainer ring 105 that is fastened to internal cable 90 , exerts a rightward force on internal cable 90 , thereby causing it to move within the cable tubing 91 . This movement causes the latch mechanism 40 , previously described, to trip the valve 29 to a closed condition. Once the source of the water leak is repaired and any water leakage removed, the water sensor assembly 25 can be restored to a normal status by simply twisting and withdrawing the water sensor cartridge 98 to remove it from the upper and lower sections of the water sensor assembly 25 . A new cartridge can be installed by reversing the procedure. Of course it is also possible to make provisions for the water-soluble element 108 to be replaced within the cartridge 98 without having a removable cartridge.
One of the primary advantages of the described invention relative to the prior art is the ease with which it can be installed without disrupting the existing water supply lines or the water connections to the applicable appliances. When installing the described shutoff valve and sensor to the water sources for a clothes washing machine, the first step is to turn off the faucets or valves 21 and 21 a controlling the hot and cold water to the clothes washing machine as viewed in FIG. 1 . Next, the washing machine hoses 23 and 23 a are disconnected from the hot and cold water faucets or valves 21 and 21 a . One of the described is shutoff valves 22 is now threaded onto the hot water faucet and another shutoff valve 22 a is threaded onto the cold water faucet. Then the previously removed washing machine hoses 23 and 23 a are threaded onto the threaded outlets of the hot and cold shutoff valves 22 and 22 a respectively. The sensor assemblies 25 and 25 a would now be placed on the floor adjacent to the washing machine or in a location that would optimize the possibility of detecting any future water leakage. Once the water source faucets or valves 21 and 21 a are opened to allow flow to the washing machine the installation is complete.
In summary, the foregoing disclosure describes a pilot operated valve system having a water sensor assembly and an activation mechanism, which provides a means to turn off a water supply when a water leak is detected. This disclosure focuses primarily on specific applications such as clothes washing machines, dishwashing machines, toilets, sinks, and refrigerators equipped with ice cube makers, but could apply to appropriate, non-water, fluid-handling applications. Because of its design this valve system requires no electrical power to function. It should be understood, however, that anyone skilled in the art might provide a switching means to detect when the valve has been shut off, and utilize the switching means to activate an audible or visual alarm. Likewise, the water sensor and associated activation cable could be replaced by an electrical solenoid, controlled by a separate electronic water sensing and control system. In addition, it should be understood that the above valve description should not preclude the incorporation of the valve shutoff system as an integral part of the manual shut off valves which have been designated by items 21 , 21 a , and 28 in FIGS. 1 through 4 . In addition it should be noted that the pilot valve design, described herein, avoids many of the shortcomings associated with previous designs. Two such shortcomings are the previously described hydraulic lock condition that can exist, and the requirement that the valve be used in conjunction with flexible hose coupling only. This was due to the fact that the prior art valve had to physically elongate upon activation, thus precluding the use of rigid tubing to couple the valve to any external appliances. Although a particular pilot valve design has been used in the description of this invention, it should be understood that other pilot valve configurations could be used without departing from the spirit of this invention. The description of this invention is illustrative and not limiting; further modifications will be apparent to one skilled in the art, in the light of this disclosure and the appended claims. | A pilot operated shutoff valve system with leak detector for automatically shutting off a water supply to appliances such as a clothes washing machine, dishwashing machine, sink, toilet, or refrigerator equipped with an ice maker, comprising a sealing member movable within said valve body between an open position wherein the sealing member does not block main fluid flow, and a closed position wherein the sealing member blocks main fluid flow. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of U.S. application Ser. No. 12/604,831 filed on Oct. 23, 2009.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
BACKGROUND OF THE INVENTION
[0003] A common industrial problem involves the cutting of tubular shape objects at points that are inaccessible, impractical, or unsafe using conventional torches or other human-held cutting tools. An example of this problem involves the demolition of offshore oil and gas production platforms. The legs of these production platforms are typically made from large diameter tubular steel members that are partially embedded on one end into the sea floor. These tubular legs then extend upward through the water to the surface where the external production structure is attached. These tubular legs serve both to anchor the platform to a fixed point and to support the super-structure at the surface where the oil and gas recovery and processing operations are performed. When the platform is demolished, the operations structure is first removed and the remaining platform and tubular legs must be subsequently disconnected from the sea floor. For complete removal of navigation hazards and elimination of hazards to the fishing and shrimping industries, it is necessary to comply with government requirements that the tubular legs be severed at a point below the sea floor level or “mud-line.” The preferred method is to sever the tubular members using explosives below the mudline from the inside of the tubular member. It is desirable to use the smallest amount of explosives possible to achieve severance of the tubular members and not disturb the surrounding marine environment.
[0004] Most tubular members used in the oil and gas platform construction are generally comprised of short sections of pipe connected together by special load-bearing connectors. Therefore, the tubular member provides an open annulus where jetting and vacuum lines could be inserted and used to remove the mud to a point below the natural sea floor. One particular problem to placing and operating lines and cutting tools within the annulus results from the load-bearing connectors, which form internal constrictions at the various joining points within the interior of the length of pipe. Lines and cutting equipment must be able to navigate these constrictions without becoming snagged or jammed.
[0005] Many different types of cutting equipment are available, such as water jet cutters, underwater torches, underwater cutting wheels, etc. However, the most popular and cost effective means to cut these tubular members involves the use of commercially available linear explosive shape charges. Linear explosive shape charges, which use small amount of explosives to produce a directed cutting blaze, are particularly well suited for such applications and are comprised of elongated masses of explosive material having V-shape cross-sections. These types of charges must be positioned in a nearly continuous circle within the tube adjacent to the wall in order to achieve the complete circumferential severance of the tubular member. Upon detonation of such linear shape charges, because of the housing material and shape of the explosive, a substantial unidirectional explosive jet of high temperature and velocity is produced capable of deep penetration of metal thicknesses. However, it is essential that an air space exist between the shape charge and the target to be severed in that the jet produced must travel a distance before meeting incompressible liquids or other obstructions in order to achieve proper penetration. The length of the air space required between the shape charge and the target to achieve proper penetration of the target is known in the art as the “stand-off” distance. The requirement of placing the shape charge in a chamber that will provide this air space that can be transported to the depth needed and then expanded so that the chamber is within close proximity to the tubular wall is necessary to have a successful severance of the tubular wall.
FIELD OF THE INVENTION
[0006] Attempts to utilize shape charges for severing tubular members from the inside thereof, particularly tubular members having constrictions therein, have generally been unsuccessful due to the problems involved in passing linear explosive shape charges and the tool having one or more shape charge chambers included therein through the tubular members and obtaining the required stand-off between the walls of the tubular members and the linear explosive shape charges. Further, in applications where water or other fluids are contained within the tubular member to be severed, the presence of such fluids between the shape charge chamber and the walls of the tubular member interferes with the formation of explosive jets of required penetration ability.
[0007] In U.S. Pat. No. 4,116,130, Christopher et. al, first presented a shape charge positioner comprised of a remotely extendible framework having one or more remotely detonatable shape charges attached thereto. When retracted, the framework passed through the constrictions and was then extended via a mechanical means to move the shape charges into place against the interior pipe wall at the cutting point. Christopher included an inflatable bladder that claimed to ensure that the proper standoff distance maintained relative to the pipe wall for the shape charge to be effective. This tool proved difficult to position correctly, difficult to navigate the constrictions, and had no means to verify the shape charges were in correct position before firing.
[0008] In U.S. Pat. Nos. 6,131,517 and 6,230,627, Poe presents in his fourth embodiment, an improved shape charge positioner that can be remotely set at the desired location. This embodiment includes a frame having an upper and lower section that is attached to a cable for lowering to the desired cutting point. Prior to lowering into the tubular member, four arc-shape explosive charge chambers are tensioned into a retracted position and held in place by a plurality of cables. Once lowered into position, detonators on each of the tension cables are ignited and the cables are cut. Upper and lower springs provide the tension and when the retaining cables are severed, the shape charges extend outward until they contact the inside wall of the tubular member. Due to the particular mechanical design of this retracting/extending system, the shape charges are forced to make two different semi-circular planes on the inside diameter of the tubular member. Thus, when the shape charges are detonated, a continuous cut is not achieved and the tubular member must be re-detonated with a large amount of explosives or the cut completed by some other means.
[0009] These prior art tools have several deficiencies that prevent them effectively severing these tubular members correctly and with minimal damage to the surrounding marine environment. First, they employ large explosive charges to account for their inability to position linear explosive shape charge chambers consistently in the tubular member. Excessive blasting represents a danger to nearby marine environments and fishery personnel are typically employed during blasting operations to ensure wildlife is cleared from the area prior to detonation. Secondly, they require divers to descend into treacherous and hazardous enclosed environments to place explosive shape charges. Thirdly, they have mechanisms that require multiple actuators and multiple movements, which cannot be ensured to consistently deploy on every location under widely varying conditions. Fourthly, they often do not place the explosive shape charge chamber within the correct distance required from the structural tube wall to be effective. In most cases, they do not sever the structural tube wall in one explosive detonation. Once detonated, the tool is destroyed and a new tool or additional higher explosive placement steps must be undertaken. Fifthly, they do not work in the environment created below the mud line when suction pumps have just removed the mud buildup accumulated over years of platform operation. Agitation of marine sediments from the suction pumps makes the water completely turbid. Human personnel cannot position shape charges until the sediments have settled, which can take a significant amount of time. Sixthly, these tools do not provide any confirmation to the personnel at the surface that the tool is correctly positioned and ready for operation. Seventhly, they are not capable of collapse and expansion multiple times and therefore cannot be removed if something does not work properly. Finally, the inflatable tubes used in the prior art to ensure proper distancing to the tubular wall must be puncture proof and expand evenly in environments where pressures may exceed 200 psi.
[0010] What is needed in the art is a collapsible tool that can effectively and consistently transport down a tubular member and then on command, expand into a circular formation that will correctly position one or more linear shape charge explosive chambers within the tubular member below the mud-line.
[0011] What is further needed in the art is a shape charge chamber that has a durable and precise sealed air chamber so that standoff distance and shape charge position are assured prior to detonation.
[0012] What is further needed in the art is an effective severing means that uses less explosive material and has less impact on the surrounding marine environment.
[0013] What is further needed in the art is a severing means that provides remote feedback to the surface personnel indicating that placement is correct and includes a means for retrieving or repositioning in the event the initial placement attempt is unsuccessful.
[0014] What is further needed in the art is an expandable positioner that places the linear shape charge explosive chamber along a continuous common plane so that the tubular member will be severed completely in one detonation.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention provides a collapsible shape charge positioner for the severing of tubular members at inaccessible locations. In the collapsed state, the tool folds a plurality of rigid, arc-shape chambers into a partly vertical orientation such that the outside diameter of the tool is substantially reduced. The tool employs a top and bottom cone-shape guard to facilitate movement of the tool through constrictions within the tubular member to be cut. The guards also keep the tool from tilting on its side and allow it to remain in a substantially vertical position as it descends within the tubular member. The tool further includes a pressurized air tank and a pneumatic cylinder connected to a central rotating axle through a lever arm. Compressed air from the pressurized air tank is released by an electrically actuated valve to engage the cylinder and cause the central axle to rotate. Air in the opposite end of the air cylinder is released to an initial non-pressurized receiving tank through a separate port of the electrically actuated valve. As the axle rotates, the arc-shape chambers are rotated from the partly vertical collapsed position to the horizontal extended position. When fully extended, the arc-shape chambers form a near continuous, planar circumference along the inside diameter of the tubular member. Within each arc-shape chamber is placed a linear explosive shape charge with ignition detonator. All of the charges are wired together to detonate from remote control at the surface. The circular configuration of the expanded shape charge chambers places the explosives in the correct position to ignite a linear cut around the entire circumference of the structural tube no matter the slope of the tube interior. The mechanism's movement will straighten the entire tool by making the shape charge chamber quadrant that touches the wall first push the entire tool off an angled position into the correct position in relation to the tube wall for a linear cut. Sensors on the air cylinder will signal when the tool is either fully collapsed or fully expanded and ready for ignition of explosives. The linear actuator's movement is made reversible by directing compressed air to different ends of the air cylinder and collapse or expand the tool with a remote signal many times during operation at the pressures encountered within the tubular member.
BRIEF DESCRIPTION OF THE DRAWINGS:
[0016] FIG. 1 is a side sectional view of the present invention within a vertical tubular member in the extended configuration.
[0017] FIG. 2 is a side sectional view of the present invention within a vertical tubular member in the collapsed configuration.
[0018] FIG. 3 is a plan view of the topside of the upper mounting plate showing the compressed air cylinder shaft in both the collapsed and extended position. As the cylinder shaft extends, the attached lever arm imports a rotational movement to the vertical axle.
[0019] FIG. 4 is a plan view of the operating wheel showing the arc-shape charge chambers in both the collapsed and extended position. As the axle rotates, push/pull rods attached to the arcs and the operating wheel move the shape charge chambers in a rotational manner that increases or decreases the overall diameter of the arc-shape charge chambers when the vertical movement is compelled by the stationary pivot and angular slotted pivot/guide bracket with guiding rods attached to the shape charge chambers
[0020] FIG. 5 is a plan view of the top side of the bottom rotor plate showing the stationary pivot and slotted guide vertical movement of the pivot/guide brackets with rods attached to the arc-shape chambers that move the chambers vertically into the collapsed and extended positions.
[0021] FIG. 6 shows the upper and lower pivot/guide brackets.
[0022] FIG. 7A shows a cross-section and plan view of the current invention showing an enclosed shape charge chamber with a curvature to match the tube that is to be cut and having a substantially square cross-section. The outer face of the chamber is rotated slightly about the central axis of the invention relative to the inner chamber face so that the chamber end caps form an angle.
[0023] FIG. 7B shows an alternate embodiment of FIG. 7A where the center of the inner and outer chamber faces are aligned. In this embodiment, the chamber end plates are perpendicular to the central axis of the invention. To eliminate interference between adjacent chamber ends during movement, this embodiment results in a gap between adjacent chamber ends when fully extended.
[0024] FIG. 7C shows the same basic configuration as FIG. 7A , but the top and bottom chamber plates are rotated instead of the inner and outer chamber face plates as shown in FIG. 7A . This is the preferred embodiment because the offset of the top and bottom chamber faces allows free clearance between adjacent chambers when the mechanism extends and produces the smallest gap between adjacent chambers when fully extended.
[0025] FIG. 8 shows the present invention being lowered down through a tubular member, used as an oil and gas platform leg, from a crane at the surface. The present tool is in the collapsed position.
[0026] FIG. 9 shows the tool in FIG. 8 in position and extended, below the mud-line, and ready to detonate.
DETAILED DESCRIPTION OF THE INVENTION
[0027] In reference to FIG. 1 , the current invention is shown in cross-section in the expanded position within a tubular member 1 . The shape charge tool is comprised of an upper guide cage 2 , a lower guide cage 3 , a central axle 4 , a plurality of arc-shape chambers 5 , which house the linear explosive shape charges, and upper mounting disk 6 , a lower mounting disk 7 , a pneumatic cylinder 8 connecting the pneumatic cylinder shaft to the central axle, a pressurize air tank 10 , and an air receiver tank 11 . The upper and lower guide cages 2 and 3 , are formed from a plurality of framing rods 12 that are attached together on one end and to the upper and lower mounting disks, respectively, on the other end. The plurality of framing rods 12 is evenly spaced around the circumference of the mounting disks and bent to the vertical a short distance away from the mounting disks. The bending of the rods allows the volume on the inside to be increased to accommodate the various components contained therein. A plurality of reinforcing rods 13 are evenly spaced around the axle 4 and attached on one end to the underside of the upper mounting disk and on the other to the topside of the lower mounting disk 7 . These reinforcing rods 13 provide additional lateral strength to the invention to support the weight of the loaded shape charge chambers, maintain parallel alignment of the upper and lower mounting disks, and to distribute rotational forces applied to the central axle during movement of the mechanism.
[0028] In reference to FIG. 2 , the current invention is shown in cross-section in the collapsed form within a tubular member 1 . The mechanical movement of the linear explosive shape charge chambers from expanded to collapsed position is accomplished by rotation of a central operating wheel 30 attached to the central axle 3 . As shown in FIG. 3 , the pneumatic cylinder 8 is mounted to the topside of the upper mounting disk using a pivoting bracket 14 . As compressed air enters the pneumatic cylinder, the cylinder's shaft extends. The lever arm 9 is attached on one end to the central axle 4 and on the cylinder's shaft. The extending movement of the cylinder shaft produces a rotational movement of the central axle 4 . As the axle and attached mounting disks turn, the pivot bracket 14 also turns to allow the cylinder to rotate slightly to eliminate lateral forces applied to the shaft as it moves horizontally.
[0029] FIG. 1 shows the compressed air for the pneumatic cylinder to reside in a pressurized air tank 10 . Air vented out of the pneumatic cylinder 8 during movement is collected in the air receiver tank 11 . In the preferred embodiment, these two tanks are located in the space formed by the plurality of framing rods attached to the lower mounting disk that form the lower guide cage 3 . It is understood that either of these tanks could be located in other open spaces without deviating from the basic concept presented by the current invention. Air from the pressurized air tank 10 is fed to the pneumatic cylinder 8 through an electrically actuated solenoid valve placed in the interconnecting line. When the surface operator desires to expand the tool, a switch connected to the electric solenoid valve is actuated into the position allowing the compressed air to pressurize the cylinder shaft extension port of cylinder 8 .
[0030] In reference to FIG. 4 , the central operating wheel 30 is shown in the two positions when the linear explosive shape charge chambers are in the extended and collapsed positions. Each of the shape charge chambers 5 are moved into place by a pair of push/pull rods 20 and 21 . The forward push/pull rod 20 and the rear push/pull rod 21 are attached on one end to the forward end and rear end respectively of the shape charge chambers. In the embodiment of FIG. 4 , the push/pull rods are attached to the inner face wall of the shape charge chambers near the forward and rear areas of the shape charge chambers. However, they could also engage the chambers on the lower or upper faces of the chamber. The other end of the push/pull rods is attached to the central operating wheel 30 in a plurality of spaced holes 31 placed around the outer circumference of the wheel.
[0031] The movement of the shape charge chambers from the collapsed to the extended position, and vice versa, employs both a radial displacement and an axial displacement that occurs simultaneously. This three dimensional movement is accomplished by the radial force of the push/pull rods 20 and 21 attached to each chamber 5 and the axial force of a second pair of pivot/guide rods (See FIG. 5 ) moving through pivot/guide slots attached to the upper and lower mounting plates. Since both the push/pull rods and the pivot/guide rods are connected on one end to the shape charge chamber, at some point along the rods axis, a standard swivel or universal joint is installed to allow three-dimensional rotation. In the preferred embodiment, each rod is fitted with a swivel joint near the end attached to the shape charge chamber mounting plates or the operating wheel. Thus when extended, the tool has an overall diameter as shown by the dotted line 32 in FIG. 4 . But when collapsed, the overall diameter is significantly less. This reduction in diameter allows the tool to pass through constrictions in the tubular member it is moving through and also allows the tool to move the shape charge chambers into a common plane at a larger diameter when in the desired position.
[0032] FIG. 5 shows the underside of the upper mounting plate (top figure) and the topside of the lower mounting plate (bottom figure). To each of these plates are attached a plurality of pivot/guide rod brackets 40 . Each pivot/guide bracket is formed of a channel secured on middle side to the inner face of each mounting disk. One pivot/guide bracket is provided for each pivot/rod guide. In the preferred embodiment, which uses four shape charge chambers, a total of eight pivot/guide brackets are required. As best seen in FIG. 1 , the perpendicular member of the pivot/guide bracket 40 extends toward the middle of the tool and contains an ovular slot aligned at an angle relative to the tool axis. In reference to FIG. 5 , the upper pivot/guide rods 41 are attached on one end to the shape charge chamber. As stated earlier, since these pivot/guide rods travel in three dimensions, a standard swivel or universal joint is included at some point along the axis of the pivot/guide rod. In the preferred embodiment, the swivel joint for the pivot/ guide rods is located near the end attached to the shape charge chamber. The other end of each upper pivot/guide rod is not attached and moves freely as the shape charge chamber moves both horizontally and vertically in one motion. The lower pivot/guide rods 42 are attached in a similar manner as the upper pivot/guide rods, with one end attached to the shape charge chamber with a swivel and the opposite end free to move as the shape charge chamber moves horizontally and vertically in one motion. Each of the upper and lower pivot/guide rods passes through the angled ovular slots of the bracket 40 . When the push/pull rods 20 and 21 are moved by rotational action of the operating wheel 30 , they impart a radial force on each end of each shape charge chamber. Simultaneously, the pivot/guide rods attached to the shape charge chamber with a swivel, as controlled by the angled ovular slots, direct the pivot/guide rods to provide a simultaneous axial force on each end of each shape charge chamber. The combined radial and axial forces applied to the ends of the chambers produces a vertical upward and downward motion as each chamber moves away or toward the axis of the central axle when the pneumatic cylinder 8 is extended or retracted. When fully collapsed, the shape charge chambers occupy a partly vertical position and have an overall diameter less than when extended. In the extended position, the push/pull rods push out and pivot/guide rods lower and raise each shape charge chamber and the combined motion maneuvers the shape charge chambers into a common horizontal circular plane. This common horizontal circular plane is very important to maximize the effectiveness of the shape charge explosion to sever the tubular member. By maximizing the effectiveness of the shape charge explosion, a lesser amount of the explosive may be used. When using the tool to sever underwater tubular members, the lesser the quantity of explosive used, the less impact the explosion will have on the surrounding marine environment.
[0033] In reference to FIG. 6 , the upper and lower pivot/guide brackets 40 and 45 are shown. Each bracket is comprised of one rigid piece of metal of other similar material that is bent into a u-shape or two right angled metal pieces that are then are placed together and bonded to form the u-shape. The bottom of the bracket is secured to the inner face of the upper and lower mounting disks 6 and 7 . Each pivot/guide rod 41 extends through a pivot hole 46 drilled into one side of the bracket and extends to the chamber through the ovular slot 47 . As the device rotates, the chambers are pushed outward. As the pivot/guide rods 41 extend outward as the chamber moves outward, the ovular slot 47 imparts a vertical movement on the rod, which lifts the rear end of the shaped chamber upward toward the central plane of the device. The pivot/guide rods are long enough so that when the chambers are fully extended, a portion of the rod remains extended through the pivot hole 46 .
[0034] FIGS. 7A , 7 B and 7 C show three different embodiments of the shape charge chambers that can be used in carrying out the invention. Each of these embodiments represents a trade-off between ease and cost of fabrication versus the gap between each chamber when fully extended. By minimizing the gap between the chambers when extended, the shape charges are more likely to cut the tubular member at the point adjacent to that gap. In general, the thicker the tubular member to be cut, the less of a gap between the chambers can be tolerated to ensure complete severance of the tubular member. Since the invention operates by rotating the chambers to a common horizontal plane from a substantially vertical resting position, interference between the ends of the moving chambers is avoided by shortening the overall length of the chambers or applying a rotational offset of the various face of the chamber. In reference to FIG. 7A , each shape charge chamber is comprised of an outer faceplate 60 , a top faceplate 61 , a bottom faceplate 62 , an inner faceplate 63 , a forward endplate 64 and a rearward endplate 65 . These faces form a hollow watertight chamber in which a linear explosive shape charge is inserted. The chamber is sealed with fastening devices and gaskets using various known methods. In the preferred embodiment, four linear explosive shape charges chambers are employed, which correspond to the four quadrants of the circle they form when extended in place. The required arc length and radius of each chamber is determined by the inside diameter of the tubular member to be severed. In FIG. 7A , the mid-point center of the outer faceplate 60 is rotated at an angle relative to the mid-point center of the inner faceplate 63 . This rotation of centers results in an angle B that can be selected by the user from between 0 and 45 degrees, with 30 degrees being useful for many applications. FIG. 7B shows the inner and outer faceplates 60 and 62 with no offset rotation relative to one another. This embodiment is simpler to fabricate and is generally effective for thinner tubular walls. However, this configuration results in the largest gap between the chambers when fully extended because the chamber length is shorter to allow for clearance of the chamber ends during movement of the mechanism. FIG. 7C shows a third embodiment where instead of the inner and outer faceplates at an offset angle, the rotational offset angle is applied to the top and bottom faceplates 61 and 62 . This rotation of centers results in an angle that can be selected by the user from between 0 and 45 degrees, with 30 degrees being useful for many applications. In this embodiment, the shape charge chambers create an overlap in the vertical orientation, and provide for the least amount of gap between the chambers when fully extended. This configuration is preferred for thicker tubular members.
[0035] In reference to FIG. 8 , the current invention is shown being lowered down one of the support legs of an ocean platform in the collapsed state. Prior to lowering, the tool into the tubular leg member, the mud and ocean sediments within the tubular member at the interface with the seabed are removed by others to a desired distance to create a annular space for the tool to descend below the mudline. In FIG. 9 , the devise is shown at a position below the mudline and extended so that the shape charge chambers are resting against the inside diameter of the tubular member along a common plane. The blast from the detonation of the shape charges extends into the surrounding seabed and up through the tubular member to the surface, leaving the surrounding marine life unaffected. | A method of severing tubular members using an expandable linear explosive shape charge positioner. The method involves placing a plurality of arc-shaped charge chambers along the same plane and adjacent to the interior walls of a tube. Simultaneous detonation of the charge chambers severs the tube along a common plane. The positioner is placed within a tubular member and includes a remotely extendible framework with linear explosive shape charges enclosed therein. When in the collapsed position, the apparatus passes through constrictions within the tubular members. When extended, the framework is positioned transversely to the axis of the tubular member with the shape charges positioned adjacent the interior walls thereof. Shape charge chambers with angled ends are presented to provide overlap when the device is fully extended to better ensure complete separation of the tubular member at the discontinuities of the shape charges about the plane of severance. | 5 |
TECHNICAL FIELD
The present invention relates to a ventilation system for a bathroom, and particularly, to a ventilation system for a bathroom that uses a blower to forcedly discharge air out of the bathroom to refresh the inside the bathroom.
BACKGROUND ART
In general, an apartment building, office building or other human life space has a bathroom(s). In the past, the bathroom was placed at a location isolated from the living space to treat the human excreta. However, a recent trend is towards the bathroom being housed inside the living space as the apartment is favored as a dwelling.
Following such trend, the toilet and basin installed in the bathroom goes on evolving for more sanitation. Further, a change in function of the bathroom from a mere space to treat human waste to a multi-functional room for bathing and makeup led to people staying longer in the bathroom, and the waste treatment space is thus in the trend of being equipped with higher-class facilities.
Meanwhile, an air exhausting facility mostly comes with the bathroom of an apartment house. The air exhausting facility is installed on a ceiling panel inside the bathroom, and a fan is provided on the top or a side of the facility for smooth exhaust. The air exhausting system draws the moisture or odor out of the bathroom.
However, such air exhausting facility simply exhausts air from the bathroom and cannot respond to the satisfaction when the bathroom door remains closed, i.e., in the airtight bathroom.
In other words, although for ventilation an air intake should be the same as the amount of air exhaust, the air intake in the door-closed state fails to reach the amount of air exhaust, thus rendering ventilation difficult.
SUMMARY
Objects
The present invention has been designed to address the above issues, and an object of the present invention is to provide a bathroom ventilation system that has a bi-directional ventilation tube for externally exhausting internal air while simultaneously supplying external air to the bathroom, which enables quick ventilation in the bathroom and which discharges the internal air and odor from the bathroom through an internal air traveling tube, thus preventing odors.
Solution
To achieve the above objects, according to the present invention, a ventilation system for a bathroom comprises: an external air traveling tube 100 provided at an upper side of a ceiling panel of the bathroom and having an air intake fan 150 that takes air in from an outside and moves the taken-in air to an inside of the bathroom; an internal air traveling tube 200 provided at the upper side of the ceiling panel of the bathroom and having an air exhausting fan 250 that draws air from the inside of the bathroom to the outside; and a bi-directional ventilation tube 300 provided at a ceiling of the bathroom, the bi-directional ventilation tube 300 including an air exhausting part 310 having a side connected with the external air traveling tube 100 and another side connected with the inside of the bathroom and an air intake part 320 having a side connected with the internal air traveling tube 200 and another side connected with the inside of the bathroom.
The air intake part 320 is formed to pass through the inside of the air exhausting part 310 to be opened toward the bathroom, and wherein, a guiding plate 330 is provided at the other side of the air intake part 320 , which faces the bathroom, along a periphery thereof, the guiding plate 330 projected towards the ceiling of the bathroom.
The ventilation system further comprises an intake adjusting member 400 provided at the other side of the air exhausting part 310 , which faces the bathroom, to be movable in a longitudinal direction of the air exhausting part 310 to adjust an air intake.
The intake adjusting member 400 includes:
a fixed part 410 provided at the other side of the air exhausting part 310 , the fixed part 410 including a threaded groove part 411 in a middle of the fixed part 410 and an opening 412 formed outside the threaded groove part 411 to connect the inside of the air exhausting part 310 with the inside of the bathroom; and
a moving part 420 including a bolt part 421 and a cover 422 , the bolt part 421 screw-connected to the nut part 411 , the cover 422 rotated to move up and down along the nut part 411 to open and close the opening 412 .
The internal air traveling tube 200 includes: a first exhaust pathway 210 provided at the upper side of the ceiling panel of the bathroom and having a side connected with the bi-directional ventilation tube 300 , wherein air in the bathroom is sucked through the first exhaust pathway 210 ; a second exhaust pathway 220 extended along the upper side of the ceiling panel of the bathroom to a side wall of the bathroom and having a side connected with a toilet 10 disposed in the bathroom, wherein air around the toilet 10 is sucked and flows through the second exhaust pathway 220 ; and a third exhaust pathway 230 provided at the upper side of the ceiling panel of the bathroom and connected with the first exhaust pathway 210 and the second exhaust pathway 220 , wherein the third exhaust pathway 230 is connected with the air exhausting fan 250 to exhaust the air inside the bathroom and the air around the toilet 10 to the outside.
The third exhaust pathway 230 includes: a joining section 231 connected with the first exhaust pathway 210 and the second exhaust pathway 220 , wherein an internal cross-sectional area of the joining section 231 is larger than a sum of an internal cross-sectional area of the first exhaust pathway 210 and an internal cross-sectional area of the second exhaust pathway 220 ; a exhausting section 232 having a side connected with the joining section 231 and another side connected with the air exhausting fan 250 , wherein an internal cross-sectional area of the exhausting section 232 is larger than a sum of the internal cross-sectional area of the first exhaust pathway 210 and the internal cross-sectional area of the second exhaust pathway 220 and is smaller than the internal cross-sectional area of the joining section 231 ; an adjusting plate 240 provided in the joining section 231 to, depending on a difference in amount between the air sucked through the first exhaust pathway 210 and the air sucked through the second exhaust pathway 220 , shift in a direction towards one, through which a smaller amount of air is sucked, of the first exhaust pathway 210 and the second exhaust pathway 220 .
The external air traveling tube 100 includes an air purifying filter 500 to rid the sucked external air of foreign substances and dust.
Effects
The bathroom ventilation system according to the present invention, as described above, provides the following effects.
The intake of air in the bathroom and supply of external air are simultaneously performed through the bi-directional ventilation tube 300 . Accordingly, even in the airtight state where the bathroom door stands closed, more loads are prevented from being applied to the air exhausting fan 250 , and air circulation is swiftly done. Therefore, the bathroom may remain at a pleasant atmosphere.
Formation of the downwardly-inclined guiding plate 330 along the periphery of the air intake part 320 enables the air discharged from the air exhausting part 310 to flow evenly passing the walls of the bathroom, thus quickly removing the moisture of the walls of the bathroom.
The intake adjusting member 400 is provided at a lower side of the air intake part 320 to move up and down. Accordingly, the user may adjust the amount of air exhausted from the inside of the bathroom and from around the toilet 10 , thus allowing for easier use.
The internal air traveling tube 200 includes the second exhaust pathway 220 connected with the toilet 10 . Accordingly, the odors around the toilet 10 may be quickly drawn out through the toilet 10 without passing through the inside of the bathroom, thus minimizing germ proliferation. Therefore, the bathroom may remain clean.
The adjusting plate 240 is provided in the third exhaust pathway 230 to be movable toward the first exhaust pathway 210 and the second exhaust pathway 220 depending on air intakes, thus reducing occurrence of a vortex in the joining section 231 while preventing the air sucked through the second exhaust pathway 220 from flowing back to the first exhaust pathway 210 .
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a view illustrating a side cross-sectional structure of a bathroom ventilation system according to an embodiment of the present invention.
FIG. 2 is a perspective view illustrating a bi-directional ventilation tube 300 of a bathroom ventilation system according to an embodiment of the present invention.
FIG. 3 is a view illustrating an operation state of an intake adjusting member 400 of a bathroom ventilation system according to an embodiment of the present invention.
FIG. 4 is a perspective view illustrating a third exhaust pathway 230 of a bathroom ventilation system according to an embodiment of the present invention.
FIG. 5 is an expanded view illustrating a side cross-sectional structure of a second exhaust pathway 220 and a toilet 10 of a bathroom ventilation system according to an embodiment of the present invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 is a view illustrating a side cross-sectional structure of a bathroom ventilation system according to an embodiment of the present invention. FIG. 2 is a perspective view illustrating a bi-directional ventilation tube 300 of a bathroom ventilation system according to an embodiment of the present invention. FIG. 3 is a view illustrating an operation state of an intake adjusting member 400 of a bathroom ventilation system according to an embodiment of the present invention. FIG. 4 is a perspective view illustrating a third exhaust pathway 230 of a bathroom ventilation system according to an embodiment of the present invention. FIG. 5 is an expanded view illustrating a side cross-sectional structure of a second exhaust pathway 220 and a toilet 10 of a bathroom ventilation system according to an embodiment of the present invention.
As shown in FIGS. 1 to 5 , according to an embodiment of the present invention, the bathroom ventilation system includes an external air traveling tube 100 , an internal air traveling tube 200 , a bi-directional ventilation tube 300 , an intake adjusting member 400 , and an air purifying filter 500 .
The external air traveling tube 100 is shaped as a hollow tube including a pathway through which air may flow. The external air traveling tube 100 is provided at an upper side of a bathroom ceiling panel. The external air traveling tube 100 is connected with an air intake fan 150 that takes air in from the outside and moves the taken-in air to the inside of the bathroom.
Here, the external air traveling tube 100 is preferably formed of a flexible hose for allowing the external air traveling tube 100 to be freely adjusted in shape and arrangement upon installation. The air intake fan 150 has the same structure as that of a typical blower and detailed description thereof is skipped.
Further, the air purifying filter 500 to be described below is provided in a middle section of the external air traveling tube 100 to remove foreign substances or dust from the air taken in from the outside.
Like the external air traveling tube 100 , the internal air traveling tube 200 is shaped as a hollow tube including a pathway through which air may flow. The internal air traveling tube 200 is provided at an upper side of the bathroom ceiling panel. The internal air traveling tube 200 is connected with an air exhausting fan 250 that draws air from the inside of the bathroom to the outside.
Here, the internal air traveling tube 200 is preferably formed of a flexible hose for allowing the external air traveling tube 100 to be freely adjusted in shape and arrangement upon installation. The air exhausting fin 250 has the same structure as that of a typical blower and detailed description thereof is skipped.
Further, the internal air traveling tube 200 sucks the air in the bathroom through the bathroom ceiling and is connected with the toilet 10 installed in the bathroom to suck odors around the toilet 10 and to draw the odors to the outside.
Specifically, the internal air traveling tube 200 includes a first exhaust pathway 210 , a second exhaust pathway 220 , and a third exhaust pathway 230 .
As shown in FIG. 1 , the first exhaust pathway 210 is mounted at an upper side of the ceiling panel of the bathroom, and its side, i.e., left side, is connected with the bi-directional ventilation tube 300 , and the other side, i.e., right side, is connected with the third exhaust pathway 230 to be described below.
The air in the bathroom is sucked and is rendered to flow the third exhaust pathway 230 through the first exhaust pathway 210 .
The second exhaust pathway 220 is extended along the upper side of the ceiling panel of the bathroom and is bent to a right side wall of the bathroom. A side, i.e., a lower end, of the second exhaust pathway 220 is connected with the toilet 10 provided in the bathroom, and another side, i.e., an upper end, thereof is connected with the third exhaust pathway 230 to be described below.
The air around the toilet 10 is sucked and is rendered to flow the third exhaust pathway 230 through the second exhaust pathway 220 .
Here, as shown in FIGS. 1 and 5 , the toilet 10 is formed of a toilet seat 10 . Specifically, the toilet 10 includes a main body 11 having a hollow 11 a and a water tank 12 including an overflow tube 12 a communicating with the hollow 11 a.
A coupling structure 13 is provided in the toilet 10 . The coupling structure 13 has an end mounted on an upper end of the overflow tube 12 a and another end connected with the second exhaust pathway 220 .
The coupling structure 13 is shaped as a hollow tube. A middle part of the coupling structure 13 is bent to about 90 degrees. The coupling structure 13 is formed of rubber for easy angling upon installation.
The above configuration enables the odors created in the hollow 11 a to be sucked to the second exhaust pathway 220 through the overflow tube 12 a and the coupling structure 13 and to be exhausted to the outside.
Of course, the toilet 10 may also be configured to form a separate pathway communicating with the hollow 11 a in the main body 11 to be connected with the second exhaust pathway 220 without passing through the overflow tube 12 a.
As such, the internal air traveling tube 200 includes the second exhaust pathway 220 connected with the toilet 10 . Accordingly, the odors around the toilet 10 may be quickly drawn out through the toilet 10 without passing through the inside of the bathroom, thus minimizing germ proliferation. Therefore, the bathroom may remain clean.
Meanwhile, the third exhaust pathway 230 is provided at an upper side of the ceiling panel of the bathroom and is connected with the first exhaust pathway 210 and the second exhaust pathway 220 . The air inside the bathroom, together with the air around the toilet 10 , is exhausted through the third exhaust pathway 230 .
The third exhaust pathway 230 , as shown in FIG. 4 , is divided into a joining section 231 and an exhausting section 232 .
Left and right sides of the joining section 231 are connected with the first exhaust pathway 210 and the second exhaust pathway 220 , respectively. The internal cross-sectional area of the joining section 231 is formed to be larger than the sum of the internal cross-sectional area of the first exhaust pathway 210 and the internal cross-sectional area of the second exhaust pathway 220 .
The exhausting section 232 is disposed at an upper side of the joining section 231 . A side, i.e., a lower side, of the exhausting section 232 is connected with the joining section 231 , and another side, i.e., an upper side, thereof is connected with the air exhausting fan 250 . The internal cross-sectional area of the exhausting section 232 is formed to be the same as the sum of the internal cross-sectional area of the first exhaust pathway 210 and the internal cross-sectional area of the second exhaust pathway 220 .
Meanwhile, the joining section 231 has an adjusting plate 240 that may shift towards the first exhaust pathway 210 and the second exhaust pathway 220 .
The adjusting plate 240 is disposed midway between the first exhaust pathway 210 and the second exhaust pathway 220 , i.e., at a middle of the exhausting section 232 . The adjusting plate 240 is shaped as a rectangular plate.
The adjusting plate 240 prevents a vortex that may occur when the air sucked through the first exhaust pathway 210 and the air sucked through the second exhaust pathway 220 meet each other in the joining section 231 and allows the air to be smoothly drawn out.
Further, the adjusting plate 240 shifts depending on a difference in amount between the air sucked through the first exhaust pathway 210 and the air sucked through the second exhaust pathway 220 . For example, the adjusting plate 240 moves in a direction in which a smaller amount of air is sucked.
The amount of air sucked through the first exhaust pathway 210 may be varied by the intake adjusting member 400 to be described below. In this case, if the air intake through the first exhaust pathway 210 is smaller than the air intake through the second exhaust pathway 220 , the adjusting plate 240 shifts toward the first exhaust pathway 210 , and the inlet of the third exhaust pathway 230 communicating with the first exhaust pathway 210 is narrowed, and the inlet of the third exhaust pathway 230 communicating with the second exhaust pathway 220 is broadened.
In case the adjusting plate 240 remains at a fixed position, even when the inlet of the intake adjusting member 400 , through which air is taken in is narrowed, the inlet of the third exhaust pathway 230 connected with the first exhaust pathway 210 remains the same area. Thus, the air pressure in the first exhaust pathway 210 is decreased while the air pressure in the second exhaust pathway 220 is increased. Hence, the air around the toilet 10 , which is sucked to the exhaust pathways, is rendered to flow back to the first exhaust pathway 210 . Accordingly, the adjusting plate 240 is preferably provided to be movable in order to keep the air pressure in the first exhaust pathway 210 equal to the air pressure in the second exhaust pathway 220 .
As such, the adjusting plate 240 is provided in the third exhaust pathway 230 to be movable toward the first exhaust pathway 210 and the second exhaust pathway 220 depending on air intakes, thus reducing occurrence of a vortex in the joining section 231 while preventing the air sucked through the second exhaust pathway 220 from flowing back to the first exhaust pathway 210 .
Here, in order to enable such shift of the adjusting plate 240 , for example, a guide rail(s) 260 may be formed on an upper surface and/or lower surface of the third exhaust pathway 230 , and a guide block(s) or roller(s) may be formed on an upper surface and/or lower surface of the adjusting plate 240 to be slid on the guide rails 260 .
Meanwhile, as shown in FIGS. 1 to 3 , the bi-directional ventilation tube 300 is installed at the center of the bathroom ceiling, and the external air traveling tube 100 and the internal air traveling tube 200 each are connected to the inside of the bathroom.
Specifically, the bi-directional ventilation tube 300 includes an air exhausting part 310 and an air intake part 320 .
The air exhausting part 310 has a lower end opened and is shaped as a cylinder. A side part of the air exhausting part 310 is connected with the external air traveling tube 100 , and the lower end thereof is connected with the inside of the bathroom.
Further, the inner diameter of the air exhausting part 310 is formed to be about twice as large as the inner diameter of the external air traveling tube 100 .
The air intake part 320 is of a hollow shape having ends opened. The air intake part 320 is bent at about 90 degrees to be shaped as the letter “L.” A side, i.e., a right side, of the air intake part 320 is connected with the internal air traveling tube 200 , and another side, i.e., a lower side, thereof is connected with the inside of the bathroom.
Further, a guiding plate 330 is provided at a lower side of the air intake part 320 along the periphery thereof. The guiding plate 330 is projected towards the bathroom ceiling.
The guiding plate 330 is formed of an inclined plate of to truncated cone shape inclined downwards. The guiding plate 330 is disposed at a lower part of the outlet of the air exhausting part 310 . The guiding plate 330 is formed to be larger in diameter than the air exhausting part 310 .
The guiding plate 330 guides the air discharged from the air exhausting part 310 to be widely spread to and the ceiling wall of the bathroom.
As such, formation of the downwardly-inclined guiding plate 330 along the periphery of the air intake part 320 enables the air discharged from the air exhausting part 310 to flow evenly passing the walls of the bathroom, thus quickly removing the moisture of the walls of the bathroom.
Meanwhile, the intake adjusting member 400 is provided at a bathroom-facing side of the air intake part 320 . The intake adjusting member 400 moves up and down to adjust the air intake of the air intake part 320 .
More specifically, the intake adjusting member 400 , as shown in FIGS. 2 and 3 , includes a fixed part 410 and a moving part 420 .
The fixed part 410 is shaped as a cylinder and is fixed to the other side of the air intake part 320 . The fixed part 410 includes a nut part 411 a threaded inner circumferential surface in the middle of the fixed part 410 and an opening 412 formed through outside the nut part 411 to connect the inside of the air intake part 320 with the inside of the bathroom.
The moving part 420 includes a bolt part 421 and a cover 422 . The bolt part 421 is shaped as a long cylinder and has a threaded outer circumferential surface, like a bolt. The cover 422 is coupled with the nut part 411 and rotates to move up and down along the nut part 411 .
The cover 422 is formed at a lower end of the bolt part 421 . The cover 422 is shaped as a disc. The diameter of the cover 422 is equal or larger than the diameter of the opening 412 .
The cover 422 , as shown in FIGS. 2 and 3 , adjusts the degree of opening and closing of the opening 412 as the bolt part 421 moves up and down along the nut part 411 .
Such intake adjusting member 400 , in case the cover 422 ascends to narrow the opening 412 , reduces the air intake from the inside of the bathroom while increasing the air intake from around the toilet 10 through the second exhaust pathway 220 .
As such, the intake adjusting member 400 is provided at a lower side of the air intake part 320 to move up and down. Accordingly, the user may adjust the amount of air exhausted from the inside of the bathroom and from around the toilet 10 , thus allowing for easier use.
Meanwhile, the external air traveling tube 100 includes an air purifying filter 500 to rid the sucked external air of foreign substances and dust.
The air purifying filter 500 may be a honeycomb filter that may be semi-permanently used, and in some cases, various typical filters may be employed as the air purifying filter 500 .
In the bathroom ventilation system configured above according to the present invention, the intake of air in the bathroom and supply of external air are simultaneously performed through the bi-directional ventilation tube 300 . Accordingly, even in the airtight state where the bathroom door stands closed, more loads are prevented from being applied to the air exhausting fan 250 , and air circulation is swiftly done. Therefore, the bathroom may remain at a pleasant atmosphere.
It should be understood that the present invention is not limited to the above described embodiments, and various changes in form and details may be made thereto by one of ordinary skill in the art without departing from the spirit and scope of the present invention defined in the following claims, and such also should belong to the scope of the present invention. | The present invention aims to provide a bathroom ventilation system having a bi-directional ventilation tube that exhausts internal air to the outside while supplying external air into the bathroom to allow for quick ventilation in the bathroom and to draw toilet odors as well as air in the bathroom out of the bathroom through an internal air traveling tube, thereby minimizing occurrence of odors.
To achieve the above object, according to the present invention, a ventilation system for a bathroom comprises: an external air traveling tube 100 provided at an upper side of a ceiling panel of the bathroom and having an air intake fan 150 that takes air in from an outside and moves the taken-in air to an inside of the bathroom; an internal air traveling tube 200 provided at the upper side of the ceiling panel of the bathroom and having an air exhausting fan 250 that draws air from the inside of the bathroom to the outside; and a bi-directional ventilation tube 300 provided at a ceiling of the bathroom, the bi-directional ventilation tube 300 including an air exhausting part 310 having a side connected with the external air traveling tube 100 and another side connected with the inside of the bathroom and an air intake part 320 having a side connected with the internal air traveling tube 200 and another side connected with the inside of the bathroom. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a hydraulic control valve for a construction machine. More particularly, the present invention relates to a hydraulic control valve for a construction machine in which a hydraulic fluid discharged from a high-load hydraulic pump is unloaded to the center bypass path without any interception of the center bypass path during a combined operation in which a swing manipulation and a manipulation of a work apparatus such as an arm or the like are simultaneously performed, thereby preventing the excessive increase in the pressure of the hydraulic pump.
BACKGROUND OF THE INVENTION
[0002] In general, a hydraulic control valve for a construction machine in accordance with the prior art as shown in FIG. 1 includes:
[0003] a hydraulic pump 1 connected to an engine (not shown);
[0004] a swing spool 3 installed on an upstream side of a center bypass path 5 that fluidically communicates with a discharge flow path 2 of the hydraulic pump 1 and configured to be shifted to control a start, a stop, and a direction change of a swing motor (not shown); and
[0005] an arm spool 4 installed on a downstream side of the center bypass path 5 and configured to be shifted to control a start, a stop, and a direction change of an arm cylinder (not shown).
[0006] The discharge flow path 2 consists of the center bypass path 5 fluidically communicating therewith and a parallel line 6 that is branchedly connected thereto.
[0007] A non-explained reference numeral 14 denotes a relief valve that is installed on the cylinder lines 12 and 13 , respectively.
[0008] The swing spool 3 is shifted in a left direction on the drawing sheet by a pilot signal pressure supplied to a port (al1) to perform a swing operation of the construction machine. In this case, a hydraulic fluid discharged from the hydraulic pump 1 is supplied to a port (AL1) via a line 8 after sequentially passing through a check valve 7 installed on an inlet line 8 of the swing spool 3 and the shifted swing spool 3 so that the swing motor can be driven to swing an upper swing structure of the construction machine.
[0009] At this time, since the hydraulic fluid returned from the swing motor is supplied to a port (BL1), it is returned to a hydraulic tank through a return line 10 after passing through the shifted swing spool 3 via a line 9 .
[0010] Like this, a sufficient start pressure is needed to drive the hydraulic motor as an inertia unit. In other words, a line is made short sufficiently which interconnects the hydraulic pump 1 to the swing motor in the design of the swing spool 3 so as to increase the pressure of the hydraulic pump 1 .
[0011] In the meantime, in the case where a manipulation of a work apparatus such as an arm having a relatively low load and a swing manipulation are performed simultaneously, all the hydraulic fluid discharged from the hydraulic pump 1 is supplied to the arm side with a relatively low load, and thus the hydraulic fluid is not supplied to the swing side.
[0012] Thus, the conventional hydraulic control valve is a hydraulic system in which an orifice 11 is installed on the parallel line 6 along which the hydraulic fluid is supplied to the arm side so that the flow rate of the hydraulic fluid supplied to the arm side is restricted and simultaneously the swing operation is preferentially performed in the entire hydraulic system, and as a result, the pressure of the hydraulic pump 1 is increased due to the interception of the center bypass path 5 according to the shift of the arm spool 4 to cause the hydraulic fluid to be preferentially be supplied to the swing motor in conformity with the start pressure.
[0013] In the case where the arm is manipulated alone, the hydraulic fluid is supplied to the arm spool 4 via the orifice 11 of the parallel line 6 , and thus there occur an increase in the pressure of the hydraulic pump 1 and a loss of energy. Like this, since the orifice 11 is used to ensure that the swing operation is preferentially performed, the pressure of the hydraulic pump 1 is increased cause a loss of energy.
[0014] As shown in a graph of FIG. 2 , when an arm-in pilot signal pressure is supplied to the arm spool 4 to cause the arm spool 4 to be shifted, a pressure (b) of the hydraulic pump 1 side is formed in a similar pattern as a pressure (c) of the arm side. Thereafter, when a swing pilot signal pressure (d) is supplied to the swing spool 3 , the pressure of the hydraulic pump 1 is formed in a pattern in which it is increased up to the same pressure (300 Kgf/cm 2 ) as the swing side load (e). In this case, the arm side pressure (c) maintains the load in the range of a relatively low pressure (60-80 Kgf/cm 2 ).
[0015] Thus, the pressure of the hydraulic pump 1 follows a high swing pressure during the swing operation while the arm-in side load forms a relatively low pressure. As a result, an excessive loss of pressure occurs in the hydraulic pump 1 to cause a loss of energy, leading to a deterioration in a fuel efficiency.
[0016] In a negative control system, a direction switching valve is held in a neutral position and the hydraulic fluid from the hydraulic pump is unloaded to the center bypass path of the control valve so that the discharge flow rate of the hydraulic pump is maintained minimally. On the other hand, when at least one control valve is switched, the unloaded hydraulic fluid passing through the center bypass path is intercepted and the pressure of the hydraulic pump is increased while increasing the discharge flow rate of the hydraulic pump.
[0017] In this case, since a high drive pressure is needed at an initial stage to drive or stop the inertia unit such as the swing motor, there occurs the case in which the pressure of the relief valve is increased. Thus, since a high load pressure on the swing side has an effect on the control valve system, the pressure is further increased due to an increase in the discharge flow rate according to a manipulation of the control valve during a combined operation in which a swing drive or manipulation and a manipulation of a hydraulic actuator such as arm cylinder or the like are performed.
[0018] For this reason, a horsepower much higher than a proper horsepower required by the construction machine is used, leading to a deterioration in a fuel efficiency and thus causing an excessive loss of energy. Also, in a positive control system, since the discharge flow rate of the hydraulic pump is increased according to a manipulation amount of the control valve, the pressure of the hydraulic pump is also increased excessively to cause a loss of energy.
DETAILED DESCRIPTION OF THE INVENTION
Technical Problems
[0019] Accordingly, the present invention has been made to solve the aforementioned problem occurring in the prior art, and it is an object of the present invention to provide a hydraulic control valve for a construction machine in which a hydraulic fluid discharged from a high-load hydraulic pump is unloaded without any interception of the center bypass path on the arm side during a combined operation in which a swing manipulation and a manipulation of a work apparatus such as an arm or the like are simultaneously performed, thereby preventing the excessive increase in the pressure of the hydraulic pump to reduce a loss of energy, and thus improving a fuel efficiency.
Technical Solution
[0020] To accomplish the above object, there is provided a hydraulic control valve for a construction machine in accordance with an embodiment of the present invention ,
[0021] a hydraulic pump connected to an engine;
[0022] a swing spool installed on an upstream side of a center bypass path that fluidically communicates with a discharge flow path of the hydraulic pump and configured to be shifted to control a start, a stop, and a direction change of a swing motor;
[0023] an arm spool installed on a downstream side of the center bypass path and configured to be shifted to control a start, a stop, and a direction change of an arm cylinder; and
[0024] a center bypass control valve installed within the arm spool, the center bypass control valve being configured to be shifted by a pressure of a hydraulic fluid discharged from the hydraulic pump, which is increased during a combined operation in which a swing manipulation and an arm manipulation are simultaneously performed, and configured to unload an increased pressure on the swing side to the center bypass path 5 during the shift thereof.
[0025] In accordance with a preferred embodiment of the present invention, the set pressure of the center bypass control valve may be set by an arm load pressure and is controlled to be linearly increased by a start pressure on the swing side according to a swing pilot pressure during the swing operation.
[0026] The center bypass control valve includes:
[0027] a sleeve installed within the arm spool and having a flow path formed therein so as to fluidically communicate with the discharge flow path of the hydraulic pump;
[0028] a first piston slidably installed within the sleeve and configured to be shifted to maintain the arm side load pressure through unloading of a part of the discharged hydraulic fluid on the hydraulic pump side to the center bypass path during the combined operation in which the swing manipulation and the arm manipulation are simultaneously performed;
[0029] a second piston configured to be in close contact with one end of the first piston and to be shifted to press the first piston by the load pressure which is variably increased depending on a swing side pilot pressure that is additionally applied to the arm side load pressure during the combined operation in which the swing manipulation and the arm manipulation are simultaneously performed; and
[0030] a third piston elastically installed on the other end of the first piston by a valve spring.
[0031] The set pressure of the valve spring that supports the third piston is set to be larger than the load pressure on the hydraulic pump side during the arm operation and is set to be smaller than the load pressure on the hydraulic pump during the swing operation.
[0032] A pair of center bypass paths, which are formed in a bridge shape to fluidically communicate with each other in the hydraulic control valve so that they fluidically communicate with the discharge flow path of the hydraulic pump 1 , fluidically communicate with the center bypass path that fluidically communicates with the discharge flow path of the hydraulic pump 1 via a path formed on the arm spool and the center bypass control valve.
[0033] The hydraulic pump is controlled by a positive control system that controls the discharge flow rate of the hydraulic pump in proportion to the shift amount of the hydraulic control valve that is installed in the center bypass path.
[0034] The hydraulic pump is controlled by a negative control system that controls the discharge flow rate of the hydraulic pump in reverse proportion to the pressure of the discharged hydraulic fluid, which is formed by a pressure forming means installed on the downstream side of the center bypass path.
Advantageous Effect
[0035] The hydraulic control valve for a construction machine in accordance with embodiments of the present invention as constructed above has the following advantages.
[0036] The center bypass control valve is installed within the control valve spool on the arm side so that a hydraulic fluid discharged from a high-load hydraulic pump is unloaded to the center bypass path through the center bypass control valve during a combined operation in which a swing manipulation and a manipulation of a work apparatus such as an arm or the like are simultaneously performed so as to reduce the pressure of the discharged hydraulic fluid, thereby reducing the high load pressure generated from the hydraulic pump, and thus decreasing a loss of energy, leading to improvement of a fuel efficiency.
BRIEF DESCRIPTION OF THE INVENTION
[0037] The above objects, other features and advantages of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which:
[0038] FIG. 1 is a circuit diagram showing a hydraulic control valve for a construction machine in accordance with the prior art;
[0039] FIG. 2 is a graph showing a pressure during a combine operation in which a swing manipulation and an arm manipulation are simultaneously performed in a hydraulic control valve for a construction machine in accordance with the prior art;
[0040] FIG. 3 is a circuit diagram showing a hydraulic control valve for a construction machine in accordance with the present invention; and
[0041] FIG. 4 is a cross-sectional view showing a hydraulic control valve for a construction machine in accordance with an embodiment of the present invention.
EXPLANATION ON REFERENCE NUMERALS OF MAIN ELEMENTS IN THE DRAWINGS
[0000]
1 : hydraulic pump
3 : swing spool
5 : center bypass path
7 : check valve
9 : line
11 : orifice
13 : cylinder line
15 : arm spool
17 : flow path
19 : first piston
21 : valve spring
23 : hydraulic control valve
25 : center bypass path
27 : line
31 : line
33 : valve spring
35 : parallel line
37 : orifice
39 : spool notch
41 : flow path
43 : spool notch
45 : pocket
PREFERRED EMBODIMENTS OF THE INVENTION
[0064] Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The matters defined in the description, such as the detailed construction and elements, are nothing but specific details provided to assist those of ordinary skill in the art in a comprehensive understanding of the invention, and the present invention is not limited to the embodiments disclosed hereinafter.
[0065] A hydraulic control valve for a construction machine in accordance with an embodiment of the present invention as shown in FIGS. 3 and 4 includes:
[0066] a hydraulic pump 1 connected to an engine (not shown);
[0067] a swing spool 3 installed on an upstream side of a center bypass path 5 that fluidically communicates with a discharge flow path 2 of the hydraulic pump 1 and configured to be shifted to control a start, a stop, and a direction change of a swing motor (not shown);
[0068] an arm spool 15 installed on a downstream side of the center bypass path 5 and configured to be shifted to control a start, a stop, and a direction change of an arm cylinder (not shown); and
[0069] a center bypass control valve 16 installed within the arm spool 15 , the center bypass control valve being configured to be shifted by a pressure of a hydraulic fluid discharged from the hydraulic pump 1 , which is increased during a combined operation in which a swing manipulation and an arm manipulation are simultaneously performed, and configured to unload an increased pressure on the swing side to the center bypass path 5 during the shift thereof.
[0070] In this case, the set pressure of the center bypass control valve 16 is set by an arm load pressure and is controlled to be linearly increased by a start pressure on the swing side according to a swing pilot pressure during the swing operation.
[0071] The center bypass control valve 16 includes:
[0072] a sleeve 18 installed within the arm spool 15 and having a flow path 17 formed therein so as to fluidically communicate with the discharge flow path 2 of the hydraulic pump 1 ;
[0073] a first piston 19 slidably installed within the sleeve 18 and configured to be shifted to maintain the arm side load pressure through unloading of a part of the discharged hydraulic fluid on the hydraulic pump 1 side to the center bypass path during the combined operation in which the swing manipulation and the arm manipulation are simultaneously performed;
[0074] a second piston 20 configured to be in close contact with one end of the first piston 19 and to be shifted to press the first piston 19 by the load pressure which is variably increased depending on a swing side pilot pressure that is additionally applied to the arm side load pressure during the combined operation in which the swing manipulation and the arm manipulation are simultaneously performed; and
[0075] a third piston 22 elastically installed on the other end of the first piston 19 by a valve spring 21 .
[0076] The set pressure of the valve spring 21 that supports the third piston 22 is set to be larger than the load pressure on the hydraulic pump 1 side during the arm operation and is set to be smaller than the load pressure on the hydraulic pump 1 side during the swing operation.
[0077] A pair of center bypass path 24 and 25 , which are formed in a bridge shape to fluidically communicate with each other in the hydraulic control valve 23 so that they fluidically communicate with the discharge flow path 2 of the hydraulic pump 1 , fluidically communicate with the center bypass path 5 that fluidically communicates with the discharge flow path 2 of the hydraulic pump 1 via a path 26 formed on the arm spool 15 and the center bypass control valve 16 .
[0078] The hydraulic pump 1 is controlled by a positive control system that controls the discharge flow rate of the hydraulic pump in proportion to the shift amount of the hydraulic control valve 23 (referring a spool of MCV) that is installed in the center bypass path 5 .
[0079] The hydraulic pump 1 is controlled by a negative control system which controls the discharge flow rate of the hydraulic pump in reverse proportion to the pressure of the discharged hydraulic fluid, which is formed by a pressure forming means installed on the downstream side of the center bypass path 5 .
[0080] Hereinafter, a use example of the hydraulic control valve for a construction machine in accordance with an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
[0081] As shown in FIG. 3 , in the case where a combined operation is carried out in which arm manipulation and a swing manipulation is performed simultaneously, the arm spool 15 is shifted in a left direction on the drawing sheet in response to an arm-in pilot signal pressure supplied to a port (al2). Thus, a hydraulic fluid discharged from the hydraulic pump 1 is supplied to a port (AL2) along a cylinder line 12 after passing through the shifted arm spool 15 via an orifice 11 of a parallel line 6 and a check valve 7 so that the hydraulic fluid is supplied to the non-illustrated arm cylinder to perform an arm-in operation.
[0082] In the meantime, the hydraulic fluid being supplied to the center bypass path 5 from the hydraulic pump 1 is supplied to only the parallel line 6 since the center bypass path 5 is in a state of being interrupted according to the shift of the arm spool 15 .
[0083] At this time, a load pressure formed on the arm side is transferred to the pressure of the hydraulic pump 1 as it is, and a pressure is also formed on the center bypass path 5 . This pressure is supplied to an inlet of the center bypass control valve 16 via a line 27 , and simultaneously acts as a pressure that shifts the center bypass control valve 16 in a left direction on the drawing sheet through a path 28 . The pressure that shifts the center bypass control valve 16 forms equilibrium with the valve spring 21 . But, the set pressure of the valve spring 21 is previously set to be larger than the load pressure on the hydraulic pump 1 side during the arm operation and to be smaller than the load pressure on the hydraulic pump 1 side during the swing operation.
[0084] Meanwhile, when the arm operation is performed alone, the center bypass control valve 16 is operated, but when the arm and the swing operations are simultaneously performed, the swing spool 3 is shifted in a left direction on the drawing sheet by the pilot signal pressure supplied to the port (al1) so that the hydraulic fluid discharged from the hydraulic pump 1 is supplied to a port (AL1) via a line 8 after sequentially passing through the check valve 7 installed on an inlet line of the swing spool 3 and the shifted swing spool 3 . This drives the swing motor to cause the upper swing structure of the construction machine to be swung.
[0085] In this case, since the hydraulic fluid returned to the swing motor is supplied to a port (BL1), it is returned to a hydraulic tank T through a return line 10 after passing through the shifted swing spool 3 via a line 9 so that the arm operation and the swing operation can be simultaneously performed.
[0086] In the meantime, since the arm spool 15 is in a state of having been shifted completely, the center bypass path 5 has also been interrupted. For this reason, a pressure of the hydraulic pump 1 is also increased gradually due to an increase in the discharged hydraulic fluid of the hydraulic pump side according to a manipulation amount of a manipulation lever. But, when the pilot signal pressure is supplied to the port (al1), it is transferred to the third piton 22 adjacent to the center bypass control valve 16 via a shuttle valve 30 and a pilot line 31 .
[0087] Like this, when the pressure is transferred to the third piston 22 , a swing pilot pressure applied to the port (al1) is variably transferred to the cross section of the third piston 22 with respect to an elastic force of the valve spring 21 that is set to be large than the arm side pressure at the right side of the third piston 22 . The load pressure is variably increased depending on the swing side pilot pressure, which is additionally applied to the initial arm side load pressure.
[0088] At this time, the swing side pilot pressure applied to the hydraulic pump 1 shifts the center bypass control valve 16 in the left direction on the drawing sheet as it is sufficiently large. Thus, the hydraulic fluid having passed through the center bypass path 5 of the swing spool 3 is unloaded to the center bypass path 5 via the arm spool 15 through a line 32 after passing through the shifted center bypass control valve 16 , and thus is returned to a hydraulic tank T.
[0089] As shown in FIG. 4 , when an arm-in pilot signal pressure is supplied to a port (a), the pilot signal pressure transferred to the arm spool 15 exceeds the elastic force of the valve spring 33 to cause the arm spool 15 to be shifted in the right direction on the drawing sheet. Since the hydraulic fluid supplied from the discharge flow path 2 presses a poppet 34 in an upward direction on the drawing sheet, it is supplied to the parallel line 35 . Simultaneously, the hydraulic fluid supplied to the discharge flow path 2 presses the poppet 38 via the orifice 37 of a plug 36 . For this reason, the hydraulic fluid that presses the poppet 38 joins the hydraulic fluid flowing in the parallel line 35 via a groove formed on the slidable outer surface of the poppet 38 , and then is supplied to the cylinder line 12 via a spool notch 39 formed on the arm spool 15 . Thus, the hydraulic fluid supplied to the cylinder line 12 is supplied to a non-illustrated arm cylinder via the port (AL2) to perform an arm-in operation. The hydraulic fluid returned from the arm cylinder is supplied to the cylinder line 13 via a port (BL2), and thus is returned to the hydraulic tank through a tank line 50 via the spool notch 40 formed on the shifted arm spool 15 .
[0090] The operation of the center bypass control valve 16 installed within the arm spool 15 shifted in the right direction on the drawing sheet will be described hereinafter.
[0091] The pressure of the discharge flow path 2 is supplied to a groove 19 a of the first piston 19 through a path 42 formed in the sleeve 18 via a flow path 41 formed in the arm spool 15 . The center bypass paths 24 and 25 are formed in a bridge shape to fluidically communicate with each other in the hydraulic control valve 23 so that the pressure supplied from the hydraulic pump 1 is uniformly applied to the center bypass paths 24 and 25 . When the pressure from the hydraulic pump 1 is applied to the center bypass path 24 , it is supplied to a spool notch 43 of the shifted arm spool 15 and a line 28 so that it presses the left side of the second piston 20 that is in close contact with the first piston 19 while sliding within the sleeve 18 .
[0092] The second piston 20 must exceed the elastic force of the valve spring 21 that is disposed adjacent to a plug 44 and is supported by the third piston 22 in order to be shifted in the right direction on the drawing sheet. In this case, when an initial control pressure of the valve spring 21 is set to about the load pressure (60-80 Kgf/cm 2 ) of the arm and then exceeds the set pressure, the second piston 20 is shifted in the right direction on the drawing sheet. At this time, as the first piston 19 is shifted in the right direction on the drawing sheet, the pressure of the hydraulic pump is applied to the groove 19 a of the first piston 19 so that the groove 19 a fluidically communicates with the flow path 17 of the sleeve 18 , and then fluidically communicates with the center bypass path 25 via the line 26 of the arm spool 15 . Then, the center bypass path 25 fluidically communicates with the center bypass path 24 in a bridge shape in the hydraulic control valve 23 so that the hydraulic fluid is bypassed and is returned to the hydraulic tank. In other words, a part the hydraulic fluid on the hydraulic pump 1 side is unloaded to the center bypass path 5 so that the arm side load pressure can be constantly maintained.
[0093] In the meantime, in the case where a combined operation is carried out in which arm manipulation and a swing manipulation is performed simultaneously, the swing pilot pressure is supplied to the pocket 45 via the line 31 while being supplied to a swing port (sw), and is applied to the right end of the third piston 22 via the line 46 of the arm spool 15 shifted in the right direction on the drawing sheet to compress the valve spring 21 . For this reason, the load pressure is variably increased depending on the swing side pilot pressure that is additionally applied to the initially set arm load pressure.
[0094] Meanwhile, similarly to the arm-in operation alone, a sufficiently high load pressure applied to the hydraulic pump 1 according to the swing operation is applied to the left side of the second piston 20 installed within the shifted arm spool 15 . In this case, the high load pressure exceeds the load pressure which is variably increased depending on a swing side pilot pressure that is additionally applied to the arm side load pressure. Then, when the second piston 20 is shifted in the right direction on the drawing sheet, the first piston 19 is also shifted to the right. Similarly, the pressure from the hydraulic pump 1 is applied to the groove 19 a of the first piston 19 so that the groove 19 a fluidically communicates with the flow path 17 of the sleeve 18 , and then fluidically communicates with the center bypass path 25 via the line 26 of the arm spool 15 . Then, the center bypass path 25 fluidically communicates with the center bypass path 24 in a bridge shape in the hydraulic control valve 23 so that the hydraulic fluid is bypassed and is returned to the hydraulic tank. In other words, a part the hydraulic fluid on the hydraulic pump 1 side is unloaded to the center bypass path 5 so that an overload according to the swing operation can be prevented and the swing side load pressure can be maintained variably in proportion to the swing pilot pressure.
[0095] For this reason, the excessive increase of pressure on the hydraulic pump side can be prevented to reduce over-consumption of horsepower and loss of energy and thus improve a fuel efficiency.
[0096] Thus, in case of the negative control system, a swivel angle of swash plate of the hydraulic pump is reduced owing to an increase in the negative control pressure according to an increase in the center bypass flow rate so that the discharge flow rate of the hydraulic pump can be decreased, thereby preventing an excessive increase in the pressure of the hydraulic pump.
[0097] On the other hand, in case of the positive control system, the hydraulic fluid from the hydraulic pump increased according to an increase in the manipulation amount is unloaded to the center bypass path so that excessive increase in the pressure of the hydraulic pump is prevented. In addition, when the arm operation and the swing operation are performed simultaneously, an excessive increase in the pressure of the hydraulic pump according to the interception of the center bypass path can be prevented. In this case, the center bypass control valve is installed within the arm spool so that a hydraulic fluid discharged from the high load hydraulic pump is unloaded to the center bypass path without any interception of the center bypass path when the swing manipulation and the swing manipulation are simultaneously performed, thereby preventing an excessive increase in the pressure of the hydraulic pump and thus reducing a loss of energy.
[0098] While the present invention has been described in connection with the specific embodiments illustrated in the drawings, they are merely illustrative, and the invention is not limited to these embodiments. It is to be understood that various equivalent modifications and variations of the embodiments can be made by a person having an ordinary skill in the art without departing from the spirit and scope of the present invention. Therefore, the true technical scope of the present invention should not be defined by the above-mentioned embodiments but should be defined by the appended claims and equivalents thereof.
INDUSTRIAL APPLICABILITY
[0099] As described above, hydraulic control valve for a construction machine in accordance with an embodiment of the present invention, in the hydraulic control valve in which the swing spool is installed on the upstream of the center bypass path and the arm spool is installed on the downstream thereof, and the discharge flow rate is controlled by the positive control system, the center bypass control valve is installed within the arm spool so that a hydraulic fluid discharged from a high-load hydraulic pump is unloaded to the center bypass path through the center bypass control valve during a combined operation in which the swing manipulation and the manipulation of a work apparatus such as an arm or the like are simultaneously performed, thereby reducing the high load pressure generated from the hydraulic pump and thus decreasing a loss of energy. | Provided is a hydraulic control valve in which a center bypass passage is not blocked, but is unloaded when a swing and an arm are operated at the same time to prevent the pressure in a hydraulic pump from being increased. The hydraulic control valve includes: a hydraulic pump connected to an engine; a swing spool disposed upstream of a center bypass passage communicating with a discharge passage of the hydraulic pump to control the operation and stopping of a swing motor and directional switching of the swing motor when switched; an arm spool disposed downstream of the bypass passage to control the operation and stopping of an arm cylinder and directional switching of the arm cylinder when switched; and a center bypass control valve disposed within the arm spool, the center bypass control valve being switched by a discharge flow pressure of the hydraulic pump which is increased when a multi operation for simultaneously operating the swing and the arm is performed, and unloading the increased swing side pressure to the center bypass passage when switched. | 8 |
cross-reference to related applications
[0001] This application is a continuation under 35 U.S.C. §120 of U.S. patent application Ser. No. 13/734,032, filed Jan. 4, 2013, which claims the benefit of U.S. Provisional Patent Application No. 61/691,396, filed Aug. 21, 2012, U.S. Provisional Patent Application No. 61/683,794, filed Aug. 16, 2012, U.S. Provisional Patent Application No. 61/656,832, filed Jun. 7, 2012, U.S. Provisional Patent Application No. 61/602,456, filed Feb. 23, 2012, and U.S. Provisional Patent Application No. 61/582,990, filed Jan. 4, 2012. Each of the above-referenced patent applications is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The disclosed subject matter relates to systems and methods for duplicating keys.
BACKGROUND
[0003] A lock and key are used as one way of limiting access to places (e.g. homes, places of business, storage, etc.) and other types of property (e.g., vehicles, etc.) to a person in possession of a key that can operate the lock. A problem arises when a person who would normally be authorized to enter or use the property protected by the lock does not have physical access to the appropriate key. For example, if a user locks themselves out of their home with the key inside, they cannot gain access to the home because they do not have access to the key. As another example, if a user loses a key to a safe, the user cannot access property that may be inside the safe. One way that users solve the problem is by calling a skilled locksmith that is able to open the lock without a key and/or is able to create a new key for the lock without using an existing key as a template. However, skilled locksmiths are expensive and may not be readily available when the user is in need. Another way that users solve the problem is by hiding a copy of an important key in a place that is not secure, such as under a doormat or in a fake rock placed somewhere accessible by the user. This presents a security risk as a person other than the user can use the hidden key to gain access to the lock.
[0004] Therefore, there is a need for mechanisms for duplicating keys that do not require the services of a skilled locksmith and are secure, among other things.
SUMMARY
[0005] In accordance with various embodiments of the disclosed subject matter, systems and methods for duplicating keys are provided.
[0006] In accordance with some embodiments, systems for creating keys are provided, the systems comprising: at least one hardware processor that: receives security information from a user; and receives geometric information about a first key associated with the security information from a storage device; and a key shaping device that creates a second key using the geometric information.
[0007] In some embodiments, systems for creating keys are provided, the systems comprising: a key receiver that receives a first key; a key scanner that captures geometric information about the first key; a hardware processor that determines a key type and bitting pattern of the first key based on the geometric information; and a key shaping device that creates a second key based on the key type and bitting pattern determined by the processor.
[0008] In some embodiments, methods for creating keys are provided, the methods comprising: receiving security information from a user; receiving geometric information about a first key associated with the security information from a storage device; and creating a second key using the geometric information.
[0009] In some embodiments, methods for creating keys are provided, the methods comprising: receiving a first key; scanning geometric information about the first key; determining a key type and bitting pattern of the first key based on the geometric information; and creating a second key based on the key type and bitting pattern determined by the processor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above and other objects and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
[0011] FIG. 1 shows an illustrative example of a schematic diagram of a system for duplicating keys in accordance with some embodiments of the disclosed subject matter;
[0012] FIG. 2 shows an illustrative example of a perspective view of a kiosk for duplicating keys in accordance with some embodiments of the disclosed subject matter;
[0013] FIG. 3 shows an illustrative example of a process for duplicating keys in accordance with some embodiments of the disclosed subject matter;
[0014] FIG. 4A shows an illustrative example of a scanning arrangement for capturing geometric information about a key in accordance with some embodiments of the disclosed subject matter;
[0015] FIG. 4B shows an illustrative example of a mechanisms for holding a key in a particular position while geometric information about the key is captured in accordance with some embodiments of the disclosed subject matter;
[0016] FIG. 5 shows an illustrative example of geometric information about a key captured from a side view of the key in accordance with some embodiments of the disclosed subject matter;
[0017] FIG. 6 shows an illustrative example of geometric information about a key captured from an end view of the key in accordance with some embodiments of the disclosed subject matter;
[0018] FIG. 7 shows an illustrative example of a physical scanning arrangement for capturing geometric information about a key in accordance with some embodiments of the disclosed subject matter;
[0019] FIG. 8 shows an example illustrating the concept of returning a key bite pattern to factory specifications when making a duplicate key in accordance with some embodiments of the disclosed subject matter;
[0020] FIG. 9A shows an illustrative example of a rotating carousel of magazines for use in a key duplicating system in accordance with some embodiments of the disclosed subject matter;
[0021] FIG. 9B shows an illustrative example of a rotating carousel of magazines installed in a system for duplicating keys in accordance with some embodiments of the disclosed subject matter;
[0022] FIG. 10 shows an illustrative example of a kiosk with horizontally installed magazines in accordance with some embodiments of the disclosed subject matter;
[0023] FIG. 11A shows an illustrative example of a kiosk with vertically installed magazines and a funnel and alignment mechanism in accordance with some embodiments of the disclosed subject matter;
[0024] FIG. 11B shows an illustrative example of a perspective view of a kiosk with multiple rows of vertically installed magazines and a funnel and alignment mechanism in accordance with some embodiments of the disclosed subject matter; and
[0025] FIG. 12 shows an illustrative example of different key types arranged in one magazine in accordance with some embodiments of the disclosed subject matter.
DETAILED DESCRIPTION
[0026] In accordance with various embodiments, systems and methods for duplicating keys are provided.
[0027] In some embodiments, these systems and methods allow a user to create a copy of a key. For example, a user can create a copy of a key if the key has been lost, if the user wishes to make a copy for a friend, or for any other suitable reason. In order to do so, in some embodiments, these systems and methods can detect a bitting pattern and a blank type of a user's key. This bitting pattern, blank type, and any other suitable information can then be stored in any suitable storage mechanism. At a suitable subsequent point in time (such as when the user has lost the key), these systems and methods can generate a duplicate of the key without the presence of the original key. This can be accomplished by retrieving the stored information from storage, selecting a blank key corresponding to the blank type, cutting the blank key according to the bitting pattern, and dispensing the key to the user. Any suitable security mechanisms can be included in these systems and methods to prevent unauthorized key duplication.
[0028] One of the uses of such systems and methods can be to provide a user with a way of creating a duplicate key when the original is not available, for instance during a lockout situation. Another use of these systems and methods can allow a user to obtain a duplicate key in a self-service fashion without assistance from, for example, a skilled locksmith or an employee at a hardware store that duplicates keys. Additionally, the systems and methods can be used to verify user identification through biometric scanning to provide a secure method for duplicating sensitive keys (e.g., a home key, a vehicle key, etc.).
[0029] Turning to FIG. 1 , an example of hardware 100 that can be used in some embodiments is illustrated. As shown, hardware 100 can include a display 102 , one or more input device(s) 104 , one or more key detector(s) 106 , storage 108 , a hardware processor 110 , a communication network interface 112 , a key movement mechanism 114 , a key cutting and cleaning mechanism 116 , and/or any other suitable components.
[0030] This hardware can be arranged in any suitable manner in some embodiments. For example, this hardware can be arranged in a kiosk, such as kiosk 200 of FIG. 2 , in some embodiments.
[0031] In some embodiments, a subset of the hardware shown in FIG. 1 can be implemented in a scan-only kiosk that can be used to save a key template but not to create a key copy. For example, such a kiosk can omit mechanisms 114 , 116 , and 118 in some embodiments.
[0032] Display 102 can be any suitable display, such as an LCD display, a cathode ray tube display, an electronic paper display, etc. Input device(s) 104 can include any suitable input devices, such as a keypad, a keyboard, a fingerprint reader, an eye scanner (e.g., a retina or iris scanner), a touchpad, a credit card scanner, a smart card reader, a near field communication device, an RFID scanner, a touch sensor, a camera, a Quick Response code (QR code) reader, a barcode reader, etc. In some embodiments, display 102 and an input device 104 can be combined as a touch sensitive display (or touchscreen device).
[0033] Key detector 106 can be any suitable mechanism for detecting the bitting pattern and/or the blank type of a key. For example, the key detector can be any suitable device that detects the bitting pattern and/or blank type of a key using any suitable technology such as optical technologies, mechanical technologies, electrical technologies, and/or any other technology, as described further below. More generally, key detector 106 can detect geometric information about a key. For example, key detector 106 can detect the dimensions of a key (e.g., length, width, height, profile, shoulder shape, etc.) and features of the key. Examples of features of the key can include, but are not limited to, a bitting pattern, protuberances, dimples, voids, grooves, a milling profile, a milling pattern of the key from one or more side views, a milling pattern of the key from a front view (e.g., looking from the tip of the key toward the head of the key), etc.
[0034] In some embodiments, key detector 106 can detect the presence of an instruction to not duplicate the key. For example, such an instruction can be printed or engraved on a key by words, such as, “do not duplicate.” As another example, such an instruction can be embedded in the key as an RFID chip, or the like. As another example, such an instruction can be indicated by the presence of a physical indication to not copy the key. For instance, a notch can be cut in the top of the key, or material can added to a portion of the key that is not inserted into a lock. In such embodiments, the presence of an instruction to not duplicate the key can cause the mechanisms described herein to inhibit scanning and/or duplication of the key as described herein.
[0035] Storage 108 can be any suitable storage. For example, storage 108 can be random access memory (RAM), electrically erasable programmable read only memory (EEPROM), flash memory, disk memory, network storage, a database, any other suitable storage, or any suitable combination thereof.
[0036] Hardware processor 110 can be any suitable processing hardware. For example, hardware processor 110 can be a microprocessor, a microcontroller, dedicated logic, a field programmable gate array, a general purpose computer, a special purpose computer, a client, a server, and/or any other suitable processing hardware.
[0037] Communication network interface 112 can be any suitable interface facilitating communications on a communication network. For example, communication network interface can be a wired network interface (such as an Ethernet network interface card (NIC), a USB interface, a cable television network interface, a telephone network interface, etc.), a wireless network interface (such as an IEEE 802.11x interface, a Bluetooth interface, a mobile telephone interface, a wireless data network interface, a satellite communications interface, etc.), an optical interface, and/or any other suitable interface.
[0038] Key movement mechanism 114 can be any suitable mechanism for moving a key from a key blank storage area 118 to key cutting and cleaning mechanism 116 . For example, key movement mechanism 114 can include a key blank holding mechanism connected to one or more belts and/or stabilizer bars in which the position and operation of the gripper is controllable by hardware processor 110 and/or any other suitable mechanism. As another example, key movement mechanism 114 can be a robotic arm that is controllable by hardware processor 110 and/or any other suitable mechanism. Additionally or alternatively, as described in more detail below in connection with FIG. 11 , key movement mechanism 114 can include a funnel and/or alignment mechanism that receives a key blank from a stack and positions the key blank to be moved to key cutting and cleaning mechanism 116 .
[0039] In some embodiments, key blank storage 118 can house an inventory of any suitable number of types of key blanks (sometimes referred to herein as “blanks”) In some embodiments, keys of each blank type (e.g., key blanks with different milling patterns, key blanks of different sizes, etc.) can be stored in stacks within the storage area. Each stack can include any suitable number of blanks Inventory levels of blanks can be monitored (locally or remotely) to keep track of how many key blanks are remaining in each stack. In some embodiments, each stack can have one or more sensors which can be used to determine how many blanks remain in the stack. In some embodiments, in response to sensing that the number of blanks in a stack (or the number of blanks of a certain type) has fallen below a threshold, a technician can be alerted and dispatched to add blanks. The technician can be alerted using any suitable communication method. For example, an email, a text message or a voice message can be sent to the technician. As another example, a message can be sent to the technician using a specialized application that includes software for managing inventory levels of key blanks
[0040] In some embodiments, blanks can be removed from a stack as needed by key movement mechanism 114 . For example, the magazines holding stacks of inventoried key blanks can be aligned vertically, in some embodiments. This can allow for key blanks to be fed to the bottom of the magazine by gravity as key blanks are removed by key movement mechanism 114 . If the stacks are aligned vertically, the blank on the bottom of each stack can be removable by key movement mechanism 114 . In an alternative example, if the stacks are aligned vertically, the blank at the top of each stack can be removable by key movement mechanism 114 . In yet another example, key movement mechanism 114 can remove a blank from an arbitrary position in each stack. In some embodiments, stacks can be arranged in any suitable orientation, such as horizontally.
[0041] In some embodiments, a magazine can hold the stacks of inventories blanks. These magazines can be, for example, a storage and feeding device for holding a stack of inventory blanks The magazines for holding the stacks of inventory can be made from any suitable material, such as: steel, aluminum, plastic, rubber, carbon fiber, etc. The magazines can be shaped to facilitate selection and removal of key blanks from the stack of blanks by key movement mechanism 114 . In some embodiments, the magazines can be replaceable in a housing that houses hardware 100 to facilitate placement of blanks for use by allowing multiple keys to be placed at the same time. For example, if a technician is alerted that an inventory of a particular type of blank is below a threshold, the technician can refill the inventory of the particular type of blank.
[0042] In some embodiments, the magazines holding stacks of inventoried key blanks can be placed on a rotating carousel. An illustrative example is shown in FIGS. 9 a and 9 b . Such an embodiment can allow for a greater number of magazines, and correspondingly unique key types, within a given kiosk volume compared with a mounted set of static magazines. Alternatively, key movement mechanism 114 can rotate to reach surrounding magazines to achieve a similar result of accommodating a large number of magazines inside the small interior of a kiosk, in some embodiments.
[0043] In some cases in which the kiosk height is greater than its width, for example, magazines can be aligned horizontally so that the number of magazines which can be accommodated is increased in some embodiments. This can allow for more types of keys to be stocked, for example, in a kiosk having a limited footprint. An illustrative example is in FIG. 10 . In some embodiments, a passive push mechanism (e.g., a spring or springs) or active push mechanism (e.g., a screw mechanism, a conveyer, etc.) can apply pressure to the horizontally stacked key blanks and the blanks can be retrievable by key movement mechanism 114 at one or both sides of each stack.
[0044] In some embodiments, key blanks can be dispensed from the magazines (using any suitable mechanism) into a funnel and alignment mechanism where they can be properly oriented and then retrieved by key movement mechanism 114 . It should be noted that the funnel and alignment mechanisms along with mechanisms for dispensing blanks from the magazines can be thought of as part of key movement mechanism 114 , in some embodiments. An illustrative example is shown in FIG. 11A . Such a method can allow for significant freedom in the placement of magazines within the kiosk, so that a large number of magazines can be accommodated. For example, magazines can be arranged in a two dimensional array. FIG. 11B shows an illustrative example of a perspective view of kiosk 200 in which the vertical magazines can be arranged in rows from one side of kiosk 200 to the other and in rows from the front of kiosk 200 toward the back of kiosk 200 . Alternatively, the magazines can be arranged in any suitable configuration that allows blanks stored in the magazines to be dispensed into the funnel and alignment mechanism included in key movement mechanism 114 to be oriented and then retrieved by a key gripping and moving mechanisms that is included in key movement mechanism 114 .
[0045] In some embodiments, each magazine can contain an inventory of multiple key types so that the number of magazines does not restrict the number of key types which can be accommodated in a kiosk. An illustrative example is shown in FIG. 12 . In this embodiment, a key type detection method (e.g., optical imaging), can be used to identify the location of a given blank type within a magazine. Key movement mechanism 114 can then retrieve a required key blank type from an appropriate location within the magazine.
[0046] Key cutting and cleaning mechanism 116 can be any suitable mechanism for cutting and cleaning a key. For example, key cutting and cleaning mechanism 116 can include a key blank holding mechanism, a cutting tool, a deburring tool, a scrap metal guard and debris container, and/or any other suitable key cutting and/or key cleaning device. In some embodiments, various parts described herein can be part of a computer numerical control (CNC) machine used to create a duplicate key. For example, mechanisms 114 and 116 combined can together be part of a CNC machine that can be precisely controlled. For example, such a CNC machine can have a key blank holding mechanism attached one or more belts and/or stabilizing bars that can receive a blank key from key storage area 118 . The key blank holding mechanism of the CNC machine can then be moved with the blank key to a cutting blade of the cutting tool under the control of the hardware processor and cause the key to be cut according to specifications. After a key is cut, the CNC machine can then move the blank key to the deburring tool to be cleaned of burrs that can result from the cutting process. After deburring is complete, the holding mechanism can release the new key into a key dispensing chute where it can be retrieved by the user.
[0047] As another example, mechanism 116 can include a CNC machine having a robotic arm that can be precisely controlled. A key blank holding mechanism can be attached to the end of such a robotic arm that can be used to retrieve a key from key movement mechanism 114 (e.g., the funnel and alignment mechanism described above). The robotic arm of the CNC machine can then move the blank key to a cutting blade of the cutting tool under the control of the hardware processor and cause the key to be cut according to specifications. After a key is cut, the CNC machine can then move the blank key to the deburring tool to be cleaned of burrs that can result from the cutting process. After deburring is complete, the holding mechanism can release the new key into a key dispensing chute where it can be retrieved by the user.
[0048] A scrap metal guard and debris container can include one or more flaps surrounding the cutting blade. These flaps can contain and direct scrap metal generated during the cutting process to the scrap metal container. This container can be located below the cutting tool. The container can be easily accessible to facilitate convenient removal of scrap metal during routine maintenance.
[0049] In some embodiments, a key can be replicated by an additive manufacturing process such as three-dimensional printing, whereby a new key is fabricated by laying successive layers of an inventoried material to the desired specifications. Such a technique can allow for the duplication of a large number of different key types and can negate the need for inventoried blank keys.
[0050] In some embodiments, keys can be replicated from a sheet, bar or coil of metal (generally referred to herein as “stock”). For example material to create a new key can be removed from the stock as needed. Any suitable technique can be used for removing a required amount of material from the stock to create a new key. For example, a required amount of material can be removed from the stock by stamping. As another example, a required amount to material can cut from the stock using any suitable technique (e.g., cut with a blade, milled, cut with a laser, cut with a plasma tool, a water jet cutting tool, etc.). The material removed from the stock can then be shaped into a new key using any suitable techniques. For example, the CNC machine described above can be used to shape a new key from material removed from the stock. Such a technique can allow for the duplication of a large number of different key types and can negate the need for inventoried blank keys.
[0051] In some embodiments, keys can be replicated from a material such as hard plastic (e.g., thermoplastics or thermosetting polymers, such as, polyethylene, polypropylene, polystyrene, polyvinyl chloride, and polytetrafluoroethylene, etc., polyvinyl chloride (PVC), or any other suitable plastic). In such an embodiment, a block (or blocks) of such a plastic can be stored to be used to replicate keys. A required amount of material for replicating a key can be removed from the block as required and can be shaped into an appropriate shape for replicating a particular key. Such a technique can allow for the duplication of a large number of different key types and can negate the need for inventoried blank keys. In other embodiments, key blanks can be made of plastic rather than metal. Using plastic rather than metal to replicate keys can allow for keys to be replicated that can be easily and safely disposed of by a user after the key has fulfilled a particular purpose. For example, if the user gets locked out of their home, the user can create a replica key from plastic and retrieve the original key. The user can then dispose of the plastic replica key (e.g., by cutting up or shredding the key) so that there are not multiple unused copies of the key for the user to keep track of. Using plastic can also allow for keys to be more easily created as shaping plastic is generally easier than shaping metal.
[0052] Any suitable material can be used for replicating keys using the mechanisms described herein.
[0053] In some embodiments, a user can supply an appropriate key blank for replicating a particular key. In such an embodiment, a user can determine a type of key blank required for replicating a particular key and obtain that type of key blank to use in replicating the key. For example, the user can look up the type of key blank using a computer application, mobile application, or web platform. In some cases a user can buy a blank of the required type at a retail location (e.g., a hardware store), or blanks can be available at a location where the kiosk for replicating keys is located where the user can select a key blank herself or acquire the appropriate blank from an attendant (e.g., a clerk). When the user has acquired the appropriate blank type, the user can supply the blank to the mechanism for replicating the key. In such an embodiment, the mechanism can verify that the blank supplied by the user is the correct type of blank for the particular key to be replicated. This can be done by capturing one or more images of the blank, or by using any other suitable technique for determining the properties of the blank, such as the techniques for determining the properties of a key described herein. Such a technique can allow for the duplication of a large number of different key types and can negate the need for inventoried blank keys.
[0054] Turning to FIG. 3 , an example of a process 300 that can be used to control the creation of keys by hardware, such as hardware 100 of FIG. 1 , is illustrated in accordance with some embodiments. This process can be executed in hardware processor 110 .
[0055] As shown, after process 300 begins at 302 , the process can receive a user input of an action to be taken. For example, in some embodiments, this action can be to immediately create a duplicate of a key, to save a template of a key, or to recreate a key from a template. Any other actions can additionally or alternatively be taken in some embodiments. This user input can be received in any suitable manner. For example, in some embodiments, this user input can be specified by the user pressing a button on a touch screen interface, by a user inserting a key in to a key detector, by a user swiping a finger on a fingerprint reader or scanning an eye with a retina scanner, and/or by the user taking any other suitable action.
[0056] If the user selects to immediately duplicate a key, then process 300 can branch at 306 to 308 where payment information can be received. Any suitable mechanism for receiving payment information can be used. For example, in some embodiments, credit card information can be entered via user input device(s) 104 . As another example, in some embodiments, an electronic device (such as a mobile phone) can be brought into proximity or tapped against a user input device 104 . As yet another example, payment information can be received as an electronic message received via communication network interface 112 . As still another example, input device(s) 104 can scan an image presented by the user that contains payment information such as an account number, etc. In such an example, the payment information can be encoded in the image so that it is difficult or impossible for a human to discern the payment information with the naked eye.
[0057] Next, at 310 , process 300 can scan a key presented by the user. Any suitable approach to scanning a key can be used in some embodiments. For example, a key can be scanned as described below in connection with FIGS. 4-7 . This key scanning can detect the key bitting pattern and/or the key blank type in some embodiments.
[0058] Then, at 312 , process 300 can replicate the scanned key. This replication can be performed in any suitable manner. For example, in some embodiments, the key can be replicated by the hardware processor 110 : (a) controlling the key movement mechanism 114 to retrieve an appropriate key blank from a key repository and move the key to the key cutting and cleaning mechanism 116 ; and (b) controlling the key cutting and cleaning mechanism 116 to cut the key according to the detected bitting pattern and then clean the key to remove burrs, etc.
[0059] Finally, at 314 , the process can cause the key to be dispensed to a user. For example, the hardware processor can control the key cutting and cleaning mechanism 116 to drop the key in the key dispensing chute.
[0060] If the user selects to save a key template, then process 300 can branch at 306 to 316 where user information can be received. Any suitable user information can be received, and this information can be received in any suitable manner, in some embodiments. For example, in some embodiments, a user name, a key name, a user physical address, a user phone number, a user credit card number, a user identification number (e.g., social security number, driver's license number, passport number, etc.), a user name, a user email address, and/or any other suitable user information can be received using one or more user input device(s) 104 . In some embodiments, receiving user information can be omitted from process 300 .
[0061] At 318 , process 300 can then receive security information. Any suitable security information can be received and this information can be received in any suitable manner, in some embodiments. For example, in some embodiments, a user password, a user spoken word, a user fingerprint scan, a user retina or iris scan a face image, a DNA sample, a palm print, a hand geometry measurement and/or any other suitable security information can be received using one or more user input device(s) 104 . In some embodiments, receiving security information can be omitted from process 300 .
[0062] Next, at 320 , process 300 can scan a user's key. Any suitable approach to scanning a key can be used in some embodiments. For example, a key can be scanned as described below in connection with FIGS. 4-7 . This key scanning can detect the key bitting pattern and/or the key blank type in some embodiments.
[0063] Finally, at 322 , the information received at 316 , 318 , and/or 320 can be stored. This information can be stored in any suitable manner and at any suitable location. For example, in some embodiments, this information can be stored in storage 108 . As another example, in some embodiments, this information can be transmitted via communication network interface 112 to a remote storage device. As yet another example, in some embodiments, some information can be stored locally and some information can be stored remotely. In some embodiments, any suitable security procedures can be performed in connection with storing the information. For example, in some embodiments, the information can be encrypted prior to being stored. The information stored at 322 can then later be accessible by the same hardware and/or any other suitable hardware. For example, if a first kiosk is used to save a key template, a second kiosk can be configured to recreate a key from that template in some embodiments. Such a second kiosk can be nearby or remote from the first kiosk.
[0064] In some embodiments, a user can have the option to save key information after immediately creating a duplicate key. In such a case, if a user elects to save the key information, similarly to what is described above in connection with 316 , 318 , and 322 , the user can be prompted to enter user information and/or security information and that information, along with the bitting pattern and key blank type information, can be stored. If a user does not choose to save key information after immediate duplication, or if the option to do so is not presented to the user, the key information can be deleted to protect the security of the user.
[0065] In some embodiments, information on a key type and bitting information of a key provided by the user can be sent to the user in addition to, or instead of, being stored in storage device 108 . For example, the information can be sent to the user by e-mail, text message, mail, or any other suitable manner of sending the information. This can allow for a user to have access to the information on the type of key and bitting information without relying on storage 108 . In a case where the information is not stored in storage 108 , this can allow a user that is especially concerned with privacy to know that information required to create a replica of the key is not stored with personal information of the user.
[0066] In some embodiments, when a key is scanned at 320 , an anonymous entry can be created corresponding to the key and the entry can be assigned an index number. The index number, bitting information, key type information, and/or information entered by a user (e.g., a password, a pin number, etc.) can be used to create a unique number that corresponds to the key. The user can then use the unique number to obtain a replica of the key, or give the unique number to another user so that the second user can obtain a replica of the key. This can allow for a user that is especially concerned with privacy to know that information required to create a replica of the key is not stored with personal information of the user, because the entry corresponding to the key is anonymous.
[0067] In some embodiments, a user can have the option to immediately create a duplicate key after saving a key template. In such a case, if a user elects to create a duplicate key, similarly to what is described above in connection with 308 , 312 , and 314 , the user can be prompted to enter payment information and the key can be replicated and dispensed.
[0068] If the user selects to recreate a key from a template (e.g., because the user has lost his or her key), then process 300 can branch at 306 to 324 where user and security information can be received. Any suitable user information and/or any suitable security information can be received, and this information can be received in any suitable manner, in some embodiments. For example, this information can be received to securely identify the user and/or the key. More particularly, this information can include a user name and a password, a fingerprint scan, a face image capture, a credit card swipe, a key name for a previously stored key template, any other suitable information, or any suitable combination thereof. As an even more particular example, the user can be prompted to select a key from the list of those that were previously stored. Such a list can include descriptive names entered during a key template storage process, key images, etc.
[0069] Next, at 326 , payment information can be received. Any suitable mechanism for receiving payment information can be used. For example, in some embodiments, credit card information can be entered via user input device(s) 104 . As another example, in some embodiments, an electronic device (such as a mobile phone) can be brought into proximity or tapped against a user input device 104 . As yet another example, payment information can be received as an electronic message received via communication network interface 112 .
[0070] Then, at 328 , process 300 can replicate the desired key. This replication can be performed in any suitable manner. For example, in some embodiments, they key can be replicated by the hardware processor 110 : (a) controlling the key movement mechanism 114 to retrieve an appropriate key blank from a key repository and move the key to the key cutting and cleaning mechanism 116 ; and (b) controlling the key cutting and cleaning mechanism 116 to cut the key according to the stored bitting pattern and then clean the key to remove burrs, etc.
[0071] In some embodiments, the bitting pattern from the originally scanned key can be compared to a database of known bitting specifications for keys and locks. From this comparison, an inference can be made as to the factory specifications of the bitting of the to-be-copied key. When a duplicate is created, it can be cut to these factory specifications instead of merely replicating the original key's bitting profile. This allows for correction of flaws in the original key resulting from wear-and-tear, previous duplications, or other ca uses. An example of this is shown in FIG. 8 . In doing so, a duplicated key can be more accurate than a previous copy. Additionally or alternatively, a user can identify the type of lock that the key is for by entering a make and/or model of the lock. The make and/or model of the lock can be compared to a database to determine factory specifications corresponding to the lock type and key identified by the user, and the duplicate can be replicated using the original bitting profile as described above.
[0072] In addition to correcting for imperfections in a key's bitting depths during a duplication, other imperfections in a previous key can also be corrected. For example, the bitting platform length, the platform spacing, the platform offset, localized deformations, and/or bitting angles can be corrected in some embodiments. In some embodiments keys at custom, non-factory specifications can additionally be produced.
[0073] Finally, at 330 , the process can cause the key to be dispensed to a user. For example, the hardware processor can control the key cutting and cleaning mechanism 116 to drop the key in the key dispensing chute.
[0074] In some embodiments, a subset of what is shown in process 300 can be used. For example, when hardware 100 is implemented as a scan-only kiosk, only steps 316 , 318 , 320 , and 322 can be performed by a corresponding process.
[0075] It should be understood that some of the above steps of the flow diagram of FIG. 3 can be executed or performed in an order or sequence other than the order and sequence shown and described in the figure. Also, some of the above steps of the flow diagram of FIG. 3 can be executed or performed substantially simultaneously where appropriate or in parallel to reduce latency and processing times.
[0076] Referring to FIGS. 4-7 , key scanning in accordance with some embodiments is further described.
[0077] As shown in FIG. 4A , in order to be scanned, a key 402 can be inserted by a user into a slot 404 . The key scanning slot can be able to accommodate a variety of blank types with varying lengths, widths, and shapes. The key scanning slot can properly position the key to ensure the scanning process is successful. The key scanning slot can be positioned at a downward angle so that the key gravity will assist the user in ensuring that the key is inserted fully. The key scanning slot can allow a user to maintain contact with the handle of the key at all times in some embodiments. The key scanning slot can permit the key to remain attached to a keychain (or key ring, or any other key retention device) during key scanning.
[0078] As shown in FIG. 4B , key 402 can be fixed in position between a mobile surface 410 and a fixed surface 412 while key 402 is being scanned in accordance with some embodiments. In such an embodiment, the force from mobile surface 410 applied to the teeth of key 402 can fix key 402 in place against fixed surface 412 . This can allow for keys to be scanned to be aligned in the same position each time a key is inserted and ensure that there is no movement of the key when geometric information about the key is being scanned.
[0079] Once in the slot, one or more imaging devices 406 and 408 can be used to optically detect a bitting pattern and a key blank type of the key in some embodiments. For example, as shown in FIG. 5 , an imaging device 406 can be used to capture an image 502 of key 402 . As another example, as shown in FIG. 6 , an imaging device 408 can be used to capture an image 602 of key 402 . Using these two images, parameters unique to each key can be detected in order to correctly determine both the bitting pattern and key blank type of the key.
[0080] In order to do so, in some embodiments, a thresholding algorithm, such as Otsu's Method (described, for example, in N. Otsu, “A thresholding selection method from gray level histogram”, IEEE Trans. on Systems, Man and Cybernetics, 9 (1), 62-66, January 1979, which is hereby incorporated by reference herein in its entirety), can first be used to pre-process the images and remove any spectral noise data. Then, once pre-processing of both images has been accomplished, a corner detection algorithm, such as Harris' Method (described, for example, in C. Harris and M. J. Stephens. “A combined corner and edge detector”, Alvey Vision Conference, pages 147-152, 1988, which is hereby incorporated by reference herein in its entirety), can be used to detect reference points 504 and 604 in images 502 and 602 , respectively.
[0081] As shown in FIG. 6 , point 604 can be the left-most, lower corner of the key. From this point, width variations in the z-axis of the key can be measured over regular increments along the y-axis. These width variations can be compared to known key blank data to determine a key blank type (or milling type). This data can be used to select the appropriate blank type during the key replication.
[0082] As shown in FIG. 5 , point 504 can be the tip of the key end. From this point, height variations in the y-axis of the key can be measured over regular increments along the x-axis. These height variations can be used to determine the bitting pattern of the key and to cut the key during the key replication.
[0083] Machine learning algorithms can also be employed to improve the accuracy and capabilities of the machine vision software.
[0084] In some embodiments, a laser-based mechanism, for detecting a milling type and a bitting pattern of a key can be used. Such a laser-based mechanism can be used to scan a key and detect the outline of the key from each of the perspectives illustrated in FIGS. 5 and 6 .
[0085] As described above, additionally or alternatively to detecting the bitting pattern and the blank type optically, a mechanical mechanism can be used to detect one or more of these features of a key. For example, as shown in FIG. 7 , a bitting detection finger 702 can be used to detect the bitting of a key. More particularly, for instance, the movement of the finger can be detected by suitable electromechanical sensors as key 402 is entered into slot 404 . As another more particular example, the finger can be moved automatically along the key after the key has been inserted into the slot and the bitting pattern detected based on up and down movements of the finger as detected by a suitable electromechanical sensor.
[0086] In some embodiments, rather than detecting key blank type (or milling type) as described above, a dedicated key slot for each key type available can be used. In such a case, upon entering a key into a key slot, the key blank type can be determined simply from the fact that the key fits into the slot.
[0087] In some embodiments, a tray can be provided where a user can place a key to be scanned. Such a tray can be provided in lieu of or in addition to slot 404 . Such a tray can allow for irregularly shaped keys (e.g., tubular keys, four sided keys, Zeiss keys, skeleton keys, etc.) that may not fit into slot 404 to be scanned by the kiosk using any suitable technique, such as the techniques described herein.
[0088] In some embodiments, a key to be replicated can be held in front of a particular location on a kiosk where the key can be scanned. This can allow for irregularly shaped keys (e.g., tubular keys, four sided keys, Zeiss keys, skeleton keys, etc.) that may not fit into slot 404 to be scanned by the kiosk using any suitable technique, such as the techniques described herein.
[0089] In some embodiments, any other suitable mechanisms for detecting bitting patterns and/or key blank type can be used in some embodiments. For example, in some embodiments, key bitting can be detected by: many small mechanical pins which are pushed by key bitting and the pin positions get detected by suitable electromechanical sensors; one or more LED and/or photodiode arrays which detect obstruction created by the key bitting; micro air flow detectors which detect obstructions caused by bitting; heat sensors which detect obstructions caused by bitting; ultrasonic distance sensors; etc.
[0090] In some embodiments, in addition to a key being scanned using one or more key detector(s) 106 as described above, a key can be scanned using any other suitable device(s). For example, in some embodiments, a key can be scanned using any optical detector, scanner, camera, mobile phone, smartphone, tablet computer, etc. In such embodiments, for example, a user can be able to photograph a key and supply one or more corresponding images to hardware processor 110 (or any other suitable hardware processor) so that the hardware processor can process the image(s) to detect the key's bitting pattern and/or key blank type. In some embodiments, the image(s) can contain reference objects, such as a quarter, in order to determine the size of the key.
[0091] In some embodiments, users can scan a key on their smartphone or tablet computer. Furthermore, in some embodiments, an application can be downloaded to assist users in capturing quality images of their key. From a mobile application or website platform, users can also request a duplicate of their scanned key be sent via mail to an address of their choosing, in some embodiments.
[0092] In some embodiments, a user can also authorize others to access their key information using the mobile application or website platform. Authorized recipients can use the digital key information to request a physical copy via mail order, create a physical copy at a kiosk, or make a physical copy with any suitable key duplication hardware. For example, in some embodiments, when a user is locked out, that person can retrieve his/her key type and bitting code information from the mobile application or website platform, enabling any operator of a suitable key duplication machine to create a copy without the physical presence of the original.
[0093] In some embodiments, a user can retrieve his/her key type and bitting code information from the mobile application or website platform, and order a duplicate key to be delivered to the user based on location information provided to the mobile application or website platform. For example, the location information can be provided using a mobile phone equipped with a Global Positioning System (GPS) receiver. As another example, a user can specify coordinates where the duplicate key is to be delivered. As yet another example, a user can specify an address where the duplicate key is to be delivered. The order for the duplicate key ordered by the user can be received by a key duplicating service. The key duplicating service can then use the key type and bitting information to create a duplicate key and can deliver the duplicate key to the user at the specified location. Additionally, the user can use the application or website platform to pay for the duplication and delivery of the duplicate key to their location.
[0094] In some embodiments, any suitable computer readable media can be used for storing instructions for performing the processes described herein. For example, in some embodiments, computer readable media can be transitory or non-transitory. For example, non-transitory computer readable media can include media such as magnetic media (such as hard disks, floppy disks, etc.), optical media (such as compact discs, digital video discs, BLU-RAY discs, etc.), semiconductor media (such as flash memory, electrically programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), etc.), any suitable media that is not fleeting or devoid of any semblance of permanence during transmission, and/or any suitable tangible media. As another example, transitory computer readable media can include signals on networks, in wires, conductors, optical fibers, circuits, any suitable media that is fleeting and devoid, of any semblance of permanence during transmission, and/or any suitable intangible media.
[0095] Although the invention has been described and illustrated in the foregoing illustrative embodiments, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the details of implementation of the invention can be made without departing from the spirit and scope of the invention, which is limited only by the claims that follow. Features of the disclosed embodiments can be combined and rearranged in various ways. | Systems and methods for duplicating keys are provided. In some embodiments, a system for creating keys is provided, the system comprising: a kiosk comprising: a key scanner capturing geometric information of a key; and a hardware processor that: receives security information; automatically determines a key type and bit heights of the key and causes these, along with first identifying information based on the first security information, to be stored at a remote storage device; receives second security information corresponding to second identifying information; verifies the second security information and, in response, identifies stored geometric information about one or more keys that can be made, wherein the stored geometric information includes geometric information corresponding to the second security information; and a key shaping device that creates a third key using the second geometric information. | 1 |
FIELD OF THE INVENTION
The present invention relates to a particulate cargo container support apparatus and a method for removing the container from a truck bed, more particularly, the invention relates to a support apparatus for truck mounted road salt spreader and method for removing the spreader from the truck utilizing the motive force applied by the truck for raising and lowering the truck bed.
BACKGROUND OF THE INVENTION
Particulate cargo containers, especially road salt/sand spreaders, are usually mounted on the beds of large trucks. These spreaders generally cover the entire truck bed, or at least render the truck bed unavailable for other uses. The truck is thus restricted to applying salt to roadways when the spreader is mounted thereon. While applying salt to roadways is an important function during inclimate periods of the winter months, leaving the spreader on the truck during good weather periods of the winter months idles the truck for other purposes, which is a significant waste of resources. It is desirable to remove the spreader from the truck during good weather periods of the winter months and the nonwinter months, and particularly when the spreader is not in use. Large hydraulically powered lifts, for example front end loaders, may be used to place the spreader in the truck bed. However, hydraulic lifts introduce further drawbacks due to their complexity, expense, and the extensive maintenance required to ensure that a hydraulic lift remains operational. Electric motors may also be used as lifts. If an electric lift is relied on during the winter months, it may not have a reliable electric power source due to storm activity. Conventional lifts remove the spreader from a truck and then lower the spreader to the ground. When the spreader is placed back onto the truck, the lift must be available to lift the spreader from the ground to effect placement of the spreader back onto the truck.
The use of conventional lifts may also require an operator to climb up onto at least the truck bed, and possibly into the spreader itself to secure the spreader to the hydraulic or electric lift, for example to attach a chain from the lift to the spreader. Climbing onto equipment is a safety hazard to the user. The operator must also be trained in the operation of the lift in addition to the operation on the truck and spreader. Additionally, in the case of a front end loader being the lift, the front end loader must remain at the site with the spreader so that it is available when the spreader is to be mounted on the truck.
Conventional methods for removal of a spreader from a truck usually adapt a conventional lift, designed for other purposes, to remove and replace the spreader on the truck. Conventional methods require the purchase of additional heavy equipment and training in how to operate the heavy equipment.
It is an object of this invention to provide a particulate cargo container support apparatus which is relatively inexpensive and simply relies on the motive force applied to the truck bed by devices on the truck to remove the particulate cargo container therefrom, in addition to addressing the drawbacks of the conventional lifts.
It is a further object of the invention to provide an improved method for removing a particulate cargo container from a truck bed and supporting the same utilizing the motive force of the devices on the truck for raising and lowering the truck bed.
It is a further object of the invention to provide a particulate cargo container support apparatus which is operable by a single person.
SUMMARY OF THE INVENTION
The objects and purposes of the invention are met by providing a particulate cargo container support apparatus which has plural pairs of side-by-side laterally spaced upright post members rotatably supporting shaft members extending therebetween. Hook means are positioned on the rotatable shaft members so as to be movable out of the path of a container positioned on a truck bed when the truck is positioned under the support apparatus. A control device in the form of a manually operable handle is connected to an end of the shaft member for effecting the rotation of the shaft member and hook means into and out of the path of the container on the truck bed. The hook means engage the container on the truck bed when the truck bed is lowered. When the truck bed is fully lowered, a vertical separation between the container and the truck bed is effected. The container is then fully supported on the support apparatus and the truck is free for other uses.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and purposes of the invention will be apparent to persons acquainted with apparatus of this general type upon reading the following description and reviewing the accompanying drawings, in which:
FIG. 1 is a top, front isometric view of the particulate cargo container support apparatus and a container supported thereon;
FIG. 2 is a sectional side view showing a first stage in the process of effecting a removal of a container from a truck bed by the support apparatus;
FIG. 3 is a view similar to FIG. 2 showing a second stage in the removal of the container by the support apparatus;
FIG. 4 is a view similar to FIG. 3 showing a final stage of the container being supported by the support apparatus;
FIG. 5 is a side view of the support apparatus supporting the container above the truck bed;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5;
FIG. 7 is a sectional view taken along line 7--7 in FIG. 1;
FIG. 8 is an enlarged side view of the upper portion of the post and handle arrangement;
FIG. 9 is a sectional view taken along line 9--9 in FIG. 1; and
FIG. 10 is a sectional view taken along line 10--10 in FIG. 5.
DETAILED DESCRIPTION
FIG. 1 shows a support apparatus 20 supporting a conventional particulate cargo container 21. The container 21 is particularly adapted to spread a particulate onto a road, the particulate being salt, sand, or a combination thereof. The support apparatus 20 includes, in this embodiment, four lower upright members or posts 22, 23, 24, 25 which stand upright on a floor surface or on the ground. Each lower post member is hollow and has a rectangular or square cross section. Since the lower post members 22, 23, 24, 25 are otherwise identical in structure, only one post member 25 will hereinafter be described in detail. A flat plate 26 is secured, as by welding or other conventional means, to the lower end portion of the lower post member 25. Other arrangements for stabilizing the post member are deemed to be within the scope of this invention, for example bracing members extending between adjacent pairs of the upright posts 22, 25 and 23, 24. A top edge 28 of the post member has diametrically opposed, horizontally aligned, notches 30 recessed therein.
The support apparatus 20 additionally includes four hollow upper post members 32, 33, 34, 35, each of which is at least partially received within a hollow interior 27 of a respective lower post member 22, 23, 24, 25. The cross sectional shape of each upper post member is conformed to the cross sectional shape of the interior of the lower post members. Since the upper post members 32, 33, 34, 35 are identical in structure, only one upper post member 35 will hereinafter be described in detail. A plurality of vertically spaced, horizontally aligned, apertures 38 extend through a lower portion of the upper post member 35. The apertures 38 are each vertically aligned with the notches 30 in the upper edge of the lower post member 25 when the upper post member 35 is received in the lower post member 25. A securement pin 39 conforming in shape to the shape of the apertures 38, here circular, is received in a selected one of the set of horizontally aligned apertures 38. The securement pin 39 extends outwardly from opposite sides of the upper post member 35. The securement pin 39 secures the upper post member 35 relative to the lower post member 25 by being adapted to press against the lower surface of the notches 30 in the lower post member 25 and the upper surface of the apertures 38 when the upper post member 35 is received in the lower post member 25. The upper post member 35 additionally has a further horizontally aligned aperture set 40 extending therethrough adjacent the upper end thereof. Further, an arcuate bracket 41 is provided and which is secured to only two upper post members, namely, the upper post members 32, 35 at a location oriented below the aperture set 40. The arcuate bracket 41 has at least two downwardly opening recesses 42 located along an outward downwardly facing arcuate edge 43 thereof. A circularly cross-sectioned hollow bearing sleeve 44 (FIG. 6) is received and secured, as by welding, in the aperture set 40 in each of the upper post members 32, 33, 34, 35.
An elongated shaft member 45 extends between and is rotationally supported in the aligned bearing sleeves 44 in laterally spaced pairs of posts 36 (22, 23), 37 (24, 25). More specifically, each shaft member 45 has an elongated hollow tubular section 46 closed at each end by end caps 47, 48 secured to the tubular section 46. The end caps 47, 48 each have a stub shaft 49 extending outwardly therefrom coaxial with the tubular section 46. Each stub shaft 49 is rotationally received in a respective bearing sleeve 44. The stub shafts 49 received in the bearing sleeves 44 in the upper post members 32, 35 each extend entirely through and beyond the respective bearing sleeve 44. An end section 51 of each stub shaft 49 extending beyond the respective bearing sleeve 44 has a transverse bore 52 extending therethrough (FIG. 6).
A control device 55 is secured to each of the two end sections 51 of the stub shafts 49. Each control device 55 includes an elongate handle 56 extending generally radially downwardly from the stub shaft end section 51. The handle 56 has a hollow sleeve 57 located at a proximal end 58 thereof. The sleeve 57 receives the stub shaft end section 51 therein. The sleeve 57 has a radially extending hole 59 therein (FIG. 8). The axis of the hole 59 is oriented so as to be coaxial with the axis of the bore 52 in the stub shaft end section 51. A pin 60 is received in the aligned_bore 52 and hole 59 to thereby effect a securement of the handle 56 to the stub shaft end section 51 (FIG. 6). The handle 56 includes an elongate first section 61 extending from the sleeve 57 and a hollow elongate second section 62 coaxially abutting the first section 61. That is, an end face 63 of the first section 61 abuts an end face 64 of the second section 62. An internally threaded bore 65 extends from the end face 63 into the interior of the first section 61. An aperture 66 in the end face 64 of the second section 62 is coaxial with the bore 65. A threaded end 68 of an elongate bolt 67 is threadedly received in the bore 65. The elongate bolt 67 has a head end 69 distal to the threaded end 68. The bolt 67 extends through the aperture 66 into the interior 70 of the hollow second section 62. A hollow spacer 71 is positioned within the interior 70 of the hollow second section 62 with a proximal end 72 of the spacer 71 contacting an interior face 73 of the second section 62 interiorly adjacent the end face 64. A distal end 74 of the spacer 71 fixedly positions a blocking member 75 within the interior 70 of the second section 62. The blocking member 75 has a centrally disposed hole therethrough which slidably receives the shank of the bolt 67 therein. A washer 76 encircles the bolt 67 and contacts the bolt head end 69. A spring 77 is positioned between the blocking member 75 and the washer 76. A latching peg-like protuberance 78 is secured to and extends outwardly from the second section 62 and is adapted to be received in a selected one of the recesses 42 in the arcuate edge of the bracket 41. The second section 62 also has a gripping surface, such as a knurled surface 79, on the outer peripheral surface of the second section 62 distal the first section 61 which may be gripped by a user (FIG. 8). The spring 77 serves to urge the end faces 63, 64 into abutting relation and to yieldably resist efforts to separate them to facilitate a drawing of the peg 78 from the selected one of the recesses 42.
Adjustable couplings 80 are positioned on both of the elongated shaft members 45 and are slidable along the longitudinal lengths thereof. The couplings 80 each comprise a hollow sleeve with an open interior to receive the shaft members 45 therein. The wall of each of the couplings 80 has a radially extending, internally threaded bore 81 therein which receives a threaded bolt 82 (FIG. 7). The distal end of each of the bolts 82 press against the outer periphery 83 of the shaft members 45 so as to secure the coupling 80 to the shaft member 45. The couplings 80 have a transversely extending, internally threaded portion 84. A J-shaped hook 85 having an elongated stem 86, which is partially externally threaded as at 87, is received in the threaded portion 84 of each coupling 80. The hook 85 also has a curved, upwardly open, cradle part 88 extending transversely to the stem 86.
The use of the terms "front" and "rear" will refer to directions relative to a vehicle, here a truck 96, having the container 21 positioned thereon, or relative to a truck 96 positioned beneath the support apparatus 20 as described hereinafter. The container 21 has conventional structure, namely, a front end wall 91, rear end wall 92, side walls 93, a bottom wall 94, and a generally open top 95. If the container 21 is a particulate spreader, such as a road salt and/or sand spreader, then the spreading device 97 is positioned adjacent the rear end wall 92. Conventional openings, not shown, provide a pathway for particulate, housed within the container 21, to flow to the spreader device. Elongate connector rods 98 extend between and are connected to the side walls 93. In this embodiment, two connector rods 98 are parallel spaced from each other within the container 21 generally corresponding to the spacing between the side-by-side spaced post pairs 22, 25 and 23, 24. The connector rods 98 are generally longitudinally aligned with, but vertically displaced from the shaft member 45. Suspension locations 99 for supporting the container 21 on the support apparatus 20 are defined on the connector rods 98. The connector bars 98, while shown as straight horizontally aligned bars, are not limited thereto. That is, bent bars, for example, bars bent into loops, are also deemed to be within the scope of the invention.
The container 21, when positioned on the truck 96, is held thereon by conventional methods and structure with the bottom wall 94 thereof resting on the truck bed 102. More specifically, the container 21 may be held on the truck bed by the latching mechanism conventionally provided on a typical dump truck for operating the tailgate. The tailgate is not illustrated in the drawings because it is usually removed from the truck 96 when the container 21 is positioned thereon. The container 21 may also be bolted or chained to the truck bed 102. In this particular embodiment, the truck 96 also has an onboard motive device 103 for raising and lowering the truck bed 102, commonly a hydraulic powered piston-cylinder arrangement positioned beneath the truck bed 102 with one end fixed to the truck frame and the other to the truck bed 102. The motive device 103 raises and lowers the truck bed 102 about a truck bed pivot axis 104.
FIG. 5 shows an alternate embodiment with the lower post member 25 having a plurality of sets of vertically aligned apertures 30A. The apertures 30A coaxially align with the apertures 38 when the upper post member 35 is received in the lower post member 25. One of each of the coaxially aligned apertures 30A, 38 receive the securement pin 39 therethrough to secure the upper post member 35 within the lower post member 25. The apertures 30A in the lower post member allow the support apparatus 20 to adjust to trucks 96 and containers 21 which are shorter in height.
OPERATION
The length of the first pair of laterally spaced posts 36 are adjusted so as to be taller than the second pair of laterally spaced posts 37 thereby providing adequate clearance for the walls 91, 92 and 93 on a container 21 mounted on a raised truck bed 102 of a truck 96 to be positioned under the support apparatus 20 (FIGS. 2-4). The length, or height, of each of the posts is adjustable by inserting the securement pin 39 into a select aperture 38 in the upper post member 35 and into the notches 30 of the lower post member 25 to thereby orient each shaft member 45 at a sufficient elevation. This adjustment renders the entire support apparatus 20 adaptable to various truck 96 and container 21 heights and additionally renders the two shaft members 45 horizontally aligned. The front to rear spacing between the post pairs 36 (22, 23) and 37 (24, 25) is determined by the similar spacing between the connector rods 98 inside the container 21. The shaft members 45 are oriented parallel to and directly above the connector rods 98. The couplings 80 are initially adjustably positioned along the length of the shaft member 45 and are laterally spaced from one other. Each coupling 80 is secured to the shaft member 45 by the bolt 82 pressing against the outer periphery 83 of the shaft member 45. The couplings 80 are usually spaced apart a sufficient distance to prevent instability in the support of the container 21 when the container 21 is positioned on the support 20. The J-shaped hooks 85 are adjustable in length relative to the shaft member 45 by rotating the threaded portion 87 of the stem 86 into the transversely extending, threaded portion 84 of the coupling 80 to facilitate horizontal alignment therebetween when the posts are standing on an irregular floor surface. The hooks 85 received in couplings 80 secured to the shaft member 45 extending between the first pair of laterally spaced posts 36 are longer than the hooks 85 associated with the second pair of laterally spaced posts 37 so that the curved cradle parts 88 of the hooks 85 are generally at the same height relative to the ground so as to support the container 21 thereon in a level orientation. The level orientation, and width between the couplings 80, provides a stable support of the container thereon.
When it is desired to remove a container 21 from the truck bed 102, an operator must first rotate the hooks 85 into a first position out of the travel path of the container 21 on the truck bed 102. This is accomplished by the operator engaging or gripping the handle 56 of the control device 55 and pulling the second section 62 downwardly against the biasing force of the spring 77 within the hollow second section 62. The latching peg 78 will move out of one recess 42 in the bracket 41 as shown in broken lines in FIG. 8 so that the operator can now move the handle 56 in the direction of the arrow A about the axis of rotation of the stub shaft 49 to effect a rotation of the shaft member 45 connected thereto. The hooks 85 are also moved by the rotational movement of couplings 80 fixedly secured on the shaft member 45 so that they become removed from the path of the container 21 when the truck 96 with raised bed 102 is backed beneath the shaft members 45 and between the two pairs of posts 36, 37 (FIG. 2). The hooks 85 are held in this moved away position by the peg 78 being received in a remote select recess 42A, in the bracket 41.
A wheel stop 105 may be provided to indicate to the operator where to stop the truck 96 when backing beneath the shaft members 45. When the rear wheels of the truck abut the stop 105, the operator raises the truck bed 102, using the motive device 103, to the position shown in FIG. 2. Thereafter, the operator releases the peg 78 from the remote recess 42A by again gripping the handle 56 and pulling the second section 62 with attached peg 78 downwardly and moving the handle toward the initial position until the stems 86 of the hooks 85 engage the connector rods 98 (FIG. 2) thereby placing the hooks in an intermediate position. The truck bed 102 is thereafter lowered using the motive device 103 onboard the truck 96 until the hooks 85 on the shaft member 45 extending between the second pair of posts 37 receive the rear connector rod 98 in the cradle part 88 (FIG. 3). At this time, the front connector rod 98 is still adjacent the stems 86 of the hooks 85 on the shaft member 45 extending between the first pair of posts 36. If a latching mechanism or other means securing the container 21 to the truck bed 102 is present, then it is now released so that it no longer secures the container 21 to the truck bed. The pivot axis of the container 21 changes from the truck bed pivot axis 104 to a support pivot axis 106. The support pivot axis 106 is generally defined by the cusp of the cradle part 88 of the hooks 85 on the shaft member 45 extending between the second pair of posts 37. The support pivot axis 106 generally extends along the longitudinal length of the rear connector rod 98 when received in the rear set of hooks 85 provided with the second pair of posts 37. Thereafter, the truck bed 102 is further lowered about the truck bed pivot axis 104. The rear portion of the container 21 now becomes vertically separated from the truck bed 102 and is supported at the suspension locations 99 on the rear connector rod 98 defined by the contact location with the hooks 85 associated with the second pair of posts 37. Further lowering of the truck bed 104 results in the front portion of the container 21 becoming supported at suspension locations 99 on the front connector rod 98 defined by the contact location with the hooks 85, and a complete separation of the container 21 from the truck bed 102 occurs to define a gap 107 (FIG. 4) between the truck bed 102 and the bottom wall 94 of the container 21. At this time, the container 21 is completely supported on the support apparatus 20 (FIGS. 1, 4 and 5) and with the hooks 85 in a second position. At this location, the pegs 78 are again received in the notches 42 as shown in solid lines in FIG. 8. The container 21 is now supported in a level relationship relative to the ground on container support apparatus 20.
Electrical connections between the container and the truck, if any, may be disconnected at any time. The truck is now free for other uses. The container 21 may be placed back upon the truck bed 102 by reversing the above procedure.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A particulate cargo container support apparatus having plural pairs of side-by-side laterally spaced upright post members rotatably supporting shaft members extending therebetween. Hook members are positioned on the rotatable shaft member so as to be movable out of the path of a container on a raised truck bed when the truck is positioned under the support apparatus. A control device in the form of a manually operable handle is connected to an end of the shaft member for effecting the rotation of the shaft member and hook members into and out of the path of the container on the truck bed. The hook members engage the container on the truck bed when the truck bed is lowered. When the truck bed is fully lowered, a vertical, separation between the container and the truck bed is effected. The container is then fully supported on the support apparatus and the truck is free for other uses. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to apparatus for the protection of plumbing systems of recreational vehicles, vacation homes and the like against freezing in winter which has long been a source of inconvenience and concern for the owner.
A number of procedures have been utilized. In the simplest case, the water source is turned off and the pipes are drained by opening valves. In most cases, however, not all the pipes are properly inclined to permit total drainage and compressed air is commonly employed to blow out the remaining water. Even then, the air may pass over the surface of water lying in a nearly level water line so that sufficient water remains to cause trouble.
DESCRIPTION OF THE PRIOR ART
A semi-automatic "winterizing" system has recently been introduced employing push-button controls for the sequential energizing of solenoid valves and pump motors for charging the plumbing lines and fixtures with a non-toxic anti-freeze solution.
In some of these semi-automatic systems, "winterizing" is accomplished by first draining the water storage tank and the water heater and then sequentially operating a series of push-button switches. A by-pass solenoid is energized by means of a first push-button switch to isolate the water heater from the rest of the plumbing system. A second push button starts a water pressure pump and a third push button energizes an anti-freeze solenoid valve which transfers the water supply line from the storage tank to a reservoir containing the non-toxic anti-freeze solution. Faucets and other line terminations are then opened until the anti-freeze solution appears in the discharging water. The system is then shut down with one hot and one cold water faucet left open and "winterizing" is complete. To "de-winterize" and return to normal service, the faucets are closed, the fresh water tank is filled, the bypass solenoid is energized and the pump is turned on. In this case, the anti-freeze solenoid is not energized. Faucets are then opened until the flow of fresh water has cleared the anti-freeze solution from the lines. The by-pass solenoid is then de-energized to permit the refilling of the hot water tank.
While this system reduces the time consumed in the "winterizing" and "de-winterizing" operations, it retains certain disadvantages. Inadvertent operation of the switches in improper sequence can result in the delivery of anti-freeze solution to the water heater. Because of the geometry of the water heater and the arrangement of its inlet and outlet lines, the subsequent total removal of the solution from the tank is difficult and though the solution is non-toxic, the residue is undesirable aesthetically. The system also utilizes an anti-freeze storage tank requiring access through the outer vehicle wall. Installation of the tank involves cutting a hole through the wall and filling the tank is accomplished with difficulty and inconvenience from a stepladder. The present invention provides improvements to the above described system.
No relevant patents are known. However, U.S. Pat. No. 2,160,475 is directed to a freeze eliminator for dining car drains and U.S. Pat. No. 3,384,123 is directed to a freeze protector for self service car wash units, both of which are not believed to be pertinent to this invention.
SUMMARY OF THE INVENTION
In accordance with the invention claimed, an improved winterizing system is provided which substantially reduces the shortcomings and inconvenience of present methods, procedures and equipment.
It is, therefore, one object of the present invention to provide an improved winterizing system for use in preventing the freezing of plumbing lines and fixtures in a recreational vehicle or vacation home.
Another object of this invention is to provide in such a system a set of switches which are sequentially operated to control the essential solenoid valves and the pump as needed to execute the winterizing procedure.
A further object of this invention is to provide in such a system a means for insuring the proper sequence of switch operation and for preventing an improper sequence with its attendant undesirable effects.
A still further object of this invention is to provide for the actuation of such a system by means of a key and thereby to prevent tampering or undesired operation of the system.
A still further object of this invention is to provide in such a system a means for drawing anti-freeze solution directly from the shipping containers in which it is purchased.
Further objects and advantages of the invention will become apparent as the following description proceeds and the features of novelty which characterize the invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.
BRIEF DESCRIPTION OF THE DRAWING
The present invention may be more readily described by reference to the accompanying drawing in which:
FIG. 1 is a schematic diagram illustrating the plumbing system and the associated electrical and electromechanical control circuit comprising the winterizing system of the invention;
FIG. 2 is a perspective side view of an electrical control panel employed as a part of the winterizing system;
FIG. 3 is a cross-sectional view of a key-operated cam switch incorporated in the control panel as viewed along line 3--3 of FIG. 2; and
FIG. 4 is a front plan view of the control panel of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawing by characters of reference, FIG. 1 discloses the improved winterizing system 10 of the invention as installed in conjunction with the plumbing system of a recreational vehicle or vacation home.
The elements of the plumbing system in which the system 10 is installed include a water storage tank 11, a first or main water conduit or line 12, a filter 13, a cold water conduit or line 14, cold water faucet 15, a water heater 16, hot water conduit or line 17, a storage tank drain valve 18, a hot water faucet 19, a water heater drain valve 20 and a water pump 21 with an electric pump motor 21A. In the normal operation of the plumbing system, the pump 21 supplies pressure to deliver water from tank 11 to the cold water line 14 and via the water heater 16 to the hot water line 17. The pump 21 is essential to the operation of the system because there is typically no connection to a pressurized water system and the tank 11 is not normally elevated to permit delivery by gravity. A manually operated pump switch 22 is utilized to control voltage supplied to the pump motor 21A from a battery or other electrical power source 23.
The system 10 comprises anti-freeze containers 24 and 25, anti-freeze delivery conduits or lines 26, an anti-freeze solenoid valve 28, a water heater bypass solenoid valve 29, check valves 31 and 32 and a key operated cam switch 33.
The anti-freeze solenoid valve 28 comprises a valve assembly 28A and an electrical solenoid 28B. The valve assembly 28A has two intake ports 34 and 35 and an outlet port 36. When solenoid 28B is not energized, water received at port 34 is exhausted at port 36. When solenoid 28B is energized, water flow from port 34 to port 36 is blocked while water received at port 35 is exhausted at port 36. As shown in FIG. 1, ports 34 and 36 are serially connected in water line 12, port 34 being connected by line 12 to tank 11 through filter 13 and port 36 being connected by line 12 to the inlet port 37 of pump 21. Port 35 is connected by lines 26 to containers 24 and 25.
Bypass solenoid valve 29 comprises a valve assembly 29A and a solenoid 29B. It has an inlet port 41 and two outlet ports 31A and 42. When solenoid 29B is not energized, water passes freely through valve 29A, entering at port 41 and leaving at port 42. When solenoid 29B is energized, flow through valve 29 is blocked at port 41 and opened at port 31A. Valve 29A is serially connected in line 12 near its entry into water heater 16 with the exhaust port 42 nearest the water heater. Port 41 is connected by line 12 to outlet port 38 of pump 21.
Cold water line 14 is connected to line 12 at a point between ports 38 and 41.
Check valves 31 and 32 pass water or antifreeze in the direction of the arrows shown in the drawing under a nominal value of forward pressure; they block flow in the opposite direction.
Hot water line 17 is connected through port 31A to line 12 at a point between ports 41 and 42. The hot water port 43 of water heater 16 is connected through check valve 32 and a conduit or line 17A to line 17 at a point just downstream from check valve 31.
When solenoid 29B is not energized, water exhausted by pump 21 flows through valve 29A into water heater 16 and exhausts through valve 32 and line 17A to hot water line 17. While solenoid 29B is energized, water from pump 21 flows through port 41 and out port 31A of valve 29 and through check valve 31 directly to line 17, the valves 29A, port 42 and check valve 32 blocking entry to water heater 16.
Heretofore, three manually controlled switches have been used to control solenoid valves 28 and 29 and pump motor 21A. To winterize such a plumbing system, a first switch is closed to energize the by-pass solenoid valve 29 to block the flow of water to water heater 16. Pump motor 21A is next energized by a second switch and finally a third switch is operated to energize the anti-freeze solenoid valve 28. With all three switches closed, the anti-freeze solution is drawn from an anti-freeze tank accessed by line 26. From line 26, the solution passed through solenoid valve 28 via ports 35 and 36, pump 21 and line 12 to cold water line 14 and to hot water line 17 via ports 41 and 31A of solenoid valve 29. Tank 11 is drained through valve 18 and water heater 16 is drained through valve 20. Faucets 15 and 19 and other cold and hot water faucets connected to lines 14 and 17, respectively, are opened until the exhausted water shows the presence of the anti-freeze solution. Toilets 30 are then flushed with the anti-freeze solution. Finally, the switches are opened to shut down the system. One cold and one hot water faucet is then opened to relieve system pressure.
To de-winterize the system and return it to normal service, valves 18 and 20 are closed, tank 11 is filled, solenoid valve 29 is energized and finally, pump 21 is turned on, again operating the switches in the proper order to energize solenoid valve 29 first and then pump motor 21A. When this is accomplished, water is drawn by pump 21 from tank 11 through valve 28 via ports 34 and 36 and is delivered from port 38 to cold water line 14 and to hot water line 17 through valve 29 via ports 41 and 31A. Faucets on lines 14 and 17 are opened until the water runs clear, indicating that the anti-freeze solution has been flushed from the lines. Solenoid valve 29 is then de-energized to permit the filling of water heater 16 and the return to normal service is completed.
In utilizing such a system, the operator is compelled to observe the proper sequence of switch operation. If he inadvertently operated the switches energizing solenoid valve 28 and pump motor 21A prior to the energizing of by-pass solenoid valve 29, the anti-freeze solution is pumped into the water heater 16. The system is also vulnerable to tampering by children or vandals and thus, while it provides a measure of convenience, it is not without its drawbacks.
The present invention substantially removes the drawbacks of the earlier switch operated system through the incorporation of the key operated cam switch 33.
As shown in FIGS. 1, 2 and 3, switch 33 comprises a cylindrical barrel 45, three cam vanes 46, 47 and 48 mounted circumferentially to barrel 45, the vanes being equally-spaced and parallel to each other, and a micro-switch assembly 49 having three micro-switches 51, 52 and 53 aligned, respectively with vanes 46, 47 and 48. Barrel 45 is fashioned to receive a key 55 inserted axially into a keyway 56 by means of which the barrel 45 may be rotated about it axis causing the vanes 46-48 to be rotated past the aligned switches 51-53. As is apparent from FIGS. 1-3, each of the cam vanes has an operating surface that rises along an incline starting at the surface of the barrel 45 and rising along the incline to a cylindrical surface elevated above the surface of barrel 45. As the barrel 45 is rotated by means of a key 55 inserted in the axial keyway 56, the working surfaces of the vanes 46-48 rotate under the switches 51-53, the starting points of the inclines passing first, followed by the rising incline and finally by the elevated cylindrical surface. The inclines of the vanes are angularly displaced relative to each other about the axis of the barrel 45 such that with rotation in the direction of arrows 57, the incline of vane 46 passes first under switch 51. The incline of vane 47 then passes under switch 52, and finally, the incline of vane 48 passes under switch 53. As each incline passes under the associated switch the rising surface under the switch approaches the operating reed 58 of the switch until the inclined surface finally comes into contact with the reed 58 at a point near the transition to the elevated cylindrical surface. At this point the associated switch 51, 52 or 53 is closed. Because of the relative angular displacements of the inclines, switch 51 is closed first, switch 52 next, and 53 last as barrel 45 is rotated in the direction 57. The proper sequence of switch operation is thus assured.
An additional safety precaution is incorporated through provision of a tab 61 on barrel 45 and an aligned stop 62. The stop 62 is mechanically coupled to a push-button 63 which is accessible from the front panel or mounting plate 64 of the switch 33 as shown in FIG. 4. If push-button 63 is not depressed the stop 62 is in alignment with tab 61 and limits the rotation of barrel 45 in the direction 57 when tab 61 strikes stop 62. In this limit position switches 51 and 52 are closed but switch 53 is still open. If push-button 63 is depressed, stop 62 is moved out of alignment with tab 61 and barrel 45 may be moved past the limit position so that switch 53 will close. The limit position corresponds to the de-winterize (DW) position as shown on plate 64 of FIG. 4, with the pointer 65 directed toward the DW marker 66. When the barrel is moved past the stop or limit position while depressing push-button 63 and pointer 65 is directed toward the W marker 67, the third switch 53 is closed. The W marker indicates the winterize (W) position of switch 33.
As shown in FIG. 1, each of the three microswitches 51-53 has one terminal connected through a fuse 68 to the positive or "hot" terminal 69 of the power source 23. The negative terminal 71 of source 23 is connected to ground 72. The second terminal of switch 51 is connected to the ungrounded terminal of solenoid 29B, the second terminal of switch 52 is connected to the ungrounded terminal of motor 21A, and the second terminal of switch 53 is connected to the ungrounded terminal of solenoid 28B. The ground terminal of solenoids 28B and 29B and the ground terminal of motor 21A are connected to the common ground 72. The closing of switches 51, 52 and 53 thus energize or supply voltage to the solenoid 29B, the motor 21A and the solenoid 28B, respectively. As shown in FIG. 4, the fuse 68 is mounted for easy access on plate 64.
To winterize the plumbing system using the improved winterizing system 10, the operator first turns off the pump 21 by opening switch 22. He then depresses button 63 and turns key 55 clockwise (in the direction 57 shown in FIG. 3) until pointer 65 is directed toward the W marker 67 on plate 64. This causes the switches 51, 52 and 53 to close in the order named, properly sequencing power to the solenoid 29B, the pump 21 and the solenoid 28B. Water heater valve 20 and tank drain valve 18 are opened to drain water-heater 16, and tank 11, and each faucet on the hot and cold lines 14 and 17 is opened until anti-freeze solution appears in the discharging water, the anti-freeze solution being drawn from the containers 24 and 25 through lines 26, valve 28, pump 21 and lines 12, 14 and 17 and valve 31. When the delivery of anti-freeze solution has thus been assured and the toilet has been flushed to assure the delivery of anti-freeze there also, the system is shut down by turning key 55 and barrel 45 counter-clockwise to a position where pointer 65 is directed toward the OFF indication shown in FIG. 4. In this position of the barrel 45, the ends 73 of all three cam vanes 46, 47 and 48 will have passed under the vanes 58 of the microswitches 51, 52 and 53 and all three switches will have opened.
To de-winterize and return the water system to service, valves 18 and 20 are closed, tank 11 is filled with fresh water, and key 55 is rotated clockwise to the stop position accomplishing in succession the energizing of bypass solenoid 29B and motor 21A. Individual faucets are opened one at a time until clear water appears indicating that fresh water flowing from tank 11 has flushed anti-freeze from line 12, filter 13, valve 28A, pump 21 and lines 14 and 17. Key 55 is then rotated counter-clockwise to the OFF position and switch 22 is closed to turn on the pump 21. The water-heater fills with water and normal service is restored.
As an added convenience, the lines 26 are adapted to be coupled directly to the containers 24 and 25 through caps 75 which are provided with openings to receive flexible branch lines 26A and 26B of line 26. The containers 24 and 25 are the containers in which the anti-freeze solution is purchased. They are mounted in a suitable holder located, for convenience, inside the recreational vehicle or vacation home.
An improved winterizing system is thus provided in accordance with the stated objects of the invention, and although but a single embodiment of the invention has been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims. | An improved winterizing system for a recreational vehicle or vacation home for the prevention of freezing and damage to the plumbing, the system providing for the sequential energizing of solenoid valves and the pump switch to effect the distribution of a non-toxic anti-freeze solution throughout the plumbing lines. A special cam switch assures the proper sequence of electrical switching. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 11/173,478 filed Jun. 30, 2005, which is incorporated herein in its entirety by this reference thereto.
FIELD OF INVENTION
[0002] The present invention relates generally to medical devices and methods. More particularly, the present invention relates to minimally invasive methods and apparatus for performing uterine artery occlusion for the treatment of fibroids.
[0003] Uterine fibroids, also referred to as uterine myomas, affect a large number of women, although most fibroids are symptom free and do not require treatment. Fibroids, however, can be problematic if they grow rapidly, are large enough to displace other organs, such as the bladder, cause fertility problems, or lead to abnormal bleeding.
[0004] A number of therapies are available for treating uterine fibroids, including myomectomy, laparoscopic myomectomy, hysterectomy, fibroid embolization, and uterine artery embolization. Of particular interest to the present invention, uterine artery embolization relies on blocking or occluding the arteries that supply blood to the fibroids. A catheter is introduced to the uterine arteries under fluoroscopy, and small particles are injected into the arteries in order to block blood flow. Blocking the blood supply can shrink the fibroids in order to reduce or eliminate symptoms.
[0005] Although promising, intravascular embolization can be undesirable for a number of reasons, including ineffectiveness and patient incompatibility. Recently, it has been proposed to occlude the uterine artery in other ways, such as, using a radiofrequency ablation needle introduced through the uterine wall, optionally under the transrectal or other imaging. U.S. Pat. No. 6,905,506, describes a transvaginal approach for clamping the cervix to temporarily occlude the uterine artery and allow the fibroid to shrink. None of these approaches, however, is wholly effective or suitable for all patients. Thus, there remains a need for providing alternative methodologies, protocols, and apparatus for performing fibroid treatment by occlusion of the uterine arteries.
BACKGROUND OF THE INVENTION
[0006] U.S. Pat. No. 6,905,506 describes a method for reversibly compressing the uterine arteries using a clamp introduced to the cervix through the vagina. Clamping devices with radiofrequency electrodes are described in U.S. Pat. Nos. 6,059,782 and 5,746,750. U.S. Pat. No. 6,059,766 devices a method of embolotherapy which introduces embolic elements into uterine arteries through the uterine wall.
SUMMARY OF THE INVENTION
[0007] The present invention provides improved methods, apparatus, and systems for performing uterine artery occlusion for the treatment for uterine fibroids. According to the methods of the present invention, a tool is advanced through a vaginal wall to the uterine artery (or other artery feeding the uterus), and the tool is used to compress and apply energy to occlude the artery. The tool is preferably introduced transvaginally to a location on the vaginal wall adjacent to the cervix, typically at or near a fornix of the vagina. The vaginal wall will be penetrated, typically by making one, two, or several small incisions under direct visualization using conventional, surgical instruments. Alternatively, the tool which is introduced may itself have penetrating element, such as a blade, electrosurgical tip, or the like, in order to introduce the tool directly through the vaginal wall without a prior incision.
[0008] After the compressing tool has been introduced through the vaginal wall, it will be advanced toward the uterine or other target artery. Preferably, before the artery is compressed and/or energy is applied, the position of the tool adjacent to the uterine artery will be confirmed. Optionally, a visual or audible signal will be given when the tool is properly positioned. Confirming may comprise visualizing the tool and/or the uterine artery in any one of several ways. For example, the location of the tool relative to the uterine artery can be confirmed using laparoscopic imaging according to conventional gynecological procedures. Alternatively, the position to the tool relative to the uterine artery may be determined using external ultrasound, fluoroscopic, or other imaging. Alternatively or in addition to either laparoscopic, ultrasonic or fluoroscopic imaging, the imaging tool may carry its own optical or ultrasound imaging element in order to confirm positioning. In any event, after the device has been properly positioned, it is used to compress and apply energy to the uterine or other target artery to achieve occlusion.
[0009] In still further embodiments, the devices of the present invention may rely on blood flow detection to confirm proximity of the target artery. In such embodiments, a Doppler ultrasound element will be positioned at or near the distal end of the tool, and presence of the artery can be detected by conventional ultrasound detection and methods. Other techniques for confirming position include proximity sensing, pressure sensing, and the like.
[0010] In the exemplary embodiments, the tool comprises opposed clamping elements which effect clamping of the uterine artery. The clamping elements will typically carry electrodes or other energy (or cryotherapy) delivering components to permit permanent occlusion of the artery while it is being temporarily clamped by the clamping elements. The energy will be applied under conditions which seal the artery lumen but which leave the artery otherwise intact to avoid the need for hemostasis. The preferred energy to be delivered is radiofrequency (RF), but other energy including heat energy, ultrasonic energy, microwave energy, mechanical energy, and the like, might also be suitable. Alternatively, the tool may carry one or more fasteners, such as clips, staples, suture loops, or the like, which can be mechanically deployed to constrict the vessel.
[0011] The present invention still further provides devices for occluding the uterine or other target artery via a transvaginal approach. Such devices comprise a shaft structure having opposed clamping elements near its distal end. The shaft structure will adapted to be positioned through a vaginal wall (preferably from the vaginal cavity) to position the distal end thereof adjacent to the uterine artery. The clamping elements will have electrodes or other structures for applying energy to the uterine artery when the uterine artery is clamped therebetween. Preferred energy delivering structures are radiofrequency electrodes, but other structures would be suitable as well.
[0012] In a first exemplary embodiment, the shaft comprises a pair of hinged arms each of which carry at least one electrode, preferably a radiofrequency electrode connectable to a monopolar or bipolar power supply. In a preferred embodiment, at least one of the arms will also carry an imaging or a Doppler ultrasound element in order to permit confirmation that the clamps are adjacent to the uterine artery.
[0013] In an alternate embodiment, the shaft may consist essentially of a singular tubular element having an advanceable clamping element therein. The use of a single tubular element can be advantageous as it is easier to introduce through a small incision in the vaginal wall and does not require opening and closing of arms as with the hinged embodiments.
[0014] A variety of other clamping mechanisms would also be available, including parallelogram linkages, bimetallic actuators, solenoid devices, motorized operators, and the like.
[0015] The present invention still further provides systems for occluding uterine arteries, where the systems comprise any of the devices described above in combination with a power supply and control unit for applying energy through the energy applying means on the device. The power supply will typically be configured to delivery radiofrequency energy, but any of the other energy sources described above would also be suitable. The system will still further comprise a Doppler or optical imaging or sensing systems for confirming the presence of the device adjacent to the uterine artery prior to treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates the right and left uterine arteries in position relative to a patient's vagina and uterus.
[0017] FIG. 2 illustrates a first exemplary treatment tool constructed in accordance with the principles of the present invention.
[0018] FIGS. 3A and 3B illustrate alternative constructions of a distal end of the tool of FIG. 2 , taken along line 3 - 3 .
[0019] FIGS. 4A and 4B illustrate an alternative embodiment of the treatment tool of the present invention.
[0020] FIGS. 5A-5E illustrates the tool of FIG. 2 being used for uterine artery occlusion in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] According to FIG. 1 , a patient's right uterine artery RUA and left uterine artery LUA branch from the right and left internal iliac arteries (IIL) and enter into the walls of the uterus along a medial plain. The present invention provides for accessing the uterine arteries or other target arteries by placing a tool through the vagina V, advancing the tool upward through the vagina to a fornix F adjacent to the cervix C.
[0022] A variety of tools can be used for accessing and penetrating through the uterine wall in the region of the fornix F to access the uterine artery UA. Referring to FIGS. 2, 3A , and 3 B, a first device 10 comprises a pair of hinged arms 12 and 14 having distal clamping elements 16 and 18 , as best illustrated in FIG. 2 . The distal clamping elements 16 and 18 will carry a mechanism or structure for delivering energy (or cold) to the uterine artery when the uterine artery is clamped therebetween. The exemplary embodiments, the mechanism will comprise a pair opposed electrodes 20 suitable for delivering radiofrequency energy which may delivered from a power supply and control unit 30 which is connected to the device 10 via a cable 32 ( FIG. 2 ).
[0023] Preferably, the clamping elements 16 and 18 will also comprise a mechanism or structure for confirming proximity of the uterine artery UA. As illustrated in FIG. 3 A, a pair of ultrasonic transducers 36 and 38 are mounted proximally of the electrodes 20 . The ultrasonic transducers preferably configured for Doppler ultrasound sensing of blood flow through the uterine artery UA, allowing generation of a simple visual or audible signal to confirm proper placement of the device. Alternatively, the ultrasonic elements could provide for ultrasonic imaging in a conventional manner, or could in some cases comprises optical imaging, components, such as optical fibers, CCD's or the like. Still further alternatively, presence of the uterine artery can be sensed with a proximity sensor, pressure sensor, or other device which can provide visual or audible feedback when the clamping elements 36 and 38 are adjacent to the uterine artery UA.
[0024] As an alternative to the distal end of FIG. 3A , FIG. 3B describes clamping arms 16 ′ and 18 ′ where the electrodes 20 and ultrasonic transducers 36 and 38 are stacked above each other rather than positioned adjacent to each other in the axial direction.
[0025] A number of other specific devices can be configured for performing the methods of the present invention. For example, as illustrated in FIGS. 4A and 4B , a treatment device 50 may comprise a single shaft 52 performed as a tube having at least one lumen 54 therein. A gap 56 is provided near a distal end 58 of the shaft, and a sliding clamping element 60 can pass through the lumen 54 and have a distal end 62 and/or an advance through the gap 56 . As shown in FIG. 4B , the distal end 62 of the element 60 may comprise an electrode 70 or other energy delivering component. Similarly, an electrode 72 or other energy delivering component may be disposed in a distal surface of the gap within the shaft 52 . Preferably, an ultrasonic or other position sensor 80 could be provided along an axial wall of the gap 56 in order to permit detection of the uterine artery UA when the uterine artery is in the gap 56 . Clamping of the uterine artery can be achieved by advancing the clamping element 60 in a distal direction, as shown in broken line in FIG. 4B , to collapse the uterine artery between the electrodes 70 and 72 . Radiofrequency or other energy may then be delivered into the uterine artery in order to fuse the lumen and induce occlusion of the lumen of the uterine artery.
[0026] Referring now to FIGS. 5A though 5 E use of the device 10 for occluding a uterine artery UA in accordance with the principles to the present invention will be described. Initially, the treating physician visualizes the cervix C through the vagina V using conventional tools and techniques, as illustrated in FIG. 5A . One or more small incisions I may be made in the region of a fornix F of the rear vaginal wall. The incisions I will extend to the exterior of the vagina V at the base of the uterus U, as best seen in FIG. 5B the incisions I will be relatively close to the left uterine artery LUA.
[0027] Clamping elements 16 and 18 will be advanced through the Incisions so that they lie on the anterior and posterior sides of the left uterine artery LUA, as best seen in FIG. 5C . An alternate view is also shown in FIG. 5D . The arms 12 and 14 are then manipulated to collapse the clamping elements 16 and 18 over the uterine artery LUA as shown in FIG. 5E . Usually, prior to clamping, correct positioning of the clamping element 16 and 18 will be confirmed via the Doppler or other ultrasonic elements carried by the device. Assuming correct positioning, the uterine artery is clamped, and energy applied in order to permanently fuse and occlude the lumen of the uterine artery, as shown in FIG. 5E . Although the type and amount of energy may vary widely, radiofrequency energy at a power from 5W to 300W, typically from 10W to 50W, from 1 second to 30 seconds, should be sufficient to achieve permanent occlusion.
[0028] After the occlusion has been performed, for devices carrying the Doppler ultrasound, it will be possible to confirm that blood flow through the artery has ceased prior to withdrawing the device through the incisions I and vaginal opening. The incisions I may then be closed, and the procedure has ended.
[0029] Although the invention is described herein with reference to the preferred embodiment, one skilled in the art will readily appreciate that other applications may be substituted for those set forth herein without departing from the spirit and scope of the present invention. Accordingly, the invention should only be limited by the claims included below.
[0030] The invention has been described with reference to specific exemplary embodiments thereof and various modifications and changes may be made thereto without departing from the broad spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense; the invention is limited only by the following claims. | Uterine artery occlusion is performed for the treatment of uterine fibroid using a tool which is introduced through the vaginal wall to the exterior of the uterus. The tool carried clamping elements which may be positioned over the uterine artery. Electrodes or other energy applying devices on the clamping elements may be used to deliver energy to seal the uterine artery. Optionally, the tool may carry ultrasonic, visual, or proximity sensors for detecting the presence of the uterine artery prior to delivering energy. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of another international application filed under the Patent Cooperation Treaty on Feb. 23, 1994, bearing application No. PCT/FR94/00198 now WO 94/20200 and listing the United States as a designated and/or elected country. The entire disclosure of this latter application, including the drawings thereof, is hereby incorporated in this application as if fully set forth herein.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of another international application filed under the Patent Cooperation Treaty on Feb. 23, 1994, bearing application No. PCT/FR94/00198 now WO 94/20200 and listing the United States as a designated and/or elected country. The entire disclosure of this latter application, including the drawings thereof, is hereby incorporated in this application as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for introducing and diffusing air or some other gas into a liquid.
2. Background of the Invention
The introduction and diffusion of air into a liquid is currently achieved using compressors, blowers, turbines, which supply air under pressure; pipes transport the air thus compressed towards the point of use, perforated tubing, diffusers or other systems producing bubbles of greater or lesser size to be brought into contact with the liquid.
Surface turbines are also used, they spray the liquid into the atmosphere in order to bring it into contact with air at atmospheric pressure.
Other types of turbines are immersed, with their electric drive motors located in a sealed enclosure, the turbine being connected to the outside of the liquid by a pipe, the electric motor by cables with sealed connection. These turbines allow air or gas to be introduced into a liquid.
The water jet vacuum pumps are mounted statically on pipes under pressure, they allow air or any other gas to be introduced into the liquid passing through the water jet vacuum pump.
Diffusing a gas into a liquid by drawing gas into the liquid by "venturi effect" is known, the venturi effect being created by the rotation about a shaft of elements immersed in the liquid and which comprise a convergent/divergent nozzle with a gas inlet at the throat thus created. As the elements rotate, the gas is drawn in at the throat and is dispersed into the liquid (e.g. see the U.S. Pat. No. 2,743,914 and WO 90/05582).
SUMMARY OF THE INVENTION
The invention relates to an apparatus for diffusing air or some other gas into a liquid at a certain depth, comprising a shaft, the upper end of which is mechanically connected to a rotational drive member. The shaft is equipped at its base with several water jet vacuum pumps arranged peripherally at some distance from the axis of the shaft and fixed to this shaft by supports. Each water jet vacuum pump includes, coaxially, an outlet nozzle and a cone exhibiting a tip, and a cavity in which a vacuum is created when the assembly is rotating, the cavity being connected to the source of air or of gas by ducts integral with the supports of the water jet vacuum pumps.
According to an aspect of the invention, the base of each of cones is situated in a plane including the axis of the shaft, while the outlet nozzle is substantially centrifugal.
There are two basic reasons for such an assembly:
the liquid including the gas is ejected in a centrifugal way: this results in that the liquid including the gas is allowed to be mixed with the remaining liquid out of the processing area, and not to turn with the rotor. Consequently, the liquid including the gas is not processed by the next cone in order to avoid a local gas saturation of the liquid, and thus the efficiency of the apparatus is increased.
the liquid input is radial in order to increase the above-mentioned effect and to help the cone penetration into the liquid. This also results in that no deformation forces are applied to the cones and to the shaft, thus the apparatus driving motor does not require over-power.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will become apparent from the following description and claims, and from the accompanying drawings, wherein:
FIG. 1 is a schematic axial view of the rotating assembly according to the invention;
FIGS. 2, 3, 4 and 5 are cross-sectional view of preferred embodiments the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, the apparatus is composed of several water jet vacuum pumps placed in a ring configuration, and connected mechanically 7 to the base of a hollow drive shaft 6, the cavity of the water jet vacuum pumps 3, where the vacuum is created, is connected to the inside of the shaft by ducts 5 and the bottom end of the shaft is closed off. Orifices 8 are formed at the periphery, at the top part of the shaft, and the end of the shaft is coupled 11 to a drive member, an electric motor 9 in direct engagement or engaged via a geared motor unit 10, or to some other drive system.
The set of water jet vacuum pumps and part of the drive shaft are immersed vertically in a liquid, the motor 9 and the drive part being fixed to a support.
When, with the aid of a motor 9, this assembly is given a certain speed of rotation, a pressure is created at the inlet to the water jet vacuum pumps and on the tip of the cone 2 of the water jet vacuum pumps, this pressure being greater, the faster the speed of rotation in the liquid; a jet directed towards the outlet nozzle of the water jet vacuum pumps is produced at the outlet of the tip of the cones and the force of the jet in the nozzle 4 creates a vacuum in the volume 3 situated around the tips of the water jet vacuum pumps. This vacuum thus created, is communicated, via the ducts 5 situated in the supports 7, to the inside of the drive shaft 6 as far as the orifices 8 situated at the top part of the shaft. The vacuum created by the water jet vacuum pumps will thus allow air to penetrate through the orifices 8 to the inside of the hollow drive shaft 6 and then via the ducts 5 to the vacuum volume 3 of the water jet vacuum pumps and from there, the air will be drawn up by the jets of liquid leaving the tip 2 of the water jet vacuum pumps. The air will be mixed with the liquid in the outlet nozzle 4 of the water jet vacuum pumps, the air plus water mixture thus created will be diffused into the liquid of the tank or of the volume in which the apparatus is located.
A set of fan blades 18 (FIG. 3) may be fixed to the shaft above the set of water jet vacuum pumps, this making it possible to direct the liquid/air mixture leaving the nozzles 4 of the water jet vacuum pumps downwards, and to obtain mixing and vigorous homogenization of the air in the liquid.
The water jet vacuum pumps may be incorporated into the blades of a set of fan blades, and this will orientate the liquid/air mixture towards the bottom, which will allow better contact of the liquid with the air diffused into the liquid by the water jet vacuum pumps.
Several groups of water jet vacuum pumps may be mounted on the same shaft (FIG. 4) which may or may not be associated with sets of fan blades, this making it possible to introduce air into a liquid over a greater depth. The operation is as follows: the first set of water jet vacuum pumps which is placed the closest to the surface of the liquid will create a depression greater than the height of the liquid situated above it. The level of the liquid in the shaft will reach this first set of ejectors so as to diffuse air into the liquid. For the second set of water jet vacuum pumps to operate, it will create a depression greater than the height of liquid corresponding to the distance between the two sets of water jet vacuum pumps mounted on the same shaft, and the pressure of the air/liquid mixture leaving the nozzles of the water jet vacuum pumps must be greater than the depth of immersion in the liquid.
Several water jet vacuum pumps may be mounted on the same arm for connection to the shaft, in series, in order to increase the amount of air or gas introduced into the liquid, the vacuum volumes of the water jet vacuum pumps being connected together in series, and then connected by a duct to the inside of the drive shaft of the whole.
For the device according to the invention to operate, that is to say for the water jet vacuum pumps to begin to diffuse air into the liquid, the whole must be given a certain speed of rotation in order to obtain, on the tip of the water jet vacuum pumps, a pressure, making it possible to have in the vacuum cavity, a depression at least equal to the depth of immersion in the liquid, and a pressure at the outlet of the water jet vacuum pumps also greater than the depth of immersion.
The amount of air or of gas drawn into and diffused into the liquid by the water jet vacuum pumps will be greater, the higher the pressure on the tip of the water jet vacuum pumps, relative to the speed of rotation of the whole, therefore to the rate of penetration of the water jet vacuum pumps in the liquid.
The dispersion and diffusion of air in the liquid, that is to say the size of the bubbles, will be smaller, the greater the pressure on the tip, and therefore the greater the outlet speed from the water jet vacuum pumps, this giving better contact of the air with the liquid.
In order to use a gas other than air, with the system described hereinabove, an enclosure 16 needs to be created in line with the air inlet orifices 8 to the drive shaft, isolating them from the air as indicated in FIG. 3. A cylinder is fixed under the drive motor or under the geared motor unit 10 in a perfectly sealed manner 17, the bottom part of the cylinder dips down into the liquid and forms a hydraulic seal, on the cylinder side, and a nozzle 15 can be used to supply air or any other gas, the one which is to be diffused into the liquid, in order to subject this liquid to a specific treatment.
Depending on the gas employed, the materials used, in contact with the gas, need to be resistant to this gas or protected accordingly.
This device makes it possible, with monitoring items of apparatus placed upstream on this nozzle 15 to know very precisely the amount of gas or air diffused and introduced into the liquid.
Apparatus for diffusing air or some other gas into a liquid, at a certain depth. It is characterized by a hollow shaft 6 closed off at its lower part, orifices 8 at its upper lateral part situated above the liquid, the upper end of which is mechanically connected to the rotational drive member 9-10, this shaft is equipped at its base with several water jet vacuum pumps 1-2-3-4 arranged peripherally, some distance from the axis of the shaft and fixed to this shaft by supports, the cavity of the water jet vacuum pumps where the vacuum is created when the assembly is rotating is connected to the inside of the hollow shaft by ducts 5 integral with the supports of the water jet vacuum pumps 7.
For conveying air or gas as far as the water jet vacuum pumps, the connection with the outside is by means of a tube 19 into which the axis of the drive shaft passes, a space between the shaft and the tube allowing air or gas to pass, and the base of the tube being connected to the ducts of the supports of the water jet vacuum pumps, with the inside of the base of the tube being sealed against the liquid into which the whole dips.
In operation, this makes it possible to:
introduce air or some other gas into a liquid at a certain depth, the use of the sealed cylinder 16 as indicated in the drawing (FIG. 3) allowing a gas other than air to be used;
cause the entire volume of liquid to be set into motion.
By applying a rotational motion by means of an electric motor to the assembly thus formed and placed vertically in a liquid, the following actions will take place:
the water jet vacuum pumps will reach a certain speed in the liquid under the effect of the rotation of the shaft and of the water jet vacuum pumps fixed to the end, driven by the electric motor;
under the effect of the rotational speed of the set of water jet vacuum pumps, the liquid will reach a certain pressure on the tip 2 of the water jet vacuum pumps, and this will produce, at the outlet of the tips, a jet directed towards the outlet nozzle of each water jet vacuum pump 4, and this will give rise in the cavities 3 of each water jet vacuum pump to a depression which will be greater, the greater the speed of rotation, and therefore the higher the pressure on the tips of the water jet vacuum pumps.
This cavity in which the vacuum is created, situated at the periphery slightly set back from the outlet tip of each water jet vacuum pump, is connected to the hollow inside of the drive shaft, or to the space between the tube and the drive shaft, by a duct situated in the assembly and support piece between each water jet vacuum pump and the inside of the shaft, or the space between the tube and the shaft.
When the assembly is stationary, there is equilibrium of the liquid between the outside and the inside of the shaft, through which the air passes which travels as far as the water jet vacuum pumps when these are rotating.
When the assembly is put into operation, as soon as the pressure of the liquid on the tip of the water jet vacuum pumps has reached a certain magnitude, firstly, liquid inside the shaft assembly will be discharged as far as the cavities 3 of the water jet vacuum pumps, this discharge being brought about by the depression created by the jets at the outlet of the tips of the water jet vacuum pumps of the assembly. Once the liquid has been discharged, air or gas will be drawn up by the jets of liquid leaving the tip of the water jet vacuum pumps, and this air/liquid mixture is introduced into the liquid into which the assembly is dipped.
The greater the speed of rotation, the higher will be the pressure on the tip of the water jet vacuum pumps, the greater will be the depression obtained, and therefore the greater will be the flow rate of air or gas. It is therefore possible to vary the flow rate of air or gas introduced into the liquid as a function of the rotational speed of the whole.
The higher the speed of rotation, the higher will be the pressure on the tip of the water jet vacuum pumps, the greater will be the diffusion of air or gas, that is to say the smaller will be the air or gas bubbles, exhibiting a greater surface area for contact with the liquid, giving greater effectiveness.
This system affords very clear possibilities:
addition of air or gas to a liquid at a certain depth, therefore at a certain pressure, increasing the dissolution of the gas or air used; dimensioning of the apparatus as a function of the volume or of the flow rate of liquid into which the air or gas is to be injected;
the rotational motion of the apparatus and the addition of air or gas to the liquid will agitate the liquid, which will improve homogenization and contact of air or gas with the liquid;
the greater the rotational speed, the higher will be the pressure on the tip of the water jet vacuum pumps, the greater will be the depression obtained, the greater will be the flow rate of air or gas, and the more effective will be the diffusion of the air or gas into the liquid because the bubbles of air or gas will be smaller, exhibiting a greater surface area for contact with the liquid and therefore greater effectiveness;
the possibility of slaving the flow rate of air or gas injected to the flow rate of liquid passing through a volume by slaving the rotational speed of the set of water jet vacuum pumps to the flow rate of liquid passing through the volume;
increasing the mixing and agitation of the liquid by adding a set of fan blades to the drive shaft above the group of water jet vacuum pumps;
increasing the mixing and agitation of the liquid by incorporating the water jet vacuum pumps into the blades of a set of fan blades.
In order to introduce air or gas into a liquid, all that is required is to fix the complete apparatus equipped with an electric motor above the liquid, that end of the drive shaft which is equipped with the water jet vacuum pumps dipping down into the liquid, to connect the electric motor to a source of electrical energy, and to switch it on.
This system displays the following advantages:
the shaft and its equipment of water jet vacuum pumps which is associated with an electric motor forms an active assembly, without any mechanical parts in motion apart from the rotation of the shaft/water jet vacuum pumps assembly in the liquid;
there are no wearing components other than the shaft drive mechanism which is situated above the liquid, and therefore very accessible.
In order to increase the amount of air or gas to be introduced into the liquid, it is possible to place several water jet vacuum pumps in series on the same arm.
It is possible to introduce air or gas into the liquid at depth, by mounting several stages or sets of water jet vacuum pumps on the same shaft.
With the use of the sealed part 16 placed beneath the drive mechanism and dipping down into the liquid, forming a hydraulic seal, it is possible to inject any kind of gas, even a very oxidizing or corrosive gas into the liquid, the materials in contact with these gases being resistant to these gases or protected in order to allow them to be used.
While there have been shown and described what are present considered to be the preferred embodiments of the invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. | An apparatus includes a hollow shaft (6) with water jet vacuum pumps peripherally attached to the end thereof at a certain distance therefrom wherein the water pumps have vacuum pockets (3) communicating with the inside of the hollow shaft via ducts (5). The lower portion of the shaft is plugged, and its upper portion has peripheral perforations (8) providing free access for air or gas flowing into the shaft so that the air or gas can reach the vacuum pockets of the water pumps. The top end of the shaft is coupled to an electric motor (9) either directly or via a motor reducer (10). When the shaft and the water pumps are rotating within a liquid, the liquid pressure at the tips (2) of the water pumps create a vacuum, whereby fine bubbles of air or gas can be fed into and diffused through the liquid at a submerged depth of the water pumps. | 1 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to mufflers for internal combustion engines of the type commonly used in motor vehicles. More particularly, the present invention relates to such mufflers which provide improved engine combustion efficiency resulting in improved performance and reduced toxic exhaust emissions levels.
[0002] Motor vehicles utilizing internal combustion engines continue to be the favored form of transportation to most people in the developed countries of the world. This is in spite of their many disadvantages the more important of which include toxic exhaust emissions and exhaust noise. Although mufflers can substantially reduce or perhaps even eliminate the exhaust noise, it is commonly believed that they do so at the expense of reduced power output and reduced fuel economy.
[0003] Designers of exhaust systems have recognized that improving the effectiveness of exhaust gas flow out of the engine can provide improved combustion efficiency and thereby reduced toxic exhaust emissions. There have consequently been many exhaust system designs that have sought to increase the velocity of exhaust gas flow through the exhaust system and thereby scavenge exhaust gases from the combustion chamber and exhaust ports. Some exhaust header system designs position exhaust pipes around the inner circumference of a collector pipe to produce swirling of the exhaust gases from the collector pipe in a vortex flow and thereby enhance exhaust gas flow therefrom. Such systems have been very effective in improving exhaust as well as intake fluid flow and thereby improving combustion. However, such systems require retuning of the engine and replacement of major engine system components and are thus impractical for many motor vehicle owners.
[0004] The particular muffler design is also important in that it can substantially affect the combustion efficiency of the engine. Since muffler replacement is easier than exhaust manifold and pipe replacement, automotive engineers have sought improve the muffler design in order to provide improved exhaust flow and thereby improved combustion efficiency. A muffler is also a very important component of motor vehicles because it reduces their exhaust noise making their use in crowded cities more tolerable. Consequently, many mufflers are designed with the dual purpose of both increasing exhaust flow and attenuating exhaust noise.
[0005] There are two basic designs of muffler in contemporary use in modern motor vehicles. These designs are the dissipative type and the reactive type. A dissipative muffler absorbs the sound energy as the exhaust fluid passes through the muffler via fibers or other sound deadening material packed therein. Two primary disadvantages of dissipative mufflers are that they lose their effectiveness over time and are expensive to manufacture. Moreover, dissipative mufflers do not produce good low frequency sound attenuation. The reactive type of muffler attenuates the sound energy by reflecting the sound back toward the source. A reactive muffler is inexpensive to manufacture and provides good low frequency sound attenuation but has the disadvantage of producing high backpressure. Variations on these two basic designs have sought to produce desired sound attenuation without substantially or unacceptably increasing the back pressure on the engine since, as is commonly known, excessive muffler induced back pressure will substantially compromise engine combustion efficiency and reduce engine performance.
[0006] Exhaust noise is appreciably reduced by friction effects produced by muffler internal structures and noise-wave effects produced by resonance chambers. However, utilization of such structures increases the complexity, cost and size of the exhaust system. But, a large exhaust system is often very undesirable as motor vehicle space may be limited and ground clearance may need to be high especially for sport utility vehicles. Thus, compactness is a very desirable feature in a muffler used in modern motor vehicles. Compactness and concomitantly reduced weight are especially important for high performance vehicles wherein reduced weight can desirably improve acceleration. In attempts to provide both exhaust efficiency and compactness, many mufflers incorporate various internal structures designed to either improve sound attenuation or improve exhaust flow efficiency. An example of a compact, sound attenuating muffler specifically designed for compactness is disclosed in U.S. Pat. No. 4,574,914 to Flugger. The Flugger muffler is especially useful for high performance motor vehicles because it achieves sound attenuation without significant decrease in engine performance. The Flugger muffler is a reactive type which includes partitions as well as convergently and divergently shaped structures which change the direction of exhaust flow. The Flugger muffler is effective in both preserving exhaust flow efficiency and providing sound attenuation. Nevertheless, its size and shape render it unsuitable for some types of motor vehicles.
[0007] Some mufflers are specifically designed to reduce back pressure and thereby improve exhaust gas flow as well as intake induction and combustion efficiency. The goal is improved performance and perhaps fuel economy. An example of such a muffler is disclosed in U.S. Pat. No. 6,213,251 to Kesselring. The Kesselring muffler includes restrictor disk holes and a helical passageway therein to enhance the exhaust gas flow therethrough. The specific goal is moderate backpressure at low rpm and little or negative backpressure at high rpm. Such types of mufflers, however, have inordinate complexity.
[0008] Many muffler designs incorporate apertures in the exhaust tubes therein in order to gradually expand the gas stream flowing through the muffler. However, such designs are not very effective at this because since the tubes are straight tubes the major portion of the gas stream flows through and out of the tube and only a small portion flows out through the muffling apertures. Nevertheless, such apertured tubes are in common use in mufflers and some mufflers have used such apertures to provide a swirling exhaust gas stream in order to enhance exhaust gas flow through the muffler. An example of such a muffler pipe design is disclosed in U.S. Pat. No. 6,385,9678 to Chen. The Chen pipe has a conical structure to accelerate the gas stream and spiral portions spaced around the conical structure. However, the Chen pipe is only a part of a muffler and many types of muffler casings would not be suitable for such a pipe.
[0009] Despite the prevalence of many types of mufflers, what is needed is a muffler that can curtail reverse flow of exhaust gas toward the engine. What is also needed is a muffler that can provide adequate sound attenuation as well as fuel economy. It is also desirable that these features be provided without sacrificing power output.
SUMMARY OF THE INVENTION
[0010] It is a principal object of the present invention to provide a muffler having structural components that impart a swirling motion to the exhaust fluid flowing therethrough.
[0011] It is another object of the present invention to provide a muffler which prevents reverse flow of exhaust fluid therein.
[0012] It is also an object of the present invention to provide a muffler that reduces back pressure while providing exhaust sound attenuation.
[0013] It is also an object of the present invention to provide a muffler having exhaust fluid swirling components that are shaped to provide minimal restriction of fluid flow therethrough.
[0014] Exhaust systems generally are compromised by an inherent exhaust flow inefficiency caused by valve overlap of the internal combustion engine. At the end of the exhaust stroke of the engine's piston, the piston starts to move down while the intake valve is opening to allow the air/fuel charge into the combustion chamber. However, the valve overlap design of modern engines has the exhaust valve also open at this crucial time thereby allowing the combustion chamber to draw exhaust gases directly from the exhaust system. This is especially problematic if the exhaust gas velocity is low and exhaust system pressure is high whereupon the exhaust gases will readily flow backward into the combustion chamber rather than out from the exhaust system. Exhaust gases entering the combustion chamber will dilute the intake fluid with unburnable gases and occupy needed combustion chamber space. This can result in reduced power since there is a lower quantity of fresh air/fuel mixture in the combustion chamber than there otherwise would be. Additionally, the presence of the hot exhaust gases in the combustion chamber may raise the temperature of the mixture above the fuel's knock resistance accelerating engine wear and possibly damaging internal engine components. Consequently, it is imperative that an exhaust system have high fluid flow velocity and therefore low pressure in order to prevent or minimize these effects.
[0015] As exhaust gas temperature equalizes in the exhaust system, pressure tends to move in a reverse direction i.e., toward the combustion chamber. This normally happens during deceleration and can cause spent exhaust gases to enter the combustion chamber as a result of the valve overlap (also known as positive overlap). As a result of the reduction in the quantity of power producing fresh air/fuel mixture in the combustion chamber, there will be a slight flat spot during re-acceleration and a reduction in fuel economy.
[0016] The muffler of the present invention is specifically designed to prevent reverse flow of exhaust gases that typically occurs during decleration by providing a pocket within the muffler expansion chamber. The pocket in effect traps the exhaust gases thereby precluding their reentry into the inlet duct of the muffler. During engine operation, the hot exhaust gases discharged into the muffler expansion chamber expand to the walls thereof and upon commencement of the reverse flow move into the pocket where their movement is stopped. As a result, the exhaust gases are trapped in the pocket. The exhaust gases thus collect in the expansion chamber instead of moving back into the inlet duct. When reacceleration takes place, the pocket is emptied as the exhaust flow velocity increases producing a pressure drop in the chamber which draws the gases out of the pocket.
[0017] Backpressure which is basically resistance to fluid flow is also necessary to avoid or minimize because high backpressure causes the exhaust gases to remain in the exhaust system too long. When the exhaust gases back up in the system there is an increased tendency for the gases to reverse flow. Thus, it is advantageous for an exhaust system to produce very low backpressure or, more preferably, a vacuum within the system to induce scavenging of the exhaust gases and to thereby aid exhaust flow.
[0018] The muffler of the present invention is also specifically designed to aid fluid flow through the exhaust system by causing the fluid to swirl as it moves through the system. The swirl reduces the decrease in exhaust gas velocity that would otherwise occur yielding reduced backpressure. Consequently, this improved flow reduces the tendency of the fluid to reverse flow during deceleration. Overall performance and power output are improved as a result.
[0019] The muffler of the present invention achieves its goal of swirling the fluid flow by incorporating vanes which are positioned in the exhaust flow stream. More specifically, the vanes are secured to the inside of the inlet duct. The vanes are angled so that they deflect the fluid laterally into a rotational movement. The vanes thus impart a swirling movement to the exhaust fluid discharged into the expansion chamber thereby enhancing fluid flow in the space utilized to prevent flow reversion.
[0020] The vanes are specially curved (at their edges) and shaped for maximal efficiency in producing the swirl effect with minimal fluid flow restriction. The vanes are longitudinally longer at the inner surfaces of the walls of the inlet duct than at the central area of the duct. Thus, the peripheral portions of the vanes are larger and therefore provide more deflection than the smaller, more centrally located portions of the vanes. This is desirable because it more efficiently yields the desired swirl. This is because the swirl produced is essentially exhaust gas rotation about a central axis with the more peripheral gas at peripheral areas of the duct (or chamber) rotating more than the gas at more centrally located areas. Consequently, flow deflection at the peripheral portions of the duct is more effective in producing the desired fluid rotation about the central axis of the duct (and chamber). Similarly, near the central area of the housing the vane portions are smaller producing less deflection and concomitantly less fluid flow restriction at the duct area where swirl can less effectively be produced.
[0021] The lower or trailing edges of the vanes are also curved to streamline the vanes for reduced fluid flow resistance. The curvature is in a direction of from the periphery to the center of the duct (or chamber). Since the peripheral ends of the primary vanes are longer than the central (or inner) ends, the lower or trailing edge is angled in the direction of fluid flow and the curvature thereof is also curved in this direction.
[0022] Additionally, lower end portions and lower medial end portions of the vanes are bent in the direction of the deflection of the fluid flow. The lower end portions and lower medial end portions are thus angled laterally to enhance deflection of the fluid flow. This deflection provided by these lower portions is also very effective in producing swirl because the fluid flow has been previously deflected by upper portions of the primary vanes and has been moving downwardly alongside the vanes until it reaches these lower portions where it is further deflected to add more lateral movement and thereby more rotational movement to the fluid flow.
[0023] Also included are secondary vanes for maximal efficiency in producing the swirl effect with minimal fluid flow restriction. The secondary vanes are mounted in the duct and attached to the walls thereof. The secondary vanes are also angled the same as the primary vanes for producing the desired deflection of the fluid flow. But, the secondary vanes are shorter in width and thus extend only a short distance toward the center and into the inner area of the duct so that they are essentially located only in the inner peripheral area of the duct where there is maximal effectiveness in producing the fluid flow rotational movement.
[0024] The present invention obviates the need for a central support structure by interconnecting lateral inner ends of the vanes at the central area of the duct. The central area of the duct is thus open, and there is therefore nothing to impede fluid flow through the center of the duct. Thus, the present invention provides improved exhaust fluid flow over prior art comparable structures. Moreover, elimination of a central member does not result in reduction in the efficiency of the structures in producing fluid swirl because the swirl produced is essentially fluid rotation about a central axis i.e., the center of the duct, with the more peripheral fluid at peripheral areas of the passageway rotating more than the fluid at more centrally located areas. The overall fluid movement is thus in the shape of a spiral as it moves through the passageway. Consequently, the swirl cannot typically be effectively accomplished by means of structures located at the center of the duct but can instead be effectively accomplished by means of structures located at more peripheral portions of the duct. Indeed, maximal twisting or turning of the fluid flow is accomplished by means of structures such as the secondary vanes and structure portions such as the larger peripheral portions of the primary vanes both of which are located at the area of the inner perimeter of the duct.
[0025] The muffler of the present invention thus provides an exhaust system component that prevents or reduces reverse flow of the exhaust fluid as well as enhancing fluid flow through the exhaust system. The present invention thus eliminates or minimizes hesitation during acceleration thereby improving performance and improves fuel economy by ensuring a fresh air/fuel mixture in the combustion chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a perspective view of the muffler of the present invention shown with a portion cut away to illustrate the components thereof.
[0027] FIG. 2 is a longitudinal-sectional view of the muffler of the present invention.
[0028] FIG. 3 is cross-sectional view of the muffler of the present invention illustrating inner vane components thereof and taken along lines 3 - 3 of FIG. 2 .
[0029] FIG. 4 is a schematic drawing of the muffler of the present invention showing the movement of exhaust gas therethrough.
[0030] FIG. 5 is a side plan view of a representative primary vane of the muffler of the present invention.
[0031] FIG. 6 is a top view of a representative primary vane of the muffler of the present invention.
[0032] FIG. 7 is a rear end view of a representative primary vane of the muffler of the present inventin showing the angled lower end portion thereof and also showing the fluid flow passing thereagainst and proximal thereto.
[0033] FIG. 8 is a side plan view of a representative secondary vane of the muffler of the present invention.
[0034] FIG. 9 is a top view of a representative secondary vane of the muffler of the present invention.
[0035] FIG. 10 is a rear end view of a representative secondary vane of the muffler of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0036] Referring to the drawings, the muffler of the present invention is generally designated by the numeral 10 . The muffler 10 includes a casing 12 . The casing 12 is hollow and includes an inlet port 14 and an outlet port 16 at opposite ends thereof. The casing 12 also includes a main body 18 defining an expansion chamber 20 in the casing 12 and located between the inlet port 14 and outlet port 16 . An inlet duct 22 is connected to the inlet port 16 and has an inlet end 24 for connection to an exhaust pipe (not shown) to allow exhaust fluid 26 from an internal combustion engine (not shown) to enter the casing 12 . The inlet duct 22 extends through the inlet port 14 and has an outlet (or discharge) end 28 for discharge of the exhaust fluid 26 into the expansion chamber 20 which has a larger cross-sectional area than the inlet duct 22 (and inlet port 14 ), as is typical for conventional mufflers. The casing 12 also includes an outlet duct 30 connected to the outlet port 16 for allowing emission of exhaust fluid 26 therefrom and out of the chamber 20 . The outlet duct 30 and outlet port 16 are preferably larger in cross-sectional area than the inlet port 14 and inlet duct 22 to reduce resistance to fluid flow.
[0037] The main body 18 of the casing 12 includes a front portion 32 , a front medial portion 34 , a medial portion 36 , a rear medial portion 38 and a rear portion 40 . The front portion 32 and the rear portion 40 are located at opposite longitudinal ends of the casing 12 . The front medial portion 34 , the medial portion 36 and the rear medial portion 38 are preferably unitary and preferably cylindrical. However, other suitable shapes may also be utilized instead.
[0038] The inlet duct 22 extends into the expansion chamber 20 such that the outlet end 28 is located at the medial portion 36 of the expansion chamber 20 . The expansion chamber 20 includes a pocket 42 which is located at the inlet port 14 area. The inlet duct 22 includes an outlet end portion 44 , and the outlet end portion 36 , the front portion 38 and the front medial portion 34 together define the pocket 42 . The front portion 32 is convergently tapered toward the inlet port 14 and in an upstream direction relative to the direction of flow of the exhaust fluid 26 . Similarly, the rear portion 40 is convergently tapered toward the outlet port 16 and in a downstream direction relative to the direction of flow of the exhaust fluid 26 . The front portion 32 and the rear portion 40 are preferably frusto-conical.
[0039] During the crucial deceleration phase of engine operation, the exhaust fluid 26 tends to reverse direction and move rearward. But, the fluid 26 tends to move into the pocket 42 rather than into the inlet duct 22 because there is less pressure in the pocket 42 than in the outlet end 28 and because the expansion of the fluid outwardly from the outlet end 28 as it is discharged therefrom tends to promote flow laterally outwardly and thereby rearwardly into the pocket 42 . Once the fluid is moving into the pocket 42 , the inlet duct 22 and the front medial portion 36 (and to a certain extent the front portion 32 ) block lateral movement of the fluid such that it becomes trapped in the pocket 42 . As a result of the taper of the front portion 38 , the pocket 42 has a smaller cross-sectional area at the inlet port 14 than at the front medial portion 34 . The smaller cross-sectional area of the inlet port 14 area of the pocket 42 tends to compress fluid entering therein so that the total quantity of fluid in the pocket is thereby maximized. Consequently, there is a maximal quantity of fluid 26 in the pocket 42 concomitantly minimizing the quantity of fluid available to reverse flow into the outlet end 28 of the inlet duct 22 . After deceleration is terminated and reacceleration is commenced, the velocity of the stream of fluid 26 flowing out of the outlet end 28 causes a pressure drop in the expansion chamber 20 so that this pressure drop in conjunction with the higher pressure of the fluid in the pocket 42 due to its compression facilitates fluid flow out of the pocket and subsequently out of the muffler 10 .
[0040] The muffler 10 also incorporates a set of vanes 46 which impart a swirling motion to the exhaust fluid in order to improve the flow of exhaust fluid 26 through the exhaust system. The set of vanes include a plurality of primary vanes 48 which are preferably mounted in the inlet duct 22 . The primary vanes 48 are located at the outlet end portion 44 of the inlet duct 22 . The primary vanes 48 are preferably securely attached to the inner surfaces 50 of the walls 52 of the inlet duct 22 via welding or other suitable attachment means.
[0041] The set of vanes 46 also include a plurality of secondary vanes 54 which are also preferably mounted in the inlet duct 22 . The secondary vanes 54 are similarly located at the outlet end portion 44 of the inlet duct and preferably securely attached to the inner surfaces 50 of the walls 52 of the inlet duct 22 via welding or other suitable attachment means. Each of the secondary vanes 54 are situated between the primary vanes 48 such that the vanes 48 and 54 alternate about the circumference of the inner surfaces 50 of the walls 52 of the inlet duct 22 . Both the primary vanes 48 and the secondary vanes 54 are in the path of the exhaust fluid 26 flow.
[0042] The vanes 48 have top edges 56 that are in misalignment with bottom edges 58 thereof, and vanes 54 have upper edges 60 that are in misalignment with lower edges 62 thereof. This misalignment is with reference to the direction of fluid flow 64 passing through the muffler 10 during the acceleration phase of engine operation (or longitudinally with reference to the casing 12 ).
[0043] The primary vanes 48 are situated so that the bottom edges 58 are flush with the discharge end edge 29 of the inlet duct 22 . However, the secondary vanes 54 are medially situated on the walls 52 . Thus, the lower edges 62 are not flush with the discharge end edge 29 of the inlet duct 22 .
[0044] The primary vanes 48 thus are preferably oriented at an angle such that the flat planar outer surfaces 66 thereof face the fluid flow 64 . The secondary vanes 54 are similarly oriented at an angle such that the flat planar outer surfaces 68 thereof face the fluid flow 64 . The fluid flow 64 impinging on the surfaces 66 and the surfaces 68 thus is deflected laterally. The vanes 48 and 54 are preferably oriented at an angle of twenty-five degrees with reference to the axis 70 of the casing 12 . More specifically, the angular orientation of the vanes 48 is with reference to a plane which includes the axis 70 and the top edge 56 of the particular vane 48 . This orientation is with reference to a line or plane which connects the top edges 56 and bottom edges 58 of each particular vane 48 . Similarly, the angular orientation of the vanes 54 is with reference to a plane which includes the axis 70 and the upper edge 60 of the particular vane 54 . Since the axis 70 coincides with the direction of the fluid flow 64 , the angular orientation is also relative to the direction of fluid flow 64 entering the casing 12 . Furthermore, the vanes 48 and 54 are also oriented at an angle which is laterally clockwise from a vantage point of fluid flow 64 entering the inlet port 14 . Thus, this particular orientation of the vanes 48 and 54 deflects the fluid flow 64 laterally thereby essentially turning it and rotating it in a clockwise direction. This clockwise rotational movement of the fluid flow results in a spiral shaped movement of the fluid flow 64 that exits from the outlet end 28 .
[0045] The primary vanes 48 have main portions 72 , inner lower medial end vane portions 74 , outer lower medial end vane portions 76 , inner lower end vane portions 78 and outer lower end vane portions 80 which are all flat planar. Each of the main portions 72 are angled twelve degrees with reference to the plane of their respective top edges 56 and axis 70 . The lower medial end vane portions 74 and 76 are bent along bend lines 82 so that portions 74 and 76 are angled horizontally in a clockwise direction from the vantage point of the fluid flow entering the inlet port 14 with reference to the plane that includes the top edge 56 and the axis 70 (or direction of fluid flow 64 into the inlet port 14 ). Thus, the lower medial end vane portions 74 and 76 are oriented in the same direction as main portions 72 of vanes 48 . However, in addition to being angled twelve degrees with reference to their respective main portions 72 , these lower medial end vane portions 74 and 76 are angled in the same direction as the main portions 72 , as described in detail hereinabove. Similarly, the lower end vane portions 78 and 80 are bent along bend lines 84 and 86 respectively so that portions 78 and 80 are angled horizontally in a clockwise direction from the vantage point of the fluid flow entering the inlet port 14 with reference to the plane that includes the upper edge 60 and the axis 70 (or direction of fluid flow 64 into the inlet port 14 ). Thus, as with lower medial end vane portions 74 and 76 , the lower end vane portions 78 and 80 are oriented in the same direction as main portions 72 of vanes 48 . The lower end vane portions 78 and 80 are angled twelve degrees with reference to their respective lower medial end vane portions 74 as well as angled in the same direction as the main portions 72 . Thus, the fluid flow that has been defelected horizontally by the main portions 72 is further deflected horizontally by the lower medial end vane portions 74 and 76 and subsequently by the lower end vane portions 78 and 80 .
[0046] The fluid flow 64 which passes alongside the main portions 72 and thereby diverted from its previously solely longitudinal direction of movement into a horizontal direction acquires a certain degree of directional stability by the support provided by the angled main portions 72 . This directional stability of the fluid flow stream can be relatively easily changed by deflection via the lower medial end vane portion 74 and 76 and the lower end vane portions 78 and 80 in the same horizontal direction thereby increasing the degree of rotational movement imparted to the fluid flow 64 . The fluid flow 64 exiting the inlet duct 22 thus swirls to a greater degree due to the angled portions 74 , 76 , 78 and 80 than otherwise. Deflection of the fluid flow 64 successively in three steps is also more effective than simply angling the entire vane 48 at the same angular orientation as the lower end vane portions 78 and 80 . The bend line 86 is preferably perpendicular to the directional line of fluid flow 64 . The line 84 is preferably angled at a forty-five degree angle in the direction of fluid flow while the bend line 82 is preferably angled at a sixty degree angle in the direction of fluid flow 64 .
[0047] The vanes 48 are preferably interconnected at front or inner end portions 88 via interconnection members 90 . Vanes 48 are thus formed into pairs of vanes 48 . Interconnection members 90 are preferably laterally curved while longitudinally straight such that they are semi-cylindrical in shape. The interconnection members 90 are preferably located proximal to or more preferably adjacent to the central area 92 . The members 90 are preferably oriented at an angle of twenty-five degrees relative to the plane including the top edge 56 and the axis 70 , as with the vanes 48 and 54 . Since the interconnection members 90 interconnect the vanes 48 providing structural rigidity thereto, there is no need for a support structure at the center of the inlet duct 22 to attach the vanes 48 to and thereby provide structural support thereto. Consequently, the central area 92 of the inlet duct 22 is open allowing exhaust fluid 26 to pass freely therethrough. Since the center of the inlet duct 22 cannot pragmatically incorporate structures that can effectively provide swirl to the fluid flow, the lack of a central support structure does not reduce the swirl effect provided but instead minimizes fluid flow restriction of the inlet duct 22 .
[0048] The vanes 48 are preferably longitudinally longer at peripheral areas 94 of the inlet duct 22 than at the central area 92 . Thus, the rear end vane portions 96 are longer than the front end vane portions 98 . More specifically, the front end vane portions 98 are twenty-five percent of the length of the rear end vane portions 96 . Basically, this difference in length reduces the longitudinal length of the vanes 48 at the more central area where the vane 48 is less effective in producing swirl. In addition, front upper edges 99 of the vanes 48 are curved in the direction of fluid flow 64 and bottom edges 58 are also curved in the direction of fluid flow 64 . Edges 99 and 58 are curved toward each other into a converging direction so that the vanes 48 are substantially smaller at the central area 92 than at the peripheral area 94 . The front upper edges 99 and the top (or leading) edges 56 first meet the fluid flow 64 so the leading edge 56 is straight to provide larger vane 48 area at the peripheral area 94 where the vanes 48 can more effectively provide swirl while the front upper edge 99 is curved downwardly to provide smaller vane 48 surface area at the central area 94 where the vanes cannot relatively provide swirl.
[0049] The vanes 54 are preferably rectangular in shape. Vanes 54 are also preferably longitudinally shorter and laterally (or axially with reference to the casing 12 ) shorter than the vanes 48 .
[0050] The vanes 48 and 54 are preferably composed of stainless steel. However, other suitable materials may also be used. Similarly, the casing 12 is preferably composed of stainless steel. However, it may also be composed of galvanized steel or other suitable material.
[0051] Accordingly, there has been provided, in accordance with the invention, a muffler for preventing reverse flow of exhaust fluid therethrough and for swirling the fluid flow passing therethrough that fully satisfies the objectives set forth above. It is to be understood that all terms used herein are descriptive rather than limiting. Although the invention has been described in conjunction with the specific embodiment set forth above, many alternative embodiments, modification and variations will be apparent to those skilled in the art in light of the disclosure set forth herein. Accordingly, it is intended to include all such alternatives, embodiments, modifications and variations that fall within the spirit and scope of the invention set forth in the claims hereinbelow. | A muffler for an internal combustion engine has a casing forming an expansion chamber therein. An inlet duct is connected to the casing and projects into the expansion chamber and discharges exhaust fluid into the expansion chamber. The casing tapers in an upstream direction to form a pocket for receiving reverse flow of the exhaust gases and to minimize reverse flow from flowing back into the inlet duct in an upstream direction. In the discharge end of the inlet duct are a set of primary vanes and a set of secondary vanes. The vanes are secured to the walls of the duct and extend radially toward the central area of the duct. The vanes are angled in order to deflect the exhaust fluid flow into a swirling movement as it is discharged into the expansion chamber and maintains that swirling movement while passing out of the casing through the outlet duct. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The subject application is related to U.S. application Ser. No. 10/652,258, entitled “Relational Schema Format” filed Aug. 29, 2003 and U.S. application Ser. No. 10/652,214, entitled “Mapping Architecture for Arbitrary Data Models” filed on Aug. 29, 2003, the entireties of which are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates generally to computers and more particularly toward schema mappings and data persistence.
BACKGROUND
There are a plethora of different computer programming paradigms available today. Each paradigm has been optimized for use in its own particular problem space. However, the technological differences between models can present obstacles for user who wish to employ a plurality of different models in concert so as to leverage the benefits provided by each. For instance, object oriented programming employs of units of software called “objects” which encapsulate both data and functions. Object Oriented Programming (OOP) objects are software entities comprising data structures and operations on data. Together, these elements enable programmers to generate objects to model virtually any real-world entity in terms of its characteristics, represented by its data elements, and its behavior represented by its data manipulation functions.
The benefit of object technology arises out of three basic principles: encapsulation, polymorphism and inheritance. Objects hide or encapsulate the internal structure of their data and the algorithms by which their functions work. Instead of exposing these implementation details, objects present interfaces that represent their abstractions cleanly with no extraneous information. Polymorphism takes encapsulation one step further—the idea being many shapes, one interface. The third principle is inheritance, which allows developers to reuse pre-existing design and code. This capability allows developers to avoid creating software from scratch. Rather, through inheritance, developers derive subclasses that inherit behaviors, which the developer then customizes to meet particular needs.
The relational database model is a desirable choice of programmers for use in storing, retrieving and analyzing data. In contrast to the object oriented programming model, however, the fundamental units of operation for relational database management systems are tables. One of the significant benefits of relational databases is that they can store an extremely large quantity of data in part because data is not replicated. Furthermore, relational database are highly scalable and flexible. Additionally, relational database systems are advantageous in that they provide an easy way to analyze and retrieve large amounts of stored data. Relational database data can be analyzed utilizing structured query languages (SQL) to query data. Queries can be used to perform record retrieval and updates, perform calculations, append data to tables, or summarize data in one or more tables. Using queries, a user can specify the criteria for a search and then automatically sort and display all records matching the criteria.
Valuable software applications engage in data manipulation and processing. Accordingly, data needs to be stored somewhere to allow the data to survive the termination of the applications and/or computer shut down. This can be accomplished in a myriad of different ways such as storing data to text files, XML files or other data containers. Such storage can easily be accomplished by serializing objects and writing them to files. However, when applications deal with huge amounts of data there is a need to store data in databases such as a relational database to take advantage of the high performance query operations and consistency in data, among other things. Otherwise, an application would have to search through thousands of entries, in a file for instance, before retrieving desired information. Nevertheless, applications are most often written employing an object-oriented model while databases typically utilize the relational model. Hence, a mapping needs to be developed to provide translation from the object oriented model to the relational model and back from the relational model to the object oriented model. Conventionally, it is a developer's job to develop such a single map between the two worlds. Unfortunately, developing such a mapping component is a complex, time consuming, and error prone task.
Accordingly, there is a need in the art for a system and method to facilitate mapping between disparate domain models such as an object oriented programming model and a relational database model.
SUMMARY
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
The present invention discloses an object schema component. The object schema provides a mechanism for providing a bridge between a transient graph of objects and a related persistent data store. In particular, the object schema provides metadata describing a given set of classes in addition to a program assembly containing type definitions. The metadata can subsequently be utilized by a mapping system to translate relational data to and from user objects during a materialization or persistence process. According to one particular aspect of the present invention, the object schema is defined in a declarative manner in that it is specified as information external to programming logic. By providing this information outside of a users type definitions, the schema can be deployed independently of an associated application thereby allowing persistence storage of objects to change without forcing a user to recompile and redeploy application code.
According to another aspect of the present invention, the object schema can define classes that describe persistent objects. The object schema can also describe or define members associated with one or more classes, wherein a member can include a field or properties of a class. Furthermore, relationships between classes can be described and defined by the object schema. The object schema can also include a plurality of specifiable attributes to assist in describing classes, members, and relationships amongst them. In addition, such attributes can be utilized or specified solely to facilitate querying of an object data source.
According to another aspect of the invention, the object schema is one of three distinct schemas utilized to map objects to a relational data store, for example. A mapping system can employ an object schema, a relational schema and a mapping schema. The object schema can contain definitions of classes, members, and relationships between objects from an object oriented model. The relational schema can provide information regarding tables and fields amongst tables relating to a relational data model. Finally, the mapping schema can utilize references to both the object schema and the relational schema to provide a mapping there between.
According to still another aspect of the present invention, a schema generation system is disclosed to automatically generate an object schema from provided object code. More specifically, the system can retrieve object data from a provided application and provide it to a generation component. The generation component can subsequently utilize information concerning a corresponding relational model and object information to produce an object schema.
According to yet another aspect of the present invention a graphical user interface can be utilized to generate an object schema. A free form user interface can be provided including a plurality of graphical objects and components (e.g., buttons, tabs, text boxes, check boxes, menus . . . ) that a developer can utilize to easily specify metadata concerning objects and thereby produce an object schema. Additionally or alternatively, a wizard can be employed to guide a developer through construction of a schema from a given object program.
To the accomplishment of the foregoing and related ends, certain illustrative aspects of the invention are described herein in connection with the following description and the annexed drawings. These aspects are indicative of various ways in which the invention may be practiced, all of which are intended to be covered by the present invention. Other advantages and novel features of the invention may become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other aspects of the invention will become apparent from the following detailed description and the appended drawings described in brief hereinafter.
FIG. 1 is a schematic block diagram of an object schema data structure in accordance with an aspect of the present invention.
FIG. 2 is a schematic block diagram of a mapping system in accordance with an aspect of the present invention.
FIG. 3 is a schematic block diagram of a class structure in accordance with an aspect of the subject invention.
FIG. 4 is a schematic block diagram of a member structure in accordance with an aspect of the present invention.
FIG. 5 is a schematic block diagram of a compound member structure in accordance with an aspect of the subject invention.
FIG. 6 is a schematic block diagram of a relationship structure in accordance with an aspect of the subject invention.
FIG. 7 is a schematic block diagram of an object schema generation system in accordance with an aspect of the subject invention.
FIG. 8 is a schematic block diagram or an object schema generation system in accordance with an aspect of the present invention.
FIG. 9 is an exemplary graphical user interface that can be utilized in conjunction with an object generation system in accordance with an aspect of the subject invention.
FIG. 10 is an exemplary graphical user interface that can be utilized in conjunction with an object generation system in accordance with an aspect of the present invention.
FIG. 11 is an exemplary graphical user interface that can be utilized in conjunction with an object generation system in accordance with an aspect of the subject invention.
FIG. 12 is a flow chart diagram of a schema generation methodology in accordance with an aspect of the present invention.
FIG. 13 is a flow chart diagram of a schema generation methodology in accordance with an aspect of the subject invention.
FIG. 14 is a schematic block diagram illustrating a suitable operating environment in accordance with an aspect of the present invention.
DETAILED DESCRIPTION
The present invention is now described with reference to the annexed drawings, wherein like numerals refer to like elements throughout. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed. Rather, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention.
As used in this application, the terms “component” and “system” are intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a server and the server can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers.
Furthermore, the present invention may be implemented as a method, apparatus, or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof. The term “article of manufacture” (or alternatively, “computer program product”) as used herein is intended to encompass a computer program accessible from any computer-readable device, carrier, or media. For example, a computer readable media can include but are not limited to magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips . . . ), optical disks (e.g., compact disk (CD), digital versatile disk (DVD) . . . ), smart cards, and flash memory devices (e.g., card, stick). Of course, those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope or spirit of the subject invention.
Turning to FIG. 1 , an object schema data structure 100 is illustrated in accordance with an aspect of the present invention. An object schema data structure 100 provides persistent metadata information related to types (e.g., common language runtime (CLR) types), essentially the schema provides additional information on top of type system information supplied by a language platform. In particular, an object schema data structure 100 is a prescriptive definition of persistent objects including their relationships. The object schema data structure 100 can be one of three schemas utilized to facilitate mapping object components to relational components, for example, as described in further detail in later sections. It is to be appreciated, however, that the object schema is not limited to mapping to relational data sources. In fact, one benefit of utilizing three logical parts to the mapping is that the ends can be replaced. Object schema 100 comprises class structure(s) 110 , member structure(s) 112 , and a relationship structure 114 . Class structure(s) 110 describe programmatic objects. Member structure(s) 112 describe members of a class. Members of a class can include but are not limited to fields and properties. Together the class structure(s) 110 and associated member structure(s) 112 define a persistent view for objects. Additionally, object schema 100 includes a relationship structure 114 . Relationship structure 114 defines relationships between types, such as parent-child relationships, for example. The object schema data component can be provided in any format, however according to an aspect of the invention the schema can be written utilizing an extensible markup language (XML). The use of XML is advantageous in the present invention at least in part because it is easy to read and generate manually. Additionally, XML is flexible and widely known. The following is an exemplary object schema in accordance with an aspect of the subject invention:
<osd:ExtendedObjectSchema Name=“MyObjectSchema” xmlns:osd=“http://schemas.microsoft.com/data/2002/09/20/persistenceschema”> <osd:Classes> <osd:Class Name=“ObjectSpacesDemo.Data.Customer”> <osd:Member Name=“Id” Key=“true” KeyType=“AutoIncrement” /> <osd:Member Name=“Name” /> <osd:Member Name=“Address” /> <osd:Member Name=“City” /> <osd:Member Name=“Telephone” /> <osd:Member Name=“Invoices” /> </osd:Class> <osd:Class Name=“ObjectSpacesDemo.Data.Invoice”> <osd:Member Name=“Id” Key=“true” KeyType=“AutoIncrement” /> <osd:Member Name=“Product” /> <osd:Member Name=“Amount” /> <osd:Member Name=“Price” /> <osd:Member Name=“Customer” /> </osd:Class> </osd:Classes> <osd:ObjectRelationships> <osd:ObjectRelationship Name=“CustomerInvoices” Type=“OneToMany” ParentClass=“ObjectSpacesDemo.Data.Customer” ParentMember=“Invoices” ChildClass=“ObjectSpacesDemo.Data.Invoice” ChildMember=“Customer”/> </osd:ObjectRelationships> </osd:ExtendedObjectSchema>
The above object schema comprises metadata, which describes the following programmatic class definitions:
namespace ObjectSpacesDemo.Data {
public class Customer
{
long _id;
string _name;
string _address;
string _city;
string _telephone;
System.Collections.ArrayList _invoices;
public long Id
{
get
{return _id; }
set {_id = value; } }
public string Name
{
get
{ return _name; }
set
{_name = value; } }
public string Address
{
get
{ return _address; }
set
{ _address = value; } }
public string City
{
get
{ return _city; }
set
{ _city = value; } }
public string Telephone
{
get
{ return _telephone; }
set
{ _telephone = value; } }
public System.Collections.ArrayList Invoices
{ get { return _invoices; }
set
{ _invoices = value; } }
public Customer( ) {
_invoices = new System.Collections.ArrayList( ); }
}
public class Invoice
{
long _id;
string _product;
long _amount;
long _price;
Customer _customer;
public long Id
{
get
{ return _id; }
set
{ _id = value; } }
public string Product
{
get
{ return _product; }
set
{ _product = value; } }
public long Amount
{
get
{ return _amount; }
set
{ _amount = value; } }
public long Price
{
get
{ return _price; }
set
{ _price = value; } }
public Customer Customer
{
get
{ return _customer; }
set
{ _customer = value; } }
public Invoice( ) {}
}
Turning to FIG. 2 , a system 200 for mapping object components to relational components is described. The object schema 100 ( FIG. 1 ) of the present invention provides one portion of a three-part mapping. System 200 includes object component(s) 210 , mapping component 220 , relational component(s) 230 , mapping schema component 240 , relational schema component 250 , and object schema component 100 . Object component(s) 210 represent user programmatic structures for example as specified in an object oriented programming language (e.g., C++, C# . . . ). Relational component(s) 230 correspond to tables in a relational model. Mapping component 220 resides between object component(s) 210 and relational component(s) 230 and provides a mapping or bridge between the two disparate models (e.g., mapping data object fields to appropriate tables and rows). To provide such mappings, mapping component 220 utilizes three schema components, an object schema 100 , a mapping schema 240 and a relational schema 250 . The object schema component 100 , as described herein, describes data classes as well as relations there between as specified in an object-oriented model, for example. Relational schema component 250 contains information describing tables and associated data records in a relational database model, for instance. Stated differently, the relational schema component 250 can utilize metadata associated with a database to generate an implementation neutral or implementation specific format that represents the precise database structure and data. Further information regarding the relational schema component 250 can be found in U.S. application Ser. No. 10/652,258, entitled “Relational Schema Format” filed Aug. 29, 2003 which is incorporated herein by reference. Mapping schema component 240 provides the mapping between the object schema 100 and the relational schema 250 . Further information concerning the mapping schemas component 240 can be found in U.S. application Ser. No. 10/652,214, entitled “Mapping Architecture for Arbitrary Data Models” filed Aug. 29, 2003, which is incorporated herein by reference. The disclosed system 200 is advantageous at least in that applications do not need to be rebuilt and redeployed if the manner in which data is persisted changes, for example if table names change or tables are broke up into smaller tables. Rather the appropriate schema components can be easily modified to effectuate such alternations. It should also be appreciated and noted that mapping component 220 can support basic functionality on object data such as create, read, update, and delete. To provide for such functionality the mapping component can facilitate object data querying. Querying relational data is quite simply-just utilize a structured query language (SQL). However, querying an object data source is somewhat different. In fact, a special language can be employed to query object data sources (e.g., OPath). Accordingly, the object schema can also supply metadata that relates to supporting querying of an object data source.
Turning to FIG. 3 , a class structure 110 is depicted in further detail in accordance with an aspect of the present invention. Class structure 110 can comprise a plurality of attributes including but not limited to name 310 , base class 320 , persistence service class 330 , persistence service assembly 340 , and paths 350 . The name attribute 310 provides a string representative of the name of the class. When necessary this can be a fully qualified name, for example to distinguish between two customer classes defined in different namespaces. Base class 320 provides the name of a base class for instance when inheritance is used as part of the schema description. Persistence service class 330 can provide the name of a persistence service to use when persisting a particular class with which this attribute is associated. If not specified, a default persistence service can be employed. Persistence service assembly attribute 240 can provide the name of an assembly or other group of files that contains a user defined persistence service class. Paths 350 can be an optional attribute that is utilized as an identifier in different contexts in a given object graph. For example, in a sample containment hierarchy, Customer/Address and Employee/Address are the same underlying address type but may have different mappings. The paths specified by the path attribute 350 can be indicated via unique opaque strings for each context of a given class. In order to not introduce a path attribute 350 on every object schema element that refers to a class, any string that refers to a path can combine the path and the class name by delimiting the two via the “/” delimiter, or the like. In a given string the last delimiter separates the path from the class name. The paths attribute 350 can be utilized in at least two scenarios. First, the path attribute 350 can be used when a user defines a single class definition for different contexts, but requires the ability to map to each context. For example:
<osd:Class Name=“Address” Paths=“Company/Customer Company/Employee”> ... </osd:Class> ... <osd:ObjectRelationship Name=“Customer_Address” ParentClass=“Company/Customer” ChildClass=“Company/Customer/Address”.../> ...
Paths attribute 350 can also be employed when multiple class definitions are needed in addition to multiple maps. For instance:
<osd:Class Name=“Address” Paths=“Company/Customer”> <osd:Member Name=“id”> <osd:Member Name=“Bar”> </osd:Class> <osd:Class Name=“Address” Paths=“Company/Employee> <osd:Member Name=“id”> <osd:Member Name=“Foo”> </osd:Class> ... <osd:ObjectRelationship Name=“Customer_Address” ParentClass=“Company/Customer” ChildClass=“Compay/Customer/Address”.../> ...
Thus for either of the two different representations a mapping schema component 240 ( FIG. 2 ) can be defined which can map to different contexts. For example:
<m:Map Source=“C_Addresses”
Target=“Company/Customer/Address”>
...
</m:Map>
<m:Map Source =“E_Addresses”
Target=“Company/Employee/Address”>
...
</m:Map>
FIG. 4 illustrates a member structure 112 in further detail in accordance with an aspect of the subject invention. As depicted, the member structure 112 can include a plurality of attributes including but not limited to name 410 , hidden 412 , key 414 , key type 416 , key generator 418 , key generator parameter 420 , alias 422 , type 424 , array length 426 , and search inheritance hierarchy 428 . Name attribute 410 can be a string representing the name of a member (e.g., field, property). Hidden attribute 412 can be a Boolean value defining if there is a hidden member such as a field in a corresponding class. More specifically, hidden attribute 412 can represent whether or not there is a member in the corresponding type. If there is not a member in the corresponding type, then that the value needs to be maintain out of band of the runtime object. Hidden 412 can be employed for implicitly managed keys as well as time stamp and row version properties. Users don't want to complicate their object model with such properties, so they can be hidden members. The present invention provides for hidden member storage and manages them in a transparent fashion. Users can choose to expose hidden members in the object model if they so desire by setting hidden=“false” or by not utilizing the hidden attribute. Key 414 is a Boolean attribute that defines weather the member associated therewith is part of an object key. If key 414 is not specified, false can be assumed. If key 414 is true and hidden 412 is false can indicate that key 414 is explicitly managed by user assigned values. It should be appreciated that it is possible to create a class that does not have a key defined and does not inherit from a class that has a key defined in the appropriate format. Such a class can be considered “read-only” and can be materialized but not persisted. Key type 416 describes the kind of key supported (e.g., custom). Key type 416 can be required if hidden 412 and key 414 are true. Key generator attribute 418 names the user class that will act as a custom key generator. Key generator parameter 420 can be utilized to pass parameters to the key generator (e.g., to the initialize function of the generator). Alias 422 provides a name of a member that can be utilized as an alias to the member with which this attribute is associated. This can be employed in queries. For example, alias 422 can be employed by a query language to identify the private member to use to generate a query. Its value points to a public member that can be utilized instead of the associated private member in the text of a query. Type 424 is an attribute that identifies the type of a member. This can be utilized to override the type specified in a parent type's definition. Array length 426 is utilized when a member stands for an array. Array length 426 is an integer that designates the length of the corresponding array. This attribute can be used in mapping validation. For example assuming a class account is defined as
Class Account { int id; string[] segments; } and a table represents accounts as Accounts (ID, SEGMENT1, SEGMENT2, SEGMENT3), then the object schema can be specified as follows: <osd:Class Name=“OrderLine”> <osd:Member Name=“id”> <osd:Member Name=“segments” ArrayLength=“3” Type=“System.String”> </osd:Class>
Search inheritance hierarchy 428 is a Boolean flag that tells a search system to search the inheritance hierarchy for a private member. If the value is false, private members in base classes will not be searched for unless the base type is also a persistent type defined by the object schema. For example, if the object models is specifies
Public abstract class CompanyBase { //Fields private string name; } public abstract class Company : CompanyBase { //Fields private string id; } then the an object schema relationship can be specified as follows: <osd:Class Name=”Company”> <osd:Member Name = “id” Key=”true”> <osd:Member Name = “name” SearchInheritanceHierarchy=”true”> </osd:Class>
It should be noted that in this example CompanyBase is not a persistent type, so it is not in the identified in the schema.
Member structure(s) 112 can also comprise compound members. Compound members allow mapping of complex members as inline members of a given class. For instance, this can allow inline mapping of arrays, structs, and entity key members. Each compound member can contain members or other compound members. Turing to FIG. 5 , a compound member 500 is depicted in accordance with an aspect of the subject invention. Compound member can include attributes such as name 510 , key 520 , type 530 , array length 540 , and search inheritance hierarchy 540 . Name attribute 510 specifies the name of the member (e.g., field, property . . . ) to which a compound member maps. Key 520 is a Boolean value that defines whether a compound member is part of an object key. If key 520 is not specified, then false can be assumed. A key 520 being true means all sub-members of compound members are part of a key. If compound member is a key its sub-members key types can define a key generation scheme. Type 530 specifies the type of a member. It stands for an element type in case the compound member is an array. Where reflection cannot provide the type intended for a member, the type attribute 530 is mandatory. Array length 540 can be provided as an attribute if the compound member is an array. Array length 540 specifies that a member is a fixed length array with the length specified. Furthermore, this attribute can be utilized in mapping validation. Search inheritance hierarchy is a Boolean flag, which can be employed by a user to specify that private members in an inheritance hierarchy can be searched. For purposes of clarity and understanding, the following is an exemplary compound member that can be a part of an object schema in accordance with the present invention. The example illustrates a class with a member and a compound member with a member and compound member embedded within a compound member.
<osd: Class Name=“Foo”> <osd:Member Name=“id”/> <osd:CompoundMember Name=“Bar” Type=“Foo+Bar”> <osd:Member Name=“id”/> <osd:CompoundMember Name=“Bar2” Type=“Foo+Bar+Bar2”> <osd:Member Name=“a”/> <osd:Member Name=“b”/> </osd:CompoundMember> </osd:CompoundMember> </osd:Class>
An inline class (struct) can define a function within a class. An inline class can be represented as a compound member. For example assume the object model is specified as follows:
Class OrderLine { int id; Quantity q1; } struct Quantity { int unit; float value; }
This inline class and associated function can be represented in an object schema as follows:
<osd:Class Name=“OrderLine”>
<osd:Member Name=“id”>
<osd:CompoundMember Name=“q1”>
<osd:Member Name=“unit”/>
<osd:Member Name=“value”/>
</osd:CompoundMember>
</osd:Class>
Turning to FIG. 6 , a relation structure 114 is illustrated in accordance with an aspect of the present invention. Relation structure 114 can be utilized to specify relationships amongst objects or classes. Relation structure 114 can comprise a plurality of attributes utilized to describe object relationships including but not limited to name 610 , type 612 , parent class 614 , child class 616 , parent member 618 , child member 620 , composition 622 , parent cardinality 624 , child cardinality 626 , and default span 628 . Name attribute 610 specifies a unique name identifying a relationship (e.g., customer invoice, customer order . . . ). Type 612 can be used to identify a predefined relationship (e.g., one-to-one, one-to-many, many-to-many . . . ). Parent class 614 identifies the parent class in a relationship, while child class 616 identifies the child class in the relationship. Parent member 618 is an optional attribute that specifies the name of a parent class' member that is related. Child member 620 is an optional attribute that names a child class' member that is related. Composition 622 is a Boolean value that defines whether or not a relationship is a composition. If not specified, composition 622 can be assumed to be false. Parent cardinality 624 is an optional attribute that defines parent cardinality for a relationship. Child cardinality 626 is an optional attribute, which specifies child cardinality for a relationship. Both parent cardinality 624 and child cardinality 626 can have values corresponding to one, zero or more, or many. Finally, a relation structure 114 can include a default span optional attribute 628 . Default span 628 defines the default span for a relationship and can include values such as parent-to-child, child-to-parent, and both sides. If a value is parent-to-child this means that when the parent type is loaded, the child side will be loaded by default. A value of child-to-parent indicates that when the child side is loaded, the parent side will be loaded by default. If the value is both sides then when either side (e.g., parent or child) is loaded, the other side will be loaded by default. To further appreciate the use of some of the above described attributes the following sample object schema is provided:
<ExtendedObjectSchema Name=“northwindOBJ” xmlns=http://schemas.microsoft.com/data/2002/09/20/extendedobjectschema> <Classes> <Class Name=“Customer”> <Member Name=“customerId” Key=“true”/> <Member Name=“contactName” /> <Member Name=“contactTitle” /> <Member Name=“companyName” /> <Member Name=“address” /> <Member Name=“city” /> <Member Name=“region” /> <Member Name=“postalCode” /> <Member Name=“phone” /> <Member Name=“fax” /> <Member Name=“myOrders” /> </Class> <Class Name=“Order”> <Member Name=“orderId” Key=“true”/> <Member Name=“orderDate”/> <Member Name=“requiredDate”/> <Member Name=“shippedDate”/> <Member Name=“freight”/> <Member Name=“my Customer”/> </Class> </Classes> <ObjectRelationships> <ObjectRelationship Name=“CustomerOrder” Type=“OneToMany” ParentClass=“Customer” ChildClass=“Order” ParentMember=“myOrders” ChildMember=“myCustomer”/> </ObjectRelationships> </ExtendedObjectSchema>
This object schema sets forth two classes: customer and order. The object relationship attributes indicated that the relationship name is CustomerOrder and the type of relationship is OneToMany. A one-to-many relationship indicates that one object class is associated with more than one other object class. Here, each customer can be associated with a plurality of orders. Accordingly, parent class is set to customer and child class to order. Furthermore, parent member is associated with the myOrders field in the parent class and child member is associated with the myCustomer field of the child class.
It should be appreciated that what has been described thus far are exemplary object schemas and portions thereof. The present invention contemplates multiple different types of object schemas specified in different languages (e.g., other than XML) with more, less, and/or different attributes associated therewith. The provided object schemas and description thereof have been supplied for purpose of clearly describing various aspects of the subject invention and are not meant to limit the scope of the present invention in any way.
Turning to FIG. 7 , a system object schema generation system 700 is depicted in accordance with an aspect of the subject invention. Object schema generation system includes code reader component 710 , object schema generator component 720 and data store information component 730 . Code reader component 710 is adapted to read and/or retrieve information from a particular program or group of programs. According to an aspect of the invention the program is an object-oriented program. The program can describe objects via classes and class members. The code reader component 710 can provide the retrieved code to the schema generation component 720 . For example, code can be provided in real time, as it is being read or transferred en masse upon complete reading of the code. Code generation component 720 can subsequently utilize the code provided by the code reader component 710 to produce a schema. The schema provides metadata concerning objects and their relationships beyond that provided by the type system of the code language. The code generation component 720 can generate classes and members of classes to represent specified objects. The code generation component can also generate a relationships section to define the relations amongst classes and members. Classes, members of classes and relationships are all provided to facilitate persistence to a data store. The data store can be a relational database, for example. In accordance with an aspect of the subject invention the code generation component can generate the object schema in an extendible markup language (XML). Furthermore, data base information component 730 can be utilized by the generation component 720 to develop a schema. Information component 730 provides information concerning the data store to which data is to be persisted thereby facilitating production of an appropriate object schema. It should be appreciated that schema generation component 720 can employ a myriad of methodologies and technologies to produce a schema. According to one aspect of the subject invention, generation component 720 can employ artificial intelligence technologies to generate a schema from provided code. For example, the generation component 720 could utilize a rule-based system to provide the heuristics necessary to build a schema. Furthermore, the subject invention also contemplates employment of statistical methodologies (e.g., neural networks, Bayesian networks . . . ) to infer the proper schema structure from the provided code.
In accordance with the present invention an object schema can be written by hand by a developer, automatically generated, or generated by a developer with the help of a graphical user interface or wizard, for example. Turning to FIG. 8 , a system 800 for generating an object schema is depicted in accordance with an aspect of the present invention. System 800 comprises an interface component 810 and a schema generator component 820 . Interface component 810 receives input from users, such as a developer. Furthermore, the interface component 810 can also receive a program such as an object-oriented program as input. The interface component 810 can be a graphical user interface containing a plurality of graphical components that facilitate generation of a schema including but not limited to a buttons, text boxes, drop-down menus, tabs, hyperlinks, check boxes, and scroll bars. A user can then interact with the interface component utilizing input devices such as a keyboard and/or a pointing device (e.g., touch pad, touch screen, stylus, mouse, track ball . . . ). The interface component 810 can be a free form tool for use by a developer or a wizard that specifies a series of steps, wherein each step must be completed before a user is allowed to advance to the next step in the series. The schema generator component 820 receives and/or retrieves information from the interface component 810 . Subsequently and/or concurrently therewith, the generator component 820 can produce a schema in accordance with the data provided by the interface component 810 . In accordance with an aspect of the subject invention the generator can produce an XML schema describing declared objects and their relations as specified in an object oriented programming language, for example. Furthermore, it is to be appreciated that generator component 820 can utilize adaptive artificial intelligence technologies (e.g., expert systems, Bayesian networks, neural networks . . . ) to further facilitate development of a schema.
FIGS. 9-10 illustrate various aspects of an exemplary graphical user interface that can be employed in accordance with the subject invention. Turning first to FIG. 9 , a graphical user interface 900 is illustrated in accordance with an aspect of the subject invention. Interface component 900 includes a myriad of different graphical components to facilitate specification of a schema. Selectable tabs 910 provide a means for selecting amongst a plurality of schema structure categories including assembly, classes, inheritance, members, hidden members, keys, aliases, and relationships. Here, tab 912 has been selected corresponding to classes. Text box or window 914 is provided to facilitate interaction with class components. In particular, the text box 914 allows a user or developer to select classes to be persisted by checking the classes off using a check box 916 . Classes associated with a program can be automatically revealed in text box 914 for selection, by providing the program as input into the interface. However, text box 914 can just as easily provide an editable space for manually inputting classes to be persisted. Tabs 918 can provide a mechanism for switching between the schema builder components and the produced object schema, here in XML. Finally, buttons 920 can be provided to save the generated schema and/or close out of the builder interface.
FIG. 10 illustrates a graphical user interface 1000 that can be utilized in conjunction with a schema generation system or builder in accordance with an aspect of the subject invention. In particular, graphical user interface 1000 includes selectable tabs 910 . Here, the tab 1010 associated with schema keys has been selected. Accordingly, a text box 1012 can be provided for locating member keys. Specifically, a hierarchical expandable tree 1014 can be utilized for displaying classes 1016 to be persisted and their associated members 1018 . A developer can select a class with a “+” sign utilizing a pointing device or a keyboard to view class members. The member can be selected as a key by selecting a check box associated with and located proximate to the member. A developer can also select a class with a “−” sign to collapse the tree and remove the members associated with the class from view. Furthermore, drop down menu 1020 can be utilized to select a key type or text box 1022 can be employed to specify a key generator parameter. As with the GUI 900 , tabs 918 can be used to selectively view either the interface builder components or the actual schema being generated by the interface. Buttons 920 can be employed to save the current schema and close out of the interface.
FIG. 11 depicts an exemplary graphical user interface 1100 in accordance with an aspect of the subject invention. Interface 1100 includes selectable tabs 910 . The present interface illustrates the selection of relationship tab 1110 . Text box 1112 displays the name of defined relationships. A user or developer can employ button 1114 to add a new relationship or button 1116 to delete a previously defined relationship. To define a new relationship text boxes and drop down menus 1118 - 1128 can be utilized. Text box 1118 can be utilized to receive the name of the relationship being defined. Drop down menu 1120 can be employed to define, via selection, the type of relationship (e.g., one-to-one, one-to-many, many-to-many . . . ). Drop down menu 1122 provides a mechanism for specifying a parent class while drop down menu 1124 provides a means to specify a child class. A developer can further indicate a parent member using drop down menu 1126 and a child member utilizing drop down menu 1128 . After a relationship has been completely specified, it can be added by selecting button 1114 . Additionally, a developer can switch between interface components and the schema as coded by a interface component utilizing tabs 918 . Finally, the interface can be closed and/or newly defined properties can be saved utilizing either of buttons 920 .
In view of the exemplary system(s) described supra, a methodology that may be implemented in accordance with the present invention will be better appreciated with reference to the flow charts of FIGS. 12-13 . While for purposes of simplicity of explanation, the methodology is shown and described as a series of blocks, it is to be understood and appreciated that the present invention is not limited by the order of the blocks, as some blocks may, in accordance with the present invention, occur in different orders and/or concurrently with other blocks from what is depicted and described herein. Moreover, not all illustrated blocks may be required to implement the methodology in accordance with the present invention.
Additionally, it should be further appreciated that the methodologies disclosed hereinafter and throughout this specification are capable of being stored on an article of manufacture to facilitate transporting and transferring such methodologies to computers. The term article of manufacture, as used, is intended to encompass a computer program accessible from any computer-readable device, carrier, or media.
FIG. 12 depicts a schema generation methodology 1200 in accordance with an aspect of the subject invention. At 1210 , the classes to be persisted to a data store are specified. Classes can correspond to types defined using an object oriented language such as C#, or other common language runtime (CLR) lanuages, for example. Furthermore, according to one aspect of the invention the data store can be a can be a relational database. At 1220 , members associated with each class to be persisted are identified. Members can include class fields and properties. Furthermore, members can be compound member s comprising at least one field or property and another compound member. Thus, a compound member can be an array. Still further yet, it should be appreciated that member attributes can also be specified. For example, a member can be identified as a key or a member can identify an alias. At 1230 , relationships between classes can be defined. For example, classes can be related in one-to-one, one-to-many or many-to-many fashion. Defining relationships amongst classes can include specifying a parent class and a child class, as well as specifying a member associated with the parent and a member associated with the child. According to an aspect of the invention, the classes, members, and relationship can all be specified utilizing XML file or document. This document can then be utilized together with a relational schema and a mapping schema to facilitate mapping objects to relation database tables to facilitate object persistence.
FIG. 13 illustrates a methodology 1300 for generating an object schema in accordance with an aspect of the subject invention. At 1310 , a program code is received which defines objects. Such program code can specified utilizing an object oriented programming language, for instance. At 1320 , developer input is received and/or retrieved. A developer can provide input utilizing a graphical user interface, for example. Such developer input can correspond to defining classes and members to be persisted to a database. Furthermore, a developer can utilize an interface to specify relationships amongst classes. At 1330 , object schema can be generated, for example, in XML format. The object schema can then be utilized in conjunction with a relational schema and a mapping schema to facilitate mapping objects to relational database tables, for example.
In order to provide a context for the various aspects of the invention, FIG. 14 as well as the following discussion are intended to provide a brief, general description of a suitable computing environment in which the various aspects of the present invention may be implemented. While the invention has been described above in the general context of computer-executable instructions of a computer program that runs on a computer and/or computers, those skilled in the art will recognize that the invention also may be implemented in combination with other program modules. Generally, program modules include routines, programs, components, data structures, etc. that perform particular tasks and/or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the inventive methods may be practiced with other computer system configurations, including single-processor or multiprocessor computer systems, mini-computing devices, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like. The illustrated aspects of the invention may also be practiced in distributed computing environments where task are performed by remote processing devices that are linked through a communications network. However, some, if not all aspects of the invention can be practiced on stand-alone computers. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
With reference to FIG. 14 , an exemplary environment 1410 for implementing various aspects of the invention includes a computer 1412 . The computer 1412 includes a processing unit 1414 , a system memory 1416 , and a system bus 1418 . The system bus 1418 couples system components including, but not limited to, the system memory 1416 to the processing unit 1414 . The processing unit 1414 can be any of various available processors. Dual microprocessors and other multiprocessor architectures also can be employed as the processing unit 1414 .
The system bus 1418 can be any of several types of bus structure(s) including the memory bus or memory controller, a peripheral bus or external bus, and/or a local bus using any variety of available bus architectures including, but not limited to, 11-bit bus, Industrial Standard Architecture (ISA), Micro-Channel Architecture (MSA), Extended ISA (EISA), Intelligent Drive Electronics (IDE), VESA Local Bus (VLB), Peripheral Component Interconnect (PCI), Universal Serial Bus (USB), Advanced Graphics Port (AGP), Personal Computer Memory Card International Association bus (PCMCIA), and Small Computer Systems Interface (SCSI).
The system memory 1416 includes volatile memory 1420 and nonvolatile memory 1422 . The basic input/output system (BIOS), containing the basic routines to transfer information between elements within the computer 1412 , such as during start-up, is stored in nonvolatile memory 1422 . By way of illustration, and not limitation, nonvolatile memory 1422 can include read only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable ROM (EEPROM), or flash memory. Volatile memory 1420 includes random access memory (RAM), which acts as external cache memory. By way of illustration and not limitation, RAM is available in many forms such as synchronous RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), enhanced SDRAM (ESDRAM), Synchlink DRAM (SLDRAM), and direct Rambus RAM (DRRAM).
Computer 1412 also includes removable/non-removable, volatile/non-volatile computer storage media. FIG. 14 illustrates, for example disk storage 1424 . Disk storage 4124 includes, but is not limited to, devices like a magnetic disk drive, floppy disk drive, tape drive, Jaz drive, Zip drive, LS-100 drive, flash memory card, or memory stick. In addition, disk storage 1424 can include storage media separately or in combination with other storage media including, but not limited to, an optical disk drive such as a compact disk ROM device (CD-ROM), CD recordable drive (CD-R Drive), CD rewritable drive (CD-RW Drive) or a digital versatile disk ROM drive (DVD-ROM). To facilitate connection of the disk storage devices 1424 to the system bus 1418 , a removable or non-removable interface is typically used such as interface 1426 .
It is to be appreciated that FIG. 14 describes software that acts as an intermediary between users and the basic computer resources described in suitable operating environment 1410 . Such software includes an operating system 1428 . Operating system 1428 , which can be stored on disk storage 1424 , acts to control and allocate resources of the computer system 1412 . System applications 1430 take advantage of the management of resources by operating system 1428 through program modules 1432 and program data 1434 stored either in system memory 1416 or on disk storage 1424 . Furthermore, it is to be appreciated that the present invention can be implemented with various operating systems or combinations of operating systems.
A user enters commands or information into the computer 1412 through input device(s) 1436 . Input devices 1436 include, but are not limited to, a pointing device such as a mouse, trackball, stylus, touch pad, touch screen, keyboard, microphone, joystick, game pad, satellite dish, scanner, TV tuner card, digital camera, digital video camera, web camera, and the like. These and other input devices connect to the processing unit 1414 through the system bus 1418 via interface port(s) 1438 . Interface port(s) 1438 include, for example, a serial port, a parallel port, a game port, and a universal serial bus (USB). Output device(s) 1440 use some of the same type of ports as input device(s) 1436 . Thus, for example, a USB port may be used to provide input to computer 1412 and to output information from computer 1412 to an output device 1440 . Output adapter 1442 is provided to illustrate that there are some output devices 1440 like monitors, speakers, and printers, among other output devices 1440 that require special adapters. The output adapters 1442 include, by way of illustration and not limitation, video and sound cards that provide a means of connection between the output device 1440 and the system bus 1418 . It should be noted that other devices and/or systems of devices provide both input and output capabilities such as remote computer(s) 1444 .
Computer 1412 can operate in a networked environment using logical connections to one or more remote computers, such as remote computer(s) 1444 . The remote computer(s) 1444 can be a personal computer, a server, a router, a network PC, a workstation, a microprocessor based appliance, a peer device or other common network node and the like, and typically includes many or all of the elements described relative to computer 1412 . For purposes of brevity, only a memory storage device 1446 is illustrated with remote computer(s) 1444 . Remote computer(s) 1444 is logically connected to computer 1412 through a network interface 1448 and then physically connected via communication connection 1450 . Network interface 1448 encompasses communication networks such as local-area networks (LAN) and wide-area networks (WAN). LAN technologies include Fiber Distributed Data Interface (FDDI), Copper Distributed Data Interface (CDDI), Ethernet/IEEE 802.3, Token Ring/IEEE 802.5 and the like. WAN technologies include, but are not limited to, point-to-point links, circuit switching networks like Integrated Services Digital Networks (ISDN) and variations thereon, packet switching networks, and Digital Subscriber Lines (DSL).
Communication connection(s) 1450 refers to the hardware/software employed to connect the network interface 1448 to the bus 1418 . While communication connection 1450 is shown for illustrative clarity inside computer 1412 , it can also be external to computer 1412 . The hardware/software necessary for connection to the network interface 1448 includes, for exemplary purposes only, internal and external technologies such as, modems including regular telephone grade modems, cable modems, DSL modems, power modems, ISDN adapters, and Ethernet cards.
What has been described above includes examples of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art may recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes or having” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. | The present invention relates to a system and methodology to facilitated data object persistence. An object schema is utilized to provide metadata for types in addition to what is provided by the type system for an underlying programming language. This metadata is then utilized by the system to translate data to and from user objects during a materialization or persistence process. The object schema provides information external to programming logic and type definitions. Consequently, the object schema can be deployed independent of an application thereby allowing the persistence storage of user objects to change without force the user to recompile and deploy application code. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to pyrrolidine sulfonamides, pharmaceutical compositions containing them, and their use as urotensin II antagonists
BACKGROUND OF THE INVENTION
[0002] The integrated control of cardiovascular homeostasis is achieved through a combination of both direct neuronal control and systemic neurohormonal activation. Although the resultant release of both contractile and relaxant factors is normally under stringent regulation, an aberration in this status quo can result in cardiohemodynamic dysfunction with pathological consequences.
[0003] The principal mammalian vasoactive factors that comprise this neurohumoral axis, namely angiotensin-II, endothelin-1, norepinephrine, all function via an interaction with specific G-protein coupled receptors (GPCR). Urotensin-II, represents a novel member of this neurohumoral axis.
[0004] In the fish, this peptide has significant hemodynamic and endocrine actions in diverse end-organ systems and tissues:
[0005] smooth muscle contraction
[0006] both vascular and non-vascular in origin including smooth muscle preparations from the gastrointestinal tract and genitourinary tract. Both pressor and depressor activity has been described upon systemic administration of exogenous peptide
[0007] osmoregulation:
[0008] effects which include the modulation of transepithelial ion (Na + , Cl − ) transport. Although a diuretic effect has been described, such an effect is postulated to be secondary to direct renovascular effects (elevated GFR)
[0009] metabolism:
[0010] urotensin-II influences prolactin secretion and exhibits a lipolytic effect in fish (activating triacylglycerol lipase resulting in the mobilization of non-esterified free fatty acids)
[0011] (Pearson, et. al. Proc. Natl. Acad. Sci . ( U.S.A .) 1980, 77, 5021; Conlon, et. al. J. Exp. Zool. 1996, 275, 226.)
[0012] In studies with human Urotensin-II it was found that it:
[0013] was an extremely potent and efficacious vasoconstrictor
[0014] exhibited sustained contractile activity that was extremely resistant to wash out
[0015] had detrimental effects on cardiac performance (myocardial contractility)
[0016] Human Urotensin-II was assessed for contractile activity in the rat-isolated aorta and was shown to be the most potent contractile agonist identified to date. Based on the in vitro pharmacology and in vivo hemodynamic profile of human Urotensin-II it plays a pathological role in cardiovascular diseases characterized by excessive or abnormal vasoconstriction and myocardial dysfunction. (Ames et. al. Nature 1999, 401, 282; Douglas & Ohlstein (2001). Trends Cardiovasc. Med., 10: in press). Compounds that antagonize the Urotensin-II receptor may be useful in the treatment of congestive heart failure, stroke, ischemic heart disease (angina, myocardial ischemia), cardiac arrhythmia, hypertension (essential and pulmonary), COPD, fibrosis (e.g. pulmonary fibrosis), restenosis, atherosclerosis, dyslipidemia, asthma, (Hay D W P, Luttmann M A, Douglas S A: 2000, Br J Pharmacol: 131; 10-12) neurogenic inflammation and metabolic vasculopathies all of which are characterized by abnormal vasoconstriction and/or myocardial dysfunction. Since U-II and GPR14 are both expressed within the mammalian CNS (Ames et. al. Nature 1999, 401, 282), they also may be useful in the treatment of addiction, schizophrenia, cognitive disorders/Alzheimers disease, (Gartlon J. Psychopharmacology (Berl) 2001 June; 155(4):426-33), impulsivity, anxiety, stress, depression, pain, migraine, and neuromuscular function. Functional U-II receptors are expressed in rhabdomyosarcomas cell lines and therefore may have oncological indications. Urotensin may also be implicated in various metabolic diseases such as diabetes (Ames et. al. Nature 1999, 401, 282, Nothacker et al., Nature Cell Biology 1: 383-385, 1999) and in various gastrointestinal disorders, bone, cartilage, and joint disorders (e.g. arthritis and osteoporosis); and genito-urinary disorders. Therefore, these compounds may be useful for the prevention (treatment) of gastric reflux, gastric motility and ulcers, arthritis, osteoporosis and urinary incontinence.
SUMMARY OF THE INVENTION
[0017] In one aspect this invention provides for pyrrolidine sulfonamides and pharmaceutical compositions containing them.
[0018] In a second aspect, this invention provides for the use of pyrrolidine sulfonamides as antagonists of urotensin II, and as inhibitors of urotensin II.
[0019] In another aspect, this invention provides for the use of pyrrolidine sulfonamides for treating conditions associated with urotensin II imbalance.
[0020] In yet another aspect, this invention provides for the use of pyrrolidine sulfonamides for the treatment of congestive heart failure, stroke, ischemic heart disease (angina, myocardial ischemia), cardiac arrhythmia, hypertension (essential and pulmonary), COPD, restenosis, asthma, neurogenic inflammation, migraine, metabolic vasculopathies, bone/cartilage/joint diseases, arthritis and other inflammatory diseases, fibrosis (e.g. pulmonary fibrosis), sepsis, atherosclerosis, dyslipidemia, addiction, schizophrenia, cognitive disorders/Alzheimers disease, impulsivity, anxiety, stress, depression, pain, neuromuscular function, diabetes, gastric reflux, gastric motility disorders, ulcers and genitourinary diseases.
[0021] The urotensin antagonist may be administered alone or in conjunction with one or more other therapeutic agents, said agents being selected from the group consisting of endothelin receptor antagonists, angiotensin converting enzyme (ACE) inhibitors, A-II receptor antagonists, vasopeptidase inhibitors, diuretics, digoxin, and dual non-selective β-adrenoceptor and α 1 -adrenoceptor antagonists.
[0022] Other aspects and advantages of the present invention are described further in the following detailed description of the preferred embodiments thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention provides for compounds of Formula (I):
[0024] wherein:
[0025] R 1 is phenyl, furanyl, thienyl, pyridyl, benzofuranyl, naphthyl, benzothiophenyl, benzimidazolyl, indolyl, or quinolinyl, substituted or unsubstituted with one, two or three halogen, C 1-6 alkyl, trifluoromethyl, C 1-6 alkoxy, or methylenedioxy groups;
[0026] X 1 and X 2 are hydrogen, halogen, C 1-6 alkyl, C 1-6 alkoxy, nitro, CF 3 , or CN;
[0027] n is 1, 2, or 3;
[0028] m is 1, 2 or 3;
[0029] or a pharmaceutically acceptable salt thereof.
[0030] When used herein, the term “alkyl” includes all straight chain and branched isomers. Representative examples thereof include methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, t-butyl, n-pentyl and n-hexyl.
[0031] When used herein, the terms ‘halogen’ and ‘halo’ include fluorine, chlorine, bromine and iodine and fluoro, chloro, bromo and iodo, respectively.
[0032] The compounds of the present invention may contain one or more asymmetric carbon atoms and may exist in racemic and optically active form. All of these compounds and their diastereoisomers are contemplated to be within the scope of the present invention.
[0033] Preferred compounds are those wherein:
[0034] m is 1 or 2;
[0035] n is 1, 2, or 3;
[0036] R 1 is phenyl, substituted or unsubstituted with one or two halogens;
[0037] X 1 is hydrogen, 3-bromo, or 3-chloro; and
[0038] X 2 is hydrogen or 5-chloro.
[0039] Preferred compounds are chosen from the group consisting of:
[0040] 3,4-Dichloro-N-{1-[4-(piperidin-4-yloxy)-benzenesulfonyl]-azepan-3-yl}-benzamide;
[0041] 3,4-Dichloro-N-{(R)-1-[3-chloro-4-(piperidin-4-yloxy)-benzenesulfonyl]-pyrrolidin-3-yl}-benzamide;
[0042] 3,4-Dichloro-N-{1-[3-chloro-(piperidin-4-yloxy)-benzenesulfonyl]-azepan-3-yl}-benzamide;
[0043] 3,4-Dichloro-N-{1-[3-chloro-(piperidin-4-yloxy)-benzenesulfonyl]-piperidin-4-yl}-benzamide;
[0044] N-{1-[3-Bromo-4-(piperidin-4-yloxy)-benzenesulfonyl]-azepan-3-yl}-3,4-dichloro-benzamide;
[0045] N-{1-[3-Bromo-4-(piperidin-4-yloxy)-benzenesulfonyl]-piperidin-4-yl}-3,4-dichloro-benzamide;
[0046] 3,4-Dichloro-N-{(S)-1-[3-chloro-4-(piperidin-4-yloxy)-benzenesulfonyl]-pyrrolidin-3-yl}-benzamide;
[0047] N-{(S)-1-[3-Bromo-4-(piperidin-4-yloxy)-benzenesulfonyl]-pyrrolidin-3-yl}-3,4-dichloro-benzamide;
[0048] N-{1-[3-Bromo-4-((S)-pyrrolidin-3-yloxy)-benzenesulfonyl]-piperidin-4-yl}-3,4-dichloro-benzamide; and
[0049] 3,4-Dichloro-N-{1-[3,5-dichloro-4-(piperidin-4-yloxy)-benzenesulfonyl]-piperidin-4-yl}-benzamide.
[0050] Compounds of Formula (I) may be prepared as shown in scheme 1.
[0051] Conditions: a) 2-nitrobenzenesulfonyl chloride, pyridine, CH 2 Cl 2 , 0° C.-rt; b) 4 M HCl in 1,4-dioxane, methanol, rt; c) 2,6-dimethoxy-4-polystyrenebenzyloxy-benzaldehyde (DMHB resin), Na(OAc) 3 BH, diisopropylethylamine, 1% acetic acid in 1-methyl-2-pyrrolidinone, rt; d) R 1 COOH, 1,3-diisopropylcarbodiimide, 1-hydroxy-7-azabenzotriazole, 1-methyl-2-pyrrolidinone, rt; e) K 2 CO 3 , PhSH, 1-methyl-2-pyrrolidinone, rt; f) (X 1 )(X 2 )-4-hydroxy-benzenesulfonyl chloride, 1,2-dichloroethane, 1-methyl-2-pyrrolidinone, rt; g) potassium trimethylsilanolate, tetrahydrofuran, rt; h) R 2 OH, diisopropyl azodicarboxylate, PPh 3 , tetrahydrofuran, −78° C.-rt; i) 50% trifluoroacetic acid in 1,2-dichloroethane, rt.
[0052] As shown in scheme 1, resin-bound amine 3 was prepared by reductive amination of 2,6-dimethoxy-4-polystyrenebenzyloxy-benzaldehyde (DMHB resin) with N-nosylated diamine HCl salt 2 which was prepared from (S)-pyrrolidin-3-yl-carbamic acid tert-butyl ester, (R)-pyrrolidin-3-yl-carbamic acid tert-butyl ester, azepan-4-yl-carbamic acid tert-butyl ester, or piperidin-4-yl carbamic acid tert-butyl ester (1). Reactions of resin-bound amine 3 with various benzoic acids resulted in the corresponding resin-bound amides 4. Amides 4 were treated with potassium carbonate and thiophenol to remove the protecting group and give secondary amines 5. Sulfonylation of resin-bound amines 5 with various hydroxy-benzenesulfonyl chlorides, followed by treatment with potassium trimethylsilanolate, produced resin-bound phenols 6. Phenols 6 were then reacted with various alcohols in the presence of triphenylphosphine and diisopropyl azodicarboxylate to give the corresponding resin-bound phenol ethers which were treated with 50% trifluoroacetic acid in 1,2-dichloroethane to afford targeted compounds 7.
[0053] With appropriate manipulation, including the use of alternative nitrogen protecting group(s), the synthesis of the remaining compounds of Formula (I) was accomplished by methods analogous to those above and to those described in the Experimental section.
[0054] In order to use a compound of the Formula (I) or a pharmaceutically acceptable salt thereof for the treatment of humans and other mammals it is normally formulated in accordance with standard pharmaceutical practice as a pharmaceutical composition.
[0055] Compounds of Formula (I) and their pharmaceutically acceptable salts may be administered in a, standard manner for the treatment of the indicated diseases, for example orally, parenterally, sub-lingually, transdermally, rectally, via inhalation or via buccal administration.
[0056] Compounds of Formula (I) and their pharmaceutically acceptable salts which are active when given orally can be formulated as syrups, tablets, capsules and lozenges. A syrup formulation will generally consist of a suspension or solution of the compound or salt in a liquid carrier for example, ethanol, peanut oil, olive oil, glycerine or water with a flavoring or coloring agent. Where the composition is in the form of a tablet, any pharmaceutical carrier routinely used for preparing solid formulations may be used. Examples of such carriers include magnesium stearate, terra alba, talc, gelatin, agar, pectin, acacia, stearic acid, starch, lactose and sucrose. Where the composition is in the form of a capsule, any routine encapsulation is suitable, for example using the aforementioned carriers in a hard gelatin capsule shell. Where the composition is in the form of a soft gelatin shell capsule any pharmaceutical carrier routinely used for preparing dispersions or suspensions may be considered, for example aqueous gums, celluloses, silicates or oils and are incorporated in a soft gelatin capsule shell.
[0057] Typical parenteral compositions consist of a solution or suspension of the compound or salt in a sterile aqueous or non-aqueous carrier optionally containing a parenterally acceptable oil, for example polyethylene glycol, polyvinylpyrrolidone, lecithin, arachis oil, or sesame oil.
[0058] Typical compositions for inhalation are in the form of a solution, suspension or emulsion that may be administered as a dry powder or in the form of an aerosol using a conventional propellant such as dichlorodifluoromethane or trichlorofluoromethane.
[0059] A typical suppository formulation comprises a compound of Formula (I) or a pharmaceutically acceptable salt thereof which is active when administered in this way, with a binding and/or lubricating agent, for example polymeric glycols, gelatins, cocoa-butter or other low melting vegetable waxes or fats or their synthetic analogues.
[0060] Typical transdermal formulations comprise a conventional aqueous or non-aqueous vehicle, for example a cream, ointment, lotion or paste or are in the form of a medicated plaster, patch or membrane.
[0061] Preferably the composition is in unit dosage form, for example a tablet, capsule or metered aerosol dose, so that the patient may administer to themselves a single dose.
[0062] Each dosage unit for oral administration contains suitably from 0.1 mg to 500 mg/Kg, and preferably from 1 mg to 100 mg/Kg, and each dosage unit for parenteral administration contains suitably from 0.1 mg to 100 mg, of a compound of Formula (I) or a pharmaceutically acceptable salt thereof calculated as the free acid. Each dosage unit for intranasal administration contains suitably 1-400 mg and preferably 10 to 200 mg per person. A topical formulation contains suitably 0.01 to 1.0% of a compound of Formula (I).
[0063] The daily dosage regimen for oral administration is suitably about 0.01 mg/Kg to 40 mg/Kg, of a compound of Formula (I) or a pharmaceutically acceptable salt thereof calculated as the free acid. The daily dosage regimen for parenteral administration is suitably about 0.001 mg/Kg to 40 mg/Kg, of a compound of the Formula (I) or a pharmaceutically acceptable salt thereof calculated as the free acid. The daily dosage regimen for intranasal administration and oral inhalation is suitably about 10 to about 500 mg/person. The active ingredient may be administered from 1 to 6 times a day, sufficient to exhibit the desired activity.
[0064] These sulphonamide analogs may be used for the treatment of congestive heart failure, stroke, ischemic heart disease (angina, myocardial ischemia), cardiac arrhythmia, hypertension (essential and pulmonary), COPD, restenosis, asthma, neurogenic inflammation and metabolic vasculopathies, addiction, schizophrenia, impulsivity, anxiety, stress, depression, neuromuscular function, and diabetes.
[0065] The urotensin antagonist may be administered alone or in conjunction with one or more other therapeutic agents, said agents being selected from the group consisting of endothelin receptor antagonists, angiotensin converting enzyme (ACE) inhibitors, vasopeptidase inhibitors, diuretics, digoxin, and dual non-selective β-adrenoceptor and α 1 -adrenoceptor antagonists.
[0066] No unacceptable toxicological effects are expected when compounds of the invention are administered in accordance with the present invention.
[0067] The biological activity of the compounds of Formula (I) are demonstrated by the following tests:
[0068] Radioligand Binding:
[0069] HEK-293 cell membranes containing stable cloned human and rat GPR-14 (20 ug/assay) were incubated with 200 pM [125I] h-U-II (200 Ci/mmol −1 in the presence of increasing concentrations of test compounds in DMSO (0.1 nM to 10 uM), in a final incubation volume of 200 ul (20 mM Tris-HCl, 5 mM MgCl2). Incubation was done for 30 minutes at room temperature followed by filtration GF/B filters with Brandel cell harvester. 125 I labeled U-II binding was quantitated by gamma counting. Nonspecific binding was defined by 125 I U-II binding in the presence of 100 nM of unlabeled human U-II. Analysis of the data was performed by nonlinear least square fitting.
[0070] Ca 2+ -mobilization:
[0071] A microtitre plate based Ca 2+ -mobilization FLIPR assay (Molecular Devices, Sunnyvale, Calif.) was used for the functional identification of the ligand activating HEK-293 cells expressing (stable) recombinant GPR-14. The day following transfection, cells were plated in a poly-D-lysine coated 96 well black/clear plates. After 18-24 hours the media was aspirated and Fluo 3AM-loaded cells were exposed to various concentrations (10 nM to 30 uM) of test compounds followed by h-U-II. After initiation of the assay, fluorescence was read every second for one minute and then every 3 seconds for the following one minute. The inhibitory concentration at 50% (IC50) was calculated for various test compounds.
[0072] Inositol Phosphates Assays:
[0073] HEK-293-GPR14 cells in T150 flask were prelabeled overnight with 1 uCi myo-[ 3 H] inositol per ml of inositol free Dulbecco's modified Eagel's medium. After labeling, the cells were washed twice with Dulbecco's phosphate-buffered saline (DPBS) and then incubated in DPBS containing 10 mM LiCl for 10 min at 37° C. The experiment was initiated by the addition of increasing concentrations of h-U-II (1 pM to 1 μM) in the absence and presence of three different concentrations (0.3, 1 and 10 uM) of test compounds and the incubation continued for an additional 5 min at 37° C. after which the reaction was terminated by the addition of 10% (final concentration) trichloroacetic acid and centrifugation. The supernatants were neutralized with 100 ul of 1M Trizma base and the inositol phosphates were separated on AG 1-X8 columns (0.8 ml packed, 100-200 mesh) in formate phase. Inositol monophosphate was eluted with 8 ml of 200 mM ammonium formate. Combined inositol di and tris phosphate was eluted with 4 ml of 1M ammonium formate/0.1 M formic acid. Eluted fractions were counted in beta scintillation counter. Based on shift from the control curve K B was calculated.
[0074] Activity for the compounds of this invention range from (radioligand binding assay): Ki=10 nM−10000 nM (example 5 Ki=1500 nM)
[0075] The following Examples are illustrative but not limiting embodiments of the present invention.
EXAMPLE 1
[0076] Preparation of 3,4-Dichloro-N-{(S)-1-[4-(Piperidin-4-yloxy)-benzenesulfonyl]-pyrrolidin-3-yl}-benzamide
[0077] a) (S)-1-(2-nitro-benzenesulfonyl)-pyrrolidin-3-ylamine HCl Salt
[0078] To a solution of (S)-pyrrolidin-3-yl-carbamic acid tert-butyl ester (20.00 g, 107 mmol) in 240 mL of anhydrous methylene chloride at 0° C. was added 13.03 mL (161 mmol) of anhydrous pyridine, followed by slow addition of 24.99 g (112.7 mmol) of 2-nitrobenzenesulfonyl chloride. The mixture was warmed to rt over 1 h and was stirred at rt for 19 h. The mixture was poured into 230 mL of 1 M aqueous NaHCO 3 solution. After the resulting mixture was stirred at rt for 30 min, the organic layer was separated and was washed with 175 mL of 1N aqueous HCl solution twice. The resulting organic layer was dried over MgSO 4 and concentrated in vacuo. The residue was used for the next step without further purification.
[0079] To a mixture of the above residue (33.19 g, 89 mmol) in 33 mL of anhydrous methanol and 33 mL of anhydrous 1,4-dioxane was added 133.5 mL (534 mmol) of 4 M HCl in 1,4-dioxane solution. The mixture was stirred at rt for 16 h, concentrated in vacuo, redissolved in methanol and concentrated in vacuo again. The residue was further dried in a vacuum oven at 35° C. for 24 h to yield (S)-1-(2-nitro-benzenesulfonyl)-pyrrolidin-3-ylamine HCl salt as a yellow solid (30.5 g, 92% over the two steps): 1 H NMR (400 MHz, d 6 -DMSO) δ 8.56 (s, 3H), 8.08-7.98 (m, 2H), 7.94-7.82 (m, 2H), 3.89-3.79 (m, 1H), 3.65-3.52 (m, 2H), 3.43-3.32 (m, 2H), 2.27-2.14 (m, 1H), 2.02-1.91 (m, 1H).
[0080] b) 4-Hydroxybenzenesulfonyl Chloride
[0081] To chlorosulfonic acid (248 mL, 3.37 mol) cooled to −3° C. was added dropwise a solution of phenol (70 g, 0.744 mol) in 250 mL of anhydrous methylene chloride over a period of 1 hour under argon. The mixture was warmed to rt over 1 h and was stirred at rt for 1.5 h. The mixture was poured over ice, stirred for 30 min, and was extracted with methylene chloride (4×2 L). The resulting organic layer was dried over MgSO 4 and concentrated in vacuo to yield 4-hydroxybenzenesulfonyl chloride as a sticky brown solid (41.49 g, 29%): 1 H NMR (400 MHz, d 6 -DMSO) δ 7.29-7.38 (d, 2H), 6.58-6.69 (d, 2H).
[0082] c) 3,4-Dichloro-N-{(S)-1-[(piperidin-4-yloxy)-benzenesulfonyl]-pyrrolidin-3-yl}-benzamide
[0083] To a mixture of 20.0 g (28.8 mmol, 1.44 mmol/g) of 2,6-dimethoxy-4-polystyrenebenzyloxy-benzaldehyde (DMHB resin) in 437.3 mL of 1% acetic acid in anhydrous 1-methyl-2-pyrrolidinone was added 26.6 g (86.4 mmol) of (S)-1-(2-nitro-benzenesulfonyl)-pyrrolidin-3-ylamine HCl salt and 25.08 mL (144 mmol) of diisopropylethyl amine, followed by addition of 30.52 g (144 mmol) of sodium triacetoxyborohydride. After the resulting mixture was shaken at rt for 65 h under argon, the resin was washed with CH 2 Cl 2 /methanol (1:1, 3×400 mL), DMF (3×400 mL), CH 2 Cl 2 (1×400 mL) and methanol (2×400 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. Elemental analysis N: 4.56, S: 3.32.
[0084] To a mixture of 10 g (10.61 mmol, 1.061 mmol/g) of the above resin in 165 mL of anhydrous 1-methyl-2-pyrrolidinone was added 10.14 g (53.05 mmol) of 3,4-dichlorobenzioc acid and 1.44 g (10.61 mmol) of 1-hydroxy-7-azabenzotriazole, followed by addition of 10.04 mL (63.66 mmol) of 1,3-diisopropylcarbodiimide. After the resulting mixture was shaken at rt for 44 h, the resin was washed with 1-methyl-2-pyrrolidinone (3×150 mL), dichloroethane/methanol (1:1, 3×150 mL) and methanol (3×150 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. An analytical amount of resin was cleaved with 50% trifluoroacetic acid in dichloroethane for 2 h at rt. The resulting solution was concentrated in vacuo: MS (ESI) 444 [M+H] + .
[0085] To a mixture of 200 mg (0.1793 mmol) of the above dry resin in 6 mL of 1-methyl-2-pyrrolidinone was added 248 mg (1.793 mmol) of K 2 CO 3 and 0.0985 mL (0.8965 mmol) of PhSH. After the resulting mixture was shaken at rt for 4 h, the resin was washed with methanol (1×10 mL), H 2 O (3×10 mL), methanol (1×10 mL), 1-methyl-2-pyrrolidinone (1×10 mL), CH 2 Cl 2 /methanol (1:1, 3×10 mL) and methanol (3×10 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. An analytical amount of resin was cleaved with 50% trifluoroacetic acid in dichloroethane for 2 h at rt. The resulting solution was concentrated in vacuo: MS (ESI) 517 [2M+H] + , 259 [M+H] + .
[0086] To a mixture of 200 mg of the above dry resin in anhydrous dichloroethane/1-methyl-2-pyrrolidinone solution (1:1, 7.5 mL) was added 0.2264 mL (2.799 mmol) of pyridine followed by the slow addition of 0.5393 g (2.799 mmol) of 4-hydroxybenzenesulfonyl chloride. After the resulting mixture was shaken at rt for 96 h, the resin was washed with 1-methyl-2-pyrrolidinone (3×10 mL), dichloroethane/methanol (1:1, 3×10 mL), dichloroethane (3×10 mL), methanol (1×10 mL), and dichloroethane (2×10 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. To a mixture of the dry resin in anhydrous tetrahydrofuran (9.38 mL) was added 0.4713 g (3.674 mmol) of potassium trimethyl silanolate. After the reaction mixture was shaken for 23 h, the resin was washed with tetrahydrofuran (3×10 mL), 1-methyl-2-pyrrolidinone (2×10 mL), tetrahydrofuran (3×10 mL), dichloroethane/methanol (5×10 mL), and dichloroethane (3×10 mL). An analytical amount of resin was cleaved with 50% trifluoroacetic acid in dichloroethane for 2 h at rt. The resulting solution was concentrated in vacuo: MS (ESI) 415 [M+H] + .
[0087] To a mixture of 200 mg of the above dry resin in 8.75 mL of anhydrous tetrahydrofuran was added 443 mg (2.199 mmol) of 4-hydroxypiperidine-1-carboxylic acid tert-butyl ester and 577 mg (2.199 mmol) of triphenylphosphine. After the mixture was cooled to −70° C., 433 μL (2.199 mmol) of diisopropyl azodicarboxylate was added to the cold mixture. The resulting mixture was kept at −70° C. for 30 min while shaking., The mixture was then allowed to warm to 0° C. over 1 h and shaken at rt for 19 h. The resin was washed with tetrahydrofuran (3×10 mL), CH 2 Cl 2 /methanol (1:1, 10×10 mL). The resulting resin was dried in vacuum oven at 35° C. for 24 h. The dry resin was treated with 4 mL of 50% trifluoroacetic acid in dichloroethane at rt for 2 h. After the cleavage solution was collected, the resin was treated with another 4 mL of 50% trifluoroacetic acid in dichloroethane at rt for 10 min. The combined cleavage solutions were concentrated in vacuo. The residue was purified using a Gilson semi-preparative HPLC system with a YMC ODS-A (C-18) column 50 mm by 20 mm ID, eluting with 10% B to 90% B in 3.2 min, hold for 1 min where A=H 2 O (0.1% trifluoroacetic acid) and B=CH 3 CN (0.1% trifluoroacetic acid) pumped at 25 mL/min, to produce 3,4-dichloro-N-{(S)-1-[4-(piperidin-4-yloxy)-benzenesulfonyl]-pyrrolidin-3-yl}-benzamide as a mono-trifluoroacetic acid salt (white powder, 27.7 mg, 27% over 9 steps): MS (ESI) 498 [M+H] + .
Compounds derived from Scheme 1: Ex- MS ample R1 R2 X1 X2 (ES+) m/e 2 3,4-dichloro- piperidin-4-yl H H 498 (M + H) phenyl 3 3,4-dichloro- piperidin-4-yl 3-chloro H 532 (M + H) phenyl 4 3,4-dichloro- piperidin-4-yl 3-bro- H 577 (M + H) phenyl mo 5 3,4-dichloro- piperidin-4-yl 3-chloro 5-chloro 566 (M + H) phenyl 6 3,4-dichloro- pyr- H H 484 (M + H) phenyl rolidin-3(S)-yl 7 3,4-dichloro- pyr- 3-chloro H 518 (M + H) phenyl rolidin-3(R)-yl 8 3,4-dichloro- pyr- 3-bro- H 563 (M + H) phenyl rolidin-3(R)-yl mo 9 3,4-dichloro- piperidin-4-yl H H 512 (M + H) phenyl 10 3,4-dichloro- piperidin-4-yl 3-chloro H 546 (M + H) phenyl 11 3,4-dichloro- piperidin-4-yl 3-bro- H 591 (M + H) phenyl mo 12 3,4-dichloro- piperidin-4-yl 3-chloro 5-chloro 580 (M + H) phenyl 13 3,4-dichloro- pyr- 3-bro- H 577 (M + H) phenyl rolidin-3(R)-yl mo 14 3,4-dichloro- pyr- 3-chloro 5-chloro 566 (M + H) phenyl rolidin-3(R)-yl 15 3,4-dichloro- pyr- 3-chloro H 532 (M + H) phenyl rolidin-3(S)-yl 16 3,4-dichloro- pyr- 3-bro- H 577 (M + H) phenyl rolidin-3(S)-yl mo 17 3,4-dichloro- piperidin-4-yl H H 526 (M + H) phenyl 18 3,4-dichloro- piperidin-4-yl 3-chloro H 560 (M + H) phenyl 19 3,4-dichloro- piperidin-4-yl 3-bro- H 605 (M + H) phenyl mo 20 3,4-dichloro- piperidin-4-yl 3-chloro 5-chloro 594 (M + H) phenyl 21 3,4-dichloro- pyr- H H 512 (M + H) phenyl rolidin-3(R)-yl 22 3,4-dichloro- pyr- 3-bro- H 591 (M + H) phenyl rolidin-3(R)-yl mo 23 3,4-dichloro- pyr- 3-bro- H 591 (M + H) phenyl rolidin-3(S)-yl mo 24 3,4-dichloro- pyr- 3-chloro H 546 (M + H) phenyl rolidin-3(S)-yl
EXAMPLE 25
[0088] Formulations for pharmaceutical use incorporating compounds of the present invention can be prepared in various forms and with numerous excipients. Examples of such formulations are given below.
Tablets/Ingredients Per Tablet 1. Active ingredient 40 mg (Cpd of Form. I) 2. Corn Starch 20 mg 3. Alginic acid 20 mg 4. Sodium Alginate 20 mg 5. Mg stearate 1.3 mg 2.3 mg
[0089] Procedure for Tablets:
[0090] Step 1: Blend ingredients No. 1, No. 2, No. 3 and No. 4 in a suitable mixer/blender.
[0091] Step 2: Add sufficient wafer portion-wise to the blend from Step 1 with careful mixing after each addition. Such additions of water and mixing until the mass is of a consistency to permit its conversion to wet granules.
[0092] Step 3: The wet mass is converted to granules by passing it through an oscillating granulator using a No. 8 mesh (2.38 mm) screen.
[0093] Step 4: The wet granules are then dried in an oven at 140° F. (60° C.) until dry.
[0094] Step 5: The dry granules are lubricated with ingredient No. 5.
[0095] Step 6: The lubricated granules are compressed on a suitable tablet press.
[0096] Inhalant Formulation
[0097] A compound of Formula I, (1 mg to 100 mg) is aerosolized from a metered dose inhaler to deliver the desired amount of drug per use.
[0098] Parenteral Formulation
[0099] A pharmaceutical composition for parenteral administration is prepared by dissolving an appropriate amount of a compound of formula I in polyethylene glycol with heating. This solution is then diluted with water for injections Ph Eur. (to 100 ml). The solution is then sterilized by filtration through a 0.22 micron membrane filter and sealed in sterile containers.
[0100] The above specification and Examples fully disclose how to make and use the compounds of the present invention. However, the present invention is not limited to the particular embodiments described hereinabove, but includes all modifications thereof within the scope of the following claims. The various references to journals, patents and other publications which are cited herein comprise the state of the art and are incorporated herein by reference as though fully set forth. | The present invention relates to pyrrolidine sulfonamides, pharmaceutical compositions containing them and their use as urotensin II antagonists. | 2 |
BACKGROUND
1. Technical Field
Embodiments of the invention relate to the field of warping looms in textile weaving and manufacturing.
2. Description of the Related Art
Since before the industrial revolution, the heddles used on handlooms have been similar in design. Heddles generally have a closed loop in the center through which the ends of warp threads are threaded. The top and bottom of the heddles have loops through which the heddles are attached to the harness or shaft frame. Heddles are typically made of polyester, twisted wire, or are pressed from sheet metal. Warp threads extend from a beam on one end of the loom, through a heddle, and attach to another beam at the other end of the loom.
One disadvantage of a closed loop heddle is that, once it is attached to the frame, it cannot be removed from the frame. Nor can the warp threads be removed from the heddles, once warping begins, since the warp threads are threaded through the heddle's center. Advanced weavers create complex weaving patterns using shaft switching. Shaft switching is the changing of the harness on which a single warp thread is moved. When switched to another harness, those warp threads can then change the pattern being woven. Shaft switching is not easily accomplished with conventional closed loop heddles. If a mistake is made during the warping process, all of the ends of the warp threads must be unthreaded back to the point at which the mistake was made to correct the problem. While some complex assemblies have been designed that open and close the eyelet of the heddle, the complex assemblies consist of several moving parts and are not readily adaptable to existing looms.
The warp beams or tie rods used on most handlooms are similar in design. The beams consist of a metal rod or wooden stick onto which the ends of the warp threads are tied. The traditional warp beams, and looms, do not provide any means to measure out the length of the warp threads. The warp beams are not meant to be used when removed from the loom. They also do not have means for maintaining a fixed distance between warp threads. The warp beams are seldom, if ever, removed from the loom. Clamps have been developed to attach warp thread to a beam without tying knots. However, the clamps have several disadvantages including multiple warp threads bunched together without separation, requiring drilling many holes into existing warp beams, having multiple parts, and using a series of springs with inconsistent tension on the warp threads across the beam.
Groups of 8 or more warp threads are typically tied to a warp beam in a single knot, which causes the threads to fan out from the knot to the heddles. The fan-out of the warp threads causes a scalloped edge at the beginning portion of a warp, and is referred to as the draw-in effect. For this reason, several inches of cloth must be woven before the scallops even out and the actual project may be started. This consumes time, adds to the amount of wasted material, and increases the overall length of the required warp.
An alternate means of attaching warp threads to a loom is to wind individual warp threads over a strip of adhesive on the beam and around the circumference of the beam. The disadvantages of this method include the potential for adhesive residue on the warp threads, potential release of the adhesive on one or more warp threads and attendant variations of tension, and a lack of positive and consistent control of the separation between warp threads. In addition, the method is not conducive to removal and replacement of the entire warp due to an inability to replicate the initial tension. This method also does not allow loading or removing the warp without removing all heddles from their frame.
Attaching the warp threads to the warp beams, also referred to as warping, in the traditional manner is very tedious. Traditional weavers usually install yards and yards of warp thread at one time. This permits the weaver to weave many projects before re-warping the loom. Unfortunately this means waiting until the entire warp is used before the individual projects can be removed from the loom. This can be especially frustrating for beginning weavers.
SUMMARY
It is therefore desirable to provide quick threading, openable heddles and a warp beam that provides even spacing of warp thread, even tension on the warp thread, and rapid set-up.
In some embodiments, a heddle for a weaving loom includes an eyelet with a break in the circumference of the eyelet. The break allows insertion and removal of a warp thread in the eyelet while both ends of the warp thread are attached to the weaving loom.
In other embodiments, a method of warping a loom includes positioning the warp thread against the periphery of an eyelet in the heddle; and moving the warp thread through a break in the periphery of the eyelet.
In still other embodiments, a warp beam includes a deck and a plurality of retaining members configured in spaced relationship to one another on the deck. Each retaining member retains a strand of warp thread that is substantially parallel to lines of warp thread retained by the other retaining members.
In further embodiments, a kit for retrofitting a loom includes a first warp beam and a second warp beam. The first and second warp beams include retaining members for retaining portions of warp thread in spaced apart substantially parallel relation, and the first and second warp beams are attachable to existing warp beams on the loom.
The foregoing has outlined rather broadly the features and technical advantages of embodiments of the present invention so that those skilled in the art may better understand the detailed description of embodiments of the invention that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention may be better understood, and their numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference symbols in different drawings indicates similar or identical items.
FIG. 1A is a front view of an embodiment of a heddle for threading warp thread in a loom.
FIG. 1B shows detail of the eyelet portion of the heddle of FIG. 1A .
FIGS. 1C and 1D show how a warp thread can be inserted in the eyelet of the heddle of FIGS. 1A and 1B without removing either end of a warp thread from a warp beam.
FIG. 2A is a front view of another embodiment of a heddle that can be threaded without removing either end of a warp thread from a warp beam.
FIG. 2B shows detail of the eyelet portion of the embodiment of the heddle shown in FIG. 2A .
FIG. 3A shows another embodiment of a heddle that can be threaded without removing either end of a warp thread from a warp beam.
FIG. 3B shows a side view of the heddle of FIG. 3A .
FIG. 4 shows a perspective view of another embodiment of a heddle that can be threaded without removing either end of a warp thread from a warp beam.
FIG. 5A shows another embodiment of a portion of a heddle that can be threaded without removing either end of a warp thread from a warp beam.
FIG. 5B shows the apparatus in FIG. 5A in the open position.
FIG. 5C is a cross-sectional view of a finger portion engaged in a channel portion of the heddle of FIGS. 5A and 5B .
FIG. 6 is a perspective view of a series of heddles installed on a frame.
FIG. 7 is a side view of loom components including frames and warp beams.
FIG. 8 is a perspective view of an embodiment of a warp beam.
FIG. 9 is a top view of a conceptual diagram of a warp utilizing the warp beams of FIG. 8 .
FIG. 10 is a top view of a loom utilizing the warp beams of FIG. 8 .
FIG. 11 is a side view of loom components including frames and the warp beams of FIG. 8 .
DETAILED DESCRIPTION
Embodiments of heddles and warp beams are disclosed that facilitate warping a loom by allowing the beams to be warped before being attached to the loom. Additionally, the warp threads can be threaded through an opening in the eyelets of the heddles while both ends of the warp thread remain attached to the warp beams.
Referring to FIGS. 1A and 1B , an embodiment of heddle 100 is shown with eyelet 110 that includes opening 112 in the circumference of eyelet 110 . Opening 112 allows warp thread to be inserted and removed without removing either end of the warp thread from a warp beam. In the embodiment shown, eyelet 110 is formed from a spiral loop 120 of material, such as plastic, metal, or other suitable material capable of substantially retaining its shape. In one embodiment, spiral 120 includes approximately one and one-half turns (coils) of material. Ends 122 of heddle 100 can include J-hooks or other fastening means to allow heddle 100 to be attached to, and detached from, a frame (not shown).
As shown in FIGS. 1C and 1D , heddle 100 can be threaded by raising one end 122 of heddle 100 to be substantially parallel to warp thread 124 . Warp thread 124 is positioned through opening 112 of spiral 120 and captured within eyelet 110 when end 122 of heddle 100 is lowered. The end 122 of heddle 100 can then be reattached to a frame.
FIGS. 2A and 2B depict another embodiment of a heddle 200 comprising an interlocking closure 202 in the circumference of eyelet 204 . The circumference of eyelet 204 is constructed from a flexible material, such as plastic, that allows bending of the ends of interlocking closure 202 in opposite directions to create an opening between adjacent portions of interlocking closure 202 . When interlocking closure 202 is open, warp thread 124 ( FIG. 1C ) can be inserted into eyelet 204 without removing either end of the warp thread from a warp beam, as well as without detaching either end 122 of heddle 200 from a frame (not shown).
FIGS. 3A and 3B depict an embodiment of a portion of another heddle 300 including a V-shaped break 302 in the circumference of eyelet 304 . As shown in FIG. 3B , one end of break 302 includes an inner V-shaped portion that engages an outer V-shaped portion of the other end of break 302 . The V-shapes retains the ends of break 302 in alignment during use of the loom. In some embodiments, a gap between the ends of break 302 allows a warp thread 124 ( FIG. 1C ) to be inserted into eyelet 304 without removing either end of the warp thread from a warp beam and without removing heddle 300 from a frame (not shown). A user simply raises the warp thread to the gap in break 302 , and exerts a slight inward pressure against break 302 to force the ends of break 302 apart. A slight upward and downward movement, or vice versa depending on the orientation of the V-Shape of break 302 , may be required, depending on the height of the vertex of the V-shape. In some embodiments, the circumference of eyelet 304 is fabricated with a flexible material that allows the ends of break 302 to bend open to insert or remove warp thread 124 . The material is sufficiently elastic to return the ends of break 302 to a substantially closed position when released.
FIG. 4 depicts an embodiment of a portion of another heddle 400 with a break 402 that can be configured in the circumference of an eyelet (not shown) to allow warp thread 124 ( FIG. 1C ) to be inserted and removed from the eyelet while the heddle remains attached to a frame, and the ends of warp thread 124 remain attached to the loom.
In the embodiment shown, break 402 includes two overlapping portions 404 , 406 formed or cut in the sidewall of the circumference of the eyelet. Overlapping portions 404 , 406 are fabricated from rigid material with flexible properties that allows overlapping portions 404 , 406 to be separated to insert and remove warp thread 124 from the eyelet, and return to their original position when released. In some embodiments, overlapping portions 404 , 406 can include a fastener to retain overlapping portions 404 , 406 in a closed position to retain warp thread 124 in the eyelet. The fastener can be disengaged to move overlapping portions 404 , 406 apart to remove warp thread 124 from the eyelet. An example of a fastener than can be used on overlapping portions 404 , 406 includes one or more protuberances 408 that are sized and shaped to snap into and out of corresponding indentation(s) (not shown) in overlapping portion 404 . Other suitable fasteners for opening and closing overlapping portions 404 , 406 can be utilized, in addition to, or instead of, protuberances 408 and corresponding indentations.
FIGS. 5A and 5B depict another embodiment of a heddle 500 that includes a finger portion 502 and channel portion 504 . Finger portion 502 is movable to engage channel portion 504 in a closed position, and to disengage channel portion 504 in an open position. Finger portion 502 can be moved to open or closed positions by exerting lateral force on the outer periphery of finger portion 502 . Any suitable angle can be utilized between finger portion 502 and channel portion 504 to help discourage warp threads 124 ( FIG. 1C ) from snagging in the eyelet. FIG. 5C is a cross sectional view of finger portion 502 engaged in channel portion 504 . Finger portion 502 and channel portion 504 can be formed by any suitable means such as extrusion, injection molding, or other fabrication process.
Referring now to FIG. 6 , heddles 100 , 200 , 300 , 400 , 500 , collectively referred to herein as heddles 600 , can replace closed heddles in most looms. Most frames 602 include a flat thin steel bar or rod 604 at the top and bottom of frame 602 . A series of heddles 600 are suspended onto rods 604 . The end portions of heddles 600 can be shaped to accommodate various frames 602 .
Referring now to FIG. 7 , loom 700 is shown with a plurality of frames 602 . Warp threads 124 are inserted through heddle eyelets (not shown) mounted in frames 602 . Warp threads 124 extend from front beam 702 through heddles in frames 602 to back beam 704 . During operation, frames 602 alternately raise and lower warp thread 124 . Typically, half of the frames 602 alternate with adjacent frames 602 between up and down positions. Back roller 706 is unwound to allow unwoven warp thread stored on it to move through the heddles, and front roller 708 winds up woven cloth.
Referring now to FIG. 8 , warp beam 800 includes a plurality of retaining members 802 protruding from a rounded edge 804 of deck 806 . Retaining members 802 retain parallel strands of warp thread 124 ( FIG. 1C ) in a spaced relationship to one another, typically evenly spaced at intervals depending on the desired tightness of the weave. Alternatively, retaining members 802 can be relatively closely spaced, and a user can skip one or more alternating retaining members 802 to achieve the desired weave density. One advantage of warp beam 800 over known configurations is that retaining members 802 evenly space warp thread 124 over the width of the loom. The even spacing provides consistent warp tension, and produces more evenly woven material. A common spacing of retaining members 802 is five retaining members 802 per inch. Other spacing intervals can be used, however. Some embodiments of warp beam 800 include a plurality of attachment points 810 connected to deck 806 . Attachment points 810 can be eyebolts, snap hooks, hooks or other means for attaching warp beam 800 to various portions of loom 700 , either directly or by means of rope, hooks or other fastening material.
Referring to FIGS. 7 , 8 and 9 , a top view of a conceptual diagram of warp 900 includes parallel lines of warp thread 124 created by the consecutive back and forth winding of a single length of warp thread 124 between two spaced warp beams 800 . Warp beams 800 are typically used in pairs, and can be positioned the desired distance apart on a table or other surface, and “warped” by winding warp thread 124 between retaining members 802 . The warp beams 800 can be held in place during the warping process with C-clamps or other suitable attachment, with retaining members 802 facing outward. Warp 900 can then be fastened to existing front and back beams 702 , 704 on loom 700 . Alternatively, warp beams 800 can be fastened to loom 700 before installing warp thread 124 on retaining members 802 . Once warp 900 is completed, each parallel line of warp thread 124 can be inserted through a corresponding heddle 600 ( FIG. 6 ).
Warp beams 800 can include warp thread attachment points to retain the ends of warp thread 124 . The ends of warp thread 124 can be tied or otherwise fastened to retaining members 802 , or other suitable structure. In one embodiment, a knot is tied in warp thread 124 to fasten the end of warp thread 124 to one of retaining members 802 , or other suitable structural component on warp beam 800 or loom 700 . In alternate embodiments, the ends of warp thread 124 can be adhesively attached, positioned in a notch, or clamped to warp beam 800 . In some situations, for example in the production of multi-colored or striped material, more than two attachments for the ends of warp threads 124 may be required. In such embodiments, different warp threads 124 can be wound on warp beam 800 , with each end of warp thread 124 being attached to an intermediate retaining member 802 , or other suitable structural component, on warp beam 800 .
A single length of warp thread 124 can be used to warp loom 700 by winding warp thread 124 in consecutive parallel lines between two spaced apart warp beams 800 . Accordingly, parallel lines of warp thread 124 are evenly spaced over their entire length between warp beams 800 , and very few knots or other means for attaching warp threads 124 are required. The even spacing between parallel lines of warp thread 124 over their entire length eliminates the “draw-in effect” found on conventional looms, which is caused by attaching multiple warp threads 124 to one location on a warp beam.
In some embodiments, warp thread 124 is attached to warp beam 800 by inserting a portion of warp thread 124 between retaining members 802 and retention strip 808 . Retention strip 808 can be fabricated with elastic material capable of deflecting when warp threads 124 are inserted around portions of the retaining members 802 . Retention strip 808 substantially maintains to its original shape to provide compressive force on warp thread 124 against retaining members 802 . Retention strip 808 can be positioned adjacent retaining members 802 to keep warp thread 124 in place by providing compression against the portion of warp thread 124 positioned between retaining members 802 and retention strip 808 .
Sufficient tightness of retention strip 808 is typically developed to hold the warp thread in place if warp thread 124 breaks. Alternatively, a strip of adhesive tape or other retention mechanism placed under and over the ends of warp thread 124 , adjacent to retention strip 808 , can retain warp thread 124 in the event of a break.
In some embodiments of warp beam 800 , retaining members 802 comprise snap hooks or other suitable fasteners that grasp a portion of warp thread 124 . Such embodiments may not require retention strip 808 . Retaining members 802 can be spring-mounted to create consistent tension between parallel lines of warp thread 124 . Further, certain types of fasteners such as snap hooks can be used as retaining members 802 to reduce or even eliminate the need to tie knots in warp thread 124 to attach the ends of warp threads 124 to retaining members 802 . The snap hooks, or other fasteners, can be installed at any desired spacing along warp beam 800 .
Warp beams 800 can be attached to loom 700 ( FIG. 7 ) using large metal snap hooks or other suitable fasteners. Fasteners may be attached to the loom's original warp beam or to ropes used to secure the original warp beams 702 , 704 to loom 700 . Warp beams 800 can be strapped or tied to existing warp beams 702 , 704 , or attached with a variety of mating interlocking mechanisms, such as hooks and eyes, and dovetails. Other suitable attachment means may also be used to attach warp beams 800 to loom 700 .
Referring now to FIGS. 7 , 8 , 9 , 10 and 11 , alternate embodiments of warp beams 800 can be attached to loom 700 using attachment points 810 . (In FIG. 10 , front beam 702 and back beam 704 have been removed for clarity.) In one embodiment, attachment point 810 comprises an eyebolt through which attachment media 1010 is threaded. Attachment media 1010 is typically comprised of nylon rope when it is used to attach a tie rod in traditional looms. However, attachment media 1010 could be made of other suitable material, such as rope, chain, or twine. One section of attachment media 1010 attaches a first warp beam 800 to roller 706 , and another section of attachment media 1010 attaches the other warp beam 800 to roller 708 . In some embodiments, many yards of warp thread 124 are suspended between two warp beams 800 . Excess warp thread 124 can then be wound around back roller 706 , together with one warp beam 800 at the beginning of weaving, and then unwound as needed in the weaving process. Later, the completed cloth would follow the first section of attachment media 1010 and the front warp beam 800 as they are all wound onto front roller 708 .
A loom assembly that includes warp beams 800 and heddles 600 can be warped in much less time than conventional looms. The various alternate embodiments of heddles 600 described herein enable warp threads 124 to be threaded through heddles 100 after the entire warp 900 is attached to loom 700 . Additionally, warp beams 800 and heddles 600 enable different warps 900 to be easily interchanged to switch weaving projects before the projects are finished. The various embodiments of heddles 600 also allow warp thread 124 to be removed without removing either end of warp thread 124 from loom 700 . Once unthreaded, individual heddles 600 can be removed from frame 602 while the rest of warp 900 remains intact on loom 700 . Heddles 600 also allow shaft switches to be easily made to create complex weaving patterns.
Unlike conventional closed loop heddles, embodiments of heddles 600 can easily be inserted or removed from frame 602 . Instead of threading ends of warp thread 124 through eyelets with closed circumferences, the weaver can lift warp thread 124 that has already been warped on the loom, and insert it through an opening in heddle 600 . Warp threads 124 can be reinserted in heddles 600 while warp thread 124 remains attached to front and back warp beams 800 (or 702 , 704 ) on loom 700 .
While the invention has been described with respect to the embodiments and variations set forth above, these embodiments and variations are illustrative and the invention is not to be considered limited in scope to these embodiments and variations. Accordingly, various other embodiments and modifications and improvements not described herein may be within the scope of the present invention, as defined by the following claims. | An apparatus and method for warping a loom includes a heddle with an open or openable break in the circumference of its eyelet that allows insertion and removal of warp thread with simple motions through the break while both ends of the warp threads are fastened to the loom. A warp beam includes a plurality of retaining members that retain parallel strands of warp thread in a spaced relationship to one another. A length of warp thread is wound in consecutive parallel lines between two spaced apart warp beams. The combination of openable heddles and warp beams with warp thread retaining members allow a loom or knitting device to be rapidly set-up, allow for easy correction of mistakes, and for the removal and reloading of the heddles or a weaving project in mid-production. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 10/795,491, filed Mar. 8, 2004, now U.S. Pat. No. 7,090,699, which is a continuation of application Ser. No. 10/057,469, filed Jan. 25, 2002, now U.S. Pat. No. 6,755,869, which is a continuation of application Ser. No. 10/007,819, filed Nov. 9, 2001, now abandoned, the disclosures of which are hereby expressly incorporated by reference.
FIELD OF INVENTION
[0002] The present invention pertains to a resilient, flexible, compressible, bio-compatible prosthesis insertable into the stomach to effect weight loss over a controlled period.
BACKGROUND
[0003] The incidence of obesity and its associated health-related problems have reached epidemic proportions in the United States. See, for example, P. C. Mun et al., “Current Status of Medical and Surgical Therapy for Obesity” Gastroenterology 120:669-681(2001). Recent investigations suggest that the causes of obesity involve a complex interplay of genetic, environmental, psycho-behavioral, endocrine, metabolic, cultural, and socio-economic factors. Severe obesity is frequently associated with significant comorbid medical conditions, including coronary artery disease, hypertension, type II diabetes mellitus, gallstones, nonalcoholic steatohepatitis, pulmonary hypertension, and sleep apnea.
[0004] Estimates of the incidence of morbid obesity are approximately 2% of the U.S. population and 0.5% worldwide. Current treatments range from diet, exercise, behavioral modification, and pharmacotherapy to various types of surgery, with varying risks and efficacy. In general, nonsurgical modalities, although less invasive, achieve only relatively short-term and limited weight loss in most patients. Surgical treatments include gastroplasty to restrict the capacity of the stomach to hold large amounts of food, such as by stapling or “gastric banding.” Other surgical procedures include gastric bypass and gastric “balloons” which, when deflated, may be inserted into the stomach and then are distended by filling with saline solution.
[0005] The need exists for cost effective, less invasive interventions for the treatment of morbid obesity.
SUMMARY
[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0007] The present invention provides a novel system for treatment of morbid obesity by use of a bioabsorbable gastric prosthesis placed in the stomach through a minimally invasive procedure. The prosthesis takes up space in the stomach so that the stomach can hold a limited amount of food, and preferably exerts pressure on the upper fundus to create a sensation of being full. The material of the prosthesis can be selected to degrade over a predetermined period and pass out of the patient without additional intervention.
[0008] In the preferred embodiment, the prosthesis is a porous weave of bioabsorbable filaments having an open mesh configuration. The prosthesis can be formed from a cylindrical stent, such as by reverting the ends of the cylinder and joining them at the center. The filaments preferably have memory characteristics tending to maintain an oblate shape with sufficient resiliency and softness so as not to unduly interfere with normal flexing of the stomach or cause abrasion of the mucus coat constituting the inner lining of the stomach. The prosthesis may be free floating in the stomach, but is shaped so as to be biased against the upper fundus, or it may be tacked in position adjacent to the fundus by bioabsorbable sutures.
DESCRIPTION OF THE DRAWINGS
[0009] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0010] FIG. 1 is a somewhat diagrammatic elevation of a stomach and adjacent parts of the alimentary canal, with the wall adjacent to the viewer partially broken away to reveal an intragastric prosthesis in accordance with the present invention;
[0011] FIG. 2 is a side elevation of a cylindrical stent from which a prosthesis in accordance with the present invention may be formed;
[0012] FIG. 3 is a side elevation of a prosthesis in accordance with the present invention, formed from the stent of FIG. 2 ; and
[0013] FIG. 4 is a diagrammatic elevation corresponding to FIG. 1 , illustrating insertion of a prosthesis in accordance with the present invention through the esophagus and into the stomach.
DETAILED DESCRIPTION
[0014] The present invention provides a volume-filling prosthesis insertable into the stomach for treatment of morbid obesity by taking up space in the stomach to reduce its capacity and by exerting pressure to create a sensation of being full, particularly on the upper fundus.
[0015] FIG. 1 illustrates a central portion of the alimentary canal including the distal segment of the esophagus 10 , the stomach 12 , and the duodenum 14 (proximate segment of the small intestine). The esophagus 10 opens into the stomach 12 toward the top of the lesser curvature 16 adjacent to the fundus 18 . The pyloric part 20 of the stomach leads to the duodenum by way of the gastric outlet or pylorus 22 which forms the distal aperture of the stomach and has an enclosing circular layer of muscle which is normally contracted to close the aperture but which relaxes to provide an open but restricted passage. Although subject to substantial variation in different individuals, representative dimensions for the stomach are approximately 8 cm long (fundus to pylorus) by 5 cm wide (greatest distance between lesser and greater curvatures), with the esophageal opening being approximately 2 cm in diameter and the pylorus having a maximum open diameter of about 2 cm.
[0016] In accordance with the present invention, an oblate, volume-filling prosthesis 24 is held within the stomach, sized for reception in the proximate portion adjacent to the opening of the esophagus and fundus. Such prosthesis preferably is a porous body formed of a loose weave of thin polymer filaments 26 , having large spaces between filaments for an open area of at least about 80%, preferably more than 90%, so as not to impede the flow of gastric juices or other functioning in the stomach. The filaments 26 have substantial memory characteristics for maintaining the desired oblate shape and size. However, the filaments preferably are sufficiently soft and flexible to avoid abrasion of the mucus coat forming the inner lining of the stomach and to enable normal flexing and shape changes. The size of the prosthesis 24 is substantially greater than the opening of the esophagus, at least about 3 cm in the narrowest dimension, preferably at least about 4 cm. The longer dimension of the oblate prosthesis is greater than 4 cm, preferably at least about 5 cm to prevent the prosthesis from free movement within the stomach. The size and shape of the prosthesis tend to maintain it in the position indicated in FIG. 1 , adjacent to the fundus 18 and remote from the pyloric part 20 . Thus, while the prosthesis occupies a substantial portion of the volume of the stomach, preferably approximately one-half the volume, the prosthesis does not interfere with normal digestion of food, such as by gastric juices (hydrochloric acid and digestive enzymes) nor with passage of food through the pyloric part 20 and its opening 22 to the duodenum 14 .
[0017] With reference to FIG. 2 , the prosthesis can be formed from a substantially cylindrical stent 28 having the desired porous weave and large open area. The filaments 26 and weave pattern are selected to achieve memory characteristics biasing the prosthesis to the cylindrical condition shown. In the preferred embodiment, the opposite ends 30 of the stent are reverted, the end portions are rolled inward, and the ends are secured together such as by suturing. Alternatively, a disk of the same pattern and material can be used in securing the reverted ends together. The resiliency of the filaments tends to bulge the resulting prosthesis 26 outward to the desired oblate shape.
[0018] Prior to reversion of the ends, stent 28 in the condition shown in FIG. 2 can be approximately 2-3 cm in diameter and approximately 8-10 cm long, in a representative embodiment. The filaments can have a diameter of about 0.010 inch to about 0.25 inch. The filaments may be coated or impregnated with other treating agents, such as appetite suppressants, or agents to decrease the likelihood of gastric problems, such as ulcers, due to the presence of a foreign object. However, such problems are unlikely due to the biocompatible nature and the resilient flexibility of the prosthesis.
[0019] It is preferred that the filaments 26 be formed of a bioabsorbable polymer such as a polyglycolic acid polymer or polylactic acid polymer. Similar materials are used for some bioabsorbable sutures having “forgiving” memory characteristics and sufficient “softness” that tissue abrasion is inhibited. The absorption characteristics of the filaments 26 can be selected to achieve disintegration of the prosthesis 26 within the range of three months to two years, depending on the severity of obesity. In the preferred embodiment, the prosthesis will absorb and pass naturally from the stomach approximately 6 months after deployment.
[0020] Non-bioabsorbable materials may be used, such as Nitinol, which exhibit the desired springiness but which would require that the prosthesis be retrieved. An advantage of the preferred, bioabsorbable embodiment of the invention is that delivery can be through the esophagus, with no additional intervention being required.
[0021] With reference to FIG. 4 , preferably from the condition shown in FIG. 3 , the prosthesis 26 can be compressed to a generally cylindrical shape having a diameter of no more than about 2 cm such that the compressed prosthesis can be carried in a short (approximately 5 cm to 6 cm long) loading tube 32 . The loading tube can be advanced along the esophagus by a central tube 34 of smaller diameter, under the visualization allowed by a conventional endoscope 36 . The tube 34 can enclose a core wire 38 to actuate a pusher mechanism 40 for ejecting the prosthesis 26 when the opening of the esophagus into the stomach has been reached. The endoscope and deployment mechanism can then be retracted.
[0022] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. For example, while it is preferred that the prosthesis be sized for self-retention in the desired position in the stomach, it also may be secured in position by a few sutures applied endoscopically, preferably in or adjacent to the fundus area of the stomach. | A porous weave of bioabsorbable filaments having an open mesh configuration is formed into an oblate shape having dimensions greater than the esophageal opening and gastric outlet of a stomach. The resulting prosthesis is deployed in the stomach and is of a size to be retained in the proximate portion thereof for exerting pressure on the upper fundus. The prosthesis limits the amount of food that may be held within the stomach, and exerts pressure on the fundus to create a sensation of being full, resulting in weight loss. | 0 |
BACKGROUND OF INVENTION
There is no question that this country's total waste dilemma will continue well into the twenty-first century. Fundamental advances, new discoveries, and technological developments in pollution control have not kept pace with our nation's needs for environmental management. The United States produces roughly 700,000 tons of hazardous waste each day, has identified more than 25,000 potentially dangerous hazardous waste sites across the nation, and has roughly 1,000,000 additional sites that have resulted from leaking underground storage tanks including those used for gasoline storage at local gas and service stations. When coupled with the particularly onerous wastes that are injected to hundreds of deep wells, the tens of thousands of municipal landfills, and the innumerable liquid and gaseous discharges from existing municipal and industrial facilities, the total accumulated environmental debt for the nation easily matches the current federal deficit of more than $2 trillion.
That this environmental debt is not being met is apparent. An annual payout for pollution control of only $90 billion has provided active cleanup of less than 200 sites and complete cleanup of less than 10% of the highest-priority 1200 sites. Public outcry following such disasters as Love Canal, Bhopal, Monongahela, and Valdez focuses attention on the consequences of overlooking pollution control issues. The public is demanding more aggressive cleanup programs and stricter disposal regulations. Yet neither the problem nor the solution belongs solely to the government. In the United States, for example, industry has tended to view pollution control as a cost, an inconvenience that must be resolved, rather than an area worthy of intensive research. The total new plant and equipment expenditures planned for 1988 for this country's non-farm business (i.e., durable and nondurable goods, mining, transportation, utilities, trade and services, and communication) was $477 billion. Only $9 billion of this total, nearly 2%, was planned for pollution abatement. (The percentage of total expenditures for a particular industry can, of course, be significantly greater, or smaller, than the industrial average.) Marginal industries cannot afford these costs; they cannot afford to pay for the environmental debt that they have accumulated.
One result of even reluctant investment in pollution control research and facilities is a reduced ability of U.S. industry to compete in the international marketplace. A contributing factor, of course, is that countries with either no or notably less stringent pollution control regulations (note: Japan has not yet begun to address the hazardous waste issue), provide their industries with a competitive edge over this country's industries, with obvious damaging impact on those that are marginal. And while direct expenditures by U.S. industry for pollution control (e.g., health and environmental management, testing and monitoring, recycle/recovery, and site remediation), was expected to be roughly $10 billion in 1989, the corresponding costs in Western Europe and Japan were about $6.4 billion and $3.6 billion. respectively. Developing nations have little impact on cost estimates at this time, however the pollution control industry can look to these countries as an almost limitless future market. New technologies must be developed which will allow U.S. industry to complete more effectively in the international marketplace and reduce the cost of the environmental debt that has been accumulated by both government and industry.
BRIEF DESCRIPTION OF THE INVENTION
This invention, a periodic multistage process which minimizes fugitive pollutant emissions, has been developed for the removal and destruction of volatile, semi-volatile, and non-volatile organic contaminants from either water, wastewater, or spent granular activated carbon (GAC). Specifically, this invention relates to methods, materials, and systems for treating organic contaminants present in water, chemical process wastewaters, gaseous emissions from industrial processes, landfill leachates, and leaking underground storage tanks, by a process which uniquely combines granular activated carbon adsorption with biological treatment.
In addition, this invention relates to improving the ability of periodic fixed film biological systems to destroy organic contaminants by using a process which involves the following:
1. Analyzing the organic contaminants to determine the composition of the contaminants to be removed.
2. Preparing a culture of microorganisms specifically selected for their ability to degrade organics present in the water, wastewater, or spent GAC.
3. Inoculating the system with the microbial culture prepared in Step 2 for the formation of a biofilm (i.e., attached growth) on the exterior walls of a gas permeable membrane.
4. Supplying of an electron acceptor (oxygen) and, when needed, a supplemental electron donor (e.g., methane gas) through, for example, the lumen of a semipermeable silicone rubber membrane tubing to allow the selective attachment and growth of the microbial culture prepared in Step 2 to the exterior walls of the silicone tubing as a biofilm.
5. Developing a dense, adhesive biofilm on the surface of the gas permeable membrane in Step 4 by providing high liquid flow past the biofilm.
6. Adding GAC to the system for the purpose of adsorbing organics present in water, chemical process wastewaters, landfill leachates, and/or water contaminated by leaking underground storage tanks, or adding spent GAC which was obtained from treatment processes used to adsorb organic contaminants present in water, chemical process wastewaters, gaseous emissions from industrial processes, landfill leachates, and/or water contaminated by leaking underground storage tanks.
7. Desorbing the organics adsorbed on the GAC added to the system in Step 6.
8. Employing the organism system obtained in Step 4 to biodegrade the organics that are desorbed from the GAC added to the system in Step 6 and/or present in water, chemical process wastewaters, landfill leachates, and/or water contaminated by leaking underground storage tanks.
9. Periodically filling and drawing the system when treating contaminated water or wastewater and simply recirculating waters from a bulk storage tank when the system is used solely to bioregenerate spent GAC.
10. Disposing of the waste effluent and waste biomass produced.
Because the flow of gases through the gas permeable membrane is limited to that which is needed the demand of the microorganisms, there is little or no gas flow through the reactor and, thus, little or no loss of organics to the environment by either volatilization or stripping. In addition, the Granular Activated Carbon-Sequencing Batch Biofilm Reactor offers several other advantages: (1) microorganisms attached to biofilms are better suited for the treatment of waters or wastewaters with low concentrations of organic compounds than those that are present in suspended growth activated sludge processes including conventional Sequencing Batch Reactors (SBRs); (2) large numbers of slow-growing organisms can be maintained in the Granular Activated Carbon-Sequencing Batch Biofilm Reactor system, even under high hydraulic loading rates; (3) organisms that are capable of degrading key organics but have either low yield or poor settling characteristics would be washed out of suspended growth reactors and maintained in the Sequencing Batch Biofilm Reactor; (4) peak loadings or flow variations can be handled without disruption of performance because of the redundancy provided by both the GAC and the elevated oxygen uptake rates that can be met by the oxygen supplied by the gas permeable membrane; and (5) effluent requirements can be met for short periods using the granular activated carbon adsorption system (e.g., for one week or more depending upon the quantity and type of GAC used) if failure of the biological treatment portion of the system occurs.
THE PRIOR ART
Biological systems that are related to the invention described in this application and which are being used or developed for the treatment of organic contaminants present in water, chemical process wastewaters, landfill leachates, leaking underground storage tanks, and spent activated carbon are as follows:
1. conventional suspended growth Sequencing Batch Reactors (SBRs),
2. convention suspended growth SBRs used to pretreat hazardous wastes prior to final polishing by GAC,
3. continuous flow or batch activated sludge systems that have powdered activated carbon (PAC) added directly to the biological reactor,
4. conventional suspended growth SBRs that use semipermeable silicone rubber membrane tubing to meet high oxygen uptake rates,
5. biofilms attached to spent GAC that are supplied oxygen thru semipermeable silicone rubber membrane tubing, and
6. biofilms attached to semipermeable silicone rubber membrane tubing.
Except for the powdered activated carbon system listed as Item 3, the coinventors of this application have been involved in the development and implementation of all of the above technologies. Each of these technologies is discussed below.
Conventional suspended growth SBRs are currently being used extensively for the treatment of both domestic and industrial wastewaters. A typical system consists of a single aeration tank or several aeration tanks operated in parallel with a fixed cycle time consisting of five stages: fill, react, settle, draw, and idle. Typical SBR applications involve the use of a suspended culture where mixing and/or aeration are used to keep the microorganisms in suspension. During settle, draw, and idle, mixing and aeration are turned off to allow the microorganisms to settle, thus allowing clear supernatant to be removed from the reactor while maintaining an active culture within the reactor. A complete summary of conventional Sequencing Batch Reactors is described by Robert L. Irvine and Lloyd H. Ketchum, Jr., two of the coinventors of this application and the creators of the conventional suspended growth SBR, in an article titled "Sequencing Batch Reactors for Biological Wastewater Treatment," which appeared in 1989 in the CRC Critical Reviews in Environmental Control, Vol. 18, starting on page 255 and continuing thru page 294. The SBR system has been found to be effective in the treatment of a wide variety of organic contaminants present in waters and wastewaters but is not able to treat effectively waters and wastewaters that have low concentrations of organic contaminants, does not fully control either volatilization or stripping of volatile organics present in waters and wastewaters that have high concentrations of organic contaminants, and is not used to bioregenerate spent GAC. Our invention, the Granular Activated Carbon-Sequencing Batch Biofilm Reactor, significantly modifies conventional suspended growth Sequencing Batch Reactor technology as will be described in more detail later.
Conventional suspended growth SBRs have also been used to pretreat hazardous wastes prior to final polishing by GAC. Two such systems were described in a view article by Robert L. Irvine and Peter A. Wilderer, another of the coinventors of this application. The paper, "Aerobic Processes," edited by Harry M. Freeman and published by McGraw-Hill Book Company, appeared in pages 9.3 thru 9.18 of the Standard Handbook of Hazardous Waste Treatment and Disposal (1988). Initial studies for the two systems, a bench scale treatment of Occidental Chemical Company's Hyde Park leachate and the full scale treatment of CECOS International's wastewaters at their hazardous waste disposal site in Niagara Falls, were carried out under the direction of Robert L. Irvine. Both studies demonstrated that biological treatment in a suspended growth conventional SBR would markedly reduce the load of organics to the GAC. Additional information on these systems may be found in the following publications: (1) "Enhanced Biological Treatment of Leachates from Industrial Landfills," by Robert L. Irvine, Stanley A. Sojka, and Joseph F. Colaruotolo, in Hazardous Waste, Vol. 1, pp. 123 thru 135 (1984); ( 2) "Biological Treatment of a Landfill Leachate in Sequencing Batch Reactor," by Wei-chi Ying, Robert R. Bonk, Vernon J. Lloyd, and Stanley A. Sojka, in Environmental Progress, vol 5, pp. 41 thru 50 (1986); and (3) "Biological Treatment of Hazardous Waste in Sequencing Batch Reactors," by Philip A. Herzbrun, Robert L. Irvine, and Kenneth C. Malinowski, in Journal Water Pollution Control Federation, Vol. 57, pp. 1163 thru 1167 (1985). Unlike the Granular Activated Carbon-Sequencing Batch Biofilm Reactor described in this application, the conventional suspended growth SBR used in these studies works independently of the GAC reactors and is in no way involved with the bioregeneration of spent GAC.
Powdered activated carbon has also been added directly to suspended growth biological reactors that are operated in either the continuous flow or batch mode. These systems combine physical adsorption and biological treatment in the same reactor and have been used to treat waste streams with a wide variety of organic contaminants. Because the PAC is added to the biological reactor, the mass of microorganisms that can be used in the system is limited. In addition, significant quantities of spent PAC removed from the reactor on a regular basis must be regenerated and replaced. Examples of this system can be seen in: M. J. Dietrich, M. W. Copa, A. K. Chowdhury, and T. L. Randall, "Removal of Pollutants from Dilute Wastewater by the PACT™ Treatment Process," in Environmental Progress, Vol. 7, pp. 143 thru 149 (1988); and Wei-chi Ying, Robert R. Bonk, and Stanley A. Sojka, "Treatment of a Landfill Leachate in Powdered Activated Carbon Enhanced Sequencing Batch Bioreactors," in Environmental Progress, Vol. 6, pps. 1 thru 8 (1987). This technique for treating organic contaminants is expensive, inefficient, and leaves room for improvement because the waste biological solids and the spent PAC are commingled and the PAC is not regenerated by the process.
Some variations to the conventional suspended growth SBRs have been examined, including oxygenation of these suspended growth reactors through gas permeable membranes. A recent development for the use of semipermeable silicone rubber membrane tubing in SBRs to meet high oxygen uptake rates is reported by Peter A. Wilderer, J. Brautigam, and I. Sekoulov, in a paper titled "Application of Gas Permeable Membranes for Auxiliary Oxygenation of Sequencing Batch Reactors," in Conservation and Recycling, Vol. 8, pp. 181-192 (1985). Peter A Wilderer and R. G. Smith also described the use of silicone membranes in conventional suspended growth SBRs for the treatment of hazardous wastes in May 1986 during a presentation at the 41st Purdue Industrial Waste conference in West Lafayette, Ind. The presentation, titled "Treatment of Hazardous Landfill Leachate Using Sequencing Batch Reactors with Silicone Membrane Oxygenation," is published in the conference Proceedings, pp. 272-282 (1987). The studies described in these papers did not investigate the volatilization or stripping of organics present at high concentrations; they considered the growth of biomass on the surface of the silicone rubber membrane tubing as a nuisance (i.e. biofouling) which would minimize the transfer of oxygen to the organisms growing either in suspension or on other support medium; and they did not involve the use of any type of activated carbon. The GAC-SBBR minimizes fugitive emissions, maximizes biofilm growth on gas permeable membranes, and utilizes GAC.
Because of both the high cost associated with the thermal regeneration of spent GAC and the observation that bacteria colonizing GAC extended the time between GAC replacements, there has been considerable interest in the development of bioregeneration techniques for GAC. Examples of some of the early work in this area can be found in: (1) A. Benedek, "Simultaneous Biodegradation and Activated Carbon Adsorption--A Mechanistic Look," in Activated Carbon Adsorption of Organics From the Aqueous Phase, Vol. II, pp. 273-302, edited by M. J. McGuire and I. H. Suffet, published by Ann Arbor Science Publishers, Inc., Ann Arbor, Mich. (1980); (2) A. Benedek and A. Najak. "The Biological Regeneration of Activated Carbon," in a paper presented at 48th Annual Water Pollution Control Federation Conference, Miami Beach, Fla. (1975); (3) W. A. Chudyk and V. L. Snoeyink, "Bioregeneration of Activated Carbon Saturated With Phenol", in a paper presented at the AIChE Annual Meeting, New Orleans, La. (November, 1981); and (4) in a book edited by R. Rice and M. Robson, titled Biological Activated Carbon, Enhanced Aerobic Biological Activity In GAC Systems, published by Ann Arbor Science Publishers, Inc., Ann Arbor, Mich. (1982). In order to accelerate the growth of microorganisms on the surface of the GAC, Peter A. Wilderer and coworkers recently investigated using semipermeable silicone rubber tubing membranes to supply oxygen to biofilms attached to spent GAC. They found that spent GAC saturated with 3-chlorobenzoate was entirely regenerated after 67 days. A description of this study was provided by Von Mustafa Ali Jaar, Harald Krebs, Miguel A. Rubio, and Peter A. Wilderer, "Biologische Regeneration einer mit 3-Chlorbenzoat Beladenen Activkohle," in Journal of Wastewater Research (Z. Wasser- Abwasser Forsch), Vol. 22, pp. 1-4 (1989). Unfortunately, because of the organism growth directly on the GAC, these systems can become clogged with biomass slime and have limited utility after regeneration. This difficulty is avoided in the Granular Activated Carbon-Sequencing Batch Biofilm Reactor described in this application.
The initial work with semipermeable silicone rubber membrane tubing was directed at the supply of oxygen and not at the attachment of biofilms on the membrane surface. The reason for this was that the desired high oxygen transfer rates required that pure oxygen rather than air be used as the source of oxygen. Until recently, investigators believed that biomass attachment on silicone tubing was not possible when pure oxygen was used because oxygen is toxic when present at high concentrations. The first investigators to report on the use of silicone rubber tubing for organism attachment were Eberhard Bock, Peter A. Wilderer, and Annette Freitag in an article titled "Growth of Nitrobacter in the absence of Dissolved Oxygen," in Water Research, Vol. 22, pp. 245-250 (1988). In this study air was passed through the silicone rubber tubing in such a way that the Nitrobacter attached to the tubing and the concentration of dissolved oxygen in the bulk liquid was essentially zero. While this study was focused on a basic research question and does not have direct application to the treatment issues addressed in this application, it did demonstrate the potential value of biofilm attachment on silicone tubing or any other gas permeable membrane.
When air or oxygen flows continuously through the lumen of the silicone tubing, volatile organics which dissolve readily in the silicone rubber escape into the gas phase. Miguel A. Rubio, Harold Krebs, Peter A. Wilderer, and Oliver Debus addressed this problem in a poster presentation titled "Aerobic Degradation Of Benzene, Toluene, and the Isomeric Xylenes by Microorganisms Immobilized on Gas Permeable Membranes," at the Forum on Innovative Hazardous Waste Treatment Technologies: Domestic and International, in Atlanta, Ga., Jun. 19-21, 1989. They reported that the loss of such volatile organics can be minimized by microorganisms which attach to the silicone tubing by forming to biofilm "barrier" to the escaping volatile organics. Results from a similar study were presented by Peter A. Wilderer at conference on the Physiology of Immobilized Cells in Wageningen, The Netherlands, Dec. 10-13, 1989. The title of Peter A Wilderer's presentation was "Immobilization of Cells at Gas Permeable Membranes." In the invention described in this application, we have extended these studies by: (1) providing biofilm growth on gas permeable membranes by using oxygen for the supply of the electron acceptor and other organics (e.g., methane), as needed, for the supply of alternative electron donors, (2) limiting the flow of gases through the gas permeable membrane to that which is needed to meet the demand of the microorganisms only and, thus, minimize the escape of volatile organics in the carrier gases, (3) bioregenerating GAC while minimizing the attachment of biomass to the GAC, and (4) periodically operating the Granular Activated Carbon-Sequencing Batch Biofilm Reactor to remove and destroy volatile, semi-volatile, and non-volatile organic contaminants present in either water, wastewater, or spent GAC.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the complete Granular Activated Carbon-Sequencing Batch Biofilm Reactor system.
FIG. 2 is a drawing illustrating the major elements incorporated into the Sequencing Batch Biofilm Reactor vessel.
FIG. 3 is a detailed sketch of a representative section of the gas permeable membrane mat gas transfer system utilized in the Sequencing Batch Biofilm Reactor.
FIG. 4 is a detailed cross-sectional view of the gas permeable membrane showing the locations of the micro-organism layer in the exogenous electron acceptor or donor gases.
FIG. 5 is a schematic of the laboratory reactor granular activated carbon-sequencing batch biofilm reactor used in the example.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be construed as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed structure.
This multistage process may be used to treat liquid streams or spent granular activated carbon. The contaminants can originate directly from lightly contaminated groundwater, heavily contaminated groundwater (i.e., leachates), landfills, contaminated soils, leaking underground storage tanks, spills and other contaminated dumps, surface water, an industrial or commercial process, spent granular activated carbon, or any other water or wastewater treatment system. The contaminants consist principally of volatile, semi-volatile, and non-volatile organic compounds. Characteristically, the concentration of contaminants in the source water will vary markedly with time. The principal concerns in detoxifying the polluted water or spent granular activated carbon include: (1) the elimination of fugitive contaminant emissions into the atmosphere, (2) ensuring that all the treated waters regardless of their original level of contamination meet the highly stringent clean-up levels established by the governing regulatory agency, and (3) producing granular activated carbon that is regenerated. The subject invention meets these requirements in both an unique and highly efficacious manner.
The mode of operation for the Granular Activated Carbon-Sequencing Batch Biofilm Reactor depends upon what is to be treated. Three cases are described for this invention.
Case 1. In order to ensure that the microorganisms are not exposed to lethal concentrations of the contaminants, the following steps are followed when the system is used to treat water or wastewater that has contaminants present at high concentrations:
1. collecting and otherwise pretreating the waters in a bulk storage tank,
2. adsorbing the biodegradable and nonbiodegradable hazardous and polluting compounds on a granular activated carbon filter,
3. desorbing the biodegradable pollutants off the granular activated carbon creating a waste stream with a relatively uniform concentration of diodegradable contaminants and providing a feed stock for the microorganisms growing as a biofilm on the gas permeable membrane in the Sequencing Batch Biofilm Reactor.
4. destroying the waste stream biodegradable contaminants in a Sequencing Batch Biofilm Reactor using specialized microbes.
Case 2. When the system is used to treat water or wastewater that has contaminants present at low concentrations, the order of the steps described above is modified as is shown below to ensure that there is sufficient substrate (food) for the microorganism to grow:
1. collecting and otherwise pretreating the waters in a bulk storage tank,
2. destroying the biodegradable waste stream contaminants in a Sequencing Batch Biofilm Reactor using specialized microbes,
3. adsorbing residual biodegradable and nonbiodegradable hazardous and polluting compounds on a granular activated carbon filter, and
4. desorbing the biodegradable pollutants off the granular activated carbon creating a waste stream with a relatively uniform concentration of contaminants which are destroyed by the microbes on the biofilm.
Case 3. When the system is used to bioregenerate spent granular activated carbon, the simple recirculation mode of operation described below is followed:
1. the suppling of recirculation waters from a bulk storage tank,
2. desorbing the biodegradable pollutants off the spent granular activated carbon, and
3. destroying the desorbed biodegradable contaminants in a Sequencing Batch Biofilm Reactor using specialized microbes.
In all three cases, the periodic stressing of the microbial consortia and the delivery of the necessary exogenous electron acceptor and donors via the gas permeable membrane in the Sequencing Batch Biofilm Reactor eliminate unwanted transfer of the pollutants from the liquid to the vapor phase, enrich for microorganisms that are capable of destroying contaminants that may have been previously been characterized as nonbiodegradable, and destroy the biodegradable contaminants in a cost effective manner. The use of the granular activated carbon filter to stabilize and concentrate the incoming waste stream allows the biological treatment of contaminated waters in situations where the pollutant concentration is either highly variable and/or normally insufficient to support a viable and efficacious microorganism population.
FIG. 1 is schematically representative of the Granular Activated Carbon-Sequencing Batch Biofilm Reactor treatment system.
A detailed description of the operating characteristics of the Granular Activated Carbon-Sequencing Batch Biofilm Reactor is provided below for each of the major system components shown in FIG. 1. The indicating and controlling devices are described first. This is followed by a description of the equipment.
INDICATING DEVICES
Stock Tank 1 Liquid Level Indicators
LEVEL 1 Emergency High Water Level (HWL). To prevent emergency overflow. Provides alarm and shut down of influent pump system or Valve 6 (if wet).
LEVEL 2 Normal HWL. For normal shut down of influent pump system or Valve 6 (if wet).
LEVEL 3 Low Water Level (LEL). To prevent Draw in Sequencing Batch Biofilm Reactor (SBBR) Tank 3 if there is insufficient volume in Stock Tank 1 to complete Fill (if dry).
SBBR Tank 3 Liquid Level Indicators
LEVEL 4 HWL for normal ending of Fill (if wet).
LEVEL 5 LWL for normal ending of Draw (if dry).
Specific Ion Probe
SBBR Tank 3 recycle outlet line. To indicate and record specific ions (e.g., a pH probe for hydrogen ions).
DO Probes
Two units in series in the SBBR Tank 3 recycle outlet line. To indicate Dissolved Oxygen (DO), record the average value if the difference is equal to or less than some specified low DO (e.g., 0.2 mg/L), and to control the oxygen supply Valve 7. If the difference is greater than the specified difference, an alarm is actuated and Valve 7 fails open.
CONTROLLING DEVICES
VALVE 1 To fill Granular Activated Carbon Tank 2 first either when used to bioregenerate spent granular activated carbon or when used to treat water or wastewater that has contaminants present at high concentrations and to fill SBBR Tank 3 first when used to treat water or wastewater that has contaminants present at low concentrations. Normally closed. Open if LEVEL 2 INDICATOR is wet and Fill is to begin. Closes when Fill ends as indicated by LEVEL 4 INDICATOR becoming wet.
VALVE 2 To provide recycle around SBBR Tank 3 only during the first part of React when used to treat water or wastewater that has contaminants present at low concentrations, and to provide recycle around both Granular Activated Carbon Tank 2 and SBBR Tank 3 when used to bioregenerate spent granular activated carbon, or during the latter part of React when used to treat water or wastewater that has contaminants present at low concentrations, or throughout React when used to treat water or wastewater that has contaminants present at high concentrations. Normally open. Closes at the beginning of Fill and opens when Fill ends.
VALVE 3 To provide SBBR Tank recycle when Granular Activated Carbon Tank 2 is not on line. Normally open when Valve 4 closed. Closed when Valve 4 open.
VALVE 4 To provide recycle around both Granular Activated Carbon Tank 2 and SBBR Tank 3 when Granular Activated Carbon Tank 2 is on line. Normally closed when Valve 3 open. Opens at appropriate time during React or when used to bioregenerate spent granular activated carbon. Closes after predetermined period of time and before Draw begins.
VALVE 5 To provide gravity Draw. Normally closed. Opens if LEVEL 2 INDICATOR is wet and after React has been completed. Closes after LEVEL 5 INDICATOR (i.e., dry) indicates that the SBBR Tank 3 is empty.
VALVE 6 To control flow into the Stock Tank 1. Normally open. Closes if LEVEL 2 INDICATOR (i.e., wet) shows the tank to be full or if LEVEL 1 INDICATOR (i.e., wet) shows alarm and LEVEL 2 INDICATOR failed to provide adequate control.
VALVE 7 To control the flow of oxygen and other gases to the gas permeable membranes in SBBR Tank 3. Normally open. Closes if the DO exceeds some specified limit (e.g., 1.0 mg/L) and opens if it is less than some other lower specified limit (e.g., 0.3 mg/L).
VALVE 8 To control the flow of other gases (i.e., electron donors) to the gas permeable membranes in SBBR Tank 3. Normally open during React and closed during other cycle periods.
Duplex Pumps Between Valves 1 and 3
Two pumps, with one manually selected as a lead pump. Fill to begin with Valve 1 open and lead pump on. Pumping continues throughout React with recycle valves changing as described above. The operating pump shuts off at the end of the required React time.
EQUIPMENT DESCRIPTION
Stock Tank 1
The source water will initially be pumped into Stock Tank 1. Stock Tank 1 is constructed with an integral vapor recovery system and incorporates access for the periodic removal of tank bottoms. Stock Tank 1 serves as: (1) a buffer to stabilize the feed rates into the treatment system for situations where the feed flow rate is highly variable (2) a catch basin to accumulate feed water during periods when maintenance is performed on the treatment system (3) a settling basin to remove suspended solids from the feed water, and (4) a mixing tank to provide an initial stabilization of the contaminant load levels. The Stock Tank 1 is sized to accommodate a minimum of one day's feed fluid flow. It is insulated, has three liquid level indicators, appropriate inlet and outlet connections, and provisions for nutrient supply. All other tanks overflow back to Stock Tank 1. Exhaust gas is diverted to the carbon trap.
Granular Activated Carbon Tank 2
It is insulated as desired and has the appropriate quantity (e.g., to provide adsorption capacity for one week or more) and type of granular activated carbon. The influent is provided at the bottom through a distributor to prevent fluidizing the granular activated carbon bed. The outlet is near the top. Exhaust gas is diverted to the carbon trap.
SBBR Tank 3
FIG. 2 schematically illustrates the internal workings of the Sequencing Batch Biofilm Reactor Tank 3. Feed liquor enters at the top of the reactor and passes over gas permeable membrane mats 4 where the contaminants are removed from the water and destroyed. The gas permeable membrane mats are illustrated in detail in FIG. 3. The mats serve two primary functions. First they supply the necessary exogenous electron acceptors and donors for supporting the appropriate microorganisms without volatizing the contaminants. Second, they provide a surface from which the growth of microorganisms can be controlled. As shown in FIG. 3 the exogenous electron acceptor, either air or oxygen for aerobic metabolism or an alternative electron donor (e.g., methane), is introduced thru the lumen of the tubing. The gas within the lumen of the tubing is normally kept at a positive pressure relative to the rest of the reactor vessel. The exogenous electron acceptor and/or donor gases diffuse from the lumen thru the wall of the tubing to the outer surface of tubing where a thin layer of microorganisms grow. These microorganisms immediately capture the exogenous electron acceptor and donor (if supplied) gas molecules and then, utilizing the liquor pollutants as a carbon source, mineralize the contaminants. Upon completing the mineralization of the contaminants a brief period of quiescence is employed to allow the settling of any suspended solids in the liquor. The treated water is then decanted from the Sequencing Batch Biofilm Reactor Tank 3 and either reused or disposed of appropriately. When used for the bioregeneration of spent granular activated carbon, regenerated granular activated carbon is returned to its source. The entire treatment process is then repeated. The Sequencing Batch Biofilm Reactor Tank 3 is insulated as desired, has two liquid level indicators, an overflow connection to Stock Tank 1, a recycle outlet, a recycle inlet, a withdrawal device, an exhaust gas connection to the carbon trap, and a removable top to examine and replace the gas permeable membrane system.
Gas Supply System
Near optimal conditions for microbial growth in the Sequencing Batch Biofilm Reactor Tank 3 are achieved by maintaining the concentration of DO in the liquor as close to zero as possible. Control of the diffusion rate across the gas permeable membrane is achieved by dynamic adjustment of the source exogenous electron acceptor and electron donor gas pressure. A step down regulator is followed by Valve 7 to prevent high DO in the bulk liquid, and an adjustable pressure regulator is used to hold the pressure in the gas permeable membrane within an appropriate range. A step down regulator and an adjustable pressure regulator are used in conjunction with Valve 8 to control the flow of the electron donor or donors. The material for the gas permeable membrane may be either silicone rubber or any other material that meets different system objectives.
Carbon Trap
In order to prevent the escape of volatile organics from all tanks, exhaust gases are collected and vented through a carbon trap.
Controller
A Microprocessor controller with appropriate number of inputs (e.g., 50) and outputs (e.g. 25), a system clock, and battery backup, is used to provide nearly complete automatic control.
Additional Valves and Piping
Manually operated shutoff valves, check valves, and piping for liquid gas, and electrical controls, are all insulated and are used as described in this section.
EXAMPLE OF THE INVENTION
The following example is given to further describe our invention. It is provided for illustrative purposes only and is not intended to limit the scope of our invention except as defined in the appended claims. This example summarizes the performance of a bench scale granular Activated Carbon-Sequencing Batch Biofilm Reactor which was used for the biodegradation of the volatile organics benzene, toluene, ethylbenzene, and xylenes (i.e BTEX). The material for the gas permeable membrane was silicone rubber. The study was conducted between Aug. 30 and Oct. 11, 1989.
PROCESS DESCRIPTION
The experimental system used is shown in FIG. 4. It was operated as a single tank GAC-SBBR in which wastewater organics were first adsorbed onto a fixed bed of GAC and subsequently degraded by specialized microorganisms inhibiting the system.
During the Fill and React periods, the organics remaining in the liquid phase were biologically converted to carbon dioxide, water, and biomass by the bacteria which grew as a biofilm on the surface of the silicone tubing. As more of the organics were degraded and removed from the bulk liquid, some organics adsorbed on the carbon were desorbed back into solution in order to maintain equilibrium conditions. The rate at which the organics desorbed from the GAC was dependent on the overall absorptive capacity of the GAC and on the rate at which they were metabolized in the bulk liquid by the microorganisms.
The reactor was seeded with Pseudomonas putida-MT2 strain, a bacteria known to degrade BTEX under aerobic conditions. A small portion of activated sludge from a local municipal wastewater treatment plant w as also added to increase the diversity of the bacterial population and possibly provide additional treatment of the wastewater.
Pure oxygen was supplied to the system by diffusion through pressurized (5 psig) silicone rubber tubing which nearly extended the full depth of the reactor. The dissolved oxygen concentration in the bulk liquid was maintained between 0.8 to 1.6 mg/L. During React, maximum contact between the organics in solution and the bacteria was accomplished by using an internal recycle system as depicted in FIG. 4.
ANALYTICAL METHODS
Chemical Oxygen Demand (COD): Method 508C: Closed Reflux, Colorimetric, Standard Methods for the Examination of Water and Wastewater, 16th Edition, 1985.
Total Organic Carbon (TOC): Method 505A: Combustion Infrared Method; Standard Methods, with an Ionics Model 1270 TOC analyzer.
Individual BTEX's: USEPA Method 5030 (Purge and Trap) followed by Method 820 (GC) for volatile non-halogenated aromatics as described in: Test Methods for Evaluating Solid Waste, Vol. 1B: Lab Manual, Physical/Chemical Methods; USEPA SW-846, 3rd edition, November 1986.
GAC Extraction Procedure: OSHA Method #12: Benzene Analysis for Air and bulk samples, in: Organic Methods, OSHA Analytical Laboratory Salt Lake City, Utah, 1980.
Dissolved Oxygen: Was measured in the reactor using a YSI Model 5300 Biological Oxygen Monitor.
WASTEWATER CHARACTERISTICS
The wastewater used in this study was acquired from a BTEX contaminated aquifer. Because most of the original BTEX in the sample had been lost during shipping and storage, the wastewater was spiked in the laboratory with additional amounts of BTEX to bring their concentration up to the levels detected at the well site. Additionally, the wastewater was found to be low in essential macro-nutrients, such as phosphorus and nitrogen. These, along with other necessary micro-nutrients that are listed below were added to the wastewater prior to treatment.
______________________________________ ConcentrationCompound mg/L______________________________________K.sub.2 HPO.sub.4 1,250Na.sub.2 HPO.sub.4 1,730(NH.sub.4).sub.2 SO.sub.4 185MgSO.sub.4.7H.sub.2 O 74CaCl.sub.2.2H.sub.2 O 4(NH.sub.4).sub.6 Mo.sub.7 O.sub.24.4H.sub.2 O 0.04FeSO.sub.4.7H.sub.2 O 2ZnSO.sub.4.7H.sub.2 O 2MnSO.sub.4.H.sub.2 O 0.4CuSO.sub.4.H.sub.2 O 0.04CoCl.sub.2.6H.sub.2 O 0.06Na.sub.2 B.sub.4 O.sub.4.10H.sub.2 O 0.04EDTA 1.0______________________________________
The feed and reactor pH were maintained between 6.8-7.0 by the addition of a 15 mM phosphate buffer.
The average organic composition of the wastewater is listed below.
______________________________________ ConcentrationCompound mg/L______________________________________Benzene (B) 33.8Toluene (T) 43.8Ethyl-Benzene (E) 9.1p-Xylene (p-X) 8.8m-Xylene (m-X) 9.0o-Xylene (o-X) 12.8Total Chemical Oxygen Demand (COD) 397Total Organic Carbon 116______________________________________
The daily reactor fill volume and chemical characteristics of wastewater supplied to the reactor are listed below. The fill volume for each cycle was 600 mL.
__________________________________________________________________________Total Fill Daily Influent CharacteristicsDate per day COD TOC B T E p-X m-X o-X(1989) mL mg/L mg/L mg/L mg/L mg/L mg/L mg/L mg/L__________________________________________________________________________09/18600 433 126 26.10 46.60 12.93 11.95 12.68 18.2009/19600 302 88 21.37 33.26 7.41 6.71 7.17 10.8309/20600 319 93 16.20 37.84 9.00 8.03 8.60 12.3009/21600 499 146 42.51 44.36 15.19 13.89 14.61 19.3009/22600 357 104 24.51 37.71 9.93 9.04 9.60 13.3809/23600 300 88 20.82 30.08 8.36 7.68 8.13 11.1209/24600 300 88 20.82 30.08 8.36 7.68 8.13 11.1209/25600 342 100 22.70 43.49 7.99 6.84 7.97 10.6709/26 1200 353 103 14.77 47.35 10.12 8.42 9.73 12.5109/27 2400 459 134 41.34 48.41 10.28 10.96 10.67 15.8309/28 2400 422 123 37.25 52.84 6.33 8.00 8.20 12.6609/29 2400 442 129 38.38 53.69 9.97 8.13 8.97 12.6809/30 1200 443 129 38.38 53.69 9.97 8.13 8.97 12.6810/01 1200 372 109 40.79 44.49 3.38 5.97 5.67 9.2010/02 2400 400 117 39.10 41.48 7.89 8.71 8.56 12.4710/03 2400 342 100 36.45 35.60 6.42 6.17 5.88 9.3110/04 2400 382 112 37.86 44.45 7.24 6.85 6.54 9.8010/05 2400 448 131 42.76 45.15 11.02 10.69 10.20 13.7710/06 2400 453 133 43.15 49.77 10.29 9.88 9.39 12.9610/07 1200 453 133 43.15 49.77 10.29 9.88 9.39 12.9610/08 1200 429 126 39.60 41.97 10.32 10.66 10.32 14.7310/09 2400 440 129 44.47 47.74 8.77 9.02 8.88 12.3410/10 2400 440 129 44.47 47.74 8.77 9.02 8.88 12.34__________________________________________________________________________
EFFLUENT CHARACTERISTICS
During the period of operation, Sep. 18 thru Oct. 11, 1989, effluent COD and individual BTEX compounds were monitored daily. The average effluent characteristics at hydraulic residence times (HRT) of 10-40 hours were as follows:
______________________________________ ConcentrationCompound μg/L (range) % Removal______________________________________Benzene 18 (<0.2-61) >99.9Toluene 11 (<0.2-35) >99.9Ethyl-Benzene 3.8 (<0.2-22) >99.9p-Xylene 3.7 (<0.2-25) >99.9m-Xylene 3.1 (<0.2-26) >99.9o-Xylene 3.8 (<0.2-28) >99.9COD <24,000 >94TOC <5,700 >95______________________________________
Little variation in effluent quality was noted over entire range of HRT's tested. Daily average effluent BTEX, COD and TOC concentrations are shown below.
__________________________________________________________________________Daily Effluent CharacteristicsCOD TOC B T E p-X m-X o-XDate mg/L mg/L μg/L μg/L μg/L μg/L μ/L μg/L__________________________________________________________________________09/20/89-- -- 14.9 23.8 13.3 17.4 17.0 18.609/21/89-- -- 26.7 34.0 14.0 14.1 11.4 9.109/22/89-- -- 14.0 19.7 6.0 7.0 7.0 6.709/25/8931 11 6.8 6.7 ND* ND ND ND09/26/8923 4 ND 8.3 ND ND 3.3 ND09/27/89<25 5 4.0 2.0 1.2 1.3 1.3 1.909/28/89<25 3 0.2 ND 0.2 0.7 0.4 0.509/29/89<25 4 ND ND ND ND ND ND10/02/8923 4 ND ND ND ND ND ND10/03/8923 4 40.0 13.0 2.5 1.9 0.7 2.510/04/8921 4 30.0 12.0 1.5 1.3 0.6 1.610/05/8929 5 57.5 22.5 7.5 7.0 4.0 8.010/06/8928 5 57.0 26.5 4.6 3.8 2.8 4.710/07/89-- -- 19.0 7.0 2.0 2.0 1.0 2.010/08/8928 8 28.1 10.2 3.0 2.0 2.0 3.010/09/8926 11 3.0 2.0 7.0 1.2 0.3 1.410/11/8916 6 1.0 1.0 0.2 2.0 ND 3.0__________________________________________________________________________ *ND = not detected with method detection limit of 0.2 μg/L for each compound.
VOLATILIZATION
As previously mentioned, volatilization was minimized by the use of the silicone rubber tubing oxygen supply system. The total mass of BTEX lost due to volatilization was very small, approximately 1 mg total over 23 days and 58 operating cycles. This was less than 0.05% of the total mass of BTEX applied to the system over the same period.
ADSORPTION AND BIODEGRADATION
At the end of the 23 day testing period, portions of the reactor GAC were extracted with carbon disulfide (OSHA method #12, 1980) and analyzed for BTEX. Based on these measurements it was estimated that 55% of the total mass of BTEX added was present on the activated carbon. The removal of BTEX by biodegradation was estimated to be approximately 45% of the total mass added during the period.
OXYGEN UPTAKE RATES
Measured oxygen uptake rates in the reactor ranged from 13-28 mg/L (of reactor volume) per hour. These relatively aggressive rates confirm the biological degradation of 45% of the BTEX added during the study period.
Although our invention has been described using the above example and certain preferred embodiments thereof, we do not intend that our invention be limited in scope except as expressly defined in the appended claims. | A periodic multistage process which minimizes fugitive pollutant emissions has been developed for the removal and destruction of volatile, semi-volatile, and non-volatile organic contaminants from either water, wastewater, or spent granular activated carbon. This invention relates to methods, materials, and systems for treating these contaminants by a process and devices which uniquely combine granular activated carbon adsorption and desorption with biological treatment. The process and devices extend existing treatment systems by: (1) providing biofilm growth in a Sequencing Batch Biofilm Reactor on gas permeable membrane which uses oxygen for the supply of the electron acceptor and other organics (e.g., methane), as needed, for the supply of alternative electron donors, (2) limiting the flow of gases to that which is needed to meet the demand of the microorganisms only and, thus, minimize the escape of volatile organic contaminants in the carrier gases, (3) bioregenerating granular activated carbon while minimizing the attachment of biomass to the granular activated carbon, and (4) periodically operating the Granular Activated Carbon-Sequencing Batch Biofilm Reactor system to remove and destroy the organic contaminants present in either water, wastewater, or spent granular activated carbon. The system also optimizes the use of nutrient additives and minimizes the production of unwanted waste byproducts while ensuring that all treated waters, regardless of their original level of contamination, meet the highly stringent clean-up levels established by governing regulatory agencies, and producing granular activated carbon that is regenerated. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a connector for a brassiere. More particularly, the present invention relates to a shaped connector for connecting a brassiere shoulder strap preferably to a brassiere, preferably to a back panel of the brassiere.
[0003] 2. Description of Related Art
[0004] The common problem with a shoulder strap of a brassiere is that the strap can be misaligned on a wearer's shoulder and, thus, will dig into the shoulder due to the connection of the shoulder strap to the back panel of the brassiere. Even if the shoulder strap is aligned properly, it may nonetheless become uncomfortable after use due to the shape of the shoulder strap, its alignment with the back panel, and the anatomy of the shoulder and back of the wearer.
[0005] There is a need for a brassiere strap that avoids misalignment, improves the connection between the back panel and shoulder strap to provide angular flexibility to adapt or conform to the actual anatomy of a top of a wearer's shoulder, thereby enhancing comfort for the wearer. Accordingly, such a connector needs to be angled so that the shoulder strap, at its connection to the back panel, is angularly biased thereby enhancing comfort, since there is no slippage of the shoulder strap off the shoulder.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a connector for a brassiere shoulder strap that connects a shoulder strap to a brassiere, preferably at a back panel of the brassiere.
[0007] It is an additional object of the present invention to provide a connector for a brassiere shoulder strap that connects a shoulder strap to a brassiere at a front panel of the brassiere.
[0008] It is another object of the present invention to provide a connector for a brassiere shoulder strap that biases the shoulder strap as desired while on the shoulder of the wearer.
[0009] It is still another object of the present invention to provide such a connector for a brassiere shoulder strap that has a triangular shaped configuration.
[0010] It yet another object of the present invention to provide such a connector that forms a heart shape.
[0011] It is a further object of the present invention to provide such a connector for a brassiere shoulder strap that has two arms that meet at one edge and angle away from each other at the distal edges.
[0012] It is a still further object of the present invention to provide such a connector for a brassiere shoulder strap that has two arms that meet at one edge and form the same angle away from each other.
[0013] It is a yet further object of the present invention to provide such a connector for a brassiere shoulder strap that has two arms that meet at one edge and form an angle away from each other, which angle is an acute angle.
[0014] It is a still yet further object of the present invention to provide such a connector for a brassiere shoulder strap that has two arms that meet at one edge and form an angle away from each other, which angle is about forty degrees.
[0015] These and other objects and advantages of the present invention are achieved by the connector of the present invention. The connector is for use, preferably to connect a brassiere shoulder strap to the brassiere. The connector comprises a first arm having a first end and a second end, a second arm having a first end connected to the first end of the first arm and having a second end that angle away from the second end of the first arm. Preferably, the connector has a wave or top portion that connects the second end of the first arm and the second end of the second arm together. In a preferred embodiment, the first arm is positioned for sliding engagement with a shoulder strap of a brassiere, and the second arm is positioned for sliding engagement with an edge of a back panel of the brassiere so that the shoulder strap and the edge form that same angle. The connector provides that the shoulder strap and back panel angle towards the spine of a wearer.
[0016] The wave portion can form an opening for sliding engagement the shoulder strap and back panel to the connector. In preferred embodiments, the wave portion has a flange to separate or space the shoulder strap from the material that is connected to the back panel. Also, the wave portion preferably has tapered sides of the flange to engage the shoulder strap and the material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other features, aspects, and advantages of the present disclosure will become better understood with regard to the following description, appended claims and accompanying drawings:
[0018] FIG. 1 is a plan view of an example fastener of the present invention;
[0019] FIG. 2 is a side view of the fastener of FIG. 1 ;
[0020] FIG. 3 is a plan view of the fastener of FIG. 1 engaging a shoulder strap and back panel of a brassiere;
[0021] FIG. 4 is a second plan view of the brassiere of FIG. 3 ;
[0022] FIG. 5 is a plan view of a second embodiment of the fastener of the present invention engaging a shoulder strap and a back panel of a brassiere; and
[0023] FIG. 6 is a second plan view of the brassiere of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring to the drawings and, in particular, FIGS. 1 and 2 , there is shown a first embodiment of a fastener of the present invention generally represented by reference numeral 100 . In this first embodiment, the fastener 100 has a first side or arm 110 with a first end 112 and a second end 114 , and a second side or arm 120 with a first end 122 and a second end 124 . The first end 112 of the first arm 110 and the first end 122 of the second arm 120 preferably meet or connect at point or plane 130 . Preferably, connector 100 has a third or top or wave portion 140 that connects together the second end 114 of first arm 110 and the second end 124 of second arm 120 .
[0025] The first arm 110 and second arm 120 form an angle 150 with respect to each other. The angle 150 determines the bias of the shoulder strap and the other part, such as a back panel, of a brassiere with respect to each other. The angle 150 is any acute angle, such as between about 25 to 45 degrees, and preferably about 27 to 41 degrees.
[0026] The third or wave portion 140 has a pair of symmetric arcuate portions 142 that meet at a flange 145 . The flange 145 preferably aligns axially with the point 130 of connection of first end 112 of first arm 110 and the first end 122 of second arm 120 . The flange 145 preferably has a pair of tapered sides 146 , separating the shoulder strap and back strap or any extension of the back strap, such as, for example, the back elastic. In a front-opening brassiere, the flange 145 separates the shoulder strap and front strap. Preferably, the tapered sides 146 taper at an angle that makes the sides parallel to first and second arms 110 , 120 . Thus, a pair of slots 148 are formed therebetween.
[0027] The connector 100 has any angular configuration in which there are two arms or portions that provide a non-parallel relationship with respect to each other. Preferably, connector 100 has a triangular shape configuration. More preferably, connector 100 has a heart shape configuration.
[0028] As shown in FIG. 2 , connector 100 has a thin profile so as not to appear bulky or feel heavy when on the shoulder of a wearer. In the back closure brassiere shown in FIGS. 3 to 6 , connector 100 separates the shoulder strap and back strap.
[0029] Referring to FIGS. 3 and 4 , connector 100 is shown in position on a brassiere 200 . First arm 110 engages a shoulder strap 300 by being positioned in a hollow end 304 of the shoulder strap. Likewise, second arm 120 engages a hollow edge or material 314 of a back panel 310 . In this embodiment, shoulder strap 300 and back panel 310 are angled inward towards each other and towards the spine of the wearer, or generally towards the center or spine of a wearer's back, forming a v-shape.
[0030] The angle of the shoulder strap 300 and material 314 of back panel 310 comes from the angle 150 of fastener 100 . The angle 150 can be varied to achieve various effects. In the embodiment shown, both first arm 110 and second arm 120 are angled away from plane 130 . However, in an alternative, less preferred embodiment, first arm 110 or second arm 120 may be parallel to plane 130 , while the other of the first and second arms is angled away from each other.
[0031] The flange 145 , due to its width between its pair of sides 146 , separates shoulder strap 300 and material 314 . The sides 146 of flange 145 and first arm 110 and second arm 120 preferably form parallel edges to form a pair of slots 148 for receipt of hollow end 304 of shoulder strap 300 and material 314 of back panel 310 .
[0032] As stated before, connector 100 may also be used on any extensions of the back strap. Connector 100 may also be used with a front strap for a front-opening brassiere. Connector 100 is made of any material conventionally used for brassiere connectors, such as metal or plastic. Preferably, connector 100 is made of high carbon steel coated with nylon powder. Thus, a preferred connector 100 has a weight of about 85% steel and 15% nylon.
[0033] FIGS. 5 and 6 show a second embodiment of the fastener 100 of the present invention. In this embodiment, fastener 100 has an oval configuration or shape. Also, fastener 100 has a pair of angles 160 . As a result, shoulder strap 300 and material 314 of back panel 310 again are angled or biased with respect to each other.
[0034] It is to be understood that the drawings and detailed description are intended to be illustrative and not restrictive. Embodiments other than the examples in the drawings and detailed description may be used. Other embodiments will be apparent to those of skill in the art upon reviewing the above description, such as square, octagon, triangle, and other shapes and various angles for the fastener. Structural, mechanical, and material changes may be made without departing from the spirit and scope of the present disclosure. Various designs of brassieres and other intimate apparel are contemplated by the present disclosure, even though some minor elements would need to change, such as design and function. The present invention has applicability to fields other than brassieres, such as athletic apparel. Therefore, the scope of the present invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | A brassiere shoulder strap connector is shaped so that the shoulder strap is positioned at a desired angle to better accommodate the anatomy of the wearer's shoulder. Preferably, the connector has a triangular shape. | 0 |
TECHNICAL FIELD
The present disclosure relates to a method for determining parameters of a reaction of a gamma quantum within a scintillator of a PET scanner.
BACKGROUND
Images of the interiors of bodies may be acquired using various types of tomographic techniques, which involve recording and measuring radiation from tissues and processing acquired data into images.
One of these tomographic techniques is positron emission tomography (PET), which involves determining spatial distribution of a selected substance throughout the body and facilitates detection of changes in the concentration of that substance over time, thus allowing to determine the metabolic rates in tissue cells.
The selected substance is a radiopharmaceutical administered to the examined object (e.g. a patient) before the PET scan. The radiopharmaceutical, also referred to as an isotopic tracer, is a chemical substance having at least one atom replaced by a radioactive isotope, e.g. 11 C, 15 O, 13 N, 18 F, selected so that it undergoes radioactive decay including the emission of a positron (antielectron). The positron is emitted from the atom nucleus and penetrates into the object's tissue, where it is annihilated in reaction with an electron present within the object's body.
The phenomenon of positron and electron annihilation, constituting the principle of PET imaging, consists in converting the masses of both particles into energy emitted as annihilation photons, each having the energy of 511 keV. A single annihilation event usually leads to formation of two photons that diverge in opposite directions at the angle of 180° in accordance with the law of conservation of the momentum within the electron-positron pair's rest frame, with the straight line of photon emission being referred to as the line of response (LOR). The stream of photons generated in the above process is referred to as gamma radiation and each photon is referred to as gamma quantum to highlight the nuclear origin of this radiation. The gamma quanta are capable of penetrating matter, including tissues of living organisms, facilitating their detection at certain distance from object's body. The process of annihilation of the positron-electron pair usually occurs at a distance of several millimeters from the place of the radioactive decay of the isotopic tracer. This distance constitutes a natural limitation of the spatial resolution of PET images to a few millimeters.
A PET scanner comprises detection devices used to detect gamma radiation as well as electronic hardware and software allowing to determine the position of the positron-electron pair annihilation event on the basis of the position and time of detection of a particular pair of the gamma quanta. The radiation detectors are usually arranged in layers forming a ring around object's body and are mainly made of an inorganic scintillation material. A gamma quantum enters the scintillator, which absorbs its energy to re-emit it in the form of light (a stream of photons). The mechanism of gamma quantum energy absorption within the scintillator may be of dual nature, occurring either by means of the Compton's effect or by means of the photoelectric phenomenon, with only the photoelectric phenomenon being taken into account in calculations carried out by current PET scanners. Thus, it is assumed that the number of photons generated in the scintillator material is proportional to the energy of gamma quanta deposited within the scintillator.
When two annihilation gamma quanta are detected by a pair of detectors at a time interval not larger than several nanoseconds, i.e. in coincidence, the position of annihilation point along the line of response may be determined, i.e. along the line connecting the detector centers or the points within the scintillator strips where the energy of the gamma quanta was deposited. The coordinates of annihilation place are obtained from the difference in times of arrival of two gamma quanta to the detectors located at both ends of the LOR. In the prior art literature, this technique is referred to as the time of flight (TOF) technique and the PET scanners utilizing time measurements are referred to as TOF-PET scanners. This technique requires that the scintillator has time resolution of a few hundred picoseconds.
Light pulses reaching the scintillator can be converted into electric pulses by means of photomultipliers or photodiodes. Electric signals from the converters carry information on positions and times of the annihilation quanta subject to detection, as well as on the energy deposited by these quanta.
The principal elements of the signal processing system within the radiation detectors are leading edge discriminators and constant fraction discriminators. These elements, combined with time-to-digital converters, facilitate the measurement of time at which the electric signals generated at these detectors exceed a preset reference voltage or a preset signal amplitude fraction, respectively. Said discriminators are built on the basis of standard electronic components and include, among other components, a current source, a preamplifier, a comparator, a shaper, capacitors, resistors, diodes, transistors and transmission lines. If the detector signal is higher than the threshold voltage set at the discriminator, a logical signal is generated at the discriminator output, carrying information on the time at which the gamma quantum was recorded. The charge is measured by means of analog-to-digital converters.
Temporal resolutions of leading edge and constant fraction discriminators are limited by the dependence of the discriminator response on the shape of signals and, in case of leading edge discriminators, also on the amplitude of input signals. Due to the so-called time walk effect, time determined using leading edge discriminators changes along with the signal amplitude. The effect may be adjusted to a certain degree if the signal charge or amplitude is measured simultaneously. In case of constant fraction discriminators, the time at which the signal exceeds the preset amplitude fraction is generally not dependent on the amplitude, but it may change depending on the shape of the signal (i.e on the temporal distribution of photons).
Logical signals generated at discriminators are processed by means of sequences of logical operations within a triggering system. These operations result in a logical signal providing information on whether the recorded event should be subjected to further electronic processing. The sequences of logical operations are selected depending on the types of detectors, configuration of modules and the frequencies of recorded events; the main objective of these operations is to discard signals that are not useful for image reconstruction and thus to minimize acquisition dead times as well as times required to process the data and reconstruct the images.
The PCT applications WO2011/008119 and WO2011/008118 describe various aspects of PET scanners that may be of relevance for understanding this description, in particular, a method for determining the place of ionization on the basis of the distribution of times or amplitudes of signals measured at different positions along the scintillator. These documents describe solutions that are based on the measurements of the times of flight required for light pulses to reach detector edges. Changes in shapes and amplitudes of signals depending on the place of ionization and the quantity of energy constitute a constraint in temporal resolutions that can be achieved using the technique. The larger the scintillator, the larger the variations in signal shapes and amplitudes. For the above reasons, temporal resolutions of less than 100 ps cannot be obtained for large scintillator blocks according to the prior art. Temporal resolution also impacts the resolution of ionization place determination. In case of polymer scintillators (preferred due to their low price), amplitudes of signals generated by the gamma quanta, including annihilation gamma quanta used in positron emission tomography, are characterized by continuous distribution resulting from interactions between gamma quanta and electrons occurring mostly via the Compton effect with a negligibly low probability of a photoelectric effect. As a consequence, signal amplitudes in polymer scintillators may change even if the signals originated in the same position. In case of Compton interactions, constraints in the achieved resolution are due to the fact that the amplitude of electric signals generated by the photomultipliers depends on two unknown values, namely on distance between the ionization place and the photomultiplier and on energy deposited by the gamma quantum. The effects described above contribute to deterioration in both temporal and spatial resolution also in case of monoenergetic energy-loss distributions, which occur e.g. in the photoelectric effect.
As evidenced by the shortcomings of the state of the art signal analysis techniques described above, there is a need to significantly improve temporal and spatial resolution of detectors being used in medical diagnostic techniques that require the recording of ionizing radiation. The need to improve resolution is particularly high in large-sized detectors.
One of the developed improvement methods is continuous sampling of analog signals in temporal domain. Continuous sampling known from the state of the art is associated with operation of an ADC converter which collects a specific number of analog signal samples at predefined time intervals. However, the method is not capable of improving results in case of rapid signals from polymer scintillators, characterized by decay and rise times on the order of 1 ns. Sampling frequencies that may be practically applied in devices featuring a large number of detectors are on the order of 100 MHz (Flash ADC). This sampling frequency corresponds to sampling intervals of 10 ns, which are comparable to the duration of the signal itself. Therefore, even if the sampling frequencies were higher by an order of magnitude, they would still be insufficient for analyzing signals from polymer scintillators.
It would be desirable to develop a detector and a method for determining the position and time of ionization in polymer scintillators.
SUMMARY
There is presented a method for determining parameters of a reaction of a gamma quantum within a scintillator of a PET scanner, comprising transforming a signal measured in the scintillator using at least one converter into an electric measurement signal, wherein the method comprises the steps of: obtaining access to a reference parameters memory comprising reference signals represented in a time-voltage (W t-v ,) coordinate system and in a time-amplitude fraction (W t-f ) coordinate system and having associated reaction parameters; sampling the electric measurement signal (S) measured in the time-voltage (P t-v ) coordinate system and in the time-amplitude fraction (P t-f ) coordinate system; comparing results of the sampling (P t-v , P t-f ) of the electric measurement signal (S) with the reference signals (W t-v W t-f ) and selecting reference shape parameters so that the reference (W) is best fitted to the results of the sampling (P t-v , P t-f ) of the electric measurement signal (S); and determining the parameters of the reaction of the gamma quantum within the scintillator for the electric measurement signal (S) based on pre-calibrated functions that determine the values of parameters of signal shape depending on the parameters of the reaction of gamma quantum within the scintillator.
Preferably, sampling in the time-voltage coordinate system and in the time-amplitude fraction coordinate system is performed by means of a multithreshold leading edge discriminator and a multithreshold constant fraction discriminator.
Preferably, the parameters of the reaction of the gamma quantum include energy deposited within the scintillator as well as position and time of the reaction.
Preferably, the fit quality is determined from the minimum chi-square value (χ 2 min).
There is also presented a system for determining parameters of a reaction of a gamma quantum within a scintillator of a PET scanner wherein the signal measured in the scintillator is transformed using at least one converter into an electric measurement signal (S), the system comprising a reference parameters memory comprising reference signals in a time-voltage (W t-v ,) coordinate system and in a time-amplitude fraction (W t-f ) coordinate system along with reaction parameters assigned to the reference signals; a multithreshold leading edge discriminator configured to sample the electric measurement signal (S) in the time-voltage (P t-v ) coordinate system; a multithreshold constant fraction discriminator designed to sample the electric measurement signal (S) in the time-fraction (P t-f ) coordinate system; a comparator configured to compare the results of the sampling (P t-v , P t-f ) of the electric signal (S) with the reference signals (W t-v , W t-f ) and to select the parameters determining the shape of the reference (W) that are best fitted to the results of the sampling (P t-v , P t-f ) of the electric signal (S) and to determine the parameters of the reaction of the gamma quantum within the scintillator from pre-calibrated functions that determine the values of parameters of signal shape depending on the parameters of the reaction of the gamma quantum within the scintillator.
The presented method is distinguished by the fact that a signal from a single photomultiplier is sufficient for determination of the parameters and in that it allows to achieve temporal and spatial resolutions better than those of the solutions known from the state of the art when a higher number of photomultipliers is used. In general, the presented method also allows to determine the time of interaction, the distance between the place of interaction and the converter as well as the energy deposited by the gamma quanta within large-size polymer detectors even when a single photomultiplier is used, which has not been attainable in solutions known in the art.
BRIEF DESCRIPTION OF FIGURES
Example embodiments are presented on a drawing wherein:
FIG. 1 presents the outline of an example detection system;
FIGS. 2A and 2B present the sampling in voltage and amplitude fraction domains;
FIG. 3A-3D compare the effects of sampling in voltage and amplitude fraction domains;
FIG. 4 presents the effect of the distance between the place of the reaction and the converter on the signal profile;
FIG. 5 presents an example strip detector;
FIG. 6 presents example detector responses for three different places of reactions of a gamma quantum within the scintillator.
DETAILED DESCRIPTION
FIG. 1 presents the outline of the detection system. The system comprises scintillator 1 and converter 2 that converts the light signals from the scintillator into electric signals S. The electric signals S are delivered to multifractional constant fraction discriminator 3 and a multithreshold leading edge discriminator 4 . Discrimination of signals is carried out with respect to a triggering signal generated by the triggering system 5 . In addition, the system consists of a TDC converter 6 , an ADC converter 7 and a computer 12 comprising a threshold setting and data readout system 8 used to define thresholds at discriminators 3 , 4 and to read the data delivered from the TDC converter 6 and the ADC converter 7 . In addition, computer 12 comprises a comparator 9 that collects and compares information from the threshold setting and data readout system 8 and the reference parameters memory 10 , allowing to determine the similarity of data and thus to obtain the parameters 20 . The entire process is described in more detail below.
FIG. 2A presents the sampling of the signal in the voltage domain using a multithreshold (n-threshold) leading edge discriminator 4 , while FIG. 2B presents the sampling of the signal in the amplitude fraction domain using a multifractional (m-fractional) constant-fraction discriminator 3 . Simultaneous sampling of the signal in both domains facilitates precise determination of the position and the time of the interaction between the gamma quantum and the scintillator strip as well as determination of the energy deposited by the gamma quantum within the scintillator. The reconstruction method transforms the defect consisting in a variation in signal shape and amplitude dependent on the distance between the place of ionization and the photomultiplier (cf. FIG. 4 ) to an advantage facilitating reconstruction of said place on the basis of said variation. The method for reconstructing the ionization place was developed on the basis of the following findings:
(a) the shape of the light signal (number of photons as a function of time) at the ionization place does not depend on the place of reaction of the gamma quantum; (b) the signal amplitude increases monotonously with the energy deposited by the gamma quantum; (c) the shape of the light pulse reaching the photomultiplier depends on the distance between the ionization place and the photomultiplier; (d) the image of the signal sampled within the amplitude fraction domain does not depend on the shape of that signal; (e) the image of the signal sampled within the voltage domain depends on both the amplitude and the shape of the signal ( FIG. 3 ).
Characteristics (a) and (b) are commonly known and require no explanation.
Characteristic (c) is derived from observation that photons diverge at different angles from the place of pulse generation and therefore the distances (and thus times) traveled by individual photons from the ionization place to the photomultiplier depend on the angle of photon emission.
Characteristics (d) and (e) were concluded from the fact that the output of the leading edge discriminator preset with the reference voltage of V 0 is time “t” being the solution of the equation V(t)=V 0 , where V(t) is the voltage vs. time relationship (signal shape—solid line in FIG. 2 ). At the same time, a constant-fraction discriminator provides a value of variable “t” that “solves” the equation V(t)=f·A where A is the signal amplitude and f is the fraction set at the discriminator. For a particular pulse shape, e.g. g(t), the function of amplitude may be expressed as: V(t)=A·g(t). This means that given a particular signal shape and a preset fraction f, the constant fraction discriminator operating on signal V(t) should give the value of time t that provides the solution for equation g(t)=f that depends only on the preset fraction f and not on the signal amplitude A. This has been visually illustrated on the right side of FIG. 3 .
FIGS. 3A-3D present a scheme that illustrates qualitative differences between discretization of signals within the voltage-time space as shown in FIGS. 3A and 3C and within the amplitude fraction-time space as shown in FIGS. 3B and 3D . An example of sampling of signals of the same shape but amplitude differing by a factor of 2 is presented. The graph illustrates the fact that the trace of the signal discretized in the amplitude fraction domain does not depend on the amplitude itself. At the same time, the shape of the signal discretized within the voltage domain depends on the amplitude.
The signal discretized using an n-threshold leading edge discriminator consist of a set of points (V i ,t i ) where i=1, 2 . . . , n—this signal corresponds to results of sampling within the P t-v representation system. Discretization using an m-fraction constant fraction discriminator provides a set of points (f j ,t j ) where j=1, 2 . . . , m, wherein this set corresponds to results of sampling within the P t-f representation system. The change in the shape may be measured for example by deviation from a predefined reference W. The reference W may consist in the shape of the signal generated by an infinitesimally small scintillator and expressed within the time-voltage representation system (referred to as reference W t-v ) and the time-amplitude fraction representation system (W t-f ); in general, however, the reference may be of any shape, for example that of a straight line approximating the shape of the rising edge:
V std ( t )= a sp —std ·t+b sp
and
f std ( t )= a sf _ std ·t+b sf
In the above example of a straight line, the shape V(t) is given by a linear function with slope a and intercept b. The reference slope in fraction vs. time representation system may differ from this in the voltage vs. time representation system. The shape is determined by slope a.
The consistency of the signal with the reference is measured by the minimum chi-square value (χ 2 min ) obtained from the fitting of the reference shape to the discretized signal when b is the only variable parameter. Chi-square is the standard measure of consistency between the function being fitted and the results of the measurement, used for example in the least square fitting method.
Therefore, the distance between the ionization place x and the photomultiplier ( FIG. 4 ) may be determined from discretization of the signal within the amplitude fraction domain from the relationship χ sf 2 min (x) obtained after previous calibration, for example using a collimated beam of annihilation quanta. Calibration consists in determination of the function χ sf 2 min (x); given a collimated beam, one may perform measurements for different x values and determine χ sf 2 min of the recorded signals for every x.
χ sp 2 min is the minimum value of function
χ sf 2 ( a sf _ std, b sf )=Σ( t j _ fit ( a sf _ std ,b sf )− t j ) 2
with b sf as the free fit parameter. In the above definition, t j stands for the signal time measured for the j-th amplitude fraction and t i _ fit (a sf _ std , b sf ) stands for the time of the j-th amplitude fraction calculated from the fitted curve f std (t). The place of ionization x may also be determined from the relationship a sf (x) obtained from previous calibration. In this case, the f fit (t)=a sf ·t+b sf function is being fit with both a sf and b sf as free parameters.
Next, following determination of the ionization place, the signal amplitude is determined on the basis of the signal discretized within the voltage domain from the relationship a sp (A,x) or χ sp 2 min (A,x) obtained after previous calibration, for example using a collimated beam of annihilation quanta. χ sp 2 min is the minimum value of function
χ sp 2 ( a sp _ std ,b sp )≡Σ( t j _ fit ( a sp _ std ,b sp )− t j ) 2
with both a sp and b sp as free parameters. The signal amplitude may also be determined as the highest reference voltage at which a logical pulse has been generated by the discriminator.
With the knowledge of the signal amplitude and the distance between the ionization place and the photomultiplier, the energy deposited within the scintillator is determined from previously prepared calibration curves. To this end, one should establish independent calibration references E(x,A)—for each position x, the relationship E(A), where E is the deposited energy and A is the signal amplitude, should be determined.
Next, the photomultiplier signal onset time (t 0 ) can be determined from functions V fit (t) and f fit (t), for instance as a weighted average with weights consisting of the uncertainties of fitting, using the following equations: V fit (t 0 )=0 and f fit (t 0 )=0.
The photomultiplier signal onset time can be determined after parameters of functions V fit (t) and f fit (t) are established. The functions are fitted to the measurement results. In the example embodiment described herein, the function is a straight line approximated to the rising edge of signal, but it may also be another function that would better reflect the shape of the signal onset. Regardless of the shape of the function, the effective signal onset may be calculated, for example as a solution of the equation V fit (t)=0. Thus, in case of a straight line, solution of the equation would involve identification of a parameter t at which the line intercepts the x axis.
Preferably, the shapes of the fitting functions V fit (t,x) and f fit (t,x) are independently tabulated for every detection module after being calibrated using appropriate radiation type, for example annihilation radiation in case of detectors used in positron emission tomography. Preferably, the light signal from the scintillator is converted into an electric impulse in more than one place.
FIG. 4 presents changes in the shapes of light pulses resulting from propagation of the pulse from the reaction place to the converter.
FIG. 5 presents an example of a strip detector with an electronic readout system that facilitates signal sampling in voltage and amplitude fraction domains as well as determining signal charges. The chart presents a schematic discretization of signals for four voltage thresholds and four amplitude fractions. Signals measured at the right end are marked as squares while signals measured at the left end are marked as circles. Based on the method disclosed herein, sampling in the voltage and amplitude fraction domains facilitates determination of the place and the time of the reaction of the gamma quantum as well as of the energy deposited within scintillator 1 on the basis of the signal from the left photomultiplier 21 and independently on the basis of the signal from the right photomultiplier 22 . Signals from converters 21 , 22 are sent to two sampling systems 111 , 112 and to respective ADC converters 71 , 72 (as shown in FIG. 1 ). The sampling systems 111 , 112 generate points presented in the graphs. The ADC converters 71 , 72 are used to measure the charge of signals from the converters. Determination of the place of the reaction of a gamma quantum may also be made on the basis of the difference in times being determined on the left and on the right side of the strip and application of the procedure disclosed in a PCT application WO2011/008119, with photomultiplier signal onset time being determined using the above-described method of the disclosed solution. The use of two converters 21 , 22 on the opposite sides of the strip 1 significantly enhances the sensitivity of the method for determining the place of ionization as it permits the method being disclosed in this application to be used for determining the place of ionization in several independent manners, including:
(a) from the result of sampling within the amplitude fraction domain and application of the above-described method independently for the left photomultiplier 21 and the right photomultiplier 22 . (b) from the ratio of slope factors a sp _ left /a sp _ right (x) (based on discretization in the voltage domain) (b) from the ratio of slope factors a sf _ left /a sf —right (x) (based on discretization in the amplitude fraction domain) (d) from the relationship between the differences in the times of flight Δt(f,x)≡t L −t R (f,x) and fraction f and the gamma quantum reaction place x (e) from the ratio of charges measured by ADC converters: Q L /Q R (x)
FIG. 6 presents examples of detector responses for three different places of the reaction of a gamma quantum within scintillator 1 : closer to the left converter ( 0 L), at the center ( 0 ), and closer to the right converter ( 0 R). The right side of the figure presents schematic graphs of the time differences between the left and the right pulses (Δt≡t L −t P ) depending on the amplitude fraction and place of the reaction of the gamma quantum for these three cases. As illustrated in FIG. 6 , not only the absolute value of the difference between the times of signals from the left and the right converter (Δt≡t L −t P ) as measured for a particular amplitude fraction or a reference voltage allows determination of the place of reaction of the gamma quantum, but also the shape of the function f(Δt) as determined by multi-threshold constant-fraction discriminator changes depending on the place of the reaction of the gamma quantum x, thus facilitating independent determination of x.
While the technical solutions presented herein have been depicted, described, and defined with reference to particular preferred embodiment(s), such references and examples of implementation in the foregoing specification do not imply any limitation on the invention. Various modifications and changes may be made thereto without departing from the scope of the technical solutions presented. The presented embodiments are given as example only, and are not exhaustive of the scope of the technical solutions presented herein. Accordingly, the scope of protection is not limited to the preferred embodiments described in the specification, but is only limited by the claims that follow. | A method for determining parameters of a reaction of a gamma quantum within a scintillator of a PET scanner, comprising transforming a signal measured in the scintillator using at least one converter into an electric measurement signal, wherein the method comprises the steps of: obtaining access to a reference parameters memory ( 10 ) comprising reference signals represented in a time-voltage (Wt-v) coordinate system and in a time-amplitude fraction (Wt-f) coordinate system and having associated reaction parameters; sampling the electric measurement signal (S) measured in the time-voltage (PT-V) coordinate system and in the time-amplitude fraction (Pt-f) coordinate system; comparing results of the sampling (PT-V, PM) of the electric measurement signal (S) with the reference signals (Wt-V, Wt-f) and selecting reference shape parameters so that the reference (W) is best fitted to the results of the sampling (PT-V, PM) of the electric measurement signal (S); and determining the parameters of the reaction of the gamma quantum within the scintillator ( 1 ) for the electric measurement signal (S) based on pre-calibrated functions that determine the values of parameters of signal shape depending on the parameters of the reaction of gamma quantum within the scintillator. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to peer-to-peer networking and, in particular, to admission control of requests for video-on-demand services at the server side.
BACKGROUND OF THE INVENTION
[0002] Traditionally, the client-server service model has been used to provide streaming service. A client sends a request to a server, which then streams the content to the client if the server has enough resources to serve the client's request and there is enough bandwidth along the path between the server and the client.
[0003] Due to the limited computation and storage resource at the server and limited bandwidth in the network connecting the server and clients, scalability has been an issue with client-server streaming service. Recently, peer-to-peer techniques have been introduced into streaming service. Peers are implemented with the capabilities of clients and servers. Peer-to-peer networks alleviate the workload imposed on the server and distributes the bandwidth requirements across the network by actively caching the content and serving other peers. Studies have shown that peer-to-peer techniques greatly improve system scalability, enabling the system to serve many much more users.
[0004] There have been significant efforts to address the scalability issue presented in streaming media service using peer-to-peer networking. These efforts can be classified into two categories notably peer-to-peer live streaming and peer-to-peer stored video streaming or video-on-demand. While both services strive to support a large number of users while offering users good viewing quality, they also face different technical challenges. In peer-to-peer live streaming, minimizing the start-up delay without sacrificing the system scalability is the challenge. In peer-to-peer video-on-demand service, allowing asynchronous users to share is the challenge.
[0005] Peer-to-peer streaming schemes also distinguish themselves by the different data dissemination techniques. Two data dissemination methods have been investigated—notably the overlay-based approach and the data-driven approach. In the overlay-based approach, the peers form a mesh or tree structure where parent-child relationships are formed among the peers. A child peer receives data from its parent. In contrast, the peers in the data-driven approach do not have fixed parent-child relationships. The peers look for the missing data, and retrieve the missing data wherever available. While the overlay-based approach is widely used in early peer-to-peer efforts, the data-driven approach is becoming more popular since it addresses the churn and asymmetric bandwidth problem effectively.
[0006] While most of the prior art efforts exhibit good scalability and support a greater number of users compared to a traditional client-server service model, the prior art schemes are best-effort in nature and the support of system performance requirements has not been fully investigated. Due to the limited bandwidth at the server the perceived video quality at the client side could suffer if the server over-admits clients. Hence, admission control is necessary in order to provide an expected quality of service (QoS).
SUMMARY OF THE INVENTION
[0007] A related application is directed towards a performance aware peer-to-peer video-on-demand service. That application incorporates peer-to-peer downloading into the traditional client-server video-on-demand service model. The peer-to-peer downloading carries the major data transfer load and, thus, significantly reduces the workload imposed on the server. The server thus, devotes most of its resources to providing urgent data to meet the performance requirement. The perceived performance at the client end is improved. The peer-to-peer downloading algorithm is designed with the performance requirement in mind.
[0008] Video-on-demand service allows users to select and watch video content over a network whenever they want. The related application includes a segmented peer-to-peer video sharing model that enables content sharing in a video-on-demand setting. The performance issue is addressed by incorporating a performance aware peer-to-peer data downloading algorithm and server-assisted complementary streaming that collectively realize performance similar to the performance offered by the traditional client-server service model but supporting more users.
[0009] The present invention is directed towards further improving the clients' perceived video quality by executing admission control at the server side. The server has a number of tasks/services to perform including streaming service the leading sub-clips, performing complementary streaming and uploading content to clients/users in the peer-to-peer network. Due to the limited bandwidth resource at the server and server's responsibility to provide various services and perform various tasks, it is important to conduct admission control so that the clients' perceived video quality meets the clients' expectations.
[0010] The method and apparatus of the present invention for supporting admission control for a peer-to-peer video-on-demand service are designed to improve clients' perceived video quality in a performance aware video-on-demand service environment. The method and apparatus of the present invention monitor the current bandwidth usage and bandwidth usage history to determine if a request can be admitted into the video-on-demand system.
[0011] A method and apparatus for performing admission control in a peer-to-peer video-on-demand system are described including determining if there is sufficient bandwidth to support leading sub-clip streaming for a new request from a video playback device, determining if there is sufficient bandwidth to admit the request without sacrificing quality of service for existing requests, accepting admission of the new request if both determining acts are positive and rejecting admission of the new request if either of the determining acts are negative. Also described is an apparatus for providing content to a video playback device in a peer-to-peer video-on-demand system including an admission control unit and a data engine component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention is best understood from the following detailed description when read in conjunction with the accompanying drawings. The drawings include the following figures briefly described below where like-numbers on the figures represent similar elements:
[0013] FIG. 1 shows bandwidth usage in a performance aware peer-to-peer video-on-demand service environment from the viewpoint of the server.
[0014] FIG. 2 is an example of bandwidth usage in the servicing of a single request for video-on-demand.
[0015] FIG. 3 is a flowchart of the admission control process from the server side.
[0016] FIG. 4 is a schematic diagram of the architecture of the admission control process of the performance aware peer-to-peer streaming server.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Users of video-on-demand service watch different portions of video at any given moment. In order to enable the content sharing among users and maximize the amount of content that is delivered through a peer-to-peer network, it is assumed that each user has the storage capacity to cache a partial copy and/or the entire copy of content that has been played. This is a reasonable assumption given the rapidly increasing storage capacity of video playback devices used by (and synonymous with) clients/users. It should be noted that a video playback device is any device capable of receiving and playing back video (stored or live) including but not limited to computers, laptops, personal digital assistants (PDAs) and mobile devices. A peer-to-peer network is not limited to a wired line network and may be a wireless or wired line network or a hybrid network employing both wired line and wireless connections.
[0018] Previous studies have shown that the network bandwidth and the storage bandwidth are potential resource bottlenecks for a streaming server. It is assumed for the purposes of the present invention that the server is well provisioned so that the storage bandwidth is not a bottleneck. In the following discussion, the server side network bandwidth is assumed to be limited and thus, a bottleneck.
[0019] The server in a performance aware peer-to-peer streaming service environment is responsible for three types of services: (i) streaming the leading sub-clips to enable the clients to start the playback immediately (ii) uploading the video content of subsequent/following sub-clips to clients through peer-to-peer network by the server and (iii) serving complementary streaming of sub-clips to clients when there is missing data in a sub-clip and the deadline of this sub-clip is reached.
[0020] FIG. 1 depicts the bandwidth usage in a performance aware peer-to-peer video-on-demand streaming service environment from the point of view of the server. Herein BW is used to denote the total server bandwidth; BW streaming is used to denote the bandwidth used for streaming the leading sub-clips; BW comp-streaming is used to denote the bandwidth used for complementary streaming; and BW p2puploading is used to denote the bandwidth used for uploading content to the clients/users/video playback devices in the peer-to-peer network from the server. As can be seen from FIG. 1 BW=BW streaming +BW comp-streaming +BW p2puploading . The definitions of important symbols are listed in Table 1 below.
[0000]
TABLE 1
Symbol
Definition
BW
Total server bandwidth
BW streaming
Bandwidth usage for streaming the leading sub-clips
BW comp-streaming
Bandwidth usage for complementary streaming
BW p2puploading
Bandwidth used for uploading content to
clients/users/requests in
the peer-to-peer network by the server
BW
comp-streaming
Average bandwidth usage for complementary streaming
BW
p2puploading
Average bandwidth usage for uploading content to
clients/users/requests in the peer-to-peer network
by the server
σ
Standard deviation of aggregated complementary
streaming bandwidth usage
N
Total number of users/requests currently in the system
N streaming
The number of users/requests that receive the streamed
leading sub-clips from the server
N comp-streaming
The number of users/requests that may request
complementary streaming from the server
α
Weight in updating the average values of the bandwidth
usage for complementary streaming and the bandwidth
usage for uploading content to the clients/users
by the server
R
Video play back rate
[0021] FIG. 2 is an example of server bandwidth usage in the servicing of a single request for video-on-demand. The video consists of four sub-clips and starts at time T 0 . The content of first sub-clip is streamed. At the deadline of each following sub-clip, i.e, at time T 1 , T 2 , and T 3 , complementary streaming is initiated at the playback rate to fill in the missing data. Uploading the content to the clients/users/video playback devices in the peer-to-peer network by the server starts from the beginning T 0 and ends at the deadline of the last sub-clip T 3 . That is, the first (leading) sub-clip is streamed to the client. Uploading of the subsequent/following sub-clips (sub-clips 2 through 4 ) to the clients/users/video playback devices by the server is started at T 0 as well. At T 1 , if there is any missing data for sub-clip 2 , then the server begins complementary streaming of the missing data. At T 2 , if there is any missing data for sub-clip 3 , then the server begins complementary streaming of the missing data. Finally, at T 3 , if there is any missing data for sub-clip 4 , then the server begins complementary streaming of the missing data.
[0022] The characteristics of different bandwidth usage are described first. Then the method to estimate the mean and the variance of these bandwidth usages is described. Finally, the admission control scheme of the present invention is presented.
[0023] The required bandwidth to stream the leading sub-clips is a constant given by
[0000] BW streaming =N streaming *r, (1)
[0000] where r is video playback rate, and N streaming is the number of users currently receiving the streaming service.
[0024] The required bandwidth to support complementary streaming is a random variable. As a sub-clip reaches its deadline, the client/user/video playback device issues a complementary streaming request if some of the data is missing. The server will perform complementary streaming of the missing data if there is sufficient bandwidth available. The missing data is transmitted/forwarded to the client at the playback rate. This guarantees that all the missing data is available before playback time. If the complementary streaming is not possible due to insufficient server bandwidth, the sub-clip will be played back with missing data and the user's viewing quality is degraded. As depicted in FIG. 2 , the complementary streaming bandwidth usage can be approximated by a Bernoulli random variable. The complementary streaming rate is either r or zero.
[0025] The admission controller keeps track of the amount of data that needs to be transmitted by complementary streaming for each sub-clip. This quantity is denoted by S comp-streaming . The average complementary streaming data rate for this sub-clip is S comp-streaming /T, where T is the sub-clip length. The admission controller maintains the average complementary streaming bandwidth information, BW comp-streaming . The value of BW comp-streaming is updated whenever a new average complementary streaming rate is calculated. Specifically,
[0000] BW comp-streaming =α· BW comp-streaming +(1−α)·( S comp-streaming /T ) (2)
[0000] The weight, α, determines how quickly the average complementary streaming bandwidth usage catches up to the current value. Experiments have shown that a value around 0.95 offers good performance results.
[0026] In order to estimate the variance of BW comp-streaming , a Bernoulli distribution to approximate the complementary streaming bandwidth usage is used. The variance of BW comp-streaming can be computed as follows:
[0000] Var( BW comp-streaming )=(1− BW comp-streaming )* BW comp-streaming (3)
[0027] The server also keeps track of the amount of data that has been transmitted to the users through the peer-to-peer network. The average server peer-to-peer downloading bandwidth, BW p2puploading is updated at the deadline of the sub-clips. The amount of data uploaded for each sub-clip is denoted as S p2puploading . The average peer-to-peer uploading rate is then S p2puploading /T. Denoting the amount of data that is transferred to the user using the peer-to-peer network during one sub-clip length yields
[0000] BW p2puploading =α· BW p2puploading +(1−α)·( S p2puploading /T ) (4)
[0000] The admission control process of the present invention ignores the variance of the bandwidth used for uploading the content to the clients/users/video playback devices by the server in the peer-to-peer network.
[0028] As shown in FIG. 3 , the admission control process consists of two major steps. In the first step, the admission controller determines if the server can provide good QoS to all clients with the admission of a new client request.
Step 1 (At 305 ). Determine if there is enough bandwidth for leading sub-clip streaming
Upon the arrival of a new client request, the server must have enough bandwidth to support leading sub-clip streaming in order to admit the client. Otherwise, the client will not be able to start the playback immediately and the request has to be rejected. Therefore, the condition for admission is:
[0000] BW −( BW streaming +BW comp-streaming )> r (5)
[0030] The bandwidth used for uploading content to the clients/users/video playback devices by the server in the peer-to-peer network has lower priority compared to the bandwidth required for both streaming and complementary streaming. The peer-to-peer network includes many clients as well as the server. Even without the contribution from the server, a client can still download the data from other peers. Hence, the impact of the bandwidth required for uploading the content to the clients/users/video playback devices by the server in the peer-to-peer network can be ignored in this step of the admission control process. However, the bandwidth for uploading the content to the clients/users/video playback devices by the server in the peer-to-peer network is taken into account in the second step to ensure that clients' perceived quality is good and the probability that the data misses its playback deadline is low.
Step 2 (At 310 ). Determine if the clients' perceived QoS is good with the admission of the new client request
[0032] In the second step, the collected statistics are evaluated and it is determined if the new client request can be admitted without degrading clients' viewing quality. Specifically, the following equation is used to determine if the new client request can be admitted:
[0000] ( BW streaming +r )+ N comp-streaming ( BW comp-streaming +βσ)+ N BW p2pdownloading <BW (6)
[0000] where N comp-streaming is the number of users that require complementary streaming service, σ is the standard deviation of total complementary streaming bandwidth, and β is the standard deviation factor.
[0033] There are three items on the left-handed side of Equation (6). The value of BW streaming +r indicates the amount of bandwidth required to support leading sub-clip streaming assuming the new client is admitted. In the second term, N comp-streaming , is the number of users that may request complementary streaming. N comp-streaming =N−N streaming since all users except those who are currently receiving leading sub-clip streaming may require the complementary streaming.
[0034] The aggregated complementary streaming bandwidth usage is the sum of N comp-streaming Bernoulli random variables. In accordance with the Central Limit Theorem, the sum of random variables can be approximated by a normal distribution and its standard deviation is governed by Equation (7) below. In the second step of admission control process (see Equation (6)), β was selected to be three. For standard normal distribution, the probability that a sample deviates from its mean for more than three times the standard deviation is less than 0.005.
[0035] Hence with high probability, the users' complementary streaming requests can be satisfied. Finally, the third item is the total bandwidth required for peer-to-peer uploading service.
[0000] σ=√{square root over (Var( BW comp-streaming )/ N comp-streaming )} (7)
[0036] In the second step, the admission controller ensures that the required bandwidth is less than the available bandwidth with high probability. Thus the users' viewing quality will not degrade with the admission of a new client request.
[0037] If either step 1 (at 305 ) or step 2 (at 310 ) fail then the request is rejected (not admitted) at 320 . If both step 1 (at 305 ) and step 2 (at 310 ) are successful/pass then the request is admitted at 315 .
[0038] FIG. 4 is a schematic diagram of the architecture of the performance aware peer-to-peer streaming server with the admission control component of the present invention. The data engine component has two sub-components—a streaming engine and a peer-to-peer uploader. The streaming engine handles the streaming service and the peer-to-peer engine handles the peer-to-peer uploading service. The new client request is presented to the admission controller first (step 1). Based on the outcome of the admission controller as illustrated in FIG. 1 , the server returns the decision to the client (step 2). If the new client request is admitted, the admission control unit informs the data engine component of this decision (step 3). The data engine component starts to serve this request by streaming the leading sub-clips (step 4) and uploading the data of following sub-clips through the peer-to-peer downloader (step 5).
[0039] It is to be understood that the present invention may be implemented in various forms of hardware, software, firmware, special purpose processors, or a combination thereof. Preferably, the present invention is implemented as a combination of hardware and software. Moreover, the software is preferably implemented as an application program tangibly embodied on a program storage device. The application program may be uploaded to, and executed by, a machine comprising any suitable architecture. Preferably, the machine is implemented on a computer platform having hardware such as one or more central processing units (CPU), a random access memory (RAM), and input/output (I/O) interface(s). The computer platform also includes an operating system and microinstruction code. The various processes and functions described herein may either be part of the microinstruction code or part of the application program (or a combination thereof), which is executed via the operating system. In addition, various other peripheral devices may be connected to the computer platform such as an additional data storage device and a printing device.
[0040] It is to be further understood that, because some of the constituent system components and method steps depicted in the accompanying figures are preferably implemented in software, the actual connections between the system components (or the process steps) may differ depending upon the manner in which the present invention is programmed. Given the teachings herein, one of ordinary skill in the related art will be able to contemplate these and similar implementations or configurations of the present invention. | A method and apparatus for performing admission control in a peer-to-peer video-on-demand system are described including determining if there is sufficient bandwidth to support leading sub-clip streaming for a new request from a video playback device, determining if there is sufficient bandwidth to admit the request without sacrificing quality of service for existing requests, accepting admission of the new request if both determining acts are positive and rejecting admission of the new request if either of the determining acts are negative. Also described is an apparatus for providing content to a video playback device in a peer-to-peer video-on-demand system including an admission control unit and a data engine component. | 7 |
[0001] The present invention claims the benefit of Korean Patent Application No. 2003-55530 filed on Aug. 11, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an apparatus for a semiconductor device, and more particularly, to an apparatus having an edge frame for a liquid crystal display device and a method of using the same.
[0004] 2. Discussion of the Related Art
[0005] Liquid crystal display (LCD) devices are non-emissive devices that display images using a liquid crystal layer interposed between an array substrate and a color filter substrate. The array substrate and the color filter substrate may be fabricated by repetition of depositing a thin film on a transparent substrate such as a glass and patterning the deposited thin film. Recently, a plasma enhanced chemical vapor deposition (PECVD) method, where source gases are excited to a plasma state by an energy of high voltage and are deposited onto a substrate through a chemical reaction, has been widely used as a deposition technology of a thin film. An apparatus for an LCD device using a PECVD method will be illustrated hereinafter.
[0006] FIG. 1 is a schematic cross-sectional view showing an apparatus for a liquid crystal display device according to the related art. In FIG. 1 , an inner space of a chamber 100 is isolated from an outer space by a chamber body 30 . A susceptor 40 that a substrate 10 is loaded on is disposed in the chamber 100 and a heater (not shown) may be formed in the susceptor 40 to heat the substrate 10 when source gases are injected onto the substrate 10 . Specifically, when the source gases are activated by a PECVD method, the susceptor 40 may function as a lower electrode. A susceptor supporter 46 extends from a central bottom portion of the susceptor 40 and a driving assembly 44 is combined with a lower circumference of the susceptor supporter 46 . Since the driving assembly 44 is connected to a driving means 50 such as a motor, the susceptor 40 may move up and down according to steps of a fabrication process.
[0007] In addition, the chamber 100 includes an exhaust 38 connected to a vacuum pump (not shown). The chamber 100 may be evacuated to a high vacuum state by exhausting the inner space of the chamber 100 through the exhaust 38 during a fabrication process.
[0008] After the substrate 10 is loaded on the susceptor 40 , the susceptor 40 moves up to a reaction region of the inner space of the chamber 100 and an edge frame 20 contacts a boundary portion of the substrate 10 .
[0009] FIG. 2A is a schematic exploded perspective view showing an edge frame of an apparatus for a liquid crystal display device according to the related art and FIG. 2B is a schematic cross-sectional view showing an edge frame of an apparatus for a liquid crystal display device according to the related art. In FIGS. 2A and 2B , a susceptor 40 in a chamber 100 (of FIG. 1 ) of an apparatus includes a plurality of lift pin holes 48 and a plurality of lift pins 32 is disposed to correspond to the plurality of lift pin holes 48 . Each lift pin 32 moves up and down through the corresponding lift pin hole 48 to support a substrate 10 during a loading and unloading steps. An edge frame 20 covers a substrate boundary portion 12 and an exposed susceptor boundary portion 42 . Specifically, a substrate-covering portion 22 of the edge frame 20 contacts the substrate boundary portion 12 to prevent a leakage of source gases through a gap between the edge frame 20 and the substrate 10 . Accordingly, the substrate-covering portion 22 is formed to be thinner than the other portion of the edge frame 20 .
[0010] After the substrate 10 is loaded on the susceptor 40 , the edge frame 20 contacts the substrate 10 and the susceptor 40 to cover the substrate boundary portion 12 and the susceptor boundary 42 by moving up the susceptor 40 . At the same time, the edge frame 20 is detached from a frame supporter 34 formed on an inner wall of a chamber body 30 .
[0011] FIGS. 3A and 3B are schematic cross-sectional views showing an operation of an edge frame of an apparatus for a liquid crystal display device according to the related art. In FIG. 3A , a substrate 10 is loaded on a susceptor 40 . An edge frame 20 is supported by a frame supporter 34 such that an outer bottom surface 24 of the edge frame 20 contacts a top surface of the frame supporter 34 . The edge frame 20 covers the substrate boundary portion 12 and the susceptor boundary portion 42 and is spaced apart from the substrate 10 and the susceptor 40 . After loading the substrate 10 on the susceptor 40 , the susceptor 40 moves up to a reaction region of a chamber 100 (of FIG. 1 ).
[0012] In FIG. 3B , as the susceptor 40 and the substrate 10 loaded on the susceptor 40 move up by the operation of a driving means 50 (of FIG. 1 ) connected to the driving assembly 46 (of FIG. 1 ), the edge frame 20 approaches the substrate 10 and the susceptor 40 . Accordingly, the substrate-covering portion 22 contacts the substrate boundary portion 12 and a central portion of the edge frame 20 contacts the susceptor boundary portion 42 . In addition, as the susceptor 40 further moves up, the outer bottom portion 24 of the edge frame 20 is detached from the top surface of the frame supporter 34 . Then, the edge frame 20 moves up with the susceptor 40 . Since the substrate-covering portion 22 contacts the substrate boundary portion 12 , a leakage of source gases or plasma is prevented during a deposition process or an etch process.
[0013] However, since the edge frame 20 is formed of ceramic as a single body, the weight of the edge frame 20 is heavy and the pressure of the edge frame 20 to the substrate boundary portion 12 is high. The heavy weight and the high pressure may cause several problems in the fabrication process.
[0014] FIGS. 4A and 4B are schematic cross-sectional views showing problems caused by an edge frame of an apparatus for an LCD device according to the related art. As shown in FIG. 4A , a substrate boundary portion 12 of a substrate 10 may be broken due to the heavy weight and a high pressure of an edge frame 20 . Accordingly, process yield is reduced.
[0015] In FIG. 4B , the edge frame 20 may have a thermal damage at a central portion thereof and may be warped due to a heat from a heater in a susceptor 40 or a heat from a fabrication process. Accordingly, a substrate-covering portion 22 does not contact the substrate boundary portion 12 and the central portion of the edge frame 20 is spaced apart from the susceptor 40 so that a gap between the edge frame 20 and the substrate 10 can be generated. As a result, source gases or plasma may be leaked through the gap between the edge frame 20 and the substrate 10 and may be deposited on the substrate boundary portion 12 and the susceptor boundary portion 42 (of FIGS. 3A and 3B ). The leakage of the source gases or plasma may deteriorate uniformity of the fabrication process and may require more frequent chamber cleaning. In addition, the source gases or plasma may be consumed uneconomically.
SUMMARY OF THE INVENTION
[0016] Accordingly, the present invention is directed to an apparatus for a semiconductor device that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0017] An object of the present invention is to provide an apparatus having an edge frame that prevents break of a substrate.
[0018] Another object of the present invention is to provide an apparatus having an edge frame that prevents leakage of source gases.
[0019] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0020] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, an apparatus for a semiconductor device includes: a chamber; a susceptor in the chamber, wherein a substrate loaded on the susceptor has a substrate boundary portion and the susceptor has a susceptor boundary portion exposed outside the substrate boundary portion; an edge frame over the susceptor and the substrate, the edge frame comprising; a first sub-frame covering the substrate boundary portion and the susceptor boundary portion; and a second sub-frame surrounding the first sub-frame; and a frame supporter on a side wall of the chamber, the frame supporter supporting the second sub-frame.
[0021] In another aspect, an operation method of an apparatus for a semiconductor device includes; providing an edge frame in a chamber of the apparatus, the edge frame including a first sub-frame and a second sub-frame, the first sub-frame being supported by the second frame and the second sub-frame being supported by a frame supporter on a side wall of the chamber; loading a substrate on a susceptor in the chamber; moving up the susceptor having the substrate thereon, thereby the first and second sub-frames being supported by the susceptor; and moving up the susceptor having the substrate and the first and second sub-frames thereon, thereby the second sub-frame being detached from the frame supporter.
[0022] In another aspect, an operation method of an apparatus for a semiconductor device includes; providing an edge frame in a chamber of the apparatus, the edge frame including a first sub-frame and a second sub-frame, the first sub-frame being supported by the second frame and the second sub-frame being supported by a frame supporter on a side wall of the chamber; loading a substrate on a susceptor in the chamber; moving up the susceptor having the substrate thereon, thereby the first sub-frame being supported by the susceptor; and moving up the susceptor having the substrate and the first sub-frame thereon, wherein the second sub-frame remaining on the frame supporter.
[0023] In another aspect, an edge frame for an apparatus having a chamber, a susceptor in the chamber and a substrate on the susceptor includes: a first sub-frame covering a boundary portion of the substrate and a boundary portion of the susceptor; and a second sub-frame surrounding the first sub-frame.
[0024] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
[0026] FIG. 1 is a schematic cross-sectional view showing an apparatus for a liquid crystal display device according to the related art;
[0027] FIG. 2A is a schematic exploded perspective view showing an edge frame of an apparatus for a liquid crystal display device according to the related art;
[0028] FIG. 2B is a schematic cross-sectional view showing an edge frame of an apparatus for a liquid crystal display device according to the related art;
[0029] FIGS. 3A and 3B are schematic cross-sectional views showing an operation of an edge frame of an apparatus for a liquid crystal display device according to the related art;
[0030] FIGS. 4A and 4B are schematic cross-sectional views showing problems caused by an edge frame of an apparatus for an LCD device according to the related art;
[0031] FIG. 5 is a schematic cross-sectional view of an apparatus having an edge frame according to an embodiment of the present invention;
[0032] FIG. 6A is a schematic exploded perspective view showing an edge frame of an apparatus for a liquid crystal display device according to an embodiment of the present invention;
[0033] FIG. 6B is a schematic cross-sectional view showing an edge frame of an apparatus for a liquid crystal display device according to an embodiment of the present invention;
[0034] FIG. 7 is a schematic cross-sectional view showing an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention;
[0035] FIGS. 8A to 8 C are schematic cross-sectional views showing an operation of an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention;
[0036] FIG. 9A is a schematic exploded perspective view showing an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention;
[0037] FIG. 9B is a schematic cross-sectional view showing an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention; and
[0038] FIGS. 10A to 10 C are schematic cross-sectional views showing an operation of an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings.
[0040] FIG. 5 is a schematic cross-sectional view of an apparatus having an edge frame according to an embodiment of the present invention.
[0041] In FIG. 5 , a chamber 300 of an apparatus for a liquid crystal display (LCD) device includes a lead 120 and a chamber body 130 . A gas-injecting unit 124 is formed through the lead 120 and connected to a gas-supplying unit (not shown). A shower head 122 is disposed in the lead 120 and source gases from the gas-injecting unit 124 are sprayed onto a substrate 110 through the shower head 122 . In a plasma enhanced chemical vapor deposition (PECVD) type apparatus, for example, the shower head 122 may be connected to a radio frequency (RF) power supply and may function as an upper electrode that activates the source gases for a plasma state during a fabrication process. A susceptor 140 is disposed in the chamber body 130 and the substrate 110 is loaded on the susceptor 140 . Even though not shown in FIG. 5 , a heater may be formed in the susceptor 140 to heat the substrate 110 during a fabrication process. In a PECVD type apparatus, for example, the susceptor 140 may be grounded and may function as a lower electrode.
[0042] In addition, a susceptor supporter 146 extends from a central bottom portion of the susceptor 140 and a driving assembly 144 is combined with a lower circumference of the susceptor supporter 146 . Since the driving assembly 144 is connected to a driving means 150 such as a motor outside the chamber 300 , the susceptor 140 may move up and down according to steps of a fabrication process. Moreover, an exhaust 138 connected to a vacuum pump (not shown) is formed through the chamber body 130 . The chamber 300 may be evacuated to a high vacuum state by exhausting an inner space of the chamber 300 through the exhaust 138 during a fabrication process.
[0043] Specifically, an edge frame 200 covering a substrate boundary portion of the substrate 110 is disposed adjacent to an inner surface of the chamber body 130 . The edge frame 200 includes a first sub-frame 210 and a second sub-frame 220 contacting and surrounding the first sub-frame 210 .
[0044] FIG. 6A is a schematic exploded perspective view showing an edge frame of an apparatus for a liquid crystal display device according to an embodiment of the present invention and FIG. 6B is a schematic cross-sectional view showing an edge frame of an apparatus for a liquid crystal display device according to an embodiment of the present invention.
[0045] In FIGS. 6A and 6B , a susceptor 140 in a chamber 300 (of FIG. 5 ) of an apparatus includes a plurality of lift pin holes 145 and a plurality of lift pins 132 is disposed to correspond to the plurality of lift pin holes 145 . Each lift pin 132 moves up and down through the corresponding lift pin hole 145 to support a substrate 110 during a loading and unloading steps. As shown in FIGS. 6A , the plurality of lift pins 132 may be disposed to correspond to a substrate boundary portion 112 . As a substrate is enlarged, the plurality of lift pins 132 may be disposed to correspond to a central portion of the substrate 110 in another embodiment. A diameter of a top portion of the lift pin 132 may be greater than a diameter of the lift pin hole 145 to prevent removal of the lift pin 132 from the lift pin hole 145 . Accordingly, the top portion of the lift pin 132 may have a cone shape. Furthermore, a top portion of the lift pin hole 145 may have a shape corresponding to the top portion of the lift pin 132 .
[0046] An edge frame 200 covering the substrate boundary portion 112 and a susceptor boundary portion 142 is disposed adjacent to an inner wall of a chamber body 130 . The edge frame 200 includes a first sub-frame 210 and a second sub-frame 220 contacting and surrounding the first sub-frame 210 . For example, a width of the first sub-frame 210 may be smaller than a width of the second sub-frame 220 . The first sub-frame 210 covers the substrate boundary portion 112 and the susceptor boundary portion 142 . Specifically, a substrate-covering portion 212 of the first sub-frame 210 may be formed to be thinner than the other portion of the edge frame 200 . When the susceptor 140 moves up, the substrate-covering portion 212 contacts the substrate boundary portion 112 , and the other portion of the first sub-frame 210 and the second sub-frame 220 contact the susceptor boundary portion 142 . Accordingly, a leakage of source gases through a gap between the edge frame 200 and the substrate 110 is prevented.
[0047] In addition, a first contact portion 214 of the first sub-frame 210 and a second contact portion 224 of the second sub-frame 220 contacting each other may be inclined toward a center of the chamber 300 (of FIG. 5 ). That is, the first contact portion 214 and the second contact portion 224 may be inwardly inclined. A diameter of a top end of the first and second contact portions 214 and 224 is greater than a diameter of a bottom end of the first and second contact portions 214 and 224 . Accordingly, the first sub-frame 210 can move up higher than the second sub-frame 220 and stop when the first sub-frame 210 has the same height as the second sub-frame 220 . As a result, the first sub-frame 210 may be supported by the second sub-frame 220 . For example, inclined surfaces of the first and second contact portions 214 and 224 may have an angle within a range of about 20° to about 70° with respect to a top surface of the substrate 110 .
[0048] The second sub-frame 220 may be supported by a frame supporter 134 such that an outer bottom portion 222 contacts a top surface of the frame supporter 134 . The outer bottom portion 222 may extend from the second sub-frame 220 downwardly. Even though the susceptor 140 and the edge frame 200 have a rectangular shape in plan view, the susceptor 140 and the edge frame 200 may have various shapes such as a circle in another embodiment.
[0049] A cross-sectional shape and a position of the contact portions between the first and second sub-frames 210 and 220 may vary as an embodiment.
[0050] FIG. 7 is a schematic cross-sectional view showing an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention.
[0051] In FIG. 7 , an edge frame 200 includes a first sub-frame 210 and a second sub-frame 220 contacting and surrounding the first sub-frame 210 . A substrate-covering portion 212 of the first sub-frame 210 is thinner than the other portion of the first sub-frame 210 to contact and press a substrate boundary portion 112 (of FIG. 6B ) of a substrate 110 (of FIG. 6B ). Moreover, an outer bottom portion 222 of the second sub-frame 220 extends from the second sub-frame 220 and contacts a susceptor supporter 134 (of FIG. 6B ).
[0052] A first contact portion 214 of the first sub-frame 210 contacts a second contact portion 224 of the second sub-frame 220 . The first contact portion 214 includes a first inclined surface 214 a , a first horizontal surface 214 b and a first vertical surface 214 c , and the second contact portion includes a second inclined surface 224 a , a second horizontal surface 224 b and a second vertical surface 224 c . The first and second inclined surfaces 214 a and 224 a are inclined to have an angle with respect to a horizontal direction. For example, the first and second inclined surfaces 214 a and 224 a may have an angle within a range of about 20° to about 70° with respect to a top surface of the substrate 110 (of FIG. 6B ). The first and second horizontal surfaces 214 b and 224 b may be parallel to a horizontal line, and the first and second vertical surfaces 214 c and 224 c may be perpendicular to a horizontal line. Accordingly, the first horizontal surface 214 b is substantially perpendicular to the first vertical surface 214 c , and the second horizontal surface 224 b is substantially perpendicular to the second vertical surface 224 c . Moreover, as a whole, the first contact portion 214 is disposed over the second contact portion 224 . Since the first and second horizontal surfaces 214 b and 224 b are flat, the first sub-frame 210 is supported by the second sub-frame 220 more stably.
[0053] As compared with an edge frame of FIG. 6B , a lower portion of the first contact portion 214 of the first sub-frame 210 sinks toward a center of the chamber 300 (of FIG. 5 ) and a lower portion of the second contact portion 224 of the second sub-frame 220 protrudes toward a center of the chamber 300 (of FIG. 5 ). As a result, the first sub-frame 210 has a “T” shape in cross-sectional view such that two upper end portions are protruded outwardly.
[0054] FIGS. 8A to 8 C are schematic cross-sectional views showing an operation of an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention.
[0055] In FIG. 8A , a substrate 110 is loaded into a chamber 300 (of FIG. 5 ) and supported by a plurality of lift pins 132 through a plurality of lift pin holes 145 of a susceptor 140 . A frame supporter 134 is formed on an inner wall of a chamber body 130 . An edge frame 200 covers a substrate boundary portion 112 and a susceptor boundary portion 142 . The edge frame 200 includes a first sub-frame 210 and a second sub-frame 220 contacting and surrounding the first sub-frame 210 . Since a first contact portion 214 of the first sub-frame 210 is disposed over a second contact portion 224 of the second sub-frame 220 , the first sub-frame is supported by the second sub-frame 220 . The second sub-frame 220 is supported by a frame supporter 134 such that an outer bottom surface 222 of the second sub-frame 220 contacts a top surface of the frame supporter 134 . The first sub-frame 210 covers the substrate boundary portion 112 and the susceptor boundary portion 142 and the second frame covers the susceptor boundary portion 142 . Moreover, the first and second sub-frames 210 and 220 are spaced apart from the substrate 110 and the susceptor 140 .
[0056] In FIG. 8B , as the susceptor 140 moves up by a driving means 150 (of FIG. 5 ), the plurality of lift pins 132 relatively move down through a plurality of lift pin holes 145 . After the substrate 110 contacts the susceptor 140 , the substrate 110 is supported by the susceptor 140 instead of the plurality of lift pins 132 . The susceptor 140 having the substrate 110 thereon further moves up even after the substrate 110 contacts the susceptor 140 . Accordingly, the substrate 110 and the susceptor 140 contact the edge frame 200 such that the first sub-frame covers the substrate boundary portion 112 and the susceptor boundary portion 142 and the second frame covers the susceptor boundary portion 142 . Specifically, the first sub-frame 210 effectively covers the substrate boundary portion 112 because of a substrate-covering portion thinner than the other portion of the first sub-frame 210 . After the edge frame 200 contacts the substrate 110 and the susceptor 140 , the edge frame 200 is supported by the susceptor 140 having the substrate 110 thereon instead of the frame supporter 134 .
[0057] In FIG. 8C , the susceptor 140 having the substrate 110 and the edge frame 200 thereon further moves up to a reaction region of the chamber 300 (of FIG. 5 ) even after the edge frame 200 contacts the substrate 110 and the susceptor 140 . Accordingly, the outer bottom surface 222 of the second sub-frame 220 is detached from the frame supporter 134 . In the reaction region, the source gases may be deposited onto the substrate 110 .
[0058] The edge frame 200 is divided into the first sub-frame 210 and the second sub-frame 220 such that a width of the first sub-frame 210 is smaller than a width of the second sub-frame 220 . Accordingly, the first sub-frame 210 covering the substrate boundary portion 112 is lighter than the second sub-frame 220 . Since only the first sub-frame 210 having a lighter weight contacts and presses the substrate 110 , a break of the substrate 110 due to a weight of the edge frame 200 is prevented.
[0059] In addition, since the first sub-frame 210 is closer to a center of the susceptor 140 than the second sub-frame 220 , a heat from a heater (not shown) in the susceptor 140 is transmitted to the first sub-frame 210 first. The heat transmitted to the first sub-frame 210 is not completely transmitted to the second sub-frame 220 and some of the heat disappears during the transmission. Since the first sub-frame 210 is formed to have a width smaller than that of the second sub-frame 220 , the first sub-frame 210 is not warped due to the heat. Accordingly, the first sub-frame 210 completely contacts the substrate boundary portion 112 and the second sub-frame 220 completely contacts the susceptor boundary portion 142 . As a result, a gap is not generated between the edge frame 200 and the substrate 110 and the source gases are not deposited on the susceptor boundary portion 142 .
[0060] After finishing the fabrication process, the susceptor 140 having the substrate 110 and the edge frame 200 thereon moves down. When the second sub-frame 220 contacts the frame supporter 134 , the edge frame 200 is supported by the frame supporter 134 and separated from the susceptor 140 . After the edge frame 200 is separated, the susceptor 140 keeps moving down. The plurality of lift pins 132 relatively moves up after bottom ends of the lift pins 132 contacts a supporting means or a bottom of the chamber 300 (of FIG. 5 ). Accordingly, the substrate 110 is supported by the plurality of lift pins 132 and then unloaded by a robot arm.
[0061] FIG. 9A is a schematic exploded perspective view showing an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention and FIG. 9B is a schematic cross-sectional view showing an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention.
[0062] In FIGS. 9A and 9B , a susceptor 140 in a chamber 300 (of FIG. 5 ) of an apparatus includes a plurality of lift pin holes 145 and a plurality of lift pins 132 is disposed to correspond to the plurality of lift pin holes 145 . Each lift pin 132 moves up and down through the corresponding lift pin hole 145 to support a substrate 110 during a loading and unloading steps. As shown in FIGS. 9A , the plurality of lift pins 132 may be disposed to correspond to a substrate boundary portion 112 . As a substrate is enlarged, the plurality of lift pins 132 may be disposed to correspond to a central portion of the substrate 110 in another embodiment. A diameter of a top portion of the lift pin 132 may be greater than a diameter of the lift pin hole 145 to prevent removal of the lift pin 132 from the lift pin hole 145 . Accordingly, the top portion of the lift pin 132 may have a cone shape. Furthermore, a top portion of the lift pin hole 145 may have a shape corresponding to the top portion of the lift pin 132 .
[0063] An edge frame 300 covering the substrate boundary portion 112 and a susceptor boundary portion 142 is disposed adjacent to an inner wall of a chamber body 130 . The edge frame 300 includes a first sub-frame 310 and a second sub-frame 320 contacting and surrounding the first sub-frame 310 . Differently from the edge frame 200 of FIGS. 6A and 6B , a width of the first sub-frame 310 may be equal to or larger than a width of the second sub-frame 320 . Accordingly, the first sub-frame 310 covers the substrate boundary portion 112 and the susceptor boundary portion 142 , and the second sub-frame 320 contacts the first sub-frame 310 outside the susceptor 140 . The second sub-frame 320 does not cover the susceptor boundary portion 142 .
[0064] A substrate-covering portion 312 of the first sub-frame 310 may be formed to be thinner than the other portion of the edge frame 300 . When the susceptor 140 moves up, the substrate-covering portion 312 contacts the substrate boundary portion 112 , and the other portion of the first sub-frame 310 contacts the susceptor boundary portion 142 . Accordingly, a leakage of source gases through a gap between the edge frame 300 and the substrate 110 is prevented.
[0065] In addition, a first contact portion 314 of the first sub-frame 310 and a second contact portion 324 of the second sub-frame 320 contacting each other may be inclined toward a center of the chamber 300 (of FIG. 5 ). Accordingly, the first sub-frame 310 can move up higher than the second sub-frame 320 and stop when the first sub-frame 310 has the same height as the second sub-frame 320 . As a result, the first sub-frame 310 may be supported by the second sub-frame 320 . For example, inclined surfaces of the first and second contact portions 314 and 324 may have an angle within a range of about 20° to about 70° with respect to a top surface of the substrate 110 .
[0066] The second sub-frame 320 may be supported by a frame supporter 134 such that an outer bottom portion 322 contacts a top surface of the frame supporter 134 . The outer bottom portion 322 may extend from the second sub-frame 320 downwardly. Since the second sub-frame 320 does not move with the susceptor 140 , the second sub-frame 320 may be fixed on the frame supporter 134 . Even though the susceptor 140 and the edge frame 300 have a rectangular shape in plan view, the susceptor 140 and the edge frame 300 may have various shapes such as a circle in another embodiment. Moreover, a cross-sectional shape of the contact portions between the first and second sub-frames 310 and 320 may vary as an embodiment.
[0067] FIGS. 10A to 10 C are schematic cross-sectional views showing an operation of an edge frame of an apparatus for a liquid crystal display device according to another embodiment of the present invention.
[0068] In FIG. 10A , a substrate 110 is loaded into a chamber 300 (of FIG. 5 ) and supported by a plurality of lift pins 132 through a plurality of lift pin holes 145 of a susceptor 140 . A frame supporter 134 is formed on an inner wall of a chamber body 130 . An edge frame 300 covers a substrate boundary portion 112 and a susceptor boundary portion 142 . The edge frame 300 includes a first sub-frame 310 and a second sub-frame 320 contacting and surrounding the first sub-frame 310 . Since a first contact portion 314 of the first sub-frame 310 is disposed over a second contact portion 324 of the second sub-frame 320 , the first sub-frame 310 can be supported by the second sub-frame 320 . The second sub-frame 320 is supported by a frame supporter 134 such that an outer bottom surface 322 of the second sub-frame 320 contacts a top surface of the frame supporter 134 . The first sub-frame 310 covers the substrate boundary portion 112 and the susceptor boundary portion 142 , while the second frame does not cover the susceptor boundary portion 142 . Moreover, the first and second sub-frames 310 and 320 are spaced apart from the substrate 110 and the susceptor 140 .
[0069] In FIG. 10B , as the susceptor 140 moves up by a driving means 150 (of FIG. 5 ), the plurality of lift pins 132 relatively move down through a plurality of lift pin holes 145 . After the substrate 110 contacts the susceptor 140 , the substrate 110 is supported by the susceptor 140 instead of the plurality of lift pins 132 . The susceptor 140 having the substrate 110 thereon further moves up even after the substrate 110 contacts the susceptor 140 . Accordingly, the substrate 110 and the susceptor 140 contact the edge frame 300 such that the first sub-frame 310 covers the substrate boundary portion 112 and the susceptor boundary portion 142 . However, since the second sub-frame 320 does not cover the susceptor boundary portion 142 , the second sub-frame 320 does not contact the susceptor 140 . The first sub-frame 310 effectively covers the substrate boundary portion 112 because of a substrate-covering portion 312 thinner than the other portion of the first sub-frame 310 . In addition, the first contact portion 314 contacts the second contact portion 324 such that the first contact portion 314 is disposed over the second contact portion 324 . After the first sub-frame 310 contacts the substrate 110 and the susceptor 140 , the first sub-frame 310 is supported by the susceptor 140 having the substrate 110 thereon.
[0070] In FIG. 10C , the susceptor 140 having the substrate 110 and the first sub-frame 310 thereon further moves up to a reaction region of the chamber 300 (of FIG. 5 ) even after the first sub-frame 310 contacts the substrate 110 and the susceptor 140 . However, the second sub-frame 320 is not supported by the susceptor 140 , the second sub-frame 320 does not move up and is not detached from the frame supporter 134 . Accordingly, the first sub-frame 310 is detached from the second sub-frame 320 . Since the second sub-frame 320 is not detached from the frame supporter 134 , the second sub-frame 320 may be fixed on the frame supporter 134 . In the reaction region, the source gases may be deposited onto the substrate 110 .
[0071] In this embodiment, the edge frame 300 is divided into the first sub-frame 310 and the second sub-frame 320 such that a width of the first sub-frame 310 is equal to or larger than a width of the second sub-frame 320 . Accordingly, only the first sub-frame 310 moves up with the susceptor 140 to the reaction region and the second sub-frame remains on the frame supporter 134 in a region under the reaction region. As a result, only the first sub-frame 310 presses the substrate boundary portion 112 and the susceptor boundary portion 142 during a fabrication process. Specifically, the substrate boundary portion 112 is covered with the substrate-covering portion 312 thinner than the other portion of the first sub-frame 310 . Since the whole edge frame 300 does not press the substrate 110 , a break of the substrate 110 due to a weight of the edge frame 300 is prevented.
[0072] In addition, since the first sub-frame 310 is disposed on the susceptor 140 and the second sub-frame 320 is separated from the first sub-frame 310 , a heat from a heater (not shown) in the susceptor 140 is transmitted only to the first sub-frame 310 and the heat transmitted to the first sub-frame 310 is not transmitted to the second sub-frame 320 . Accordingly, the edge frame 300 is not warped due to the heat and the first sub-frame 310 completely contacts the substrate boundary portion 112 and the susceptor boundary portion 142 . As a result, a gap is not generated between the edge frame 300 and the substrate 110 , and a deposition of the source gases on the susceptor boundary portion 142 is prevented.
[0073] After finishing the fabrication process, the susceptor 140 having the substrate 110 and the first sub-frame 310 thereon moves down. When the first sub-frame 310 contacts the second sub-frame 320 , the edge frame 300 is supported by the frame supporter 134 and separated from the susceptor 140 . Even after the edge frame 300 is separated, the susceptor 140 keeps moving down. The plurality of lift pins 132 relatively moves up after bottom ends of the lift pins 132 contacts a supporting means or a bottom of the chamber 300 (of FIG. 5 ). Accordingly, the substrate 110 is supported by the plurality of lift pins 132 and then unloaded by a robot arm.
[0074] In an embodiment of the present invention, a weight of a portion substantially covering and pressing the substrate is reduced by using an edge frame divided into independent portions. Accordingly, a break of the substrate due to the edge frame is prevented and a production yield is improved. Furthermore, since a heat from the susceptor is transmitted to the portion substantially covering and pressing the substrate, a warpage of the whole edge frame due to a thermal stress is prevented. As a result, a leakage of source gases onto the susceptor is prevented and efficiency of an apparatus is improved due to extension of cleaning time period.
[0075] It will be apparent to those skilled in the art that various modifications and variations can be made in the apparatus having an edge frame without departing from the spirit or scope of the invention. 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. | An apparatus for a semiconductor device includes: a chamber having upper and lower portions, a volume of the lower portion being greater than a volume of the upper portion; a susceptor in the chamber, the susceptor having a substrate on a top surface thereof; an injector injecting process gases into the chamber; a coil unit over the chamber; a radio frequency power supply connected to the coil unit; and an exhaust through the chamber. | 2 |
This application claims the benefit under 35 U.S.C. § 119 (e) of U.S. Provisional Application No. 60/293,670, entitled “Reference Beam Absorber-Blockers,” naming Michael A. Klug, Deanna McMillen, and Qiang Huang as inventors, filed on May 25, 2001. The above-referenced provisional application is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention relates in general to the field of hologram production and display and, more particularly, to devices for diverting at least a portion of a reference beam from impinging upon a diffuser disposed adjacent to holographic recording material.
BACKGROUND OF THE INVENTION
One-step hologram (including holographic stereogram) production technology has been used to satisfactorily record holograms without the traditional step of creating preliminary holograms. Both computer image holograms and non-computer image holograms may be produced by such one-step technology. In some one-step systems, computer processed images of objects or computer models of objects allow the respective system to build a hologram from a number of contiguous, small, elemental pieces known as elemental holograms or hogels. To record each hogel on holographic recording material, an object beam is typically directed through the a spatial light modulator (SLM) displaying a rendered image and interfered with by a reference beam. Examples of techniques for one-step hologram production can be found in the U.S. Pat. No. 6,330,088 entitled “Method and Apparatus for Recording One-Step, Full-Color, Full-Parallax, Holographic Stereograms,” and naming Michael A. Klug, Mark E. Holzbach, and Alejandro J. Ferdman as inventors, which is hereby incorporated by reference herein in its entirety.
In many holographic recording systems, and particularly in one-step reflection holographic recording systems, a diffuser is used to evenly distribute light in the object beam on to the holographic recording material. For example, a vertical diffusing element (VDE) can be used to spread light vertically in order to increase the vertical viewzone size (e.g., increase the vertical viewing angle) for horizontal-parallax-only (HPO) holographic stereograms. Typically, the diffuser is an anisotropic diffuser. The VDE's function is to provide an anisotropic diffusion plane on which the horizontal image components are focused. The function of the VDE can be accomplished with a lenticular lens array, an interferometric holographic diffuser, a diffractive grating, a specifically designed holographic optical element (HOE) or a combination of these.
Typically, the VDE is placed in close proximity to the holographic recording material (e.g., holographic film) during exposure in order to locate the vertical focus of the hologram either on the hologram plane or as close as possible to the hologram plane. The VDE can also be image relayed to the hologram plane with an appropriate object beam lens system. Generally, it is more effective to physically place the VDE in contact or nearly in contact with the holographic recording material since this tends to provide larger viewing angles. The close proximity of the VDE to the holographic recording material also reduces artifacts that may arise due to low frequency speckle interference between neighboring diffusion elements. FIG. 1A illustrates the situation where the holographic recording material is placed close to the VDE. In this example where the VDE is a lenticular array 100 , the VDE is located so that foci of the lenticules ( 110 ) making up lenticular array 100 coincide with holographic recording material 120 . Thus, if the VDE is placed close enough to the hologram plane, the speckle artifacts are minimized because the light propagating through the VDE element forms a hologram before it can interfere with light from a neighboring VDE element. FIG. 1B illustrates the situation where the VDE is located further from the holographic recording material, thereby giving rise to the aforementioned image artifacts. As seen from detail 130 , overlapping light from adjacent lenticules creates an area of interference leading to spurious gratings and low frequency speckle.
In recording a reflection hologram, the reference beam and the object beam are directed at the holographic recording material from the opposite sides of the material. Because of the proximity of the diffuser to the holographic recording material and the relative transparency of the holographic recording material, the reference beam passes through the holographic recording material and impinges upon the surface of the diffuser. Thus, placement of the VDE in close proximity to the holographic recording material exposes the VDE to reference beam light that is transmitted through the film from the side opposite of that to which the reference beam is directed. This situation is illustrated in FIG. 2 . During hologram recording, the reference beam light 200 is reflected off the VDE elements (typically at a variety of angles) 210 and is recorded as unwanted noise gratings 220 in holographic recording material 120 . Thus, the surface of diffuser 100 typically reflects light from the reference beam back through the holographic recording material a second time.
The reflected light from the reference beam can be reflected such that it interferes with the reference beam as it traverses the holographic recording material. Light from the reference beam passes through the holographic recording material and is reflected by the VDE as reflected reference beam portions. An interference pattern corresponding to the reflected light is recorded in the holographic recording material, resulting in an undesirable artifact that resembles a vertical line seemingly positioned infinitely deep with respect to the hologram plane. This results from the recording of a single beam hologram of the diffuser surface. This artifact is both distracting to the viewer of the resulting hologram and damaging to the diffraction efficiency of the holographic recording material, thereby effecting brightness of the image. Additionally, reflected light from the reference beam can be reflected such that it interferes with the object beam, potentially creating additional unplanned interference patterns that are recorded in the holographic recording material. While in principle, those recorded interference patterns are similar to the interference patterns that are intended to be recorded (i.e., the interference pattern created by the original, un-reflected, reference beam and the object beam), the fact that the interference patterns were formed using light reflected from the reference beam means that additional distortion or unwanted artifacts may be present.
A number of strategies have been used to reduce and/or eliminate the problem of interaction between the reference beam and the diffuser. One solution is to place an anti-reflection coating on the diffuser surface. However, anti-reflective coatings usually are effective only for particular bandwidths of wavelengths and certain angles of incidence of incoming light. Due to the extreme and varied angles at which a reference beam may strike a diffuser and due to the fact that some diffusers are volumetric devices that have no surface relief, this technique has not proven successful. In practice, anti-reflective coatings typically eliminate only about 30% of reflected reference beam light, whereas to eliminate the artifacts described above a greater percentage of the reflected reference beam light should be eliminated. Furthermore, anti-reflective coatings are difficult to uniformly apply over large areas such as the surface area of a diffuser, can be fragile, and can be very costly.
Another technique is the use of a light control or “louver screen” film between the diffuser and the associated holographic recording material. As illustrated in FIG. 3A , light from the reference beam passes through the holographic recording material and impinges upon louver screen film 300 , where the light is absorbed, and/or generally prevented from reflecting back toward the reference beam by microlouvers within the film. The object beam (not shown) passes through the VDE and, because of the structure of the louvers 310 , generally passes through the louver screen film. Louver screen film is a commercially available (e.g., Light Control Film from 3M™) volumetric substrate that typically contains microscopic opaque strips or louvers, arranged in a parallel formation at a selected variable angle analogous to a venetian blind arrangement. Louver screen film is chosen with a particular louver spacing and angle that allows passage of the object beam light, for example, at angles of zero to plus or minus thirty degrees (±30°), while absorbing reference beam light incident at higher angles of, for example, approximately forty five degrees (45°). Such louver screen film successfully prevents reference beam light from striking and reflecting off the surface of diffuser 100 , and thus eliminates the unwanted artifacts.
One problem associated with using louver screen film is the film's requisite thickness (on the order of 1 mm) which necessarily further separates the diffuser from the surface of the holographic recording material. FIG. 3B illustrates a situation where the thickness of louver film 300 limits the amount of diffused object beam light that arrives at the holographic recording material. For example, while ray 320 successfully traverses louver film 300 , ray 330 does not. Because the louver screen film separates the diffuser and holographic recording material, the diffuser plane and the hologram plane are not as close together as is possible, which leads to poorer quality recorded holograms. Louver screen film may also introduce other artifacts into the hologram due to the film's periodicity and diffractive effects associated with the passage of light through the narrow louvers of the film. Additionally, it can be difficult to match the pitch of the louver film with the pitch of the lenticules in VDE 100 , and to properly register the two devices. Finally, louver film often absorbs a significant percentage of the object beam light, again due to the existence of louvers within the film material, along with intrinsic substrate and surface absorption and reflection.
Yet another solution is to use a specially designed holographic optical element, in place of the louver film, that diffracts the unwanted reference beam light away from the holographic recording material. Examples of such devices can be found in the U.S. Pat. No. 6,369,920 entitled “Reference Beam Deflecting Element for Recording a Hologram,” naming Michael A. Klug as the inventor, which is hereby incorporated by reference herein in its entirety.
Nevertheless, it is desirable to have new devices to reduce or prevent reflections of the reference beam off the VDE from striking the holographic recording material. Such devices overcome the deficiencies of the prior art, including for example, the thickness, efficiency, and ease of construction and use.
SUMMARY OF THE INVENTION
In accordance with teachings of the present invention, a device accomplishes the task of reducing or preventing reflections of the reference beam off a diffuser from striking the holographic recording material. First, the device absorbs a large percentage of the reference beam power so that portion of the reference beam never reaches the diffuser. Second, the device blocks the small amount of reference beam that is incident on the diffuser and reflects back toward the film. Thus, the proposed device operates as an absorber-blocker (AB) for the reference beam.
Accordingly, one aspect of the present invention provides a system for recording a hologram in a holographic recording material, the holographic recording material having at least a portion including a first surface and a second surface. The system includes a diffuser and an absorber-blocker. The diffuser is disposed adjacent to the second surface whereby an object beam directed at the second surface can pass through the diffuser prior to contacting the holographic recording material. The absorber-blocker disposed between the second surface and the diffuser to prevent at least a portion of a reference beam directed at the first surface from impinging on the diffuser.
The foregoing is a summary and thus contains, by necessity, simplifications, generalizations and omissions of detail; consequently, those skilled in the art will appreciate that the summary is illustrative only and is not intended to be in any way limiting. As will also be apparent to one of skill in the art, the operations disclosed herein may be implemented in a number of ways, and such changes and modifications may be made without departing from this invention and its broader aspects. Other aspects, inventive features, and advantages of the present invention, as defined solely by the claims, will become apparent in the non-limiting detailed description set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention and advantages thereof may be acquired by referring to the following description and the accompanying drawings, in which like reference numbers indicate like features.
FIGS. 1A-1B illustrate problems associated with the respective locations of a diffuser and a holographic recording material.
FIG. 2 shows the problem of reference beam reflection by a diffuser.
FIGS. 3A-3B show a prior art reference beam deflection solution using louver screen film.
FIG. 3C illustrates an example of a system for producing one-step, monochromatic, holographic-stereograms.
FIGS. 4A-4B illustrate the operation of one embodiment of the present invention where the absorber-blocker is formed on the diffuser.
FIGS. 5A-5B illustrate the operation of another embodiment of the present invention where the absorber-blocker is formed on a separate substrate.
FIGS. 6A-6B illustrate the operation of yet another embodiment of the present invention where the absorber-blocker is formed on a separate substrate.
FIGS. 7A-7B shows several alternate embodiments of the absorber-blocker.
DETAILED DESCRIPTION
The following sets forth a detailed description of the best contemplated mode for carrying out the invention. The description is intended to be illustrative of the invention and should not be taken to be limiting.
FIG. 3C illustrates a simplified example of a system (e.g., a holographic printer) for producing one-step, monochromatic, holographic-stereograms. Typically, holographic printers like that depicted in FIG. 3C include a monochromatic coherent light source such as laser 1 , lenses 42 , mirrors 40 , and optical system 29 , a shutter 10 , a mechanism for translating holographic recording material 69 , holographic recording material 70 , usually in the form of film, a computer 85 for controlling the timing of an exposure sequence, and a separate high-speed computer 87 for image calculations.
The holographic printer of FIG. 3C is typically supported by a vibration isolation table 80 . Shutter 10 is located at the output of laser 1 , and beam-splitter 15 splits beam 5 into an object beam 20 and a reference beam 25 . The polarizations of the object and reference beams are typically adjusted by a pair of half-wave plates 30 and a pair of polarizers 35 . The half-wave plates 30 and the polarizers 35 can also be adjusted to control the ratio of the intensity of the two beams 20 and 25 . A number of mirrors 40 are used to steer beams 20 and 25 as necessary, while lens 42 serves to expand the object beam prior to introduction into optical system 29 .
Optical system 29 includes a diffuser 45 , typically a band-limited diffuser, or an anisotropic diffuser, a liquid crystal display (LCD) panel 50 , and a converging lens 55 . LCD panel 50 receives image data calculated by a high-speed computer 87 via an analog or digital signal. LCD panel 50 serves as a spatial light modulator for light passing through the panel. Converging lens 55 focuses images from LCD panel 50 to the holographic recording material 70 , through diffuser 58 and holographic deflector 60 . Holographic deflector 60 is a holographic optical element designed to “deflect” light from the reference beam. Specifically, at least one of a variety of particular interference patterns is recorded in holographic deflector 60 so that light from the reference beam 25 is diffracted in a preferred direction. Thus, holographic deflector 60 includes one or more holograms that are constructed so that when they are illuminated by a light source such as reference beam 25 , light is preferentially deflected. To prevent the exposure of parts of the holographic recording material 70 that are not part of the elemental hologram meant to be exposed, an object beam masking plate (not shown) can be used. Similarly, reference beam masking plate 65 serves to prevent unwanted exposure of parts of the holographic recording material.
Although the present invention will be discussed in the context of simple monochromatic hologram production systems, those having ordinary skill in the art will readily recognize that the principles disclosed herein can be extended to multi-color hologram production systems, such as those disclosed in the aforementioned U.S. Pat. No. 6,330,088.
FIGS. 4A-4B illustrate the operation of one embodiment of the present invention where the absorber-blocker 410 is formed on the diffuser 400 . In this example, diffuser 400 is a VDE constructed from a lenticular array. The absorber-blocker material is located on the flat side of VDE 400 , and is laid out so as to allow substantially all of the diffused light from the object beam (not shown) to pass between absorber-blocker material elements 420 . For example, if the thickness of VDE 400 and the design of the VDE's lenticules is such that object beam light is focussed to points at or near the flat side of the VDE, the absorber-blocker material can absorb most of the reference beam light that passes through the holographic recording material, while still allowing most of the object beam light to pass through as well. Note that FIG. 4A illustrates the situation where some reference beam light does pass into VDE 400 , either through the spaces between absorber-blocker elements, or perhaps through absorber-blocker elements that are not completely absorbing/blocking. Such light, as shown in FIG. 4B , can be reflected or scattered back toward the absorber-blocker, but will typically be prevented from impinging upon the holographic recording material by one or more absorber-blocker material elements. Preventing these types of reflections from the VDE reduces the amount and severity of VDE-related artifacts recorded in the holographic recording material.
The effectiveness and utility of the absorber-blocker generally depends upon three properties. First, the absorber-blocker does not interfere with, block, or otherwise change the object beam. Second, the absorber-blocker nearly eliminates any reference beam reflections from striking the holographic recording material. Third, the absorber-blocker allows the desired close proximity of the VDE and the holographic recording material.
The absorber-blocker design typically includes a thin layer of material that is strongly absorptive at the wavelengths being used for holographic recording. Such materials include absorptive inks, paints and coatings, as well as photoactive materials (e.g. photographic films and emulsions) that have been exposed so as to be absorptive. Additionally, the absorber-blocker layer is fabricated in such a pattern that the absorbing material exists only where the object beam will not be incident on the layer and will not exist where the object beam is incident upon the layer. The placement of the absorber-blocker layer between the VDE and the holographic recording material is chosen to be at or very near the plane where the object beam is incident on the smallest area of any plane between the VDE and film. As illustrated in FIGS. 4A and 4B , that plane can be at or near the back side of a lenticular array when that side coincides with the focal plane of a lenticular used as the VDE. Similarly, the plane of minimum object beam area would typically be the surface, or very near the surface, of the VDE when using an interferometric holographic diffuser or diffractive grating.
FIGS. 5A and 5B illustrate another example where a lenticular array 500 is used as a VDE, albeit in a flipped orientation. Here, absorber-blocker 510 is located on a separate substrate, typically made from a transparent glass or plastic so as to have minimal effect on transmitted light and provide adequate dimensional stability. The location of the absorber-deflector is preferably chosen to coincide with the plane of minimum object beam area 520 defined by the foci of the lenticules making up lenticular array 500 . The embodiment of FIGS. 5A and 5B are particularly useful where the VDE's plane of minimum object beam area is not located on a surface of the VDE (as is often the case with “off-the-shelf” VDEs) or where some other aspect of the VDE is not conducive to the formation of absorber-blocker elements directly on the VDE. FIG. 5B illustrates the effect of absorber-blocker 510 on an incident reference beam.
Placing an absorber-blocker 610 at a plane other than the plane of minimum object beam area 620 results in a less effective absorber-blocker that might allow a small amount of reference beam to be reflected off VDE 600 and be incident upon the film, as illustrated in FIGS. 6A and 6B . Additionally, using absorber-blockers that cannot be located at the plane of minimum object beam area (perhaps because of some systematic limitation) may necessitate reducing the size of absorber-blocker elements to ensure that adequate object beam light passes through to the holographic recording material. Nevertheless, such off the plane of minimum object beam area absorber-blockers can be advantageously used in holographic production systems.
FIGS. 7A and 7B illustrate examples of absorber-blockers located at or near the plane of minimum object beam area.
Formation of the absorber-blocker elements can be accomplished using a variety of techniques, as will be well known to those having ordinary skill in the art. For example, absorber-blocker elements can be formed using established photolithographic techniques. Alternately, the absorber-blocker elements can be formed by exposing photoactive materials (e.g., photographic films, polymers, emulsions, etc.) and then processing the material accordingly. In particular, the VDE to be used with the absorber-blocker can be used to form the exposed areas in a photoactive material that is then processed appropriately. Using the designated VDE can make it easier to form absorber-blocker elements that match the pitch of the VDE, are located in the plane of minimum object beam area, and are properly registered with the VDE.
As mentioned previously, the vertical diffusers provide the vertical view zone for horizontal-parallax-only (HPO) holograms. Since hologram printers for producing HPO holograms use cylindrical lenses to produce an angular view zone along the horizontal orientation of the hologram, the vertical orientation of the cylindrical lenses typically have no power. Thus in the vertical direction, a collimated object beam propagates without any divergence. If no vertical diffuser is installed in the printer, holograms produced by the printer would show a vertically truncated image along a narrow horizontal line.
Although the disclosed embodiments have been described in detail, it should be understood that various changes, substitutions and alterations can be made to the embodiments without departing from their spirit and scope. In particular, those having ordinary skill in the art will readily recognize additional types of diffusers, absorptive materials, substrates, optical elements, and techniques for constructing same, which can be used as part of the present invention. | In accordance with teachings of the present invention, a device accomplishes the task of reducing or preventing reflections of the reference beam off a diffuser from striking the holographic recording material. First, the device absorbs a large percentage of the reference beam power so that portion of the reference beam never reaches the diffuser. Second, the device blocks the small amount of reference beam that is incident on the diffuser and reflects back toward the film. Thus, the proposed device operates as an absorber-blocker (AB) for the reference beam. | 6 |
RELATED APPLICATIONS
[0001] The present application is related to commonly assigned U.S. Pat. No. 6,016,313 entitled “System and Method for broadband millimeter wave data communication” issued Jan. 18, 2000 and currently undergoing two re-examinations under application Ser. No. 90/005,726 and application Ser. No. 90/005,974 which are hereby incorporated herein by reference.
BACKGROUND OF INVENTION
[0002] The use of highly correlated or repetitive preamble sequences is important for rapid carrier recovery, symbol timing recovery and equalization in burst mode modems. Unfortunately correlated or repetitive preamble sequences can produce undesirable spectral components at discrete locations that can exceed allowable spectral masks, which are based on the expectations of randomized sequences and averaged power level for the payload.
[0003] Some art solutions have been directed towards random preambles, phase map recovery processes, reducing preamble length much less that payload length and reducing output power.
[0004] Random preambles require increasing the length of the preamble. Furthermore symbol timing is not as robust thus symbol timing recovery takes longer.
[0005] A prior art method relies on quadrate mode slicing of a multilevel QAM constellation for carrier recovery process during the preamble, which requires only that symbols be located along the diagonal axis of the QAM constellation for proper carrier recovery. Quadrant mode slicing measures phase of the received signal relative to the diagonal of 4 quadrants and assumes received signal should be on the closest diagonal. Quadrant slicing partitions the constellation into 4 quadrants and if the received signal lands in a quadrant, the system assumes it in on the diagonal for that quadrant. This method disregards amplitude information from the signal.
[0006] Another method phase map slicing, requires symbols to be located at a valid constellation point. In phase map slicing the system determines which constellation point a received signal is closest to by comparing phase and amplitude of the received signal with the phase and amplitude of the constellation points. With phase map recovery processes, the preamble is restricted to valid symbol and the signal could still exceed the spectral mask.
[0007] Although lowering the output power of the entire signal can maintain the spikes below the spectral mask, it is an inefficient use of power spectrum capability.
[0008] Therefore, there is a need for a method of reducing spikes due to harmonics of preamble spikes while retaining the ability for rapid carrier recovery, symbol timing recovery and equalization in burst mode modems.
[0009] An object of the present invention is an improvement of a method in a communication system for transmitting a data signal. The data signal includes a preamble portion preceding a payload portion. The improvement involving decreasing the output power of the transmitter when transmitting the preamble portion.
[0010] Another object of the present invention is an improvement of a method in a communication system for transmitting highly correlated or repetitive symbols and not highly correlated symbols in an average power-limited environment. The improvement involving decreasing the output power of the transmitter when transmitting the highly correlated symbols relative to the output power of the transmitter when transmitting the non-highly correlated symbols.
[0011] Yet another object of the present invention is an improvement of a method for reducing out-of-bandwidth harmonic spikes during transmission caused by a sequence of highly correlated symbols common in a preamble portion of bursty type data. The improvement involving transmitting the highly correlated symbols at a lower transmitter power than when transmitting non-highly correlated symbols common in a payload portion of bursty type data.
[0012] Still another object of the present invention is an improvement for a method of transmitting frames of data, where the frames of data include a preamble and payload portion. The improvement involving ensuring the average power of the transmitted signal representing the preamble is less than or equal to the average power of the transmitted signal representing the payload portion.
[0013] These and many other objects and advantages of the present invention will be readily apparent to one skilled in the art to which the invention pertains from a perusal of the claims, the appended drawings, and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a graph of signal power and spectral mask in the frequency domain.
[0015] [0015]FIGS. 2A and 2B are graphs of signal amplitude for the payload and preamble portions in the time domain.
[0016] [0016]FIG. 3 is a representation of a QAM constellation with average signal power rings.
[0017] [0017]FIG. 4 is a graphical representation of peak signal amplitude for the payload and preamble portions in the time domain according to the present invention.
DETAILED DESCRIPTION
[0018] Data signals used in bursty type data transmission commonly contain a preamble portion and a payload portion. The preamble portion commonly contains sequences of highly correlated and or repetitive symbols. Preamble sequences, especially when transmitted in short bursts, introduce harmonic spikes into the signal, which often exceed the allowable spectral power constraints.
[0019] [0019]FIG. 1 shows a representation of the power of a bursty data signal 100 in the frequency domain. A spectral mask 110 defines the permissible signal power for a range of frequencies. The maximum signal power allowed is centered on the center frequency, and spans the channel bandwidth 120 before tapering off on both sides of the channel bandwidth 120 . The data signal 100 contains spikes 105 that exceed the spectral mask 110 and thus the permissible limits. These spikes are predominately caused by the harmonics of the preamble portion of the data signal.
[0020] [0020]FIG. 2A is a graphical representation of the amplitude of the symbol stream 200 of the preamble portion 201 of the data signal with respect to time. Because the length of the block of preamble symbols is short and generally restricted to 4 Quadrature Amplitude Modulation (QAM), the preamble symbol stream 200 acts similar to a sine wave. Thus modeling the preamble symbol stream 200 as a sine wave, the preamble portion of the signal has an average amplitude of 0.707 of the peak amplitude and peak power to average power (P pk /P avg ) approximately equal to 3 dB.
[0021] [0021]FIG. 2B is a graphical representation of the amplitude of the symbol stream 202 of the payload portion 203 of the data signal with respect to time. As seen from FIG. 2A the payload portion of the signal appears random. This randomness is common in payload portions for several reasons. First, the symbols in the payload portion represent the useful data in the data signal as such variation between successive symbols in likely. Also the payload section in order to contain as much information as possible can have higher signal densities or (QAM) levels higher than the 4 QAM typical of preamble portions. The length of the block of data symbols transmitted by the payload portion is also much longer than those of the preamble. Thus, the data symbol stream 202 of the payload portion 203 acts more random than does the preamble section. The result of the random nature, the payload portion 203 has a peak power to average power (P pk /P avg ) approximately equal to 12 dB.
[0022] A representation of the QAM constellation is shown in FIG. 3. The valid payload data symbols 302 are shown as points. As discussed previously the payload data is not limited in QAM level. The valid preamble data symbols 300 are shown as squares, again the preamble is generally limited to 4 QAM. The preamble symbol average output power band is shown as circle 304 while the payload symbol average output power P avg/payload band is shown as circle 305 . From FIG. 3 it is clear that P avg/preamble is much greater than P avg/payload .
[0023] Given this disparity in relative average power, it is possible to reduce P avg/preamble down to or below P avg/payload by reducing the power at which the preamble symbol stream is transmitted relative to the power at which reducing the power at which the preamble symbol stream is transmitted relative to the power at which transmits at the payload symbol stream. As a result the peak amplitude of the preamble symbol stream is reduced. The reduction of the preamble peak amplitude can reduce the magnitude of the harmonic spikes 105 to below the spectral power mask 110 .
[0024] A signal transmitted with a reduced power setting for the preamble portion compared to the payload portion is shown in FIG. 4. The signal's 400 transmit power and correspondingly its amplitude is increased the ramp up portion 411 until it reaches the transmit power and maximum amplitude of the preamble portion 401 . The signal's 400 transmit power is again increased up to the transmit power and maximum amplitude of the payload portion 403 . The transmit power is then ramped down 412 after transmission of the payload portion. In contrast the signal 400 a is shown where the transmit power is not reduced for the preamble portion 401 .
[0025] The transmit power of the preamble is preferably reduced such P avg/preamble is approximately equal to P avg/payload . The desired bandwidth of the preamble output power band (i.e. the diameter of the power band 304 shown in FIG. 3), and thus the preamble transmit power setting, is determine from several factors, most dealing with the determination of P avg/preamble . Among these factors are spectral mask type, bandwidth and filter for spectral mask, payload length relative to preamble length, modulation index, desired c/n in control channel and preamble pattern.
[0026] The characteristics of the spectral mask are necessarily a component in determining the desired preamble power bandwidth in that reducing the transmit power of the preamble is done to prevent the harmonic spike from exceeding the mask. The greater the relative length of the payload portion to the preamble portion allows the desired preamble power bandwidth to increase as does a more random preamble pattern. The modulation index of the payload portion has an inverse effect, the higher the modulation index of the payload portion compared to the preamble portion, the narrower the desired preamble power band becomes.
[0027] All of some of these factors and other may be evaluated prior to transmission of the signal in order to determine the desired preamble power bandwidth, the estimated P pk /P avg and thus the desired transmit power reduction for the preamble portion of the signal.
[0028] Transmit preamble power control as describe above can be advantageously used in communication system employing bursty type data messages, such as Time Division Duplex (TDD) and Adaptive Time Division Duplex ATDD.
[0029] The previous description of the preferred embodiments is provided to enable any person skilled in the art to make or use the present invention. The various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without the use of the inventive faculty. The present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | A method for transmitting a data signal where the data signal includes a preamble portion preceding a payload portion that reduces harmonic spikes is presented. The method reduces the transmission power for portions of bursty data signal that contain highly correlated or repetitive preamble sequences relative to the transmission power that contain non-highly correlated or repetitive payload sequences. The resultant average output power of the preamble sequences is approximately equal to the average output power of the payload sequences. | 7 |
BACKGROUND OF THE INVENTION
The present invention resides in the field of glass molds, and more particularly relates to an improved mold mechanism for opening and closing split molds utilized in blown glassware.
In the formation of hollow glassware, a charge of molten glass is usually initially formed into a parison such as by pressing or blowing such charge within a parison mold, and the thus formed parison is then transported to a blow mold for blowing the same into a finished article. Thus, it is necessary for the blow mold to open sufficiently to receive the preformed parison, close so as to form the desired mold cavity for blowing the parison into a finished article, and again open sufficiently wide so as to permit the removal of the finished article from the mold. Although some press and blow operations are accomplished with the blow mold in a stationary position, other operations include the utilization of a plurality of such blow molds positioned about a rotating table which successively receive a preformed parison carried by a conveyor, such as shown in U.S. Pat. Nos. 2,263,126 and 3,622,305.
The mold mechanism of U.S. Pat. No. 2,263,126 accomplishes both a straight line motion of the back half of a blow mold and a rotary motion of the front half of the blow mold from a single straight line driving motion imparted by an air cylinder. However, the mechanism of such patent utilizes a rack and pinion to provide the rotary motion to the front blow mold half, and due to constant wear and backlash between the rack and pinion, the mechanism becomes loose and erratic and accordingly affects glass quality produced thereby. Further, pieces of glass have a tendency to become lodged within the rack and pinion mechanism thus producing the jamming thereof and undesirable downtime.
It thus has been an object of the present invention to overcome such problems which existed with the prior art devices and provide a smooth operating mold mechanism for opening and closing the mold halves of a blow mold.
SUMMARY OF THE INVENTION
In its simplest form, the present invention relates to the mechanism for opening and closing split mold halves of a blow mold. An air cylinder having an operating rod is connected to one mold mounting member for moving the mold part mounted thereon in a linear direction while simultaneously pivoting a second mold mounting member having another mold part mounted thereon through an arcuate path by means of pivotal links actuated by the movement of said one mold mounting member to thereby open and close a two-part blow mold mounted on said mold mounting members.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a mold operating mechanism embodying the present invention, shown with the mold parts in a closed operating position.
FIG. 2 is a top plan view of the apparatus shown in FIG. 1.
FIG. 3 is an end elevational view of the apparatus as viewed from the left end of FIG. 1.
FIG. 4 is an elevational view in section taken along line 4--4 of FIG. 1, with a portion broken away to show a pivotal connection.
FIG. 5 is a sectional view in elevation taken along line 5--5 of FIG. 1.
FIG. 6 is a side elevational view of the mold operating mechanism shown in FIG. 1 but with the mold mounting members shown with the mold parts in the full mold open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, a mold mechanism support bracket or mounting frame 10 is shown having a base portion 12 which may be secured to a rotating table or other suitable support, a transverse back portion 14 and a pair of forwardly extending spaced apart arm portions 16. An air cylinder 18 is mounted upon the back portion 14 of the mounting frame 10 such as by means of a plurality of bolts 20 extending through a compression plate 22 at the rear of the cylinder and through back portion 14 so as to be held in place by tightening nuts 24. A cylinder operating rod 26 extends through an opening 28 (FIG. 2) in back portion 14, and at its outer end is provided with an adaptor 30 which is secured to a rear portion of a first or rear mold mounting member 32 by a retainer plate 34. A mold segment plate 36, having undercuts and keyway portions 38 for retaining a mold half 40, is mounted on the mold mounting member 32.
Arm portions 16 of the mounting frame 10 each have a side slot 42 which is provided with an upper slide way member 44 and a lower slide way member 46, which function as wear plates (FIGS. 1 and 5). A pair of slide blocks 48, having connecting tabs 50, are secured to a rear surface of the first mold mounting member 32 so that the slide blocks 48 may freely slide within side slot 42 between the upper and lower slide way members 44,46, respectively. A pair of slide straps 52 are bolted to the rear ends of the upper and lower slide way members 44,46, respectively, to serve as stiffeners for the slide ways. Further, a slide block retainer plate 54 is bolted to the outer face of each slide block for sliding movement with the slide block along the outer edges of the upper and lower slide way members, and thus serve as guides for centering the sliding movement of the rear mold mounting member 32.
A lower bottom link member 56 is pivotally mounted at one bossed end portion 58 to a bifurcated bossed lower end portion 60 of first mold mounting member 32 by means of a first pivot pin 62 and thrust washers 64 (FIG. 3). A central pivot link member 66 has an upper bifurcated portion 68 provided with a pair of bosses 70 having axially aligned bores extending therethrough. The arms 16 each have a bossed portion 72 at their upper end thereof provided with axially aligned bores 74 so as to pivotally mount the central pivot link member 66 to arms 16 by means of a pair of second pivot pins 76 and thrust washers 78. Each pin 76 extends through a bore 74 and one of said aligned bores passing through bosses 70 so as to pivotally mount central pivot link member 66 between the bossed portions 72 of arms 16.
The central pivot link member 66 has a lower bifurcated portion 80 which receives a bored forward end portion 82 of lower link member 56. The bifurcated end portion 80 has a pair of axially aligned bores 84 for pivotally connecting lower link member 56 by means of a third pivot pin 86 and thrust washers 88. It thus can be seen, that linear sliding movement imparted to the first mold mounting member 32 by air cylinder 18 through cylinder rod 26 causes central pivot link member 66 to pivot about the pair of second pivot pins 76, due to the action of lower link member 56 being pivotally connected at one end to the lower bifurcated end portion 60 of first mold mounting member 32 and the lower bifurcated portion 80 of central pivot link member 66.
A second mold mounting member 90 has a lower bifurcated portion 92 having a pair of axially aligned bores 94. The lower bifurcated portion 80 of central pivot link member 66 has a pair of axially aligned bores 96 (FIG. 3) located above bores 84. The second mold mounting member 90 is pivotally mounted to central pivot link member 66 by means of thrust washers 98 and a fourth pivot pin 100 extending through axially aligned bores 94 and 96 of second mold mounting member 90 and central pivot link member 66, respectively. Thus, the fourth pivot pin 100 will lie within an arc about the axis of pivot pins 76 as central pivot link member 66 is rotated about such axis.
A pair of upper link members 102, each having an enlarged bossed end portion 104 and a smaller bossed end portion 106 pivotally connect the second mold mounting member 90 to the arms 16 of mounting frame 10 (FIGS. 3 and 4). The enlarged bossed end portion 104 of each upper link member 102 has a bore 108 extending therethrough. The second mold mounting member 90 has a bore 110 extending transversely therethrough which is in alignment with bores 108. Upper link members 102 and second mold mounting member 90 are pivotally connected together by a fifth pivot pin 112 extending through bores 108 and 110, together with thrust washers 114. Suitable bushings 116 may be utilized as desired in connection with fifth pivot pin 112, as well as the other pivot pins although not expressly shown in the drawings.
The smaller bossed end portion 106 of each of the upper link members 102 is provided with a bore 118, whereas arms 16 are each provided with a bore 120 which may be provided with a suitable bushing 122. A pair of sixth pivot pins 124 and thrust washers 125 pivotally connect upper link members 102 with arms 16 of the mounting frame 10 with pins 124 extending through bores 118 and 120 of the upper link members 102 and arms 16, respectively. Thus, pivot pin 112 lies on an arc about the axis of aligned pivot pins 124.
Of the six pivot pins utilized in the mold mechanism, it will be noted that only pivot pins 76 and 124 are in a fixed or stationary position, whereas the remaining pivot pins are all movably positioned. The first pivot pin 62 is linearly movable, whereas third pivot pin 86, fourth pivot pin 100 and fifth pivot pin 112 are arcuately movable. Further, the axis of fifth pivot pin 112 lies in a vertical plane bisecting the juncture of mold halves 40 and 41 when such mold halves are in a closed operational position. The second mold mounting member 90 is provided with a mold segment plate 37 having under cut and keyway portions 39 for retaining mold half 41.
An adjustment screw 126, having a tightening nut 128, is adjustably threaded through an opening 130 in second mold mounting member 90, and has an abutment nose portion 132 for engaging a stop member 134 secured to first mold mounting member 32 so as to limit the closing of the mold parts 40,41 for proper alignment of such mold segments. Further, it will be appreciated that suitable lubrication fittings may be secured to all journals as is well known in the art.
In operation, with the mold mechanism in its closed operative position as shown in FIG. 1, such that the mold halves 40 and 41 are in a closed upright position forming a complete operative mold, air cylinder 18 is energized at its forward end to retract its piston and accordingly cylinder operating rod 26 connected thereto, so as to move first mold mounting member 32 linearly rearwardly from the position shown in FIG. 1 to the position shown in FIG. 6. As the cylinder operating rod 26 is retracted by cylinder 18, mold half 40 is moved linearly rearwardly as first mold mounting member 32 is slid rearwardly by means of slide blocks 48, connected to mounting member 32 by means of connecting tabs 50, sliding between upper and lower slide way members 44,46, respectively positioned within slide slots 42. As first mold mounting member 32 moves rearwardly, lower link member 56, pivotally connected at one end to first mold mounting member 32 by means of first pivot pin 62 and pivotally connected at its opposite end to lower bifurcated portion 80 of central pivot link member 66 by means of a third pivot pin 86, pivotally rotates central pivot link member 66 about second pivot pins 76 connecting said central pivot link member 66 to arms 16 of the mounting frame 10.
However, as central pivot link member 66 rotates about second pivot pins 76, the second mold mounting member 90 pivots about fourth pivot pin 100, connecting such second mold mounting member to the central pivot link member, as the fourth pivot pin 100 rotates through an arc about the axis of second pivot pins 76. Finally, upper link members 102, pivotally connected at one end to the second mold mounting member 90 by fifth pivot pin 112 and at their opposite ends to arms 16 of mounting frame 10 by means of sixth pivot pins 124, guide the pivotal opening movement of second mold mounting member 90 by pivoting such mold mounting member about fifth pivot pin 112 as such pin moves through an arc about the axis of sixth pivot pins 124, so as to move such second mold mounting member and accordingly mold half 41 into their full open position as shown in FIG. 6.
It will be appreciated that by energizing the rearward end of cylinder 18, its piston and operating rod 26 will be moved forwardly thus linearly moving first mold mounting member 32 and mold half 40 forwardly to its closed position while simultaneously pivotally moving second mold mounting member 90 and mold half 41 back to its closed position shown in FIG. 1 by reversing the above described pivotal movements which were performed to pivotally open such mold half. Adjustment screw 126 in conjunction with stop member 134 facilitates the correct alignment and positionment of the mold segments when moved into their closed position.
Although I have disclosed the now preferred embodiment of the invention it will be apparent to those skilled in the art that various changes and modifications may be made thereto without departing the spirit and scope thereof as defined in the appended claims. | A mold mechanism for opening and closing a split mold is described wherein a single air cylinder moves one half of the mold in a linear direction and simultaneously, through a plurality of interconnected pivotal links, rotates the other half of the mold through an arc of at least 90 degrees so as to open and close the mold halves upon actuation of the air cylinder. | 2 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to methods and devices by which metal siding can be removed from buildings preparatory to the necessary drilling of the supporting wall structures to provide access to the zones between adjacent studs for the purpose of installing blown in insulation material, and reinstalling the removed siding.
2. Description of the Prior Art
Prior methods and devices have generally comprised the removal of a longitudinal strip of metal siding and the installation of a new strip in place thereof when the insulation of the wall cavity has been completed. The removal of the original siding section usually damaged the same so that it could be replaced and the substitution of a new section of siding changed the appearance because the color, texture or faded appearance of the original siding did not match the newly installed new section.
Due to the cosmetic change in the appearance of the building, many home owners have decided not to insulate their homes.
A typical prior art metal siding is illustrated in U.S. Pat. No. 2,766,861 and those skilled in the art will observe that vinyl siding of substantially the same configuration is also widely employed.
U.S. Pat. No. 4,187,661 discloses a proposal for removing metal siding and reinstalling the same and it has been found that the use of the tool and the method of this disclosure usually results in distortion and damage of the metal siding and the inability of the reinstalled siding to remain firmly in desired position.
The present method enables a section of metal siding to be removed by simply cutting the same adjacent its uppermost edge and immediately beneath a horizontal lip portion of the siding and eventually reinstalling the removed section by first applying a longitudinally extending clamping strip having a configuration that will clampingly engage the cut edge of the metal siding strip being reinstalled.
SUMMARY OF THE INVENTION
A method of removing and reinstalling metal siding on a building is disclosed which uses a clamping strip to secure a cutaway piece of metal siding to the fastening configuration of the siding piece thereabove and immediately adjacent the horizontal portion thereof, the visual part of the strip taking the form of a narrow bead-like section which lies immediately under the horizontal portion of the siding strip above the reinstalled section and is hidden in the natural shadow line thereof.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional side elevation of a portion of a building wall and two pieces of metal siding attached thereto;
FIG. 2 is a cross sectional side elevation of a portion of a building wall showing two pieces of metal siding attached thereto, one of which has been cut longitudinally inwardly of its upper edge below its fastening configuration and reinstalled with a longitudinally extending clamping strip;
FIG. 3 is a perspective view of the clamping strip seen in FIG. 2; and
FIG. 4 is a section of the upper edge of the cut piece of metal siding showing fastening configurations stamped therein for cooperation with the clamping strip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
By referring to the drawings and FIGS. 1 and 2 in particular, it will be seen that a supporting wall 10 carries longitudinal sections of metal siding which comprise substantially vertical sections 11 and horizontal sections 12 with the upper longitudinal edges of the vertical sections 11 being attached to the supporting wall 10 by fasteners 13.
The horizontal sections 12 which form the lower edges of the sections of metal siding have upturned longitudinally extending, cross sectionally arcuate flanges 18 formed continuously therealong with are adapted to be engaged beneath continuously extending outwardly and downwardly folded lips 14 formed just below the upper edges of the vertical sections 11 of the metal siding. Those skilled in the art will understand that when the metal siding is installed on the supporting wall 10 the flanges 13 on the horizontal sections 12 of each successively installed section of metal siding is engaged under the folded lip 14 of the section of siding therebelow and then attached to the supporting wall by the fasteners along its uppermost edges.
The lowermost strip of metal siding is commonly attached to the wall by a longitudinally extending starting piece as seen for example in U.S. Pat. No. 2,766,861 and common in the art.
By referring now to FIG. 2 of the drawings in particular, it will be seen that portions of two strips of metal siding have been illustrated, each attached to the supporting wall along its uppermost edge by the fasteners 13 and each having a folded lip 14 thereon. The lowermost one of the two sections of metal siding illustrated in FIG. 2 has been cut longitudinally thereof at a cut line indicated by the letter C, the cut line C being just below the horizontal section 12 of the upper section of metal siding. The lower section of metal siding was therefore freed from its attachment to the supporting wall 10 by the fastener 13 and the cutaway section thus capable of being removed so that an opening O could be formed in the supporting wall 10 through which insulation could be blown as desired. When this has been completed the opening is usually patched by inserting a plug or the like and the cutaway section of metal siding can then be reinstalled by the method disclosed herein and through the use of an elongated section of clamping strip 15 which has an integral outwardly and downwardly hook flange 16 formed continuously thereon and inwardly of its upper and lower edges. A perspective view of a section of the clamping strip may be seen in FIG. 3 and in FIG. 2 of the drawings the clamping strip 15 will be seen installed with the uppermost flange thereof which is tapered as at 17, pushed upwardly so as to be frictionally engaged between the remaining portion of the vertical section 11 of the lower section of metal siding and the upturned arcuate flange 13 of the horizontal section 12 of the upper section of metal siding, the arrangement is such that the outwardly and downwardly extending hook flange 16 is positioned immediately below and in contact with the horizontal section 12 of the upper section of metal siding as seen in FIG. 2 of the drawings.
The lower cutaway section of metal siding 11 is then provided with a plurality of crimped or bulged fastening configurations 18 along its uppermost cut edge as best seen in FIG. 4 of the drawings and then pushed upwardly into frictional engagement with the inner surface of the outwardly and downwardly extending hook flange 16 on the clamping strip 15, while its lower edge with its horizontal section 12 and upturned arcuate flange 13 re-engages the folded lip 14 as hereinbefore described.
The reinstallation of the cutaway section of metal siding is thus completed as the fastening configurations 18 engage the hook configuration of the hook flange 16 of the clamping strip 15. The exposed portion of the hook flange 16 will thus be seen to be positioned immediately in under the horizontal section 12 of the metal siding section where it forms an inconspicuous shadow line along with the usual shadow line defined by the horizontal section 12.
The clamping strip 15 is preferably extruded of a suitable synthetic resin such as vinyl and preferably in a color matching that of the enameled finish of the metal siding with which it is used.
It will thus be seen that a novel method of removing and replacing a longitudinal section of metal siding from a supporting wall of a building has been disclosed and which utilizes the novel clamping strip disclosed herein as an essential part of the novel method. In effect the clamping strip 15 with its hook flange 16 becomes part of a combination consisting of the cutaway section of the metal siding and the clamping strip.
The combination thus formed repositions the section of the metal siding that was cut away and removed in substantially its original location and together with the lower portion of the siding section thereabove and the remainder of the cutaway section insures the desirable positioning and retention of the cutaway section on the supporting wall.
It will thus be seen that an inexpensive easily performed method of removing and reinstalling a section of metal siding has been disclosed and which method incorporates the use of a novel clamping strip which becomes part of the metal siding installation and its attachment means.
Although but one embodiment of the present invention has been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention and having thus described my invention | A method of removing and reinstalling metal siding on buildings utilizes a novel clamping strip in repositioning and attaching a section of metal siding that has been cut longitudinally from the building to provide access for the drilling of holes for the injection therethrough of blown insulation. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a loom in which use is made of a lubricant, such as oil, in particular within a shed-forming device of the dobby, cam mechanism, or Jacquard mechanism type.
2. Brief Description of the Related Art
Modern looms operate at high speeds, often faster than 900 picks per minute. The shed-forming devices associated with such looms need to develop a large amount of mechanical power, some of which is lost to friction, thereby producing heat. This heat production increases the temperature of the oil used within such a device for lubricating its moving parts. The oil heats up to a temperature such that a cover of such a shed-forming device can become too hot to touch, which is dangerous for an operator nearby. This heating also has the consequence of the oil reaching a temperature range in which its viscosity is significantly modified, to such an extent that it is no longer guaranteed that a film of oil between two contacting parts will have the necessary thickness.
It is known from JP-A-10 251943 to feed with oil several components of a loom, from a single tank. A water circuit is used to cool the content of this tank.
US-A-2003/0178089 discloses circulating the oil of a shed-forming device through an external plate heat exchanger of the water/oil type. That approach requires the use of a cold source external to the loom and requires water to be brought to the heat exchanger, thereby requiring pipes to be installed over a considerable length. Furthermore, that approach imposes mixing the oil used for lubricating the various portions of a loom in order to take the oil to the heat exchanger. Unfortunately, the oil that is best suited to lubricating the shed-forming device is not necessarily the same as the oil that is best suited to lubricating a beater box or means for controlling of a device for inserting picks in a loom. It is therefore necessary to accept a compromise concerning the type of oil that is to be used. Furthermore, in spite of settling devices being used, hard particles produced in the event of failure of one of the members of the loom or of the shed-forming device may then contaminate all of the other members and may significantly shorten the lifetime of the loom.
SUMMARY OF THE INVENTION
The invention seeks more particularly to remedy those drawbacks by proposing a novel loom that includes, amongst others, a shed-forming device that is lubricated under good conditions without spoiling the nature of the lubricant used to do this.
To this end, the invention provides a loom comprising: a subassembly including heddles, a beater, and means for inserting weft into the shed formed by warp yarns, and a shed-forming device. In this loom, lubrication means for lubricating certain components of the above-mentioned subassembly include a first circuit for circulating a first lubricant, and means for lubricating the shed-forming device and including a second circuit for circulating a second lubricant. In accordance with the invention, the loom includes a heat exchanger system for exchanging heat between the first lubricant and the second lubricant without fluid communication between these lubricants, and the heat exchanger system comprises means for circulating one of the lubricants selected from the first and second lubricants, or a coolant fluid to a zone where the lubricant or the coolant fluid is in thermal contact with another lubricant selected from the first and second lubricants.
By means of the invention, one of the lubricants, having an operating temperature that rises relatively little, is used to cool the other lubricant that has an operating temperature that rises further. In practice, the invention makes it possible to use the first lubricant that circulates through the components of the subassembly including, amongst others, the heddles, the beater, and the weft inserter means, in order to cool the second lubricant that flows through the shed-forming device. The temperature of the first lubricant is generally less than 70° C., since this lubricant comes into contact with relatively large heat exchange areas with air, whereas the temperature of the lubricant in the shed-forming device is higher because that equipment is compact.
According to aspects of the invention that are advantageous but not essential, a loom in accordance with the invention may incorporate one or more of the following features taken in any technically feasible combination:
The means for putting the lubricant into circulation comprise at least one pump and associated lines for circulating one of the lubricants selected from the first lubricant and the second lubricant or the coolant fluid to the thermal contact zone or from said zone. The loom includes at least one temperature sensor for sensing the temperature of one of the lubricants or of a coolant fluid. The loom includes regulation means for regulating heat exchange between the first and second lubricants. The regulation means advantageously comprise means for controlling the pump as a function of the signal output by the temperature sensor. The heat exchanger means comprise a heat exchanger and means for bringing the first and second lubricants to the heat exchanger. The heat exchanger means comprise a third circuit in which a coolant fluid circulates between a first zone of thermal contact with the first circuit and a second zone of thermal contact with the second circuit. At least one of the coolant fluid circulation circuits includes a volume forming a supply of lubricant circulating in said circuit, and the heat exchanger means include means for bringing a coolant fluid or the lubricant of the other circuit into the supply-forming volume. The first lubricant is used for lubricating means for driving the beater, the weft inserter means, and/or a device for driving a beam or a roller for winding the cloth.
The invention also provides a method of controlling the temperature of a lubricant in a shed-forming device suitable for use in a loom, as mentioned above. The method consists in putting said lubricant into thermal contact with another lubricant used for lubricating certain components of a subassembly of the loom, which subassembly includes heddles, a beater, and means for inserting weft into the shed formed by warp yarns.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood and other advantages thereof appear more clearly in the light of the following description of five embodiments of looms in accordance with its principle, given purely as examples and with reference to the accompanying drawings, in which:
FIG. 1 is a diagram showing the principle of a loom in accordance with a first embodiment of the invention; and
FIGS. 2 to 5 are diagrams analogous to FIG. 1 showing looms respectively in accordance with second, third, fourth, and fifth embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The loom 1 shown in FIG. 1 includes a subassembly 2 within which warp yarns and weft yarns (not shown) are woven. The subassembly 2 has a plurality of heddle frames 21 , each fitted with a plurality of heddles 212 , only some of which are shown in FIG. 1 for clarity in the drawing, each of which is provided with an eyelet 214 for passing a warp yarn. These heddle frames 21 are driven by pull rods 22 , themselves controlled by reversing levers (not shown).
The subassembly 2 also includes a beater or comb 23 for striking the weft yarns after weaving in order to make the cloth compact. The beater is hinged about an axis Y 23 perpendicular to the direction in which the heddle frame 21 oscillates vertically, as represented by double-headed arrow F 1 . A drive mechanism 24 moves the beater 23 to pivot back and forth about the axis Y 23 .
The subassembly 2 also has weft inserter means 25 and 26 disposed on either side of the frames 21 . These means 25 and 26 serve to control rapiers 252 and 262 that are used for inserting weft yarns into the shed formed by the warp yarns that pass through the eyelets 214 .
The subassembly 2 also includes a beam from which the warp yarns are unwound on their way towards the eyelets 214 of the heddles 212 , together with a roller onto which the cloth is wound progressively while it is being fabricated on the loom 1 . The beam and the roller are not shown in FIG. 1 . They are driven by respective mechanisms 28 and 29 provided for that purpose.
A circuit C 1 for circulating a first oil is provided inside the subassembly 2 in order to lubricate the mechanism 24 , the weft inserter means 25 and 26 , and the mechanisms 28 or 29 . In a variant, the circuit C 1 may be used to lubricate only some of the pieces of equipment mentioned above, or other pieces of equipment forming part of the subassembly 2 .
In FIG. 1 , the circuit C 1 is represented very diagrammatically by means of arrows that do not necessarily correspond to the path followed by the circuit C 1 in the subassembly 2 .
The circuit C 1 includes a pan 31 formed in the bottom portion of a casing 30 of the subassembly 2 . A pump 32 is installed in the pan 31 and serves to circulate the oil via ducts (not shown in detail) within the circuit C 1 , each leading to mechanisms for lubricating. The oil of the circuit C 1 also has a thermal function insofar as it serves to cool the parts of the subassembly 2 with which it comes into contact. This first oil thus performs a lubricating function and a cooling function, such as that provided by a coolant fluid.
The loom 1 also has a dobby 4 for driving the various heddle frames 21 . To do this, the dobby 4 has as many oscillating levers 42 as there are pull rods 22 in the set, each lever 42 being dynamically connected to the rods 22 of a heddle frame 21 in known manner that is represented by a chain-dotted line 44 in FIG. 1 .
A second lubrication circuit C 2 is provided inside the dobby 4 . This circuit has a pan 51 formed in the bottom portion of a casing 50 of the dobby 4 and within which there is placed a pump 52 serving to circulate a second oil via ducts (not shown) within the circuit C 2 and leading to portions of the dobby 4 that need to be lubricated.
The circuit C 2 is also shown in highly diagrammatic manner. The oil of the circuit C 2 also has a thermal function, insofar as it serves to cool those parts of the dobby 4 with which it comes into contact. This second oil thus performs both a lubricating function and a cooling function, like that of a coolant fluid.
Given its compact nature and its speed of operation, the dobby 4 tends to heat up strongly, such that the second oil flowing in the circuit C 2 and present in the pan 51 reaches a high temperature, a temperature higher than that of the first oil.
In order to limit the heating of the oil present in the dobby 4 , a heat exchanger system 6 is provided to enable the oil present in the circuit C 2 to be cooled by means of the oil present in the circuit C 1 . In operation of the loom 1 , the oil of the circuit C 1 heats up less than the oil of the circuit C 2 because the heat exchange areas of the circuit C 1 with the outside are larger. In practice, in a high-performance loom, the temperature of the oil in the circuit C 1 is of the order of 50° C. to 70° C., whereas the temperature of the oil in the circuit C 2 is of the order of 80° C. to 100° C., or even more. For this purpose, a heat exchanger 62 is installed between the subassembly 2 and the dobby 4 .
The heat exchanger 62 is fed from the pan 31 by a line 631 having a pump 641 installed therein. A return line 651 returns oil from the heat exchanger 62 to the pan 31 of the circuit C 1 .
Furthermore, a feed line 632 connects the pan 51 to the heat exchanger 62 . A pump 642 is installed in this feed line, and a return line 652 connects the heat exchanger 62 to the pan 51 .
Thus, the pumps 641 and 642 serve to convey respective quantities of oil to the heat exchanger 62 . Insofar as the oil present in the pan 31 is at a temperature that is lower than the temperature of the oil present in the pan 51 , this serves to lower the temperature of the oil in the circuit C 2 .
A temperature probe 711 is placed at the inlet to the heat exchanger 62 on the line 631 , and a temperature probe 721 is placed at the outlet from the heat exchanger 62 on the line 651 . Similarly, two temperature probes 712 and 722 are placed at the inlet and the outlet of the heat exchanger 62 , on the lines 632 and 652 respectively.
A valve 731 is installed in the line 631 between the pump 641 and the probe 711 . Similarly, a valve 732 is installed in the line 632 , between the pump 642 and the probe 712 .
An electronic control unit 66 controls the operation of the pumps 641 and 642 by means of electric signals S 641 and S 642 . The unit 66 also controls the operation of the vales 731 and 732 by means of dedicated electric signals S 721 and S 722 . The output signals from the temperature probes 711 , 712 , 721 , and 722 are delivered respectively to the unit 66 in the form of electric signals S 711 , S 712 , S 721 , and S 722 .
By construction, the oil circulation ducts of the subassembly 2 in the lines 631 and 651 and in the heat exchanger 62 are separated in leaktight manner from the oil circulation ducts of the dobby 4 in the lines 632 and 652 and in the heat exchanger 62 . In other words, the exchange of heat between the oil of the subassembly 2 and the oil of the dobby 4 does not give rise to either of these oils becoming polluted with the other.
When the loom 1 is put into operation, with the oils then being cold, the valve 732 is controlled by the unit 66 so that the oil flow rate in the line 632 is relatively low. The oil in the circuit C 2 is cooled little and heats up quickly in order to reach a temperature threshold above which its fluidity enables it to penetrate into the smallest clearances and to eliminate any risk of sticking phenomena occurring inside the dobby 4 .
Once this threshold temperature has been reached, the flow rate in the line 632 is raised progressively and then stabilized when a second threshold value is reached that is higher than the first threshold value.
The flow rate of oil from the circuit C 2 through the heat exchanger 62 may also be controlled by the signal S 642 that serves to control the speed of rotation of the pump 642 .
In practice, as mentioned above, the oil of the circuit C 2 reaches a temperature of about 90° C. under steady conditions, whereas the temperature of the oil in the circuit C 1 , in particular the temperature of the oil in the pan 31 , is of the order of 60° C. Because of the heat exchanger system of the invention, the oil temperature in both circuits C 1 and C 2 is about 70° C.
By acting on the respective degrees of opening of the valves 731 and 732 or on the speeds of rotation of the pumps 641 and 642 , it is possible to control the respective flow rates of oil in the circuit C 1 and of oil in the circuit C 2 in order to maintain a temperature difference between these oils. Maintaining such a temperature difference is nevertheless not compulsory.
The system 6 may operate without regulating the flow rate of oil in the circuit C 1 and of oil in the circuit C 2 . Nevertheless, making use of some or all of the temperature probes 711 , 712 , 721 , and 722 makes it possible to detect whenever a threshold value is exceeded that is potentially dangerous for the quality of the oils being used or for the equipment with which the oils come into contact, such as sealing gaskets. In the event of such a threshold value being exceeded, operation of the loom 1 may be stopped by the control unit 66 , or an alarm may be triggered.
In the second to fifth embodiments shown in FIGS. 2 to 5 , elements that are analogous to elements of the first embodiment are given the same references. Below, the description relates only to matters that distinguish each embodiment from the first embodiment. Unless mentioned to the contrary, the structure and the operation of the devices in FIGS. 2 to 5 are identical to those of the first embodiment.
In the second embodiment, no pumps are provided within the heat exchanger system 6 in the lines 631 and 632 feeding the heat exchanger 62 with oil from the circuits C 1 and C 2 . The pumps 32 and 52 of the circuits C 1 and C 2 are used for this purpose insofar as they deliver directly into the feed lines 631 and 632 , with the elements for lubricating being fed from the return lines 651 and 652 . This embodiment is less expensive than the preceding embodiment since it enables the pumps 641 and 642 of the first embodiment to be omitted.
In the third embodiment, a coolant fluid circuit C 3 is installed between the pan 31 of the subassembly 2 and the pan 51 of the dobby 4 . A heat exchange zone Z 1 is provided between the circuit C 3 and the content of the pan 31 , within said pan, and a second heat exchange zone Z 2 is provided between the circuit C 3 and the content of the pan 51 , within said pan. These heat exchange zones are made within the heat exchanger system 6 by means of coils 671 and 672 through which the coolant fluid flows, which coils are placed within the pans 31 and 51 . The heat exchange zones Z 1 and Z 2 are leaktight.
The coolant fluid of the circuit C 3 may be of any known type and need not necessarily be an oil, since it does not perform any lubrication function.
A pump 643 is installed in one of the pipes 633 of the circuit C 3 connecting the zone Z 1 to the zone Z 2 . This pump serves to cause the coolant fluid to circulate between the zone Z 2 and Z 1 and to return via a pipe 653 .
A valve 733 serves to regulate the flow rate of coolant fluid in this circuit, and consequently to regulate the magnitude of the heat exchange between the oils belonging respectively to the circuit C 1 and to the circuit C 2 . The valve 733 is controlled by an electronic control unit 66 via an electric signal S 733 .
In a variant, the pump 643 may be controlled by the unit 66 , as in the first embodiment.
In this embodiment, heat exchange between the oils of the circuits C 1 and C 2 is indirect, passing via the coolant fluid C 3 .
This embodiment is particularly suitable for shed-forming devices and for loom subassemblies in which no pump is provided that is equivalent to the pumps 32 and 52 of the first and second embodiments.
In the fourth embodiment, a portion of the content of the pan 31 is pumped into a circuit C 4 that includes a leaktight heat exchange zone Z 4 constituted by a coil 674 placed in the pan 51 of the dobby 4 . A pump 644 serves to circulate the oil of the circuit C 1 through the circuit C 4 that comprises a line 634 for feeding the coil 674 and a return line 654 going back to the pan 31 . Under such circumstances, the relatively cold oil of the circuit C 1 is taken to the pan 51 of the circuit C 2 in order to cool the oil located therein.
In the fifth embodiment, an approach is adopted that is the inverse of that of the embodiment of FIG. 4 . In other words, the oil of the circuit C 2 is taken to the pan of the circuit C 1 within a leaktight heat exchange zone Z 5 formed by a coil 675 forming part of a circuit C 5 within which a pump 645 is located. Oil taken from the pan 51 flows along a line 635 for feeding the coil 675 and returns to the pan 51 via a return line 655 .
In the embodiments of FIGS. 4 and 5 , valves 734 and 735 controlled by signals S 734 and S 735 delivered by an electronic control unit 66 serve to regulate the flow of oil in the circuits C 4 and C 5 and through the heat exchanger systems 6 . The valves 734 and 735 may include branch connections leading to the lines 654 and 655 .
In the embodiments of FIGS. 2 to 5 , temperature sensors 711 , 712 , 721 , and/or 722 are used, as in the first embodiment. Nevertheless, this is not compulsory.
Whatever the embodiment, heat exchange between the oil of the circuit C 1 and the oil of the circuit C 2 enables the temperature of the oil of the shed-forming device to be lowered, and this is advantageous in terms of the lubrication and in terms of the lifetime of this equipment. Insofar as the two circuits C 1 and C 2 remain separated from each other, given that the heat exchanger zone is leaktight, it is possible to use different oils in these two circuits.
The invention is described above for a shed-forming device constituted by a dobby. The dobby may be of the positive type or of the negative type. It is also possible for the shed-forming device to be a basic weave mechanism or a Jacquard machine if the loom is a Jacquard loom.
The loom may be a single-layer loom or a two-layer loom and it may be used for weaving any type of cloth.
The invention applies to looms having rapiers as shown in the figures, and also to looms using projectiles, air, or water.
In the embodiments described and shown in the figures there are pumps for circulating oil in the circuits C 1 and C 2 . Nevertheless, the invention can be used with oil-bath circuits in which it is the movement of the parts in the subassembly 2 and/or in the shed-forming device 4 that suffices to lubricate the joints by spraying.
Under such circumstances, the circuits C 1 and/or C 2 are formed by zones in which oil circulates in the equipment 2 and/or 4 .
The technical characteristics of the embodiments and variants described above may be combined with one another. | A loom having a subassembly including heddles, a beater, and a device for inserting weft into a shed formed by warp yarns and also including a shed-forming device and a lubrication system for lubricating certain components of the subassembly including a first circuit for circulating a first lubricant and a second circuit for circulating a second lubricant for lubricating the shed forming device. The loom includes a heat exchanger system for exchanging heat between the first lubricant and the second lubricant without fluid communication between the lubricants. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is generally directed to improving the quality of bass sounds generated by one or more loudspeakers within a listening area. More particularly, the invention is directed to substantially equalizing the responses generated by at least one loudspeaker within a listening area so that the responses in the area are substantially constant and flat within a desired frequency range.
2. Related Art
Sound systems typically include loudspeakers that transform electrical signals into acoustic signals. The loudspeakers may include one or more transducers that produce a range of acoustic signals, such as high, mid and low-frequency signals. One type of loudspeaker is a subwoofer that may include a low frequency transducer to produce low-frequency signals in the range of 20 Hz to 100 Hz.
The sound systems may generate the acoustic signals in a variety of listening environments. Examples of listening environments include, but are not limited to, home listening rooms, home theaters, movie theaters, concert halls, vehicle interiors, recording studios, and the like. Typically, a listening environment includes single or multiple listening positions for a person or persons to hear the acoustic signals generated by the loudspeakers. The listening position may be a seated position, such as a section of a couch in a home theater environment, or a standing position, such as a spot where a conductor may stand in a concert hall.
The listening environment may affect the acoustic signals, including the low, mid, and/or high frequency signals at the listening positions. Depending on the nature of the room and the position of a listener in a room and the position of the loudspeaker in the room, the loudness of the sound can vary for different frequencies. This may especially be true for low frequencies. Low frequencies may be important to the enjoyment of music, movies, and most other forms of audio entertainment. In the home theater example, the room boundaries, including the walls, draperies, furniture, furnishings, and the like may affect the acoustic signals as they travel from the loudspeakers to the listening positions.
The acoustic signals received at the listening positions may be measured. One method of characterizing the room is the impulse response of a loudspeaker to a microphone placed in the listening area. The impulse response is the acoustic signal measured by the microphone for a short sound burst emitted from the loudspeaker. The impulse response may allow measurement of various properties of the acoustical signals including the amplitude and/or phase at a single frequency, a discrete number of frequencies, or a range of frequencies.
An amplitude response is a measurement of the loudness at the frequencies of interest. Generally, the loudness or the amplitude is measured in decibels (dB). Amplitude deviations may be expressed as positive or negative decibel values in relation to a designated target value. The closer the amplitude values measured at a listening position are to the target values, the better the amplitude response is. Deviations from the target reflect changes that occur in the acoustic signal as it interacts with room boundaries. Peaks represent a positive amplitude deviation from the target, while dips represent a negative amplitude deviation from the target.
These deviations in the amplitude response may depend on the frequency of the acoustic signal reproduced at the subwoofer, the subwoofer location, and the listener position. A listener may not hear low frequencies as they were recorded on the recording medium, such as a soundtrack or movie, but instead as they were distorted by the room boundaries. Thus, the room can change the acoustic signal that was reproduced by the subwoofer and adversely affect the low-frequency performance of the sound system. As an example, FIG. 1 shows a sound system setup in a rectangular room. The sound system includes a receiver connected to four subwoofers, one at each corner of the room. The room is defined by four walls that can affect the low-frequency sound waves or bass sounds generated by the four subwoofers. Within the room, a seating area is provided to allow one or more persons to listen to the combined bass sound generated by each of the four subwoofers. A number of factors, as discussed above, can affect the quality of the sound within the listening area such that one person may hear a louder bass sound than another person sitting just a few feet away. For purposes of measuring the impulse response of the room, the receiver may send a logarithmic frequency sweep output signals to the four subwoofers for a predetermined amount of time. The impulse responses of the room are then picked up by four microphones P 1 , P 2 , P 3 , and P 4 positioned at different locations within the listening area of the room.
FIG. 2 shows four frequency response curves F 1 , F 2 , F 3 , and F 4 , corresponding to the measured impulse responses one may expect at the four microphone positions P 1 , P 2 , P 3 , and P 4 , respectively. As discussed earlier, subwoofers generally operate in the low frequency range of between 20 Hz and 100 Hz. FIG. 2 indicates that at about 48 Hz, the magnitude or loudness of the bass sound varies in a wide range so that the loudness of the bass sound depends on where the person is located within the listening area. For instance, the curve F 2 indicates that the bass loudness levels is about 0 dB at about 48 Hz, while the curve F 3 indicates that the bass loudness level is about −18 dB, at the same frequency point. This means that a person sitting in location P 2 hears a much louder bass sound at 48 Hz than the person sitting just behind him at location P 3 . In other words, the sound level is not the same at different locations within the listening area of the room so that each person will experience a different bass sound quality. In addition, FIG. 2 shows that the curves fluctuate within the frequency range of interest. This means that certain bass sounds will drop off such that a person cannot hear the bass sound although it was intended to be heard. For instance, the curve F 4 shows that between about 48 Hz and 55 Hz, there is a considerable drop in the bass loudness level at about 52 Hz. This means that a person sitting at location P 3 will hear the bass sound at 48 Hz but notice a sudden drop in the bass sound at 52 Hz and a sudden peak again at 55 Hz. Such fluctuations in the bass sound level can impair the listening experience.
Many equalization techniques have been used in the past to reduce or remove amplitude deviations within a listening area. One of the techniques is spatial averaging that calculates an average amplitude response for multiple listening positions, and then equally implements the equalization for all subwoofers in the system. Spatial averaging, however, only corrects for a single “average listening position” that does not exist in reality. Thus, even when using spatial averaging techniques, some listening positions still have a better low-frequency performance than other positions but other locations may be severely affected. For instance, the spatial averaging may worsen the performance at some listening positions as compared to their un-equalized performance. Moreover, attempting to equalize and flatten the amplitude response for a single location potentially creates problems. While peaks may be reduced at the average listening position, attempting to amplify frequencies where dips occur requires significant additional acoustic output from the subwoofer, thus reducing the maximum acoustic output of the system and potentially creating large peaks in other areas of the room.
Another known equalization technique is to position multiple subwoofers in a “mode canceling” arrangement. By locating multiple loudspeakers symmetrically within the listening room, standing waves may be reduced by exploiting destructive and constructive interference. However, the symmetric “mode canceling” configuration assumes an idealized room (i.e., dimensionally and acoustically symmetric) and does not account for actual room characteristics including variations in shape or furnishings. Moreover, the symmetric positioning of the loudspeakers may not be a realistic or desirable configuration for the particular room setting.
Still another equalization technique is to configure the audio system in order to reduce amplitude deviations using mathematical analysis. One such mathematical analysis simulates standing waves in a room based on the room data. For example, room dimensions, such as length, width, and height of a room, are input and the various algorithms predict where to locate a subwoofer based on data input. However, this mathematical method does not account for the acoustical properties of a room's furniture, furnishings, composition, etc. For example, an interior wall having a masonry exterior may behave very differently in an acoustic sense than a wood framed wall. Further, this mathematical method cannot effectively compensate for partially enclosed rooms and may become computationally onerous if the room is not rectangular.
There are a number of other methods that try to equalize the impulse responses in a room but the accuracy of the equalization is more by chance because of the guessing involved in determining certain parameters such as delay and gain applied to the signals. As such, in order to obtain an accurate equalization solution, it takes a tremendous amount of computational power. Moreover, these methods do not provide an equalization that results in a flat frequency response within a desired low-frequency range so that loudness of the bass level is not only consistent at each seating location but also substantially constant or flat throughout the desired low-frequency range. Therefore, a long-standing need exists for a system to accurately determine a configuration for an audio system such that the audio performance for one or more listening positions in a given space is improved.
SUMMARY
The invention addresses the widely known problem of low frequency equalization in a listening room. The invention is directed to a frequency equalization system that utilizes one or more microphones to measure the impulse responses of the room at various locations within a preferred listening area. This information is then used to filter the audio signals sent to the subwoofers in the room to improve the bass responses so that the frequency responses are substantially flat at the microphone measurement points and within the desired listening area, across the relevant frequency range.
The invention uses the impulse responses of the room to calculate coefficients to design a filter for each corresponding subwoofer so that the frequency responses are substantially flat within the listening area, across the relevant frequency range. In general, the inverses of the room responses are determined to undo the coloration added by the room. The inverses are smoothed so that sudden gains that may exceed the allowable gains that a subwoofer may handle are minimized or removed. The invention may also apply a target function on the inverse so that the equalization is applied to a desired frequency range in which the subwoofer optimally operates. The modified inverse is then used to determine the filter coefficient for each audio signal sent to its respective subwoofer. A processor such as a digital signal processor (DSP) may be used to filter the audio signal based on the filter coefficients.
Other systems, methods, features, and advantages of the invention will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.
FIG. 1 shows a typical sound system setup in a rectangular room with a subwoofer in each corner of the room and a listening area defined by P 1 through P 4 .
FIG. 2 shows four spectra F 1 , F 2 , F 3 , and F 4 , corresponding to the measured impulse responses one may expect at the four microphone positions P 1 , P 2 , P 3 , and P 4 , respectively.
FIG. 3 shows a block diagram illustrating an equalization system in accordance with the invention.
FIG. 4 shows frequency responses of the room after the input signals to the corresponding subwoofers have been filtered to equalize the responses in accordance with this invention.
FIG. 5 is a flow chart with an overview of the filter design procedure to equalize the frequency response of a room.
FIG. 6 is a flow chart showing further details of preparing the input data step in FIG. 5 .
FIG. 7 is a flow chart showing further details of determining the inversion for the frequency responses in FIG. 5 .
FIG. 8 shows curves representing the inverse of the frequency responses.
FIG. 9 shows a curve Fs( 2 ) representing the smoothed version of the curve F( 2 ) in accordance with this invention.
FIG. 10 shows four curves Fs( 1 ), Fs( 2 ), Fs( 3 ), and Fs( 4 ) representing the smooth version of the curves F( 1 ), F( 2 ), F( 3 ), and F( 4 ) in FIG. 8 , respectively.
FIG. 11 is a flow chart showing further details of determining the global equalization step in FIG. 5 .
FIG. 12 shows the frequency responses at the four microphone positions P 1 , P 2 , P 3 , and P 4 , after the filtering in accordance with the curves Fs( 1 ), Fs( 2 ), Fs( 3 ), and Fs( 4 ), respectively, shown in FIG. 10 have been applied.
FIG. 13 shows a global equalization filter that has been inverted.
FIG. 14 shows the top curve representing the difference between smoothed and unsmoothed frequency responses in FIG. 13 , raised by 10 dB, and the lower curve representing the rectified difference (lowered by 10 dB).
FIG. 15 shows the final frequency response of global equalization filter.
FIG. 16 shows a flow chart further detailing the step of limiting the maximum gains in the global equalization filter as shown in FIG. 5 .
FIG. 17 shows equalization filters for each of the subwoofers after complex smoothing of the curves Fs( 1 ), Fs( 2 ), Fs( 3 ), and Fs( 4 ) shown in FIG. 10 and applying the global equalization filter shown in FIG. 15 to the smoothed curves of Fs( 1 ), Fs( 2 ), Fs( 3 ), and Fs( 4 ).
FIG. 18 shows the filter EQ spectra after applying Maxgain and normalization to 0 dB as shown above.
FIG. 19 shows corresponding equalized impulse responses obtained for filter FIR 1 .
FIG. 20 shows magnitude responses for the filters FIR 1 , FIR 2 , FIR 3 , and FIR 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 shows a block diagram illustrating an equalization system 300 in accordance with this invention, designed to achieve an improved bass response from one or more subwoofers within a room that is flat across a predetermined low-frequency range within a desired listening area of the room. The equalization system 300 may be used to equalize the frequency responses for a variety of rooms where each room has its own unique characteristics. For instance, a room may have one or more of the following characteristics: (1) one or more walls of the room may be open; (2) a ceiling or walls of the room may have an arc; (3) drapes may cover one or more walls of the room; (4) the floor of the room may be uneven; (5) there may be one or more subwoofers in the room; (6) location of each of the subwoofers may be positioned anywhere in the room, and etc. As such, the equalization system 300 , as described in detail below, may be used to equalize the frequency responses for any room.
For purposes of this discussion, the equalization system 300 (EQ system 300 ) is used to equalize the responses for the room illustrated in FIG. 1 . The room is generally defined by four walls forming a rectangular configuration. Within the room, there is a seating area to allow one or more persons to sit as defined by positions P 1 , P 2 , P 3 , and P 4 . The seating area generally defines the listening area of the room. A receiver 308 may be located within the room to send audio signals to the subwoofers and incorporate the equalization system 300 .
The EQ system 300 includes a signal block 302 that is capable of generating test signals and designing the coefficients for each filter corresponding to the loudspeaker in the room. In this example, the signal block 302 is linked to the four subwoofers Sub 1 , Sub 2 , Sub 3 , and Sub 4 located in each corner of the room. The signal block 302 may send out output signals one at a time to each of the four subwoofers to measure the impulse response of that subwoofer to each of the microphones P 1 through P 4 placed in the room. The signal block 302 may output a logarithmic frequency sweep for a predetermined amount of time sequentially to each of the subwoofers. The logarithmic frequency sweep allows the signal block 302 to send out an output signal covering a broad frequency spectrum of interest through the subwoofers. As an example, the output signals may be sent out for about four seconds.
With each of the subwoofers sending out output signals over for a period of time, the impulse responses may be measured independently or simultaneously by the microphones located in different areas of the room (“listening positions”) such as positions represented by P 1 through P 4 in FIG. 1 . For instance, the signal block 302 may send an output signal through the Sub 1 so that the microphones may measure the impulse response of the room from the signals generated in the upper-left corner of the listening area. The signal block 302 may then send another output signal through the Sub 2 so that the microphones may measure the impulse response of the room due to the output signal source generated from the upper-right corner of the listening area. Likewise, an output signal may be sent through the Sub 3 and another through the Sub 4 so that the microphones may measure the impulse responses due to the subsequent separate signals sent from the bottom-right and bottom-left corners of the listening area, respectively. In this example, four subwoofers placed in the four corners of a rectangular room and four microphones placed within a desired listening area of the room are used to measure the impulse responses of the room. The microphones P 1 to P 4 convert the acoustic signals into electrical signals. Before the electrical signals are provided to the signal block 302 , the electrical signals may be digitized at the predetermined rate using the A/D converter.
Through the microphones, the signal block 302 may capture a predetermined number of impulse response samples per second for each combination of subwoofer and microphone. The captured impulse responses may be down-sampled to yield N samples for each measured impulse response. With four subwoofers and four microphones, this results in a set of sixteen impulse responses where each set has N number of samples. For example, the signal block 302 may capture N=2048 samples at a sampling rate of 750 samples per second.
The signal block 302 receives the measured impulse responses of the room from the microphones P 1 through P 4 . The signal block 302 calculates the filter coefficients, as described below, based on the impulse responses of the room. The signal block 302 is linked to a processor block 304 that implements the designed filters as calculated pursuant to the invention to modify each of the audio signals sent to the corresponding subwoofer to substantially equalize the in-room frequency responses due to the sound generated by the four subwoofers. In this example, the processor block 304 may filter four audio signals represented by FIR 1 , FIR 2 , FIR 3 , and FIR 4 , as shown in FIG. 3 , corresponding to each of the subwoofers Sub 1 , Sub 2 , Sub 3 , and Sub 4 , respectively. As such, the audio signal input 306 provided by a variety of sources 308 such as a TV, DVD player, audio receiver, and the like, is processed by the processor block 304 through the corresponding filters FIR 1 through FIR 4 so that the output signal sent to its respective subwoofer is filtered in accordance with the filter coefficients to equalize the frequency responses of the room. The processor block 304 may be a variety of processors such as a digital signal processor (DSP), and the filter may be a Finite Impulse Response (FIR) filter. Note that it is within the scope of this invention to have one processor perform the functions done by the signal block 302 and processor block 304 .
FIG. 4 shows frequency responses of the room shown in FIG. 1 , after the output signals to the subwoofers have been filtered to equalize the responses pursuant to the subject invention. FIG. 4 shows that the resulting amplitude responses are substantially consistent in the low frequency range relative to each other. This indicates that the responses at different locations within the listening room are substantially constant. This means that each person within the listening area is provided with a substantially similar loudness level at each frequency point. In addition, the magnitude level is substantially constant or flat across a desired low-frequency level of between about 40 Hz and about 100 Hz so that sound level dropping off is substantially minimized. Comparing FIG. 4 to FIG. 2 , the amplitude responses of the room have been substantially improved. The following is a detailed discussion of how filters are designed for each of the subwoofers pursuant to this invention.
The following discussion is for the specific case of four subwoofers and four microphones, i.e., n sub =4, and n mic =4, within a room as shown in FIG. 1 However, this invention can be used for any combination of subwoofers and microphones in a room. The audio signal sent to one or more subwoofers may be filtered in accordance with the following description.
FIG. 5 is a flow chart with an overview of the filter design procedure to equalize the frequency response of a room. In block 502 , the input data may be prepared to substantially equalize the frequency responses of the room. Preparing the data generally includes measuring the impulse responses of the room and transforming them into frequency domain. In the block 504 , an inverse for each of the frequency responses may be determined. Each of the inverses would in effect undo the coloration added by the walls of the room. In other words, filtering each of the audio signals with its respective inverse and sending the filtered signals to their respective subwoofers would produce ideal frequency responses. The inverse, however, may have local sudden peaks and dips where such sudden gains may exceed the allowable gains that a subwoofer may handle. As such, in block 506 , the local peaks and dips in the inverse may be smoothed using a complex smoothing method described in more detail below. This provides approximate inverses for the frequency responses of the room.
In block 508 , global equalization is applied to the result after approximate inverse filtering, so that a target function describing transitions at the low and high frequency band edges may be approximated. The global equalization also uses a smoothing method that addresses peaks and dips separately, as described below. As subwoofers generally operate below 100 Hz, in block 510 , a limit may be placed on the gain that may be applied to the subwoofer outside of the desired low-frequency range to protect the subwoofer, such as below 20 Hz and/or above 100 Hz. In block 512 , the inverse of the global equalization is then used to determine the filter to process each of the audio signals sent to each of the subwoofers to substantially equalize the frequency responses of the room.
FIG. 6 is a flow chart 600 showing further details of preparing the input data for the room as represented in block 502 in FIG. 5 . Preparing the input data includes block 602 that measures the impulse responses of the room, as discussed above. In block 602 , once the impulse responses have been measured, in block 604 , any common time delay from the impulse responses may be removed. This is done to allow the solvability of the mathematical problem of complex smoothing discussed below. For instance, with regard to the output signal sent by the Sub 1 , as shown in FIG. 1 , located in the upper-left corner of the room, the microphone P 1 is closest to the Sub 1 . As such, the microphone P 1 will receive the output signal from the Sub 1 before the other microphones. The time it takes for the output signal from the Sub 1 to reach the microphone P 1 is common to other microphones P 2 -P 4 . This time may be defined as a common time delay with regard to the impulse responses measured by the four microphones P 1 -P 4 for the output signal sent by the Sub 1 . Likewise, a corresponding common time delay may be measured for output signals sent by each of the other Sub 2 -Sub 4 . For instance, a common time delay for the output signal sent by the Sub 3 is the time it takes for the output signal from the Sub 3 to reach its closest microphone P 4 . The minimum delay of all the measured impulse responses is the common time delay. The common time delay may be offset or deducted from all the impulse responses measured by the four microphones.
In block 606 , the input data of the time domain impulse responses of the room, may be transformed into frequency domain using Fast Fourier Transform (FFT). In FIG. 1 for example, there are four microphones and four loudspeakers so that a set of sixteen impulse responses may be measured where each set has N number of samples. Each impulse response is transformed into frequency domain using FFT. In this example, an N point FFT is employed that yields N complex values for each measured impulse response. As such, the resulting set of [n mic ×n sub ]×N complex FFT points are represented as N number of n mic ×n sub matrices A i , where i=1 . . . N. At each i or frequency point, the FFT provides amplitude and phase.
FIG. 7 is a flow chart 700 further detailing the method of determining the inverse of the frequency responses as represented by the block 504 in FIG. 5 . In block 702 , the number of microphones n mic used to measure the impulse responses and the number of subwoofers n sub in the room are determined. In decision block 704 , if n mic =n sub , then in block 706 , exact matrix inversion method may be used to find the exact inverse of the impulse responses. On the other hand, if n mic >n sub , then, in block 708 , pseudo-inverse method may be used to find the inverse of the impulse responses. In FIG. 1 , four microphones and four subwoofers are used to measure the impulse response so that exact matrix inversion method is used to calculate the inverse. With the impulse responses transformed into the frequency domain in the block 604 , the inverse matrices may be calculated at each of the frequency points to determine the ideal equalization at that frequency point. In this regard, N number of inverse matrices B i , where i=1 . . . N, may be determined. This results in N complex-valued matrices B i , such that A i B i =1.
In the case that n mic >n sub , the method of pseudo-inverse may be used to calculate B i . The well-known method of pseudo-inverse minimizes the mean squared error between the desired and actual result. Expressed mathematically, B i is computed such that (1−A i B i )*×(1−A i B i ) is minimized where * denotes a complex-conjugate operation.
In block 710 , once the inverse matrices have been determined, a target function may be chosen for each frequency point for each of the microphone positions P 1 through P 4 . The target function is the desired frequency response at each listening position. The target function may be a complex-value vector containing n mic elements T i (i=1 . . . N). In this example of four microphones, T i contains four complex-valued elements per frequency point. A simple example of target T i is a unity vector. The vectors F i that describes n sub filters at a particular frequency point i (i=1 . . . N), are then computed as matrix multiplication F i =B i T i . The vectors F i describe filters at a particular frequency point i (i=1. . . N), that would perform an exact inverse (ideal equalization). The vectors Fi in effect undo the coloration added by the walls of the room so that multiplying A i F i =A i B i T i =T i results in an idealized equalization.
FIG. 8 is a graph showing the logarithmic magnitude of the filters F(k) (k=1 . . . n sub =4) as obtained after the matrix inversion. The target function used in this example may be a unity vector T i =[1 1 1 1], i=1 . . . N. The frequency axis f is f=(1 . . . N/2)/N*fa, where N is FFT length and fa=750 Hz is the sampling frequency. FIG. 8 shows that there are sudden peaks and dips as indicated by markings A. B, C, and D, for example. Directly applying the filters F(k) to the output signals sent to the Sub 1 -Sub 4 to equalize the frequency responses within the room may damage the subwoofers because the peaks at certain frequencies require applying significant gains at those frequencies that may be too high for the subwoofers to handle. In other words, the vectors F(k) may impose gains at certain frequencies that may exceed the maximum amount of gain that the subwoofers can handle.
Smoothing throughout the whole frequency range may be done to limit the length of the resulting filter in the time domain, which is known to converge to zero more rapidly after smoothing. The following is further discussion of smoothing the inverse of the matrices represented by the block 506 in FIG. 5 . With the sudden peaks and dips in the frequency response vectors F(k), the ideal equalization may not be directly applied to the output signal sent to the subwoofers. The peaks and dips in the vectors F(k), however, may be minimized by smoothing the complex-value vectors F(k) across frequency. This may be accomplished through the method described in an article entitled “Generalized Fractional-Octave Smoothing of Audio and Acoustic Responses,” by Panagiotis D. Hatziantoniou and John N. Mourjopoulos, published April of 2000, J. Audio Eng. Soc., Vol. 48, No. 4, pp 259-280. In particular, smoothing of the complex-valued vectors F(k) may be carried out by computing the mean values separately for the real and imaginary parts, along a sliding frequency-dependent window, resulting in Fs(k). For example, a smoothing index q between 1.0 and 2.0 may be used, where i*(q−1/q) denotes the width of the frequency-dependent sliding window. Sliding windows such as Hanning or Welch window may be used. Note that it may be useful to perform smoothing in two or more separate frequency bands by using a different value for each frequency band. At higher frequencies, fluctuations across space and frequency in a room are usually larger, so that a higher q index may be used. Since the subwoofer operates mainly below 80 Hz, a high accuracy of the inversion filter above that frequency may not be necessary, and not even desirable, because it may not apply to the whole listening area consistently, due to rapid fluctuations.
FIG. 9 shows the magnitude of the unsmoothed spectrum of the filter F( 2 ) that may be applied to the output signal sent to the Sub 2 , and curve Fs( 2 ) representing the smoothed version of filter F( 2 ) with the method discussed above. Note that in curve Fs( 2 ) local peaks and dips are smoother than in curve F( 2 ) such that much of the sudden peaks and dips present in curve F( 2 ) are more gradual in curve Fs( 2 ). As such, curve Fs( 2 ) is an approximation of the complex-valued filter F( 2 ) so that equalization may be applied to the output signal to the Sub 2 without the local excessive gain. Likewise, FIG. 10 shows curves of the magnitude responses of all four filters after smoothing, i.e., Fs( 1 ), Fs( 2 ), Fs( 3 ), and Fs( 4 ).
FIG. 11 shows a flow chart 1100 further detailing the method of determining the global equalization as represented by the block 508 in FIG. 5 . The complex smoothing of each of the complex-valued filters F( 1 ) through F( 4 ) removes the local fluctuations of peaks and dips but the extreme gains may be still present. For example, subwoofers are generally designed to handle a maximum gain of about 15 db to about 20 db. FIG. 9 shows a gain of about 30 db below 20 Hz and a gain of about 60 db above 100 Hz. Such extreme gains may not be handled by the subwoofers.
To manage the gains, a global equalization (EQ) may be performed. One of the ways of calculating the global EQ is through the method described in FIG. 11 . In block 1102 , the actual responses at each of the microphone positions or seats Fy(j) (=1 . . .n seat ) may be calculated by multiplying the original matrix A with Fs, (calculated in the above smoothing method). In other words, Fy=A*Fs. FIG. 12 shows the responses at the four microphone positions (listener seats), after the (intermediate) filters of FIG. 10 have been applied. In block 1104 , an upper curve Fymax may be determined by taking the maximum magnitudes Max{Fy(1 . . . n seat )} for each frequency points. As such, all of the responses at the seats are below the curve Fymax. FIG. 12 shows the curve Fymax raised by 10 dB to better show the Fymax curve. This means that no response is greater than the curve Fymax along any frequency point.
The curve Fymax denotes the maximum magnitudes in dB within the whole frequency range of 0 Hz to half the sample rate. Subwoofers, however, are design to operate optimally in a more limited range than the above frequency range. As such, in block 1106 , the upper curve Fymax may be limited within a predetermined frequency range that would allow the subwoofers to operate at their optimal frequency range. In this regard, a global EQ filter Fr may be computed to operate in the predetermined frequency range by dividing a target function T by Fymax or Fr=T/Fymax. The target function T is real-valued having magnitude frequency responses of high pass and low pass filters that characterize the frequency range where the respective transducer (subwoofer) optimally works. Typical filters are Butterworth high passes of order n=2 . . . 4 (corner frequencies 20 . . . 40 Hz), and Butterworth low passes of order n=2 . . . 4, corner frequencies 80 . . . 150 Hz.
FIG. 13 shows the log-magnitude response of the global EQ filter Fr. FIG. 13 shows that the response has peaks that may interfere with the quality of the sound. In this regard, in block 1108 , the peaks in the curve Fr may be removed through the following method. The smoothing method described above may be used to determine an intermediate response Frs that is the smoothed version of Fr. The peaks in Fr in essence may be “shaved off” by computing the difference between Frs and Fr, and rectifying the difference. FIG. 14 shows the top curve representing the difference between Frs and Fr (raised by 10 db), and the lower curve representing the rectified difference (lowered by 10 db). Then, as shown in FIG. 15 , the final frequency response of the global EQ filter Frsf may be obtained by subtracting the rectified difference from the original filter Fr that is the unsmoothed filter shown in FIG. 13 . The final Frsf shown in FIG. 15 shows dips but a reduced number of peaks. The unwanted peaks would attempt to amplify frequencies where dips occur in the original response, requiring significant additional acoustic output from the subwoofer, thus reducing the maximum acoustic output of the system and potentially creating large peaks in other areas of the room.
FIG. 16 shows a flow chart 1600 further detailing the method of limiting the max gain on the global EQ curve as represented by the block 510 in FIG. 5 . In block 1602 , the final EQ spectrum Feq is computed by multiplying the complex spectra Fs of the individual EQ filters, as determined above, with the global, real-valued magnitude spectrum Frsf (as determined above), respectively. FIG. 17 shows EQ filters obtained after complex smoothing and global EQ. FIG. 17 shows that there are still substantial gains above 200 Hz and below about 20 Hz. This may be due to the chosen target function that is not sufficient to limit the final gains as desired. Therefore, in block 1604 , limits may be put on the gains below a predetermined low frequency and a predetermined high frequency. For example, a limit on the maximum gain may be applied by replacing the complex-valued Feq such that the maximum magnitude is clipped to ‘Maxgain’ without altering the phase. Maxgain is a value prescribed by the user that depends on the capabilities of the particular subwoofer. Preferably, different values of Maxgain can be applied in different frequency bands. The resulting filters may be scaled so that the maximum gain does not exceed one (0 dB). FIG. 18 shows the filter EQ spectra after applying Maxgain and normalization to 0 dB as shown above. The EQ spectra is normalized to 0 dB to maximize the average gain.
In block 1606 , the final EQ filter frequency responses may be converted back to the time domain by using inverse FFT, resulting in coefficients of Finite Impulse Response (FIR) filters. A time window may be applied to the coefficients to limit the filter length. FIG. 19 shows the impulse response of one of the obtained FIR filters (filter FIR 1 ). FIG. 20 shows magnitude responses of the resulting filters FIR 1 , . . . , FIR 4 . FIG. 4 , as discussed above, shows the resulting responses at the four seats P 1 through P 4 after applying the obtained EQ filters. Note that within the target frequency range, such as between about 40 Hz and 80 Hz, the responses are consistent and flat to provide a substantial equalization within that frequency range. This means that a person sitting in any one of the locations P 1 through P 4 will hear a substantially similar loudness level of the bass sound. In other words, the sound level is substantially same at different locations within the listening area of the room so that each person will experience same bass sound quality. In addition, FIG. 4 shows that the curves are substantially flat within the frequency range of interest. This means that bass sounds will be substantially consistent within that desired frequency range so that there is minimal, if any, drop off in bass sound within the desired frequency range.
The equalization system described above may be used for a variety of rooms having different configurations with at least one subwoofer. The room may comprise any type of space in which the loudspeaker is placed. The space may have fully enclosed boundaries, such as a room with the door closed or a vehicle interior; or partially enclosed boundaries, such as a room with a connected hallway, open door, or open wall; or a vehicle with an open sunroof. In addition, a room may be an open area such as a field or a stadium with a closed or open top. Low-frequency performance in a space will be described with respect to a room in the specification and appended claims; however, it is to be understood that vehicle interiors, recording studios, domestic living spaces, concert halls, movie theaters, partially enclosed spaces, and the like are also included. Room boundaries, such as room boundary walls, include the partitions that partially or fully enclose a room. Room boundaries may be made from any material, such as gypsum, wood, concrete, glass, leather, textile, and plastic. In a home, room boundaries are often made from gypsum, masonry, or textiles. Boundaries may include walls, draperies, furniture, furnishings, and the like. In vehicles, room boundaries are often made from plastic, leather, vinyl, glass, and the like. Room boundaries have varying abilities to reflect, diffuse, and absorb sound. The acoustic character of a room boundary may affect the acoustic signal.
The loudspeakers may come in a variety of shapes and sizes. For instance, a loudspeaker may be enclosed in a box-like configuration housing the transducer. The loudspeaker may also utilize a portion of the wall or vehicle as all or a portion of its enclosure. The loudspeaker may provide a full range of acoustical frequencies from low to high. Many loudspeakers have multiple transducers in the enclosure. When multiple transducers are utilized in the loudspeaker enclosure, it is common for individual transducers to operate more effectively in different frequency bands. The loudspeaker or a portion of the loudspeaker may be optimized to provide a particular range of acoustical frequencies, such as low frequencies. The loudspeaker may include a dedicated amplifier, gain control, equalizer, and the like. The loudspeaker may have other configurations including those with fewer or additional components.
A loudspeaker or a portion of a loudspeaker including a transducer that is optimized to produce low-frequencies is commonly referred to as a subwoofer. A subwoofer may include any transducer capable of producing low frequencies. Loudspeakers capable of producing low frequencies may be referred to by the term subwoofer in the specification and appended claims; however, any loudspeaker or portion of a loudspeaker capable of producing low frequencies and responding to a common electrical signal is included.
The measurement devices such as microphones may communicate with other electronic devices such as the signal block 302 in order to measure acoustic signals in various parts of a room. The measured acoustic signal output from the different loudspeaker locations for the different listening positions may be stored, such as on the external disk. The external disk may be input to the computational device. The computational device may be another computing environment and may include many or all of the elements described above relative to the measurement device. The computational device may be incorporated into an audio/video receiver located within a room or remotely located to process the impulse responses at a different location than the room.
While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of this invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. | Frequency equalization system substantially equalizes the room frequency responses generated by at least one loudspeaker within a listening area so that the frequency responses in the listening area are substantially constant and flat within a desired frequency range. The frequency equalization system uses multiple microphones to measure the impulse responses of the room and uses the impulse responses to design filters to process the audio signals of one or more subwoofers to achieve an improved bass response that is flat across the relevant frequency range. The system employs an algorithm that is a closed-form, non-iterative, mathematical solution and features very short computation time. | 7 |
FIELD OF THE INVENTION
The present invention relates to ethernet networks. More specifically, the present invention relates to collision protocols for ethernet networks.
BACKGROUND OF THE INVENTION
Communication networks such as computer networks are increasingly used in interconnecting a plurality of computers each of which independently executes tasks while communicating information over the network for shared use. The volume of information which may be transferred over such networks has increasingly become more demanding on the structure of the networks themselves. Various network devices are known to allow the connection of a greater number of computers to a single network and further to allow more free communication of information between computers or other devices on the network or on other interconnected networks. As the number of devices on networks increases, the demands for high performance repeaters and other devices to meet the challenge of managing the information flow so that the data does not create a bottleneck effect on the network are increasingly required. Furthermore, the protocol supporting communications over such networks are typically evolving to support higher data rates and larger volumes of information transmittal over the communication networks.
One example of such a communication protocol is known as the ethernet protocol as defined by the Institute of Electrical and Electronic Engineers (IEEE) 802.3 standard. The ethernet protocol is one of the most widely implemented local area network (LAN) standards. An updated version of the ethernet protocol, fast ethernet, is specified to support data transfer rates of 100 megabits per second (Mb/s). A further version, gigabit ethernet, is specified as supporting data rates of 1,000 Mb/s. The developments in the standard related to such technical progress in general have been based on the physical layer, i.e., on the lowest or first layer of an open system interconnection (OSI). While developments and commercialization of faster physical layers has progressed, the protocols for the media access controllers (MAC) currently used in ethernet networks have seen relatively little change.
One problem encountered with ethernet as a result of the increasing performance of personal computers and the number of hosts using a single network, thereby creating increased volumes of traffic on the network, is that difficulties may occur using carrier sense multiple access/collision detection (CSMA/CD) methods such as those provided by ethernet for conventional MAC protocols. A CSMA/CD type host (terminal/computer) generally checks carriers on a transmission path of the network before transmitting frames. The host then transmits a frame during what appears to the host to be an idle period on the transmission path. However, such networks allow collisions to occur when two different connected hosts both attempt to transmit frames on the network at the same time. When the collision is detected, the ethernet protocol provides for collision recovery steps including stopping transmission of any remaining parts of a frame currently being transmitted and initiating retransmission of transmission frames which encounter the collision after some time interval which is typically specified by the collision detection recovery protocol in use on the network.
More particularly, when two transmissions of data collide, collision signals with predetermined bits indicating a collision may be transmitted to each host involved in the transmissions which collided. On receiving the collision signals, the host terminals may retransmit the data. The timing of retransmission is typically controlled using a retransmitting algorithm such as a binary exponential backoff (BEB) algorithm. The BEB algorithm generally specifies “2” as a common small constant factor by which the time between making retransmission attempts is increased for each subsequent attempt.
For example, when a host A transmits data on the network and a first collision occurs, a retransmission may be attempted after a single minute. If, during the first retransmission attempt by host A, a second collision occurs, another retransmission is attempted after two minutes. If a third collision occurs at this point, another retransmission is attempted after four minutes and so on.
One problem with this type of BEB algorithm is fairness to competing hosts attempting to access the communication channel. For example, assuming that host A attempts a retransmission after four minutes delay when a third subsequent collision occurs, a separate host, host B may transmit data while host A is delayed waiting a specified time period for a subsequent retransmission attempt. If no collision is encountered by host B during its transmission, it will have transmitted its data prior to host A even though “fairness” would dictate that host A be allowed to transmit data prior to host B as host A sought to transmit such data in advance of the request by host B. In other words, when the BEB algorithm is used, it is possible for a host which attempted to transmit data later than another host to transmit data first. This problem is generally referred to as a capture effect and reduces network performance. The capture effect is generally an intrinsic problem when utilizing the CSMA/CD method and may worsen when the number of hosts in a network is sharply increased or when a larger amount of data is transmitted over a network.
In an attempt to solve this problem various algorithms have been developed as modifications over the BEB algorithm. One such algorithm is the capture avoidance binary exponential backoff (CABEB) algorithm. Another is the binary logarithmic arbitration method (BLAM) algorithm. These algorithms are based on the BEB algorithm and may allow for improved methods for calculating the delay times while still facilitating prevention of collisions. However, the CABEB and BLAM algorithms are still subject to the problem of a lack of fairness in access to the network resource.
In a further aspect of operation of ethernet networks, when signal collisions occur in hubs or repeaters in the network, a collision truncation method which detects collisions and transmits collision signals to a host can be used. This method may reduce the delay time required for collision signals to be transmitted to the respective host so that there is less reduction in the performance of the network. Although this method may improve network performance, the problems of collision and unfairness may still exist.
Accordingly, conventional methods for collision detection and recovery create problems in fairness and may often times result in the reduction of the performance of a network. Furthermore, when the traffic load on a network is sharply increased, the data to be transmitted may surpass a maximum transmission time such that information is not successfully transmitted and is lost. Typically, such problems can only be solved in upper layers of the communication hierarchy which may adversely impact the total performance of the communications over the network.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide systems and methods for collision control on an ethernet network which may decrease the likelihood of collisions.
It is a further object of the present invention to provide systems and methods for collision control on an ethernet network which may reduce capture effect and provide for improved fairness in access to the network.
In order to provide for the foregoing and other objectives, ethernet collision control systems and methods for an ethernet network are provided which utilize a media access controller (MAC) which inserts a counter code in the inter-frame gap (IFG) between frame units when transmitting data of a data size which exceeds the capacity of a single frame of the ethernet protocol. The counter code provides a clock signal which may be received by other hosts on the network when they monitor the network to determine whether they are able to make transmissions. First, by recognizing the counter code between frames as distinguished from an idle period signal, the hosts seeking to transmit are notified that additional frames are expected in the next time window from the currently transmitting host. In addition, a counter is provided on each host which generates a count value from the received counter code received during inter-frame gaps and generates a retransmission criterion for controlling transmissions based on the received counter code. Accordingly, a counter code may be used to prioritize access to the network based upon the sequence with which additional hosts wishing to transmit data access the network responsive to an internally generated transmission request.
In one embodiment of the present invention, A collision control system for an ethernet network is provided including a media access controller (MAC) circuit that provides data for transmission in frame units. The MAC circuit further includes a code generator that generates a counter code that is transmitted in an inter-frame gap (IFG) between frame units. The counter code is distinct from an idle period code specified by the ethernet network. Also included in the collision control system is a transmitter coupling the MAC circuit to the ethernet network that transmits the frame units and the counter code on the ethernet network.
In another embodiment of the present invention, the collision control system further includes a receiver coupling the MAC circuit to the ethernet network that receives transmissions from the ethernet network including frame units and counter codes transmitted by other collision control systems coupled to the ethernet network. In this embodiment, the MAC circuit further includes a counter for generating a transmission criterion responsive to the received counter codes. The counter code may include a start-period, a clock period. The counter may generate a transmission criterion responsive to the clock period. In one embodiment, the clock period includes a plurality of clock signals and the counter generates a counter value responsive to the plurality of clock signals, the counter value specifying a priority for use as the transmission criterion. In addition, the counter code may further include an end period and the counter may be initialized by the start period and count the plurality of clock signals until the end period is received. The MAC circuit may be configured to use the counter value as a coefficient of a binary exponential backoff (BEB) algorithm to control transmission by the transmitter.
In a further aspect of the present invention, a collision control system for an ethernet network is provided including a receiver coupled to the ethernet network that receives transmissions from the ethernet network including frame units and a counter code transmitted by other collision control systems coupled to the ethernet network and a media access controller (MAC) that receives data in frame units and counter codes from the receiver. The MAC circuit includes a counter for generating a transmission criterion responsive to the received counter code.
In yet another aspect of the present invention, methods are provided for collision control for an ethernet network. Frames of data and a received counter code are received from the ethernet network. The received counter code is received between a first and a second of the frames of data. The received counter code is analyzed to determine a transmission criterion and frames of data are transmitted responsive to the transmission criterion. In one embodiment, transmitting operations include generating a plurality of frames of data for transmission, generating a transmit counter code and transmitting the plurality of frames of data on the ethernet network with the transmit counter code inserted in an inter-frame gap (IFG) between each of the plurality of frames responsive to the transmission criterion.
In one embodiment of the method aspects of the present invention, the received counter code comprise a start period and a clock period including a plurality of clock signals and the analyzing operations include generating a counter value responsive to the plurality of clock signals, the counter value specifying a priority for use as the transmission criterion. The plurality of frames of data may be transmitted at a time determined using the counter value as a coefficient of a binary exponential backoff (BEB) algorithm. In one embodiment, the received counter code further includes an end period and a counter value is generated by initializing the counter responsive to the start period, counting the plurality of clock signals and stopping the counting step and setting the counter value responsive to the end period.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of ethernet frame transmissions in a high speed (fast) ethernet network;
FIG. 2 is a schematic illustration of an inter-frame gap according to an embodiment of the present invention;
FIG. 3 is a schematic illustration of frame transmissions in a high speed ethernet network according to an embodiment of the present invention;
FIG. 4 is a block diagram of a collision control system according to an embodiment of the present invention;
FIG. 5 is a flow chart illustrating frame transmission according to an embodiment of the present invention; and
FIG. 6 is a flow chart illustrating receiving operations according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. As will be appreciated by one of skill in the art, the present invention may be embodied as methods or devices. Accordingly, the present invention may take the form of a hardware embodiment, a software embodiment or an embodiment combining software and hardware aspects.
Referring to the schematic illustration of FIG. 1, framed transmissions in a fast ethernet network will now be described. Such networks have idle periods, frames and inter-frame gaps (IFG) occurring between frames. In the idle periods, no data is transmitted over the network. In the illustrated schematic of FIG. 1, data to be transmitted over the network is divided up across three frames, frame 1 , frame 2 and frame 3 , which are transmitted over the network. The IFGs are located between frame 1 and frame 2 and between frame 2 and frame 3 . With the frame structure illustrated in FIG. 1, the codes representing the idle periods are generally identical with those representing the IFGs. Accordingly, a host seeking to make a transmission on the network detects what it recognizes as idle available period indicators in the idle periods or the IFGs and then subsequently attempts to transmit data.
In order to control and potentially prevent data collisions, the apparatus and methods of the present invention provide for specific codes (counter codes) during the IFGs which allow idle periods to be distinguished from the IFGs. Furthermore, improved BEB algorithms for retransmission are provided which beneficially utilize the counter codes provided during the IFGs. Referring now to FIG. 2, an embodiment of the present invention will be further described with reference to the schematic illustration of an IFG providing a counter code. As shown in FIG. 2, the length of the IFG is 96 bits. The corresponding counter code includes a 10 bit IFG start period in the first 10 bits (shown as 00001 0001). The following 80 bits provide a clock period which represents clock signals (shown as a repeating pattern of “0011 0011”). Finally, a 6 bit duration IFG end period is appended at the end of the counter clock period. In the illustrated embodiment of FIG. 2, the clock signals and the clock period are set to repeat a “0011 0011” pattern which, within the 80 bit clock period, provides an actual maximum clock cycle count of 20. This clock cycle amount (20) is sufficient to satisfy the requirements of the maximum retransmission trial amount count of 16 for the BEB algorithm generally recommended by the IEEE 802.3 standard.
FIG. 3 is a schematic illustration of frame transmissions in a fast ethernet network according to an embodiment of the present invention. As shown in FIG. 3, three hosts, A, B, and C are coupled to the network and, at various times, attempt data transmission over the network. Host A checks the status of the transmission path of the network at time t 1 . Because the status of the transmission path is detected as idle by host A, host A starts to transmit data during period t 2 . In the illustrated example of FIG. 3, the total data to be transmitted by host A exceeds the capacity of a single frame and is, therefore, divided into two frames, frame 1 and frame 2 . Frame 1 is transmitted during period t 2 and the IFG counter code is transmitted during the time period t 3 between frame 1 and frame 2 . Frame 2 is then transmitted during the subsequent period t 4 . Host A, after completing transmission of the data, may repeatedly transmit during period t 5 the code “101010. . . ” representing an idle period.
As shown in FIG. 3, during time period t 3 host B and then, shortly there after, host C, check the transmission path to determine if they are able to transmit data during period t 3 . As noted previously in reference to FIG. 1, for the conventional method of FIG. 1, host B and C would both read the idle period code “101010. . . ” during their check of the transmission path and, accordingly, would simultaneously attempt to transmit data during period t 4 , thereby causing a collision to occur. However, pursuant to the apparatus and methods of the present invention, both hosts B and C receive the counter code corresponding to the IFG period when checking the status of the transmission path during period t 3 . Accordingly, they receive the clock signals provided during the counter clock period which are used by both host B and host C to operate internal counters for use in generating a transmission criterion for the respective hosts. As will be described further herein, because host B checked the transmission path and detected the counter code during the IFG some time period prior to host C, host B's counter will generate a counter value greater than that generated by the counter of host C. This greater count will generate respective transmission criteria causing host B to transmit its frame of data during time period t 5 while host C waits for time period t 6 .
For example, a counter value may be used to generate a coefficient for use in a BEB algorithm that varies depending upon the counter value. More particularly, the counter of host B may provide a coefficient resulting in a shorter delay for transmission than that provided by host C based on the greater value of the count calculated by host B during reading of the counter code during period t 3 . Alternatively, a delay period within time period t 5 immediately following completion of frame transmission by host A may be inversely related to the count generated during time period t 3 and each of host B and host C may be required to check transmission path status before beginning transmissions. Accordingly, host B will begin transmission of its frame thereby resulting in a non-idle period indication on the transmission path when host C subsequently checks the transmission path at its designated delay after the end of time period t 4 . Accordingly, host C will need to wait an additional time period after the transmission of a frame by host B before it encounters, during time period t 6 , an idle period indication at its check time before transmission of its frame. Accordingly, multi-framed transmissions may be successfully provided without collisions from the individual host and the sequencing of competing additional hosts accessing the network following completion of transmissions by a first host may be provided while avoiding the occurrence of collisions on the network.
The BEB algorithm for collision control as provided by the IEEE 802.3 standard is as follows:
0 ≦r <2 k
where k=min (n, 10), and, according to the IEEE 802.3 standard, the value of n is “1” for both hosts B and C. Accordingly, host B and C, having identical n values, may use their counter value to determine which host has the transmission priority. As in the illustrated example of FIG. 3 host B has a greater counter value than host C, host B has the higher priority and, after host A completes data transmission, host B starts to transmit data during time period t 5 . Host C subsequently transmit data during time period t 6 .
An embodiment of a collision control system for an ethernet network will now be further described with reference to the block diagram of FIG. 4 . As shown in the embodiment of FIG. 4, the collision control system includes a media access controller (MAC) 100 , a transmission data path unit 200 , a code generator 300 , a transmitter 400 , a receiver 500 , a receiving data path unit 600 and a counter 700 . The MAC 100 , the transmission data path unit 200 , the code generator 300 , the receiving data path unit 600 and the counter 700 comprise a MAC circuit 101 .
The MAC 100 illustrated in the embodiment of FIG. 4 generates data and manages communications with the ethernet network pursuant to the IEEE 802.3 standard including generating data for transmission in frame units and receiving transmissions from the ethernet network in frame units. The transmitter 400 is a physical layer coupling unit which converts transmission data into electrical signals in a suitable form for transmitting the electrical signals over the transmission path of the network. Accordingly, the transmitter 400 couples the MAC circuit 101 to the ethernet network and transmits frame units on the ethernet network. Similarly, the receiver 500 provides a physical layer coupling unit which receives electrical signals from the transmission path and transforms the signals into a data format suitable for providing to the MAC circuit 101 .
The transmission data path unit 200 located between the MAC 100 and the transmitter 400 provides the data from the MAC 100 to the transmitter 400 . The code generator 300 generates the specific counter codes, such as those illustrated in the embodiment of FIG. 2, for insertion into the IFG between data frames for transmission over the network. Accordingly, the transmission data path unit 200 provides an appropriate data stream including frames containing data for transmission as well as counter codes in the IFG period between frames of a multiple frame transmission of data.
The receiving data path unit 600 which is coupled between the receiver 500 and the MAC 100 provides data received by the receiver 500 via the transmission path of the ethernet network to the MAC 100 . In addition, the counter 700 is configured to detect the start period of the counter code in the IFG and perform counter operations on the clock signals contained in the counter clock. More particularly, the counter may be initialized responsive to detection of the start period and then count a plurality of clock signals received until the end period signal is received by the counter 700 from the receiver 500 . The counter value so generated may then be provided to the MAC 100 for use in establishing a transmission criterion controlling subsequent transmissions.
Operations according to an embodiment of the present invention will now be further described with reference to the flow chart illustration of FIG. 5 . FIG. 5 illustrates operations related to frame transmission. Operations begin at block 800 when the MAC 100 generates data to be transmitted and analyzes the data length to determine whether the data may be transmitted as a single frame or must be transmitted as multiple frames. Where more than a single frame are required to support transmission of the data (block 805 ), the code generator 300 is activated (block 810 ). Subsequently, a first frame is transmitted containing a portion of the data which has been divided across a plurality of frames (block 820 ). The code generator 300 then provides a counter code to the transmission data path unit 200 for transmission by the transmitter 400 during the IFG (block 830 ). Operations of block 820 and 830 repeat for the remainder of the plurality of frames containing the data for transmission.
Where only a single frame is required for the data transmission (block 805 ), the code generator 300 is maintained in a standby mode (block 840 ). The data from the MAC 100 is then transmitted in a single frame by the transmitter 400 as the data is received from the data transmission path unit 200 (block 850 ).
Referring now to FIG. 6 operations according to an embodiment of the present invention will now be further described with reference to the flow chart illustration of receiving operations. As shown on FIG. 6 operations begin with a host computer (collision control system for an ethernet network) monitoring the transmission path of the ethernet network to determine whether the host may transmit data (block 900 ). If the host receives an IFG associated counter code such as that illustrated in FIG. 2 (block 905 ), the counter 700 is initialized and activated (block 910 ). The counter 700 then performs counting operations responsive to the clock signals contained in the counter code clock period (block 920 ). On receipt by the counter of the end period of the IFG counter code, counter operations are stopped and the respective counter value is provided to the MAC 100 by the counter 700 (block 930 ). The MAC 100 then determines transmission priorities using the counter value as a transmission criterion. Each respective host monitoring the network accordingly retransmits (or transmits) data responsive to the determined priorities.
As described above, the present invention provides for the use of a counter code which is generated during the IFG and which is received and counted by a counter operating responsive to clock signals contained in a clock period of the counter code. Resulting counter values determined during checking of the transmission path prior to transmissions are transmitted to the MAC 100 which may thereby provide for reduction or prevention of delays in utilization of the network by MAC attempts to retransmit data and may further reduce the potential for overwhelming of the network by data from a particular transmitting host. Furthermore, fairness between transmission opportunities by various hosts which occupy the transmission path after a collision and hosts which did not occupy the transmission path may also be maintained.
As will be appreciated by those of skill in this art, the above-described aspects of the present invention in FIGS. 4-6 may be provided by hardware, software, or a combination of the above. While various components of the MAC circuit 101 have been illustrated in FIG. 4, in part, as discrete elements, they may, in practice, be implemented by a processor, such as a microcontroller, including input and output ports and running software code, by custom or hybrid chips, by discrete components or by a combination of the above. For example, the code generator 300 may be contained within a processor (not shown) supporting other functions of the MAC 100 .
Operations of the present invention have been described above with reference to the flow chart and schematic block diagrams of FIGS. 4-6. It will be understood that each block of the flowchart illustrations and/or block diagrams and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These program instructions may be provided to a processor to produce a machine, such that the instructions which execute on the processor create means for implementing the functions specified in the flowchart and/or block diagram block or blocks. The computer program instructions may be executed by a processor to cause a series of operational steps to be performed by the processor to produce a computer implemented process such that the instructions which execute on the processor provide steps for implementing the functions specified in the flowchart and/or block diagram block or blocks.
Accordingly, blocks of the flowchart illustrations and block diagrams support combinations of means for performing the specified functions, combinations of steps for performing the specified functions and program instruction means for performing the specified functions. It will also be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by special purpose hardware-based systems which perform the specified functions or steps, or combinations of special purpose hardware and computer instructions.
In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. | Ethernet collision control systems and methods for an ethernet network are provided which utilize a media access controller (MAC) which inserts a counter code in the inter-frame gap (IFG) between frame units when transmitting data of a data size which exceeds the capacity of a single frame of the ethernet protocol. The counter code provides a clock signal which may be received by other hosts on the network when they monitor the network to determine whether they are able to make transmissions. First, by recognizing the counter code between frames as distinguished from an idle period signal, the hosts seeking to transmit are notified that additional frames are expected in the next time window from the currently transmitting host. In addition, a counter is provided on each host which generates a count value from the received counter code received during inter-frame gaps and generates a retransmission criterion for controlling transmissions based on the received counter code. Accordingly, a counter code may be used to prioritize access to the network based upon the sequence with which additional hosts wishing to transmit data access the network responsive to an internally generated transmission request. | 7 |
FIELD OF THE INVENTION
The present invention relates to a washing machine performing washing control utilizing fuzzy inference.
BACKGROUND OF THE INVENTION
Heretofore, a washing machine that automatically determined various washing conditions using various kinds of sensors.
For example, there exists a washing machine which is equipped with a cleaning sensor for detecting the degree of deterioration of washing water, and determines the cleaning time according to the information from this cleaning sensor. There also exists a washing machine which is equipped with a cloth amount sensor which detects the laundry volume, determines the water level, and the water flow at the time of cleaning as well as rinse according to the information from this sensor. Furthermore, there exists a washing machine which is equipped with, in addition to the above-mentioned cleaning sensor and cloth amount sensor, a manual-setting input part for manually setting various washing conditions such as laundry volume, water flow, and washing time. In the washing machines equipped with these various kinds of sensors as well as the manual-setting input part, although the various washing conditions such as washing time or the water level were determined automatically, the determination of washing conditions in accordance with the information from various sensors and the manual-setting input part were done independently.
The prior art washing machines determine washing time based one the information from the cleaning sensor. Then the relation between the degree of deterioration of washing water and the washing time is expressed by a simple mathematical formula such that the setting is done in a manner that when the degree of deterioration of washing water is great the cleaning time is made long. Then based on this mathematical formula the washing time is determined automatically. As a result, the washing time could not be determined based on a relation between the washing time and the degree of deterioration of washing water gained from the experience of a user, bringing about a great difference from the washing time which was intended by the user. This gave a problem that the most suitable washing time based on the user's experience could not be set.
Neither washing water flow nor rinse water flow can be determined uniquely by the cloth amount. These flows should be determined when considering the degree of soiling of the laundry (amount and type of soiling of the laundry). In washing machines of prior art, however, since the water flow is determined only by the information from the cloth amount sensor and the degree of soiling of the laundry is not taken into account for the determination of the water flow, there has been a problem that careful washing and rinse taking every factor into account could not be done.
Although the most suitable water level should be determined by mass, type, volume and other factors of the laundry, in the washing machines of prior art, the water level was determined only by the information from the cloth amount sensor, there has been a problem that the water level was not sufficiently determined.
Furthermore, in the washing machines of prior art, since the determination of the washing condition and the determination of the washing condition through the manual-setting input part are independent of each other, the washing condition cannot be determined by a combination of the information from the manual-setting input part, which is the information on the sort of laundry that is difficult to detect using sensors and the detected values from the various sensors. Hence there has been a problem that it was very difficult to determine the various washing conditions corresponding to laundry of a mixture of multiple sorts.
There has also been a problem that, by adding the information through the manual-setting input part given manually by a user to the determination of the washing condition obtained from the detected values output by the various sensors, "the most suitable washing" according to the various sensors and "washing according to the user's taste" could not be realized at the same time.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a washing machine controller which (1) can determine the most suitable washing time based on a user's experience, (2) can determine the washing water flow as well as the rinse water flow by also taking the degree of soiling of laundry into account, (3) can determine the most suitable water level by also referring to the detected value from a water level sensor provided in addition to a cloth amount sensor, (4) can determine various washing conditions corresponding to laundry of the mixture of a multiple sorts, and (5) can determine "the most suitable washing" according to the various sensors and "washing according to the user's taste" according to manual input for realization at the same time. Furthermore, the washing machine of the present invention can determine, first, the water level reflecting the user's taste, second, the water flow reflecting the user's taste, third, the washing time as well as the rinse time reflecting the user's taste, and fourth, various washing conditions also reflecting user's taste.
In order to achieve the above-mentioned first objective, the present invention has a cleaning sensor for detecting the degree of deterioration of washing water and a washing time inference unit which determines the washing time using fuzzy inference by inputting thereinto the time until which the detected value from the cleaning sensor reaches saturation as well as the detected value itself at the time thereof.
The washing time inference unit incorporates a user's know-how into the determination of the washing time, which depends on the soiling of laundry from the detected value of the cleaning sensor, using fuzzy inference to determine the most suitable washing time.
In order to achieve the above-mentioned second objective, the present invention has a cleaning sensor for detecting the degree of deterioration of washing water, a cloth amount sensor for detecting the quantity of laundry, a timer for measuring the washing time and the rinse time, and a water flow inference unit which receives the detected values of these cleaning sensor, the cloth amount sensor and the timer value from the timer as its input to make a fuzzy inference on the washing water flow and the rinse water flow.
Based on the degree of cleaning-up of the soiling of laundry detected by the cleaning sensor, the cloth amount detected by the cloth amount sensor, and the washing time and the rinse time detected by the timer, the washing water flow and rinse water flow are determined by the water flow inference unit.
By affording the water flow inference unit the water flow control know-how which users generally know from their experience, an appropriate determination of the water flow allowing the inclusion of a touch of humanity can be attained.
In order to achieve the above-mentioned third objective, the present invention has a cloth amount sensor for detecting the quantity of laundry, a water level inference unit for making the inference on the predetermined water level, a water level sensor for detecting the water level, and a water-supply valve control means for controlling a water-supply valve according to a comparison between the detected value of the water level sensor and the predetermined water supply level determined by the inference of the above-mentioned water level inference unit.
The predetermined water-supply water level is determined by the water level inference unit from the detected value of the cloth amount sensor immediately before the washing and rinse processes. Then the water supply is started and the water level rising rate is determined from the detecting value of the water level sensor. Further the water-supply valve control means controls the water-supply valve by comparison the above-mentioned predetermined water-supply water level and the water level rising rate, thereby the most suitable water level determination becomes possible.
In order to achieve the above-mentioned fourth objective, the present invention has a manual-setting input part for accepting the manual input by an operator on a sort and the quantity of laundry, the cloth amount sensor for detecting the cloth amount, the cleaning sensor for detecting the degree of soiling, a washing condition inference unit which receives information from the above-mentioned manual-setting input part and the detecting value of the cloth amount sensor and the cleaning sensor as its input and determines therefrom various washing conditions. A control part controls a motor, the water supply valve, and a drain valve according to the washing condition determined by the above-mentioned washing condition inference unit.
Since the fuzzy inference is made on the determination of various washing conditions with simultaneous consideration of multifold information such the sort and the quantity of laundry from the manual-setting input part as well as the detecting values of the cloth amount sensor and the cleaning sensor, the can control part controls the motor, water supply valve, and the drain valve to obtain an appropriate washing.
Furthermore, in order to achieve the above-mentioned fifth objective, the first means of the present invention has a manual-setting input part for accepting the manual input by the operator on the water volume and the extent of soiling, a cloth amount sensor for detecting the cloth amount, and a water volume determination means which receives the detected value of the above-mentioned cloth amount sensor as well as the information from the above-mentioned manual-setting input part as its input and determines the washing water level and the rinse water level by the fuzzy inference.
A second means has a manual-setting input part for accepting the manual input by the operator on the mode of washing, a cloth amount sensor for detecting the cloth amount, and a water flow determination means which receives the detected value of the above-mentioned mentioned cloth amount sensor as well as information obtained from the above-mentioned manual-setting input part as its input and determines the washing water flow and the rinse water flow by the fuzzy inference.
A third means has a manual-setting input part for accepting the manual input by the operator on the degree of soiling, a cloth amount sensor for detecting the cloth amount, a cleaning sensor for detecting the deterioration, and a washing time determination means which receives the detected value of the above-mentioned various sensors as well as information obtained from the above-mentioned manual-setting input part as its input and determines the washing time and the rinse time by the fuzzy inference.
A fourth means has a manual-setting input part for accepting the manual input by the operator on the water volume, an extent of soiling, and a mode of washing; a cloth amount sensor for detecting the cloth amount; a cleaning sensor for detecting the deterioration; and a fuzzy inference unit which receives the detected values of various sensors and the information obtained from the above-mentioned manual-setting input part as its input and determines various washing conditions of water level, washing time, rinse time, washing water flow, rinse water flow, and others.
In accordance with the above first means, although normally the adequate water level is determines by making the fuzzy inference by the water level determination means using the detected value of the cloth amount sensor, the water level is determined to reflect a user's taste in the adequate water level range according to the information obtained by the manual-setting input part; which is for accepting the manual input by the user on the water volume and the extent of soiling.
In accordance with the above second means, although normally the adequate water level is determined by making the fuzzy inference by the water level determination means using the detected value of the cloth amount sensor, the water flow is determined to reflect a user's taste in the adequate water flow range according to the information obtained by the manual-setting input part; which is for accepting the manual input by the user on the mode of washing.
In accordance with the above third means, although normally the adequate washing time as well as the rinse time are determined by making the fuzzy inference by the water level determination means using the detected value of the cloth amount sensor and the cleaning sensor, the washing time as well as the rinse time are determined to reflect a user's taste in the adequate time range according to the information obtained by the manual-setting input part; which is for accepting the manual input by the user on the extent of soiling.
In accordance with the above fourth means, an adequate water level is determined from the detected value of the cloth amount sensor, and the washing water flow and the rinse water flow are determined from this detected value and the above-mentioned adequate water level. The washing time is determined from the detected value of the cleaning sensor and the above-mentioned adequate water level and water flow. Although the above-mentioned various washing conditions are determined using a multiple-stage inference by the fuzzy inference unit, those various washing conditions are determined to reflect a user's taste in the adequate range of various washing condition according to the informations obtained by the manual-setting input part; which is for accepting the manual input by the user on water volume, extent of soiling, and mode of washing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a constitutional drawing of a washing machine according to an embodiment of the present invention.
FIG. 2 is a block diagram of a washing machine according to a first embodiment of the present invention,
FIG. 3 is a block diagram of a washing time inference unit.
FIG. 4 is a block diagram showing a washing time inference rule of the same.
FIGS. 5(a), 5(b), and 5(c) are graphs showing membership functions of saturation time, light-transmittance, and washing time, respectively.
FIG. 6 is a graph showing a result of inference of the washing time inference unit.
FIG. 7 is a graph showing a function between washing time and light-transmittance.
FIG. 8(a) is a graph of a weighted monotonous type membership function.
FIG. 8(b) is a drawing showing a fuzzy inference rule.
FIG. 9 is an input-output characteristic curve in the fuzzy inference shown in FIG. 8.
FIG. 10 is a block diagram of a washing machine according to a second embodiment of the present invention.
FIG. 11 is an explanatory drawing of inference for water flow of the second embodiment.
FIG. 12 is a drawing showing a inference rule of a inference 1 composing a part of a water flow inference unit of the second embodiment.
FIGS. 13(a) and 13(b) are graphs showing membership functions of light-transmittance and lapse time, respectively.
FIG. 14 is a block diagram of the inference 1 of the second embodiment.
FIG. 15 is a block diagram of a inference 2 composing a part of the water flow inference unit of the second embodiment.
FIG. 16 is a block diagram of an input-output characteristic curve of the inference 1.
FIG. 17 is a graph showing a fuzzy inference rule of the inference 2.
FIG. 18 is a graph showing a membership function of the cloth amount.
FIG. 19 is a graph showing functions f1(x) to f4(x) of a conclusion part of the inference 2.
FIG. 20 is an input-output characteristic curve of the inference 2.
FIG. 21 is a constitutional drawing of a washing machine according to a third embodiment of the present invention.
FIG. 22 is a block diagram of the washing machine of the third embodiment.
FIG. 23 is a inference rule of a water level inference unit third embodiment.
FIG. 24 is a graph showing membership function of the laundry volume.
FIG. 25 is a graph showing membership function of water level.
FIG. 26 is a block diagram of a water level inference unit.
FIGS. 27(a), 27(b), and 27(c) are graphs showing membership functions of water supply predetermined water level, integrated water supply predetermined water level, and judgement for completion of water supply, respectively.
FIG. 28 is a graph showing a relation between water level and water level rising rate.
FIG. 29 is a block diagram of a washing machine a fourth embodiment of the present invention.
FIG. 30 is a drawing showing a manual-setting input part.
FIG. 31 is a inference rule of a washing condition inference unit of the fourth embodiment.
FIGS. 32(a) and 32(b) are graphs showing membership functions of the cloth amount and water volume, respectively.
FIG. 33 is a block diagram of a washing condition inference unit.
FIG. 34 is a block diagram of in a first means in a washing machine of a fifth embodiment of the present invention.
FIGS. 35(a) and 35(b) are drawings showing a inference rule for determining an amount of water volume correction and the water level.
FIGS. 36(a), 36(b), and 36(c) are respectively, graphs showing membership functions of water volume, extent of soiling, and amount of correction.
FIG. 37 is a block diagram of a fuzzy inference unit for determining the amount of correction.
FIG. 38 is a block diagram of a fuzzy inference unit for determining the water level.
FIG. 39 is a block diagram of a second means in a washing machine of the fifth embodiment of the present invention.
FIG. 40 is a drawing showing a fuzzy inference rule for determining the water flow.
FIGS. 41(a) and 41(b) are graphs showing membership functions of the cloth amount and the mode of washing.
FIG. 42 is a block diagram of a fuzzy inference unit for determining the water flow.
FIG. 43 is a block diagram of a third means in a washing machine of the fifth embodiment of the present invention.
FIG. 44 is a drawing showing a inference rule for determining the washing time.
FIGS. 45(a), 45(b), 45(c), and 45(d) are graphs showing respectively membership functions of the laundry volume, light-transmittance, saturation time, and extent of soiling.
FIG. 46 is a block diagram of a fuzzy inference unit for determining the washing time.
FIG. 47 is a block diagram of a fourth means in a washing machine of the fifth embodiment of the present invention.
FIG. 48 is a block diagram showing an actual constitution of a fuzzy inference.
FIG. 49 is a drawing showing a inference rule for determining the water flow.
FIG. 50 is a block diagram of a fuzzy inference unit for determining the water flow.
FIG. 51 is a fuzzy inference unit for determining the washing time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Explanation is given on the first embodiment of the present invention referring to FIG. 1 through FIG. 9.
FIG. 1 is a constitutional drawing of a washing machine according to an embodiment of the present invention. In this figure, numeral 1 is a washing tub into which the laundry and washing water are put, numeral 2 is an outer tub in which washing water is reserved. Numeral 3 is a pulsator stirring the laundry and the washing water which is rotated by a motor 4 via a belt 5. Numeral 6 is a cloth amount sensor detecting the load loading on the pulsator 3 at the time of rotation thereof. Numeral 7 is a water level sensor detecting the water volume in the washing tub 1 by detecting the air pressure in the air trap 8. Numeral 9 is a cleaning sensor detecting the degree of deterioration of the washing water in the washing tub 1 by the light-transmittance in a drain hose. Putting in and taking out water into and from the washing tub 1 are controlled by a water supply valve 10 and the drain valve 11 which are driven by a solenoid valve.
Next, principle of action of the above-mentioned cleaning sensor 9 is explained. A light-emitting part and a light-receiving are disposed at the drain outlet in a manner that they are facing to each other. Thus the light from the light-emitting part is received by the light-receiving part, thereby the light-transmittance of the washing water can be detected by the amount of the received light. Hereupon the detected value of the cleaning sensor corresponds to the light-transmittance in the present embodiment. This light-transmittance varies depending on the turbidity of the washing water. That is the, degree of removal of soiling of laundry can be detected by the cleaning sensor 9. The variation of the light-transmittance starts, as shown in FIG. 7, from a light-transmittance of V1 at the beginning of the washing. The light-transmittance decreases because of the turbidity increases due to the proceeding of the washing, and reaches a steady state at a light-transmittance V2 after a time length T (hereinafter called as saturation time). That is, the turbidity of the washing water reaches a saturated state. At this time, V2 represents the extent of soiling and T represents the degree of difficulty of removal of soiling of the laundry (hereinafter called as type of soiling).
Hereupon, considering an efficient cleaning of soiling of the laundry, in case of keeping the washing water flow constant, the washing effectiveness is determined by the washing time. Then the consideration is given on how to determine the washing time from the above-mentioned light-transmittance and the saturation time.
Although the light-transmittance and the saturation time represent the extent of soiling and the type of soiling, respectively, determination of the washing time from these variables depends largely on intuition and experience of a user and hence, it is difficult to express it by a mathematical formula. By expressing the user's general know-how by fuzzy rules, an appropriate washing time is determined by fuzzy inference.
Next, explanation is given on the control action referring to FIG. 2. In the washing process, the pulsator 3 starts to rotate under the control of the control part 15 controlling the motor 4, thereby a predetermined water flow is produced to start washing. The washing time inference unit 14 determines the washing time by the light-transmittance and the saturation time obtained from the cleaning sensor 9. The control part 15 stops the motor 4 when the above-mentioned washing time passes. The washing process is completed by the action described above. Hereupon, the washing time inference unit 14 and the control part 15 can be realized easily by a micro-computer 16.
Next, one embodiment of the washing time determination is explained referring to FIG. 3 to FIG. 6. The washing time is determined by making the fuzzy inference from the information of saturation time and light-transmittance at the time of reaching the saturation obtained by the cleaning sensor 9. The fuzzy inference is made based on six rules such as, as shown in FIG. 4, "when the saturation time is short and the light-transmittance is high, the washing time is made very short". Such the qualitative concept, that the saturation time is "short" or the light-transmittance is "high", or making the washing time "very short", is expressed quantitatively by membership functions shown in FIGS. 5(a), 5(b), and 5(c).
An actual constitution of the washing time inference unit 14 in shown in FIG. 3. In the following, the action of the washing time determination is explained using this figure.
First, the saturation time membership value arithmetic processing means 17 receives the time until the light-transmittance reaches saturation after the washing started and calculates the grade (goodness of fit) of the saturation time based on a function stored in a saturation time membership function memory means 19 which memorizes a saturation time membership function shown in FIG. 5(a). That is, the above-mentioned saturation time membership value arithmetic processing means 17 issues two different respective classes of grade (goodness of fit) of saturation times of "short" and "long" based on the saturation time membership function. And the light-transmittance membership value arithmetic processing means 18 receives the detecting value (light-transmittance) of the cleaning sensor 9 at the saturation and calculates the grade (goodness of fit) of the light-transmittance based on a function stored in a light-transmittance membership function memory means 20 which memorizes a light-transmittance membership function shown in FIG. 5(b). That is, the above-mentioned light-transmittance membership value arithmetic processing means 18 issues three different respective classes of grade (goodness of fit) of light-transmittance of "low", "normal", and "high" based on the light-transmittance membership function. Next, an assumption part minimum arithmetic processing means 21 receives the output of the saturation time membership value arithmetic processing means 17 as well as the output of the light-transmittance arithmetic processing means 18 and at the same time accepts data of a washing time inference rule memory means 22 which memorizes a washing time inference rule. The above-mentioned assumption part minimum arithmetic processing means 21, based on the washing time inference rule memory means 22, compares the membership value of "high" of the light-transmittance membership value arithmetic processing means 18 with the membership value of "short" of the saturation time membership value arithmetic processing means 17, and takes the smaller one (MIN) out of these two membership values as the assumption part membership value in the case of "high" light-transmittance, "short" saturation time, and "very short" washing time. Similarly, an assumption part membership value in case of "normal" light-transmittance, transmittance, "short" saturation time, and "short" washing time is obtained by comparing the membership value of "normal" from the light-transmittance membership value arithmetic processing means 18 and with the membership value of "short" from the saturation time membership value arithmetic processing means 18 (sic), and taking MIN of them. Furthermore, an assumption part membership value corresponding to those six cases shown in FIG. 4 such as "low" light-transmittance, "short" saturation time, and "long" washing time is sought and the result is issued.
Next, a conclusion part minimum arithmetic processing means 23 receives the output of the above-mentioned six assumption part membership value of the assumption part minimum arithmetic processing means 21 as well as reads data of the washing time inference rule memory means 22, and at the same time, reads functions of a washing time membership function memory means 24 which memorizes membership functions shown in FIG. 5(c). The conclusion part minimum arithmetic processing means 23 calculates four different MIN's between six different assumption part membership values calculated according to the washing mode inference rule and four different grades of "very short", "short", "long", and "very long" in the membership functions. That is, the membership function of "very short" washing time is cut at its top part with the assumption part membership value (grade) in the case of "high" light-transmittance, "short" saturation time, and "very short" washing time. Similarly, the membership function of "short" washing time is cut at its top part with two different assumption part membership values (grades) in the case of "normal" light-transmittance and "short" saturation time, or in the case of "high" light-transmittance and "long" saturation time, and then the larger one is taken as (MAX) out of these two assumption part matching (grade). Then, also on the membership functions of "long" and "very long" washing time, they are cut by respective assumption part matching (grade) at their top parts, and thereby the washing time membership function of FIG. 5(c) is corrected to be a combination of trapezoids.
Finally, a center-of-gravity arithmetic processing means 25 takes the center of gravity of an area surrounded by the membership function obtained by the conclusion part minimum arithmetic processing means 23, and a washing time at this center of gravity is issued as the final washing time.
Hereupon, the light-transmittance membership function is composed of weighted monotonous type membership functions which are shown in FIG. 5(b). Its function is explained using FIG. 8 and FIG. 9. As shown in FIG. 8(a), taking labels of respective membership functions of a weighted monotonous type membership function are taken to be A, B, and C, rule of the fuzzy inference is taken to be such as shown in FIG. 8(b). In this example, the conclusion parts are taken to be real numbers. For the inference processing, an ordinary MIN-MAX method is used. In the fuzzy inference of this constitution, the input-output characteristic when the slope of the membership function C is changed becomes such as shown in FIG. 9. As shown in this figure, it is understood that, by changing the slope of the membership function C, various sorts of second-order curves can be easily expressed.
Using the effect of the weighted monotonous-type membership function as has been described above, in the present embodiment, by adjusting the slope of the membership function expressing that the light-transmittance is high shown in FIG. 5(b), a fuzzy inference unit suitable to the object can be easily constituted.
The result of inference obtained by the washing time inference unit 14 explained above expresses suitably a complex and difficult-to express relation of the washing time depending on the saturation time and the light-transmittance obtained from the cleaning sensor 9. That is, the washing time can be determined finely and most suitably responding to the degree of soiling of the laundry. And although it is considered that the degree of soiling and the washing time are in a linear relationship in a point of view of removal of soiling, if we add factors of such as the damage given by the washing on the cloth or economy onto the above view points, the above-mentioned relationship becomes nonlinear. This is easily understood from that fact that a longer washing time can remove soiling well, but gives more damage on the cloth or a longer washing time is uneconomical on the view point of efficiency. Since the washing time determination by the washing time inference unit 14 is done by adding these factors mentioned above, the most suitable washing time is obtainable.
Hereupon, in the present embodiment, although a triangular shape has been used for the washing time membership function, method in which it is realized by a linear formula or real number can also be considered. And the number of rule is not always limited to six. Moreover, it is needless to mention that the determination of the rinse time can be determined by the similar method as in determination of the washing time.
In the present embodiment, although the cleaning sensor is constituted by a light sensor detecting the light-transmittance, such the method using the change of electric conductivity or using the image processing can also be considered.
Explanation is given on a second embodiment of the present invention using FIG. 1, and FIG. 10 to FIG. 20. In FIG. 10, numeral 9 is a cleaning sensor for detecting the turbidity of the water in the washing tub 1 by the light-transmittance in a drain hose. Numerals 26 and 27 are a timer provided inside a micro-computer and a water flow inference unit, respectively.
In the following, the action of the present embodiment is explained mainly on the action of the water flow inference unit 27. Control of the water flow strength is made by receiving, as the input, the detected value of the cleaning sensor 9, the cloth amount sensor 6, the washing time after starting the washing, and the lapse time after starting the rinse by the micro-computer 26. A motor 4 is driven with ON-OFF times determined by the inference done by the water flow inference unit 27; which is realized with a micro-computer. The determination of the ON-OFF time of the motor 4 by the flow inference unit 27 is done based on the general knowledge we usually have on washing from our experience, such that when the amount of cloth is large, the standard water flow must be made strong, or when the lapse time is short and the variation ratio of the light-transmittance is small, the water flow must be made stronger than the standard water flow.
An actual process of determination of the washing water flow by the fuzzy inference is described below.
The fuzzy inference in the present embodiment comprises a fuzzy inference 1 and a fuzzy inference 2 as shown in FIG. 11. The fuzzy inference 1 (hereinafter called inference 1) determines, by making inference, the amount of correction which expresses magnitude of strengthening or weakening of the water flow from its standard value; wherein the variation ratio of the light-transmission representing the degree of removal of soiling and the lapse time after starting the washing are inputs. The inference rule is such that, for example, "when the variation ratio of the light-transmission is large and the lapse time is short, the water flow is made weaker", and it is composed of four rules shown in FIG. 12.
Such the qualitative concept that the variation ratio of the light-transmittance is "large" or the lapse time is "long" is expressed quantitatively by membership functions shown in FIGS. 13(a) and 13(b). The conclusion part of the inference 1 uses values of real numbers represented by Q11 to Q34. and R11 to R34 shown in FIG. 12. Six correction value Q1 to Q3 and R1 to R3 are issued as the inference result. Subsequently, the method of the fuzzy inference is explained. In FIG. 14, a constitution for realizing the inference 1 included in the water flow inference unit 27 is shown. Based on a rule memorized in a correction value inference rule memory means 32, in a variation ratio membership value arithmetic processing means 28, a membership value between the variation ratio of the light-transmittance (i.e., the variation ratio of the output of the cleaning sensor 9) and the membership function memorized in the variation ratio membership function memory means 30 is obtained by taking MAX between them. Similarly, in a lapse time membership value arithmetic processing means 29, a membership value between the lapse time after starting the washing and the membership function memorized in the lapse time membership function memory means 31 is obtained. In the assumption part minimum arithmetic means 33, a MIN between the above-mentioned two membership values is taken to be a membership value of the assumption part. In the conclusion part minimum arithmetic processing unit 34, the MIN between this assumption part membership value and a membership function which is memorized in the conclusion part correction value membership function memory means 35, is taken to be a conclusion for this rule.
After obtaining respective conclusions on all respective rules memorized in the correction value inference rule memory means 32, a center-of-gravity arithmetic processing means 36, takes the MAX of all conclusions and calculates their center of gravity to obtain the correction value. An example of the input-output characteristic of the inference 1 becomes as shown in FIG. 16.
The fuzzy inference 2 (hereinafter called inference 2) receives the amount of cloth as its input and determines the ON-OFF time of the motor 4 by making inference thereon. The inference rule is such that, for example, "when the amount of cloth is much, the ON time is made longer and OFF time shorter", and it is composed of four rules shown in FIG. 17.
The qualitative concept that the amount of cloth is "much" is expressed quantitatively by membership functions shown in FIG. 18. The conclusion part is expressed by f1(x) to f4(x) shown in FIG. 17, which are respectively linear functions such as;
f1(x)=a1*x+b1
f2(x)=a2*x+b2
f3(x)=a3*x+b3
f4(x)=a4*x+b4
Graphic representations of f1(x) to f4(x) are shown in FIG. 19. Wherein, f1(x0), f3(x0), f1(x1) (f2(x1)), f3(x1) (f4(x1)), f2(x2), f4(x2), which characterize respective functions, are equal to Q1 to Q3 and R1 to R3 which are the conclusions of the inference 1. That is, parameters a1 to a4 and b1 to b4 of the conclusion part functions f1(x) to f4(x) are determined by the result of the inference 1. Actual method of the inference 2 is described below. In FIG. 15, a constitution for realizing the inference 2 included in the water flow inference unit 27 is shown. Based on a rule memorized in an ON-OFF time inference rule memory means 41, a cloth amount membership value arithmetic processing means 37 obtains a membership value of the assumption part by taking the MAX of the membership function memorized in the input cloth amount membership function memory means 38. Subsequently, in a conclusion part minimum arithmetic processing means 40, the MIN is taken this assumption part membership value and a membership function memorized in the ON-OFF time membership function in the conclusion part which is memorized in the memory means 39 to obtain the conclusion for this rule. After obtaining respective conclusions on all respective rules memorized in the ON-OFF time inference rule memory means 41, a center-of-gravity arithmetic processing means 42 takes the MAX of all conclusions and calculates their center of gravity to obtain the ON-OFF time. An example of the input-output characteristic of the inference 2 becomes as shown in FIG. 20. As is understood from FIG. 20, the input-output characteristic is such that when the amount of cloth is much (i.e., large), the ON time is made longer and the OFF time is made shorter, that is, the water flow is made stronger. This is because a pulsator 3 is disposed on the bottom of the washing tub 1 as is seen in FIG. 1, then as the amount of cloth increases, propagation of the water flow up to the upper layer becomes harder and hence the water flow strength must be made stronger.
The reason for the determination of parameters of the inference 2 by six outputs of the inference 1 is because, when the water flow is made stronger, the degree of strengthening is different depending on the amount of cloth.
By setting those parameters constituting the inference 1 and the inference 2 based on the knowledge we usually have from our experience, the ON-OFF control (water flow control) of the motor 4 by the water flow inference unit 27 becomes most suitable when the amount of cloth, the degree of soiling, the washing time is taken into account.
The water flow control action by the water flow inference unit 27 becomes such as described below. That is, the washing is done with an adequate strength responding to the amount of cloth at the starting time of washing, and when the soiling seems difficult to be removed, the water flow is made stronger. Then when the soiling starts being removed, the water flow is weakened so as to avoid damages to be given on the cloth. Also in case that the soiling is not removed for a long time, the water flow is weakened for the same purpose. And, in spite of lasting the washing for a considerably longer time, the soiling is removed sufficiently (sic), the water flow is made stronger so as not to lengthen the washing time by removing the soiling quicker.
Since the water flow control in accordance with the water flow inference unit 27, as described above, makes the action which is similar that we make from our experience, an adequate washing taking the amount of cloth and the damage given on the cloth into account. Further, the washing is responsive to the soiling of the cloth.
Hereupon, in the present embodiment, although the description has been done on the washing water flow control by the water flow inference unit 27, it is needless to mention that the same can be applied also on the rinse water flow control. And although it has been described that "in spite of lasting the washing for a considerably longer time, the soiling is removed sufficiently (sic), the water flow is made stronger so as not to lengthen the washing time by removing the soiling quicker", in this case, another method wherein the removal of the soiling is made easier by supplying the water through a water supply valve 10 can also be considered. And also still another method in which the removal of the soiling is made easier by a control of the washing water temperature can be considered.
In the agitation type washing machine and the drum type washing machine, the output of the fuzzy inference is taken to be respectively the driving speed of an agitator and the revolving speed of a drum.
At this time, sensing of the amount of cloth can be detected with the load current of the agitator or the drum, and the degree of the soiling can be detected in the similar manner as in the present embodiment.
Next, explanation is given on a third embodiment of the present invention using FIG. 21 to FIG. 28. In FIG. 21, in the water-extraction process, the washing tub 1 is driven by the motor 4, and numeral 13 is a second cloth amount sensor detecting the revolving speed of the washing tub 1 during the revolution thereof by an encoder. Hereupon this second cloth amount sensor 13 is for detecting the weight of cloth. The reason for this is that the revolving speed of the washing tub 1 is determined by the weight of the cloth without depending on such as the volume of the cloth.
Next, explanation is given on the determination of the washing water level at the time of washing referring to FIG. 22. The determination of the washing water level comprises two stages of a determination, first, the water-supply predetermined water level at the starting time; and, second, a judgement of water-supply completion. The first determination of the water-supply predetermined water level is done by a water level inference unit 43 which is realized by a microcomputer 45. An inference at this time is done based on the judgement that a user of the washing machine usually does such that "when the amount of cloth is much, the water level must be high", or "when the amount of cloth is few, the water level must be low". Rule of the inference is composed of four rules shown in FIG. 23. The qualitative concept that the amount of cloth is "much" or "few" is expressed quantitatively by membership functions such as shown in FIG. 24. The qualitative concept that making the water level "high" or "low" is expressed quantitatively by membership functions such as shown in FIG. 25.
Next, an arithmetic procedure of the inference process is described based on FIG. 26. First, in a cloth amount membership value arithmetic processing means 46, a membership value of the assumption part of the input, that is, for the detected value of the second cloth amount detector 13 is obtained by taking MAX between the input and membership functions memorized in a cloth amount membership function memory means 47. Then, in a conclusion part minimum arithmetic processing means 49, based on a rule memorized in a water level inference rule memory means 48, the MIN between membership functions memorized in the water level membership function memory means 50 and the assumption part membership value is taken to be a conclusion for this rule. After getting the respective conclusions for the rules, by taking MAX out of all these conclusions by a conclusion part maximum arithmetic processing means 51, a predetermined washing water level 51 is obtained as the final conclusion. This predetermined washing water level is expressed in a shape of a membership function as shown in FIG. 27(a), which shows respective possibilities of determination of water level at respective water levels. Next, explanation is given on a judgement of the water supply completion during the second water supply referring to FIGS. 27(a)-27(c). First, the integration of the membership function of the water supply predetermined water level shown in FIG. 27(a) obtained from the first stage is normalized so that maximum value of the grade becomes 1. This takes a shape as shown by FIG. 27(b), which shows respective possibilities of completion of water supply depending upon the water levels. The water level rising rate obtained from the detected value of the water level sensor during the water supply becomes small as the water level rises and finally converges to a predetermined value as shown in FIG. 28. This decrease of the water level rising rate accompanied by the water level rising is due to a cloth density distribution caused by a stacking of the laundry inside the washing tub 1. Namely, the cloth density is highest at the bottom of the washing tub 1 and it decreases as the height from the bottom of the washing tub increases. The final convergence of the water level rising rate to a predetermined value is because the water level rising rate is determined by the size of the outer tub 2 after the laundry is submerged completely in water. Judgement of the water supply completion is made by a comparison of this water level rising rate with the above-mentioned water supply predetermined water level. As shown in FIG. 27(c), when the water level rising rate becomes lower than the water supply predetermined water level, it is taken as the water supply completion and the water supply valve 10 is closed. These comparison action and the control of the water-supply valve are made by a water-supply valve control means 44 realized by a micro-computer 45. As is easily understood from FIG. 27(c), even if the water supply predetermined water level is constant, when the volume of cloth is low, the water level becomes low, while the cloth volume is high, the water level becomes high.
Hereupon, although it is explained that the water-supply predetermined water level is expressed by a fuzzy set, and the final water level is determined by a comparison with the water level rising rate, the water level can also be determined directly by determining the water level with respect to the center of gravity of the membership function of the water-supply predetermined water level which is obtained at the initial stage.
In the above, although the explanation has been given on the determination process of the water level at the time of washing, the water level determination at the time of rinse can also be done by the similar process. By determining the water level by the process as described above, the most suitable water level which takes both the weight and volume of the cloth into account can be obtained. And, as for the second cloth amount sensor, a method in which the amount of cloth is measured directly using a weight sensor can also be considered.
Explanation is given on a fourth embodiment of the present invention using FIG. 1 and FIG. 29 to FIG. 33. In FIG. 1, numeral 12 is a manual-setting input part accepting manual inputs by an operator and it has a panel configuration as shown in FIG. 30 which accepts the sort and number of the laundry.
Next, explanation is given on the control action referring to FIG. 29. Respective basic processes are performed by means that a control part 53 controls a motor 4, a water supply valve 10, and a drain valve 11 based on various washing conditions. Various washing conditions are determined by means that the washing condition inference unit 52 makes the fuzzy inference with having detected values of the cloth amount sensor 6 and of the cleaning sensor 9 and information from the manual-setting input part 12 as the input thereof. Hereupon, the above-mentioned washing condition inference unit 52 and the control part 53 can be easily realized by a micro-computer 54.
Next, explanation is given on one embodiment of the washing water volume determination. The water volume at the initial stage of the washing is determined by the information of the manual-setting input part 12 on which the user operated and the water level information detected by the water level sensor 7. Thereafter, the determination of the washing water volume is done by making fuzzy inference from the detected value of the cloth amount sensor 6 and the information from the manual-setting input part. The control part 53 controls the water supply valve 10 based on the determined water volume. The fuzzy inference is made by a rule based on a know-how that the user generally knows such that "when the laundry is a sort of lingerie and the cloth amount is fairly much, the water volume is made fairly very much", and it comprises nine rules shown in FIG. 31. The qualitative concept that the amount of cloth is "fairly much" or the water volume is "fairly very much" is expressed quantitatively by membership functions such as shown in FIGS. 32(a) and 32(b). The membership value of the assumption part on the sort of the laundry, in case of the lingerie for example, is determined by the ratio of the amount of lingerie occupying in the total amount of the laundry.
Next, a method of arithmetic procedure of the inference process is described. In FIG. 33 an actual constitution of a washing condition inference unit 52 is shown. In the following explanation is given using this figure. First, in accordance with a rule memorized in a water volume inference rule memory means 58, a cloth amount membership value arithmetic processing means 55 inputs the detected value of the cloth amount censor 6 and takes the max of the membership functions memorized in a cloth amount membership function memory means 56. Then, in an assumption part minimum arithmetic processing means 57, the membership value of the assumption part is determined by taking the MIN of the MAX value and a ratio (grade) of the amount of input cloth sort occupying in the total amount of the laundry. Next, in the conclusion part minimum arithmetic processing means 59, by taking MIN between membership functions memorized in the water volume membership function memory means 60 and the assumption part membership value, the conclusion for this rule is taken. Moreover, after getting respective conclusions for all rules memorized in the water volume inference rule memory means 58, the center of gravity is determined by taking the MAX of all the conclusions in a center-of-gravity arithmetic processing means 61. Thus, the washing water volume is obtained as a final conclusion.
In the water volume determination by the fuzzy inference explained above, careful washing taking the sort of the laundry into account in a manner that, for susceptible laundry such as lingerie, the water volume is increased to avoid damage of cloth. Whereas, for tough washes such as jeans, the water volume is decreased to wash out soiling positively.
Hereupon, in the present embodiment, although the sorts of the laundry to be specified by the manual-setting input has been limited to be three, this limit is not necessary. It is needless to mention that the greater the number of the sorts to be specified, the more carefully the washing can be done. In the present embodiment, description has been made on the determination of the water level for the washing water, but the same can be applied also on the determination of the water level for the rinse. Moreover, by the same procedure as the determination of the washing water level, it is also possible to perform control of the washing water flow and rinse water flow, control of washing time, rinse time, water-extraction time, water-extraction revolution control, and temperature control of washing water. At this time, by applying the detected value of the cleaning sensor 9 to the input of a washing condition inference unit 52, it also becomes possible to obtain the most suitable water flow control as well as time control responding more finely to the state of soiling of the laundry. Although the conclusion part variable of the fuzzy conditioning has been taken to be a triangular shape, such a method that the realization thereof using values or a function of real numbers can also be considered.
Explanation of a fifth embodiment of the present invention is given using FIG. 1 and FIG. 34 to FIG. 51.
In FIG. 1, numeral 12 is a manual-setting input part accepting manual inputs by an operator and it is comprised of a slide resistor and has a constitution through which such quantities as the amount of the water volume, degree of the extent of soiling, and degree of the strength of the washing can be input as analogue values.
Next, explanation is given on the determination of the water level of the washing water by a first means. FIG. 34 is one embodiment of the first means, the determination of the water level of the washing water comprises two steps, that is a determination of correction value of the water level according to the input information such as the amount of the water volume, degree of the amount of soiling either from the manual-setting input part 12 and a determination of a suitable water level by the above-mentioned correction value and the detected value from the cloth amount sensor 6. These determinations of the correction value and the suitable water level are both done by the fuzzy inference in the water level determination means 64. A fuzzy inference in the first step is done based on a general judgement such that "when the water volume is fairly much and the soiling is much, the correction value is made very much". Rule of the inference comprises nine individual rules shown in FIG. 35(a). Those qualitative concepts such that the water volume is "fairly much", the soiling is "much", or the correction value is "very much" are expressed quantitatively by membership functions as shown in FIGS. 36(a), 36(b), and 36(c). The fuzzy inference has a constitution as shown in FIG. 37, wherein in a water volume membership value arithmetic processing means 65, a membership value is obtained by taking the MAX between the external input water volume and the membership functions stored in water volume membership function memory means 67. In extent of soiling membership value arithmetic processing means 66, a membership value on the amount of the soiling is similarly obtained from an externally input amount of soiling and the membership functions stored in extent of soiling membership function memory means 68. In an assumption part minimum arithmetic processing means 70, the MIN between those above-mentioned two membership values, is taken as a membership value for the assumption part. In a conclusion part minimum arithmetic processing means 71, the MIN between the assumption part membership value and the correction value membership function of the conclusion part, is taken to be a conclusion of this rule.
After obtaining each conclusion on all of the rules, the MAX of all conclusions in a center-of-gravity arithmetic processing means 73, is used to determine the the correction value.
Those membership functions concerning the water volume, amount of soiling, and correction value are obtained by referring respectively to a water volume membership function memory means 67, a extent of soiling membership function memory means 68, and a correction value membership function memory means 70. And the inference rule is obtained by referring to a correction value inference rule memory means 69.
The fuzzy inference of the second step is done based on the general judgement such that "when the cloth amount is much and the correction value is fairly much, the water level is made very high". Rule of the inference comprises four individual rules shown in FIG. 35(b). Those qualitative concepts such that the cloth amount is "much", the correction value is "fairly much", or make the water level "high" are expressed quantitatively by membership functions likewise as in the first step. The fuzzy inference has a constitution as shown in FIG. 38, wherein a water level is obtained by a similar procedure as in the first step. The water level is adjusted in a manner that it becomes a water level determined by those two steps as described above in that a control section 62 controls a water supply valve 10 according to the detected value of the water level sensor 7.
Functions of the above-mentioned water level determination means 64 and the control art 62 can be easily realized by a micro-computer 63.
Next, explanation is given on the determination of the water flow by as second means. FIG. 39 is one embodiment of the second means, the determination of the water flow is done by making a fuzzy inference in a water flow determination means 83 according to the input information of detected value from the cloth amount sensor 6 and the strength of the washing from the manual-setting input part 12. The fuzzy inference is done based on a general judgement such that "when the cloth amount is fairly much and the strength of the washing is fairly strong, the water flow is made very much". Rule of the inference comprises nine individual rules shown in FIG. 40. Those qualitative concepts such that the cloth amount is "much" or the strength of the washing is "fairly strong" are expressed quantitatively by membership functions as shown in FIGS. 41(a) and 41(b). Such the concept as "making the water flow strong" corresponds to an expression as "making ON-time long, and OFF-time short" on the motor 4, and these qualitative concepts such as making ON-time "long" or making OFF-time "short" are expressed quantitatively by membership functions likewise. The fuzzy inference has a constitution as shown in FIG. 42, wherein in a cloth amount membership value arithmetic processing means 84, a membership value of the detected value of the cloth amount sensor and the membership functions on the cloth amount is obtained by taking MAX of them. In a washing mode membership value arithmetic processing means 86, a membership value of the manual-setting input and membership function of the the washing mode is obtained similarly. In an assumption part minimum arithmetic processing means 89, the MIN between those above-mentioned two membership values is taken as a membership value for the assumption part. In a conclusion part minimum arithmetic processing means 90, the MIN between the assumption part membership value and the ON-OFF time membership function of the conclusion part is taken to be a conclusion of this rule.
After obtaining each conclusion on all of the rules, the MAX of all conclusions in a center-of-gravity arithmetic processing means 92 is used to determine, the ON-OFF time.
Those membership functions concerning the cloth amount, washing mode, and ON-OFF time are obtained by referring respectively to a cloth amount membership function memory means 85, a washing mode membership function memory means 87, and an ON-OFF time memory means 91. The inference rule is obtained by referring to an ON-OFF time inference rule memory means 88.
Water flow having an adequate strength can be obtained when the control part 62 switches ON and OFF the motor 4 based on the ON-OFF time of the motor determined by the inference explained above. The above-mentioned water flow determination means 83 and control part 62 can be easily realized by a microcomputer 63.
Next, explanation is given on the determination of the washing time by a third means. FIG. 43 is one embodiment of the third means, the determination of the washing time is done by making a fuzzy inference in a washing time determination means 93 according to the input information of detected value from the cloth amount sensor 6 and the cleaning sensor 9 and the degree of the extent of soiling from the manual-setting input part 12. Hereupon, the detected value of the cleaning sensor 9 gives two different informations, the time the light-transmission reaches its saturation and the light-transmittance at this time. The information is input to the washing time determination means.
The fuzzy inference is done based on a general judgement such that "when the cloth amount is much and the light-transmission is low, and the saturation time is long and the extent of soiling is much, the washing time is made very long". Rule of the inference comprises 24 individual rules shown in FIG. 44. Those qualitative concepts such that the cloth amount is "fairly much" or the extent of soiling is "much" are expressed quantitatively by membership functions as shown in FIGS. 45(a) to 45(d). The fuzzy inference has a constitution as shown in FIG. 46, wherein in a cloth amount membership value arithmetic processing means, 94, a membership value of the detected value of the cloth amount sensor and the membership functions on the cloth amount is obtained by the MAX of them. In a washing mode membership value arithmetic processing means 97, a membership value of the manual-setting input and the membership function on the the washing mode is obtained similarly. Also similarly, in a light-transmission membership value arithmetic processing means 95 or in the saturation time membership value arithmetic processing means 96, required membership values are obtained. In the assumption part minimum arithmetic processing means 103, the MIN among the above-mentioned four membership values is taken as a membership value for the assumption part. In a conclusion part minimum arithmetic processing means 104, the MIN between the assumption part membership value and the washing time membership function of the conclusion part is taken to be a conclusion of this rule.
After obtaining each conclusion on all of the rules, the MAX of all conclusions in a center-of-gravity arithmetic processing means 106 is used to determine the washing time.
Those membership functions concerning the cloth amount, washing mode, light-transmission/saturation time, and washing time are obtained by referring respectively to a cloth amount membership function memory means 99, a washing mode membership function memory means 101, a light-transmission membership function memory means 98, a saturation time membership function memory means 100, and the washing time membership function memory means 105. The inference rule is obtained by referring to an washing time inference rule memory means 102.
The control of the motor 4 is carried out in the control part 62 based on the washing time determined by the fuzzy inference explained above, thereby the motor is turned OFF after a determined time. The above-mentioned washing time determination means 93 and control part 62 can be easily realized by a micro-computer 63.
Next, explanation is given on the determination of various washing conditions by a fourth means. FIG. 47 is one embodiment of the fourth means, the determination of various washing conditions is done by making a fuzzy inference in a washing time determination means 107 according to the input information of detected value from the cloth amount sensor 6 and the cleaning sensor 9 and the degree of the water volume, the degree of the extent of soiling, and the strength of the washing from the manual-setting input part 12. The fuzzy inference comprises multiple-stage inference of three stages as shown in FIG. 48.
A first stage is to determine an adequate water level similarly as in the embodiment of the above-mentioned first means. A second stage is to determine the water flow by means of fuzzy inference using information of the strength of the washing from the manual-setting input part, the detected value of the cloth amount sensor, and the water level determined by the first stage. The fuzzy inference is such that "when the cloth amount is fairly much and the water level is fairly high, and the washing mode is fairly strong, the water flow is made strong", which comprises 12 rules shown in FIG. 49. The fuzzy inference has a constitution shown in FIG. 50, wherein in a cloth amount membership value arithmetic processing means 108 a membership value of the detected value of the cloth amount sensor and the membership functions on the cloth amount is obtained by taking MAX of them. In a washing mode membership value arithmetic processing means 110, a membership value of the manual-setting input and the membership function on the the washing mode is obtained similarly. Also similarly, in a water level membership value arithmetic processing means 109, a desired membership value is obtained. In an assumption part minimum arithmetic processing means 115, the MIN of the above-mentioned three membership values is taken as a membership value for the assumption part. In a conclusion part minimum arithmetic processing means 116, the MIN between the assumption part membership value and the ON-OFF time membership function of the conclusion part is taken to be a conclusion of this rule.
After obtaining each conclusion on all of the rules, the MAX of all conclusions in a center-of-gravity arithmetic processing means 118 is used to determine the ON-OFF time.
Those membership functions concerning the cloth mount, washing mode, water level, and ON-OFF time are obtained by referring respectively to a cloth amount membership function memory means 112, a washing mode membership function memory means 113, a water level membership function memory means 111, and an ON-OFF time membership function memory means 117. And the inference rule is obtained by referring to an ON-OFF time inference rule memory means 114.
A third stage is to determine the washing time by means of fuzzy inference using the detected value of the cloth amount sensor 6 and the cleaning sensor 9, the water level determined by the first stage, and the water flow determined by the second stage. Hereupon, the detected value of the cleaning sensor 9 gives two different informations, the time the light-transmission reaches its saturation and the light-transmittance at this time. This information the input for the fuzzy inference unit 107. The fuzzy inference is such that "when the cloth amount is much and the water level is fairly high, and the water flow is fairly strong, the saturation time is long, and the light-transmission is small, the washing time is made very long", which comprises 32 rules. The fuzzy inference has a constitution shown in FIG. 51, and the washing time is obtained by a similar procedure as the above-mentioned second stage.
Responding to the result of three stages explained above, water supply control, water flow control, and washing time control are carried out by that the control part 62 controls the water supply valve 9 and the motor 4. The above-mentioned fuzzy inference unit 107 and control part 62 can be easily realized by a micro-computer 63.
Hereupon, by providing a manual-setting input part concerning the sort of cleaning material and the hardness of water, a further finer determination of the washing condition including temperature control, cleaning material control and others can be attained.
INDUSTRIAL APPLICABILITY
As has been described above in accordance with the present invention, by letting a washing time inference unit have the known-how by which the washing time is determined from the degree of soiling, the washing time is determined after adding various factors as a user generally does. Thus, a most suitable washing time can obtained, enabling the realization of a more careful washing.
A most suitable washing water flow and rinse water flow can be obtained by taking into account the soiling, into the cloth amount and the damage of cloth into using a water flow inference unit; which has cloth amount, degree of the soiling, washing time, and rinse time as its inputs. This is possible because it is not difficult to give the water flow inference unit the know-how of the water flow control that we usually know from our experience.
Since the amount of the laundry is detected not only from the water level sensor but also from the water level increasing rate, the water level at the time of washing as well as at the time of rinse can be determined by a multi-dimensional information of weight and volume of the. Thereby a careful washing and rinse, responding to the quantity and the quality of the laundry, can be attained.
By, providing, besides the detected values from various sensors, to the washing condition inference unit to which, information from the manual-setting input part can be input. The determination of various washing conditions that account simultaneously for the multi-dimensional information, such as the information concerning the sort and the quantity of the laundry and the detected value from the cloth amount sensor and the soiling sensor, is carried out by the fuzzy inference. Responding to this determined washing condition, the control part controls the motor, water supply valve, and drain valve, thereby a careful and adequate washing can be realized. The fuzzy inference unit can easily be designed by letting it have the know-how that we know from our experience.
The manual-setting input part which accepts the manual input by the operator concerning the water volume and the extent of soiling, and the water level determination means, which determines the water level by both of the information obtained from the manual-setting input part and the detected value of the cloth amount sensor, make it possible to determine the water level according to the operator's taste within a range of the adequate water level determined by the detected value of the cloth amount sensor. That is, the determination of the water level taking the operator's subjective point of view into account becomes possible.
The manual-setting input part, which accepts the manual input by the operator concerning the washing mode, and the water flow determination means, which determines the water flow by both of the information obtained from the manual-setting input part and the detected value of the cloth amount sensor, make it possible to determine the water flow according to the operator's taste within a range of the adequate water flow determined by the detected value of the cloth amount sensor. That is, the determination of the water flow taking the operator's subjective point of view into account becomes possible.
The manual-setting input part, which accepts the manual input by the operator concerning the water volume and the extent of soiling, and the washing time determination means, which determines the washing time and the rinse time by both of the information obtained from the manual-setting input part and the detected value of the cleaning sensor, make it possible to determine the water flow according to the operator's taste within a range of the adequate washing time determined by the detected value of the cleaning sensor. That is, the determination of the washing time taking the operator's subjective point of view into account becomes possible. furthermore, the a fuzzy inference unit making the multiple stage determination on various washing conditions concerning the adequate water level, the washing water flow and rinse water flow, and washing time, and a manual-setting setting input part, which accepts the manual input by the operator concerning the water volume, the extent of soiling and the washing mode, makes it possible to determine various washing conditions according to the operator's taste within a range of the adequate various conditions. That is, the determination of various washing conditions taking the operator's subjective point of view into account becomes possible. By making a multiple stage inference, it becomes possible to determine more carefully various washing conditions. | The washing machine controller has a cleaning sensor, a variation detecting device, a time counter, a washing time inference unit and a control unit. The cleaning sensor detects a turbidity of water in a washing tub of the washing machine. The variation detecting device detects a variation of the detected turbidity. The time counter measures a saturation time period, from a start of washing operation to a time point of saturation. The time point of saturation is determined when the detected turbidity becomes less than a predetermined value. The washing time inference unit uses a fuzzy inference operation to make an inference as to an additional washing time necessary for the cleaning operation after the time point of saturation based on the saturation time period and the detected turbidity. The fuzzy inference operation incorporates human experience in to the washing time determination process. The control unit stops the washing operation when the additional washing time expires. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a pulsed laser beam source device including a multi-layer film with a non-linear transmittance or reflectivity. The specific contents of the conventional example are described in detail in "LASER HANDBOOK edit. Japanese Society of Laser Gakkai" (published by Ohmu-sha in Japan).
2. Related Background Art
Conventional pulsed laser beam source devices for generating short pulsed beams use saturable absorbers for passive mode locking.
SUMMARY OF THE INVENTION
The pulsed laser beam source device according to this invention comprises a laser medium; optical pumping means for pumping the laser medium; resonator means for resonating a beam from the laser medium which is along a set optical path; and a multi-layer film formed of a first layer of a first material, and a second layer of a second material, the first material changing a refractive index in accordance with an intensity of the beam.
In this invention, a multi-layer film may be formed of two or more layers of two or more kinds of materials with different refractive indexes.
In the pulsed laser beam source device according to this invention, refractive indexes of materials forming the layers of the multi-layer film change depending on intensities of the incident beams. In accordance with their changed refractive indexes, transmittances or reflectivities of the films of the multi-layer film change. By using this, pulsed laser beams of ultra-narrow pulse widths can be obtained on the same principle as the passive mode-lock.
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not to be considered as limiting the present invention.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art form this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the pulsed laser beam source device according to the first embodiment.
FIG. 2 is a block diagram for explaining outputting means.
FIG. 3 block diagram of the pulsed laser beam source device further comprising lens.
FIG. 4 is a block diagram of the multi-layer film.
FIG. 5 is a graph of the reflection characteristic of the multi-layer film.
FIG. 6 is a block diagram of the pulsed laser beam source device according to the second embodiment of this invention.
FIG. 7 is a block diagram of the pulsed laser beam source device according to the third embodiment of this invention.
FIG. 8 is a block diagram of the pulsed laser beam source device according to the fourth embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram of the pulsed laser beam source device according to a first embodiment of this invention.
To be specific, a pumping light is applied to a laser medium 4 from a light source for optical pumping 2 to excite the laser medium 4. The radiation from the laser medium 4 is fed back to the laser medium 4 by a pair of resonator mirrors M 1 , M 2 to stimulate the active materials in the laser medium 4 to emit a stimulated laser beam of a required wavelength.
A multi-layer film 6 is positioned on a optical path interconnecting the laser medium 4 and the resonator mirror M 2 . The multi-layer film 6 is a little inclined from 90° with respect to the optical path. This multi-layer film 6 has a laminar structure of alternate two different kinds of layers as has a dielectric multi-layer reflecting mirror. In the multi-layer film 6, however, refractive indexes of the layers of two kinds change depending on intensities of incident light thereon. That is, when light whose intensity changes is incident on the multi-layer film 6, a transmittance (reflectivity) of the multi-layer film 6 change depending on intensities of the light. For example, the multi-layer film 6 is designed using materials which allow, in the absence of incident light, a refractive index of one of the two kinds of films to be lower than that of the other, and, in the presence of incident light, the lower refractive index of the former film to be equal to that higher refractive index of the latter film. The thus-designed multi-layer film 6 has transmittance which is raised by the incidence of the light.
The operation of the pulsed laser beam source device of FIG. 1 will be explained. The radiation from the pumped laser medium 4 is amplified by the stimulation while reciprocating between the resonators M 1 , M 2 and becomes a laser beam. Because of the multi-layer film 6 positioned inserted in the optical path, that of the beam from the laser medium 4 which is feeble is reflected astray from the optical axis of the resonators to be a loss. As the beam increases its intensity, the multi-layer film 6 increases its transmittances, which contributes to the laser oscillation. Eventually a pulse of the beam is restricted automatically in the resonators, and the beam can have a very short pulse duration.
Means for outputting outside the thus-generated pulsed laser beam is shown in FIG. 2. This means will be briefly explained.
In the pulsed laser beam source device of FIG. 1, in the case that the resonator mirrors M 1 (M 2 ) is partially light transmitting, the output beam indicated by the broken lines a1 (a2) is obtained.
The design of the multi-layer film 6 will be briefed below.
The phenomenon that a refractive index changes depending on a light intensity is determined by a third-order non-linear susceptibility (non-linear index coefficient) χ.sup.(3). A refractive index n of mediums is expressed by
n=n.sub.c +n.sub.v I
where n c represents a refractive index of the medium independent of a light intensity, and n v represents a constant for changes of a refractive index of the medium in PG,7 proportion with an light intensity I.
When n v is expressed by χ.sup.(3),
n.sub.v [cm.sup.2 /W]=16π.sup.2 ·χ.sup.(3) [esu ]/(c·n.sub.c.sup.2)×10.sup.7 (1)
is given. c represents a light velocity (3×10 10 cm/s). As seen from the equation (1), the use of a medium with a high χ.sup.(3) greatly changes a transmittance (or reflectivities) of the multi-layer film 6.
Organic thin films as the high χ.sup.(3) -medium are exemplified by
polydiacethylene (PDA):850×10 -12 [esu]
polyacethylene:400×10 -12 [esu].
Materials of the organic thin film are diacetylene-based compound polymers, polyolefine-based compound polymers, liquid crystal high molecules comprising poly(vinyl fluoride), etc. doped with dyes. The materials are specifically exemplified by, in addition to the above-described two kinds, polysilane, polyarylene vinylene, polyparaphenylene vinylene, polybenzothiazole, etc. Other main high χ.sup.(3) -organic thin films are detailed in "Parity", Vol. 04, No. 12, 1989-12. When n v is computed by the equation (1) with n c =1.5, polydiacetylene (PDA) has ##EQU1## polyacetylene has
n.sub.v =9.4×10.sup.-12 [cm.sup.2 /W].
Here is simulated a change of a refractive index for a case where pulsed laser beam with an 100 mW-average light intensity, a 1 ps-pulse width and a 100 MHz-recurrence is incident on the these mediums. The peak power of the incident beam is
100[mW]×10-8[sec]/10-12[sec]=1[kW].
It is more effective to condense by lenses the beam entering the multi-layer film for the increase of its power density.
A modification of the first embodiment is shown in FIG. 3. This modification includes, in addition to the members of FIG. 1, lenses 91, 92 inserted in the optical axis with the multi-layer film 6 inbetween. In this arrangement, when the condensation is, e.g., 10 μmΦ, a refractive index change n v I of PDA is expressed by ##EQU2## Thus it is shown that in the case where one of the film materials is PDA, when the beam with the above-described conditions is incident, it is possible to cause a refractive index change of about 2.5×10 -2 .
Next is simulated a case where the multi-layer film is formed of PDA with a refractive index of 1.5 and a different film material with a refractive index of 1.525, and has a layer number of 2N=400.
FIG. 4 shows a structure of the multi-layer film 6. Here it is assumed that an incident beam on the multi-layer film 6 has a λ-wavelength, an optical thickness of a layer with a refractive index n 2 is n 2 h 2 =λ/4, and an optical thickness of another layer with a refractive index n 3 is n 2 h 3 =λ/4. The reflectivity and the transmittance of the multi-layer film of FIG. 4 is ##EQU3##
Transmittance T=1-R.
Here, n 1 =n e =1, n 2 =1.525, and n 3 =1.500. And n 3 increases to be close to n 2 depending on intensity of incident light.
FIG. 5 is a graph of the reflection characteristic of the multi-layer film of FIG. 4. n 3 is a parameter. As seen from the graph, this multi-layer film is used, the pulsed laser beam source device of FIG. 1 is used, and the device is operated between Point A and Point B, whereby the transmittance rises as an intensity of the beam incident on the multi-layer film increases. That is, this multi-layer film can be used equivalently to a medium whose loss decreases as an intensity of incident beam increases. This multi-layer film is considered to be a effective device in pulsed laser oscillation.
As a material of the multi-layer film 6, semiconductor doped glass may be used. Since semiconductor doped glass has a third-order non-linear susceptibility χ.sup.(3) of about 1 -2 ˜10 -3 [esu], the multi-layer film of semiconductor doped glass can further lower a light density of the incident beam on the multi-layer film, and a number of the films can be reduced.
The semiconductor doped glass which has a higher susceptibility χ.sup.(3) as a material of the multi-layer film is SiO 2 , Si, or others, doped with an additive, e.g., CuCl, CuBr, CdTe, CdSe or others.
Another material with a lower susceptibility χ.sup.(3) constituting the multi-layer film in a pair with the material with a higher susceptibility χ.sup.(3), that is, the another material with substantially linear susceptibility with respect to light intensity, is exemplified by SiO 2 , Si, ZnS, MgF, NaF, BaF 2 , As 2 S 3 , SrF 2 , ThF 4 , CaF 2 , PbF 2 , AgCl, etc. These materials as the main components are doped with conventionally known additives for changing reflectivities to obtain thin films with required reflectivites.
Cases where organic materials, semiconductor doped glass, etc. are used as materials of the multi-layer film involve the problem of a relaxation time (response time) of the materials. That is, the use of materials with shorter relaxation times of the susceptibility χ.sup.(3) is more effective for shorter-pulsed oscillation.
FIG. 6 shows a structure of the pulsed laser beam source device according to a second embodiment of this intention. The pulsed laser beam source device according to the second embodiment has a ring-shaped resonator structure (ring cavity). The ring-shaped resonator includes three resonators mirrors M 10 , M 20 , M 30 . the same light source for optical pumping 2, laser medium 4, etc. as in the first embodiment are used. It is preferable that a distance between the multi-layer film of this embodiment and the laser medium is 1/4 a cavity length.
FIG. 7 shows the pulsed laser beam source device according to a third embodiment of this invention. In the pulsed laser beam source according to the third embodiment, the same pulsed laser beam source 2 and laser medium 4 as in the first embodiment are used, and the multi-layer film M 4 functions as one of a pair of resonator mirrors. This pulse laser beam source device may further comprise a lens 93 inserted in the optical axis. Therefore, it is more effective to condense by this lens 93 the beam entering the multi-layer film M 4 for the increase of its power density. Of course, the lens 93 may be omitted from the pulse laser beam source device.
A pair of resonator mirrors is constituted by the multi-layer film M 4 and an output mirror M 5 . As in the first embodiment, the multi-layer film M 4 is formed of two different kinds of layers alternately laid one on another. A refractive index ratio of the two kinds of layers changes depending on an intensity of the incident beam. But in the multi-layer film M 4 , the two kinds of layers have substantially the same refractive index in the absence of incident beam, and in the presence of incident beam, a refractive index of one of the layers greatly changes. Eventually the multi-layer film M 4 lowers its reflectivity with respect to feeble incident beam, with the result of larger reflection loss, and with respect to incident beam of high intensities the multi-layer film M 4 lowers its reflectivity, with the result of smaller reflection loss. The use of this reflectivity characteristic of the multi-layer film M 4 enables only beam of high intensities from the laser medium 4 to be oscillated, and pulsed laser oscillation can be obtained.
FIG. 8 shows a fourth embodiment of this invention. The fourth embodiment further comprises a dye jet 10 inserted in the optical axis in the first embodiment. The provision of condensation lenses sandwiching the dye jet 10 can further improve the efficiency. The dye jet 10 is conventionally known. According to the pulsed laser beam source device according to this embodiment, the multi-layer film 6 and the dye jet 10 can synergetically generate pulsed laser beam with shorter pulse durations.
Here the relationships between the oscillation wavelength λ of the laser beam, and film thicknesses of the respective layers of the multi-layer film will be explained. The layer thicknesses of the respective layers are represented by h 2 , h 3 , and reflectivities of the respective layers are represented by n 2 , n 3 . It is preferable that the multi-layer films of the first and the second embodiments satisfy the condition
n.sub.2 h.sub.2 =n.sub.3 h.sub.3 =λ/4
when an incidence intensity is low. When this condition is satisfied, the multi-layer film can efficiently reflect light (beam) with low incidence intensities and can efficiently transmit light (beam) with high incidence intensities.
It is preferable that the multi-layer film of the third embodiment satisfies the condition
n.sub.2 h.sub.2 =n.sub.3 h.sub.3 =λ/4
when an incidence intensity is high. When this condition is satisfied, the multi-layer film can efficiently reflect light (beam) when the incidence intensity is high and can efficiently transmit light (beam) when the incidence intensity is low.
These conditions are for a case in which the beam is perpendicularly incident on the multi-layer film. In a case in which the beam is not perpendicularly incident on the multi-layer film, the layer thicknesses satisfying the above-described conditions are effective layer thicknesses which are optical distances corresponding to incident angles. That is, a positional angle of the multi-layer film with respect to the optical axis can be adjusted to change a virtual layer thickness, with the result that the multi-layer film is applicable to laser beams whose wavelengths are variable.
A frequency (f) of a pulse is determined by a cavity length. For example, in the first embodiment, a frequency
(f=1/a recurrence period) of a pulse is represented by f=c/2L
where an optical distance between the resonator mirrors M 1 , M 2 is indicated by L, and a light velocity is denoted by c. To be specific, with a cavity length L of 3 [m],
f=3×10.sup.8 [m/sec]/2×3 [m]=50 [MHz].
In the case of the second embodiment, which includes the ring cavity, f=c/L' when an optical distance of one period is L'. To be specific, with a cavity length L' of 3 [m],
f=3×10.sup.8 [m/sec]/3[m]=100 [MHz].
The pumping light may be pulsed light or continuous wave light. In a case that the pumping light is pulsed light, it is preferable that a frequency of a pulse of the pumping light is a multiple of an integer or a fraction of an integer.
It is possible to dispose extra means for selecting pulsed light (e.g., a cavity damper) for selecting required pulsed light out of a train of pulses. That is, a frequency can be varied.
This invention is not limited to the above-described embodiments. For example, the third embodiment may have the multi-layer film deposited directly on the laser medium.
As the laser medium, conventionally known various mediums are usable.
The pulsed laser beam source device may include a mechanism (e.g., a mode locker, galvanomirror, etc.) for changing a resonating state for a CW laser oscillation being followed by a pulsed oscillation.
This invention may use a mirror formed of films having randomly different refractive indexes which are changed by incident beam, and a reflectivity is changed.
As described above, according to the pulsed laser beam source device, a transmittance or a reflectivity of the multi-layer film changes depending on intensities of the incident beams. By using this, pulsed beams whose pulse durations are extremely small can be obtained. Furthermore, this invention uses the multi-layer film for passive mode locking, which enables pulse beams to be generated easily and stably.
From the invention thus described, it will be obvious that the invention may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | An object of this invention is to provide a pulsed laser beam source device which is easy to handle and is operative stably. Pumping light is irradiated to a laser medium from a light source for optical pumping. The stimulated laser medium pumps radiation of a set wavelength. This radiation is stimulated to be amplified while reciprocating between resonator mirrors. A multi layer film is inserted in an optical path of the radiation. Feeble light of the radiation from the laser medium is absorbed by the multi-layer to be weaker, and that part of the radiation having intensities above a set intensity is compressed in terms of time to be emitted outside. The emitted radiation has a very short pulse duration. | 7 |
CROSS-REFERENCE
The present application claims priority to European patent application No. 07021291.5, filed 31 Oct. 2007, which is incorporated herein by reference as if fully set forth herein, and is the national stage of PCT/EP2008/009183, filed Oct. 30, 2008.
TECHNICAL FIELD
The present disclosure relates to an apparatus for controlling valve displacement of an internal combustion engine and, more particularly, to an apparatus for adjusting or delaying the closing of inlet valves of an internal combustion engine, in particular diesel and gasoline engines.
BACKGROUND
In order to reduce NOx emissions from diesel and gasoline engines, it is known to use the “Miller process” to cool or reduce the combustion temperature. According to this process, a cooling effect is achieved by closing the intake valves very early. The subsequent expansion of the volume of gas in the combustion chamber lowers the temperature of the fresh gas mixture and the cylinder filling loss of the charged engine is compensated by an increased charging pressure generated by a turbocharger.
For transient engine conditions, in which the loaded engine must generate increased power/torque within a short time, shutting-off the Miller process is very helpful. This can be achieved by displacing the inlet cam profile by rotating the cam shaft relative to the crankshaft or by displacing the cam on the cam shaft or by modifying the coupling of the cam/valve. In all cases, a valve-opening overlap and thus evacuation of the cylinders is reduced by displacing the cam profile.
In EP 1 477 638 A1A, a device for variably controlling the opening and/or closing of inlet and/or exhaust valves of an internal combustion engine of the above-mentioned type is disclosed. This known device is adapted to delay the closing of inlet valves of an internal combustion engine, and includes a damping device integrated in a guide rod for guiding a valve actuation bridge during its up and down motion. Hence, the damping device is an integrated part of the valve actuation bridge. More particularly, in this known device, an annular recess is disposed between a guide rod of a piston and a cylinder sleeve. The annular recess is in fluid communication with an axial bore axially extending within the guide rod via a transverse bore. One end of a tap bore opens or discharges into the axial bore of the guide rod. The other end of the tap bore is in fluid communication with valve units via oil-supply lines. More particularly, the tap bore is connectable with a lubricating oil-supply port as a function of the valve position of the gas exchange valves either via a first oil-supply line controlled by a valve unit, which includes a passage and shutoff valve, or via a second oil-supply line controlled by a second valve unit, which includes a one-way valve and a throttle. Thus, controlling of the gas exchange valves as a function of the closed position and/or the opened position can be achieved by means of the valve units having the correspondingly-designed valves.
When the gas exchange valves are closed, lubricating oil contained in the annular recess can be supplied into a further valve unit via the axial bore and the tap bore, as well as via an oil-supply line. In addition, when the valve is closed, the lubricating oil can be supplied into the valve unit having the throttle so that the intake valves will assume a delayed position. In contrast, when the gas exchange valves are in a delayed position, the free or terminal end of the rocker arm that is opposite of the valve actuation bridge is pivoted about the rotational axis towards the rocker arm by means of a telescoping member, which is spring-biased and guided in the push-rod, without any play or clearance therebetween.
However, the device disclosed in EP 1 477 638 A1 requires construction space between the two inlet and/or exhaust valves and its associated springs. Furthermore, due to the integration of the damping device in the guide rod of the valve actuation bridge, the known device requires a guide rod.
U.S. Pat. No. 3,520,287 discloses an exhaust valve control for an engine braking system which also includes an arrangement having a guide rod slidably mounted on a valve actuation bridge. The valve actuation bridge and the guide rod together define a hydraulic chamber that expands when the valve bride advances to open the exhaust valves and contracts when the valve actuation bridge retracts to permit the two exhaust valves to be closed by the exhaust valve springs. Again, a damping device is integrated into the guide rod and is part of the valve actuation bridge. Hence, like the above arrangement, a construction space between the two valves is necessary and this known assembly requires a guide rod.
U.S. Pat. No. 6,905,155 discloses an apparatus for limiting the travel of a slave piston in a slave piston cylinder in a compression release engine retarder. The apparatus is connected to a hydraulic circuit and an internal passageway is defined in the slave piston head. The internal passageway comprises a vertical bore, a horizontal bore and an annular channel which together define a path for bleeding off the pressure at the top of the slave piston when the annular channel and an aperture in the slave piston cylinder are aligned. By bleeding off the hydraulic pressure at top of the slave piston, the motion of the slave piston is restricted to a desired stroke. The apparatus includes a locking adjustable foot on the slave piston stem which provides a means for adjusting the lash. Here, the known arrangement for actuating at least one engine valve requires a minimum space above the valve actuation bridge and the rocker arm.
US 2005/0121008 A1 discloses a method and apparatus for controlling a temperature in a combustion cylinder in an internal combustion engine. A rocker arm is located to move about a pivot. A push-rod provides a mechanical force against the rocker arm. An electro-hydraulic assist actuator may include a plunger assembly for providing a hydraulic force used to vary the open duration of an intake valve. In particular, the electro-hydraulic assist actuator may be used to hold the intake valve open for a period of time longer than a cam is designed to do. The plunger assembly may be located at the same side of the rocker arm as the push rod. In addition, the plunger assembly is designed to provide a mechanical force during a first rotating direction of the rocker arm. A reverse rotating direction of the rocker arm has no impact on the plunger assembly. Consequently, the known plunger assembly may be relatively slow and the reaction time could be relatively long.
US 2003/0221644 A1 shows a similar engine valve actuation system including a fluid actuator configured to selectively prevent an intake valve from moving in a first position.
Other arrangements are known from, e.g., DE 102 39 750 A1, US 2005/0121637, US 2004/0065285 A1, WO 2004/005677 A1, WO 87/07677.
The present disclosure is directed, at least in part, to improving or overcoming one or more aspects of prior devices and methods for controlling valves and, more particularly, of apparatus for adjusting or delaying the closing of inlet valves of an internal combustion engine.
SUMMARY OF THE DISCLOSURE
According to a first exemplary aspect of the present teachings, an apparatus for controlling valve displacement of an internal combustion engine comprises a rocker arm having a first arm portion and a second arm portion, said rocker arm being pivotable about a pivot interposed between said first and second arm portions. Said apparatus further comprises an actuation arrangement adapted to actuate said first arm portion of said rocker arm and a valve arrangement adapted to be actuated by said second arm portion of said rocker arm. A damper arrangement may be pivotably connected to said first arm portion and adapted for damping movement of said rocker arm around said pivot.
In a further exemplary embodiment of the disclosed apparatus said rocker arm may be pivotable about the pivot in a first rotating direction and a second rotating direction which is reverse to the first rotating direction. Said damper arrangement may be hydraulically operated by means of a hydraulic fluid and pivotably connected to said first arm portion so that movement in said first rotating direction of said rocker arm around said pivot is damped and during movement in said second rotating direction of said rocker arm said hydraulic fluid is sucked. The suction of the hydraulic fluid may be caused by the movement in said second rotating direction of said rocker arm and the pivotable or articulated or hinged connection of the damper arrangement to the rocker arm.
A further exemplary embodiment may comprise a push-rod adapted to be reciprocated, e.g. by a valve cam and a rotational drive, a rocker arm pivotable about a rotational axis, a valve actuation bridge and a damper arrangement adapted to damp the pivoting motion of the rocker arm during movement of valves, preferably during a closing of one or more of the engine valves. In this exemplary embodiment a first arm portion of the rocker arm extends from the rotational axis to a first free end of the rocker arm and a second arm portion of the rocker arm extends from the rotational axis to a second free end of the rocker arm opposite the first free end. The first arm portion of the rocker arm may be driven by the push-rod. The valve actuation bridge may be driven by the second arm portion of the rocker arm and may connect to respective valve shafts of the valves. The damping device acts on the first arm portion of the rocker arm driven by the push-rod. The valves may comprise one or more inlet valves and/or one ore more outlet valves. In one exemplary embodiment of the present teaching the damper arrangement causes a delay of the closing of inlet valves.
According to another exemplary aspect of the present teachings, a method of controlling at least one combustion chamber valve associated with a rocker arm may comprise rotating said rocker arm about a pivot interposed between first and second arm portions for actuating at least one combustion chamber valve and damping the rotation of said rocker arm with a damper arrangement jointly connected to said first portion of said rocker arm. According to a further exemplary embodiment of the disclosed method, the method may further comprise rotating said rocker arm about said pivot in a first rotating direction and simultaneously applying a force to said first arm portion of said rocker arm so that movement of said rocker arm around said pivot in said first pivoting direction is damped. Rotating the rocker arm about said pivot in a second rotating direction which is reverse to said first rotating direction may cause sucking said hydraulic fluid.
According to another exemplary aspect of the present teachings, a method of controlling at least one combustion chamber valve associated with a rocker arm may comprise rotating said rocker arm about a pivot interposed between first and second arm portions for actuating at least one combustion chamber valve and damping rotation of said rocker arm with a damper arrangement connected to said first portion of said rocker arm.
According to another exemplary aspect of the present teachings, an internal combustion engine comprises an apparatus for controlling valve displacement of said internal combustion engine. Said apparatus includes a rocker arm, said rocker arm being pivotable about a pivot interposed between first and second arm portions. Furthermore, an actuation arrangement for applying a force to said first arm portion of said rocker arm and a valve arrangement actuated by said second arm portion of said rocker arm are comprised. Finally, a damper arrangement is pivotably connected to said first arm portion and damps a movement of said rocker arm around said pivot.
As utilized herein, the terms “damping unit” and “damper arrangement” or similar terms used throughout the description are intended to cover any kind of apparatus/device that imparts a resistive decelerating force to the reciprocating movement of any kind of valves.
Representative, but not limiting, examples of suitable damper arrangements in accordance with the present teachings may include hydraulic and pneumatic cylinders, such as e.g. utilized for shock absorbing applications. In some embodiments, a spring or other resilient elastic materials or devices may be suitably utilized, particularly, if the elastic return force can be changed in operation.
Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
It is to be understood that forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an exemplary embodiment of the disclosure and, together with the description, serve to explain the principles of the disclosure. In the drawings,
FIG. 1 is a schematic illustration of a first preferred exemplary device for variably controlling the closing of inlet and/or exhaust valves of an internal combustion engine;
FIG. 2 is a schematic diagram of the hydraulic system connected to a damping unit as part of the exemplary device for variably controlling the closing of inlet and/or exhaust valves shown in FIG. 1 ;
FIG. 3 is a perspective view of a second exemplary device for variably controlling the closing of inlet and/or exhaust valves of an internal combustion engine;
FIG. 4 is a side view of the device of FIG. 3 ;
FIG. 5 is a sectional view of the device of FIGS. 3 and 4 ;
FIG. 6 is a perspective view of a part of the device shown in FIGS. 3-5 ;
FIG. 7 is a sectional view of the device of FIG. 6 ; and
FIG. 8 is a sectional view along line VIII-VIII of FIG. 7 .
DETAILED DESCRIPTION
Reference will now be made in detail to the exemplary embodiments of the present teachings, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.
Referring to FIG. 1 , an exemplary device 100 for variably controlling the opening and/or closing of inlet and/or exhaust valves 180 of an internal combustion engine (not shown), for example, a four-stroke diesel engine, is provided. The valve control device 100 may include a rocker arm 110 that may be rotatable about a rotational axis 115 . The rocker arm 110 has a first arm portion 111 extending from the rotational axis 115 to a first free end 112 of the rocker arm 110 , and a second arm portion 113 extending from the rotational axis 115 to a second free end 114 of the rocker arm 110 . The second free end 114 is opposite the first free end 112 of the rocker arm 110 .
In addition, the valve control device 100 may include an actuation arrangement. This actuation arrangement may comprise a push-rod 120 . A free end 128 of the push-rod 120 may be in contact with the free end 112 of the rocker arm 110 . The push-rod 120 may be driven by any arrangement. In one exemplary embodiment the push-rod 120 may be driven by a valve cam (not shown) and a rotational drive (not shown). However, since such a drive device for of the push-rod 120 is well known, a detailed explanation of this kind of drive device is omitted.
As shown in FIG. 1 , a valve actuation bridge 160 may be in contact with the second free end 114 of the rocker arm 110 . The valve actuation bridge 160 may have a guide rod 170 for guiding the valve actuation bridge 160 during up-and-down reciprocating motion for opening and/or closing the inlet and/or exhaust valves 180 . The valve actuation bridge might be omitted if e.g. only one valve is to be actuated.
The exhaust valves 180 may include valve discs 190 and valve shafts 185 . In one exemplary embodiment the valve shafts 185 are coupled with the valve actuation bridge 160 . A helical spring 165 may be arranged on each valve shaft 185 for urging the valve discs 190 towards respective valve seats 191 (see e.g. FIG. 5 ).
Furthermore, the valve control device 100 may include a damper arrangement or damping unit 130 for applying a damping force to the first rocker arm portion 111 of the rocker arm 110 during pivoting of the rocker arm 110 in a first pivoting direction shown by arrow 210 . By pivoting of the rocker arm 110 in the first pivoting direction of the arrow 210 , the valves 180 may be forced towards their respective valve seats 191 (see FIG. 5 ) and therefore in the direction for closing the valves 180 . The arrow 215 illustrates a second pivoting direction of the rocker arm 110 about the rotational axis 115 for opening the valves 180 , i.e. the valve discs 190 move away from their respective valve seats 191 . The damping unit 130 may include a piston 145 having a piston-rod 150 . In one exemplary embodiment the piston 145 is slidably supported in a housing 146 . The piston 145 , in combination with the housing 146 , may define a fluid chamber 140 which is in fluid communication via an oil-supply line 305 with a hydraulic system 300 schematically shown in FIG. 2 .
In FIGS. 2 and 3 , one exemplary embodiment the hydraulic system 300 is schematically shown. This hydraulic system 300 may be in fluid communication with the damping unit 130 of FIG. 1 . The hydraulic system 300 may include a control valve or shut-off valve 310 , an throttle 315 and a check valve 320 . This elements 310 , 315 and 320 may be arranged in parallel by fluid supply lines 305 , 330 . In one exemplary embodiment the fluid supply lines 305 , 330 may be adapted to supply oil and the throttle 315 may be adapted to be adjustable. As was already mentioned above, the supply line 305 may end in the fluid chamber 140 of the damper arrangement 130 . The supply line 305 may also connect with the shut-off valve 310 . In one exemplary embodiment the shut-off valve 310 may comprise a solenoid valve. It may be in fluid communication via the supply line 330 with a supply system 350 of the internal combustion engine. In one exemplary embodiment the supply system 350 may comprise a lubricating oil system.
The throttle 315 may connect with the supply line 305 and the oil-supply lines 330 and 340 . The check valve 320 may also connect with the supply lines 305 , 330 and may be arranged parallel to the throttle 315 . Hence, the fluid, e.g. oil, can flow into a collecting reservoir 335 via a bleed line (also denotes as “blood-line”). The bleed line may be connected to the supply lines 330 , 340 . Finally, the supply lines 305 , 330 and, hence, the valve 310 , the throttle 315 and the check valve 320 are connected via the oil line 340 with e.g. the engine lubrication oil system 350 as is schematically illustrated. In FIG. 3 an lubricating oil inlet and outlet port 340 are shown.
Referring now to FIGS. 3-8 , an exemplary embodiment of a valve control device 100 is explained in more details.
As shown in FIGS. 3 to 5 , the device 100 includes the push-rod 120 having a connecting part 122 , a telescoping device 124 for gap-compensating and a hollow rod member 126 closed by a cap 128 . Referring to FIG. 5 , further details of the telescoping member 124 of the push-rod 120 will now be explained. In one exemplary embodiment, a rod part of the push-rod 120 is integral with the rod member 126 of the push-rod 120 . The outer diameter of the rod part may be greater than the outer diameter of the rod member 126 for accommodating a cylindrical sleeve 125 , which receives a helical spring 127 and a cap 123 . The spring 127 may rest on a ring-shaped projection 121 of the cylindrical sleeve 125 . On the opposite side of the helical spring 127 , the helical spring 127 urges against the cap 123 . The outer end of the cap 123 may be hemispherical. Due to the telescoping device 124 , any gap or play occurring during pivoting of the rocker arm 110 may be compensated.
As shown in FIG. 3 , in one exemplary embodiment two valve bridges 160 are pivotably arranged above a cylinder head 101 having an air inlet 102 and a connecting flange 103 for mounting the cylinder head 101 at an engine housing (not shown). For illustration purposes, only one push-rod 120 is shown. However, the second rocker arm 110 may be, like the first rocker arm 110 , adapted to be driven by a push-rod 120 . The second rocker arm 110 acts on a further valve actuation bridge (not shown) which contacts a pair of outlet valves (not shown). The second rocker arm 110 may also preferably include a damping device 130 like the first rocker arm 110 as shown in FIG. 3 .
The first rocker arm 110 may be pivotably arranged about an axis 115 and its free end 114 may contact the valve actuation bridge 160 . As can be seen in FIGS. 3 and 4 and, in particular in FIG. 5 , in one exemplary embodiment two inlet valves 180 are adapted to rest on the respective seat 191 in the cylinder head 101 . Each valve shaft 185 may be biased upwards by a valve spring 165 . The arrangement of the valves 180 and their respective contacts with the valve actuation bridge 160 is basically known and therefore, a detailed explanation thereof is omitted.
The damping unit 130 shown in FIGS. 3-8 includes in one exemplary embodiment a guiding sleeve 146 sealingly arranged in the piston housing 143 . The piston-rod 150 may extend through the guiding sleeve 146 and may be adapted to reciprocate within the guiding sleeve 146 . A seal 151 arranged in the inner circumference of the guiding sleeve 146 may contact the outer surface of the piston-rod 150 such that an oil-leakage is prevented. As shown for example in FIG. 6 , a joint 410 may be provided on the end 152 of the piston-rod 150 . At this joint 410 , a forked lever 400 may be rotatably connected to the piston-rod end 152 . The forked lever 400 may have two fork parts 411 . A bearing member 117 of the rocker arm 110 may be arranged between the two spaced apart fork parts 411 . At this point, a joint connection 405 may be provided between the rocker arm 110 and fork parts 411 . Due to this arrangement, the reciprocating motion of the piston-rod 150 may be transferred to the rocker arm 110 such that the rocker arm 110 rotates about the rotational axis 115 .
A more detailed illustration of the assembly of the damping unit 130 and the rocker arm 110 is provided in FIGS. 6-8 . As shown, in one exemplary embodiment the piston housing 143 includes the guiding sleeve 146 . The end of the piston-rod 150 may extend through the guiding sleeve 146 . The forked lever 400 may be rotatably connected to the end of the piston-rod 152 as well as to the first arm portion 111 of the rocker arm 110 . In FIGS. 6 and 8 , the contacting members 116 of the two rocker arms 110 are shown, which contacting members 116 may contact the push-rod 120 (see FIGS. 1 , 3 and 4 ). The second free end 114 of the second arm portion 113 may have a contacting member 161 , which in one exemplary embodiment is part of the rocker arm 110 or of the valve actuation bridge 160 .
INDUSTRIAL APPLICABILITY
Referring to FIGS. 1 and 2 , an exemplary embodiment of a method for operating the exemplary embodiment of an apparatus 100 for variable controlling at least one engine valve 180 shown e.g. in FIGS. 3-8 will now be explained.
During normal operation, the push-rod 120 is actuated by a valve cam and a rotational drive (both not shown), thereby rotating the rocker arm 110 around the rotational axis 115 . During the upward movement of the push-rod 120 , the rocker arm 110 is urged to rotate around rotational axis 115 as indicated by arrow 215 . As a result, the valve actuation bridge 160 , which is vertically movably supported by the guide rod 170 , is being pivotably displaced or rotated against the biasing force of the valve springs 165 and the two intake valves 180 open in parallel, i.e. the valve discs 190 move away from the respective valve seats 191 , as shown in FIG. 5 . Consequently, during the downward movement of the valve actuation bridge 160 , the piston-rod 150 of the damping unit 130 is urged to move upwards due to the joint connection with the first arm portion 111 of the rocker arm 110 via the forked lever 400 . At the same time, the volume of the fluid chamber 140 increases and pressurized motor lubricating oil fills this increasing volume in an unthrottled manner via the oil-supply line 305 and the shut-off/passage valve 310 , because the check valve 320 is opened in the filling direction and the shut-off/passage valve 310 is in the position shown in FIG. 2 . As a result, the pivoting of the rocker arm 110 in the direction indicated by arrow 215 may not delayed. In particular, the positive connection, e.g., the pivot connection or hinge connection with the rocker arm 110 via, e.g., the lever 400 may generate a suction effect in the fluid chamber 140 for at least assisting the filling process of the fluid chamber 140 with fluid. Consequently, the filling process of the chamber with hydraulic fluid may be improved. In another exemplary embodiment the pivoting of the rocker arm 110 in the direction indicated by arrow 215 may be delayed with the aid of the damper arrangement 130 .
The biasing force of the valve springs 165 may cause the valves 180 , the valve actuation bridge 160 , the rocker arm 110 , the push-rod 120 to remain in series connection during this time.
The closing of the intake valves 180 may be initiated when the not-illustrated rotational drive and the push-rod 120 move downward in accordance with the further rotation of the not-illustrated cam profile. At this time, the valve actuation bridge 160 may be displaced upward by e.g. the biasing force of the valve springs 165 , whereby the volume in the fluid chamber 140 may be reduced and the lubricating oil located in the fluid chamber 140 is discharged to the lubricating oil-supply system 350 via the oil-supply lines 305 and 340 in an unthrottled throttle manner via the opened shut-off/passage valve 310 . On the other hand, when the shut-off/passage valve 310 is closed, i.e. in the shut-off position during the closing motion of the intake valves 180 , the discharge of the lubricating oil from the fluid chamber 140 no longer takes place in an unthrottled manner via the shut-off/passage valve 310 . Instead, the lubricating oil may be discharged via the throttle 315 . Consequently, the upward movement of the valve actuation bridge 160 may be hindered, damped or delayed because the cross section of the throttle 315 is restricted. As a result, in one embodiment the upward stroke of the valve actuation bridge 160 and, consequently, the closing of the intake valves 180 may be damped/delayed by e.g. reducing the throttle cross section of the throttle 315 .
Due to the arrangement and construction explained above and shown in the figures, in one exemplary embodiment a predetermined damping of the closing of the inlet and/or exhaust valves 180 can be achieved. Contrary to the known art, in which the delay device is integrated in the valve actuation bridge and the associated guide rod, the presently preferred embodiment maybe used for e.g. two and/or e.g. four valve cylinder heads with or without a guide-rod because in one exemplary embodiment the damper arrangement is disposed on the same side of the rocker arm 110 as the push-rod 120 . Therefore, in one exemplary embodiment the damper arrangement 130 may be installed independently of the structure and design of the valve actuation bridge. A further advantage may be that maintenance of the valve control devices 100 is easier than of prior art devices, because in one exemplary embodiment for example the damper arrangement may be replaced without substantial disassembly.
Although the preferred embodiments of this disclosure have been described herein, improvements and modifications may be incorporated without departing from the scope of the following claims. | An apparatus for controlling valve displacement of an internal combustion engine comprises a rocker arm having a first arm portion and a second arm portion, said rocker arm being pivotable about a pivot interposed between said first and second arm portions. The apparatus further comprises an actuation arrangement adapted to actuate said first arm portion of said rocker arm and a valve arrangement adapted to be actuated by said second arm portion of said rocker arm. A damper arrangement is pivotably connected to said first arm portion and adapted for damping movement of said rocker arm around said pivot. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a manual tool for slitting a polymeric endless power transmission belt body which has a plurality of endless V-belt elements by cutting between immediately adjacent elements to define a plurality of endless belts each having at least one belt element. It also relates to the method of performing the manual cutting.
2. Prior Art Statement
Endless power transmission belts made primarily of polymeric material are widely used in industry and there are many types of such belts including, for example, belts consisting of a single belt element and belts consisting of a plurality of belt elements which are fastened together as a unitary structure in spaced side-by-side relation and referred to as multiple-element belts. These multiple-element belts are of two main types, i.e., ribbed belts and banded belts.
However, regardless of whether such polymeric belts are of the single element or multiple element type, they are usually cut from belt sleeves each having a large number of belt elements; and, numerous power driven belt cutting machines are known in the art and used to cut such belt sleeves.
Multiple elements belts, such as banded belts, are used in applications where it is necessary to transmit large loads or forces and often require a plurality of from two to six elements in a particular banded belt. However, it is costly for a local operator, such as a warehouse operator, belt distributor, or field user to provide an inventory of banded belts of each size and having two, three four, five, and six belt elements. Accordingly, it would be desirable to stock each particular size of banded belts which is used most often in its maximum number of available belt elements and then cut same to define a banded belt having the required lesser number of elements for a specific application. It would be particularly desirable to provide the cutting without the need for special machinery.
As indicated above, power driven belt cutting machines for cutting belt sleeves are known and could be used by a local operator to provide the above-described cutting. Similarly, power driven machines of various types have also been proposed for cutting multiple element banded belts. However, such machines are expensive and basically impractical for a local operator. Typical cutting machines of this type are described in U.S. Pat. No. 3,818,576 issued to Braden et al; and U.S. Pat. No. 4,322,916 issued to Richmond.
It has also been known to hold the cutting member in a fixed position and to move the belt body against the member to accomplish the desired cut. One such arrangement is described by Howerton et al in U.S. Pat. Nos. 4,368,658 and 4,437,371 (division), utilizing a pair of rotatable wheels which fit in the grooves of the belt body and hold the knife blade between them. This assembly is mounted on a fixed support station.
U.S. Pat. No. 4,554,850, issued to Edgar et al, provides a knife blade held in a body which is supported on a movable carriage means to perform the cut when the belt body is moved toward the blade. The knife body is designed to fit within the belt body grooves in a manner similar to Howerton, et al.
SUMMARY OF THE INVENTION
The principal feature of the present invention resides in providing a manually held tool for cutting a polymeric endless power transmission belt body having alternating ribs and grooves so that a plurality of endless belts are formed having at least one rib each. The novel tool comprises a pair of holding members which retain the actual cutting blade, and a handle around the holding members by which the tool is held. The holding members are tapered to fit within the grooves to provide support while cutting.
A further feature of the invention provides for each end of the holding members to be formed of a different tip thickness to conform with belt body grooves of different widths, capable of holding a knife blade at either end in an operative position.
Another feature of the invention provides for the use of the novel tool in an environment lacking in special machinery, so that the operator can manually hold the belt body and perform the cutting.
Other objects, features, uses, details and advantages of the present invention will become apparent from the embodiments presented herein, with references to the following specification, drawings, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate the preferred embodiment of the invention, in which:
FIG. 1 is an isometric view of the novel cutting tool in one operative position;
FIG. 2 is an exploded isometric view of the novel cutting tool of FIG. 1;
FIG. 3 is a view similar to FIG. 1 with the cutting tool in the other operative position;
FIG. 4 is an isometric view illustrating an exemplary method of cutting the belt body without the use of special machinery.
FIG. 5 is an end view of the belt body with the cutting tool shown at the beginning of its cutting position, and a portion of mechanism for rotating the belt body.
DETAILED DESCRIPTION
Referring now to the drawings, the cutting tool is designated by reference numeral 11 and consists of a pair of holding members 12 and 13 retaining knife blades 15 and 15A at the ends thereof, and a handle 14 retaining the holding members. The holding members 12 and 13 are preferably made of a metal providing a minimum of friction, such as polished brass, but may also be made of a hard plastic material such as nylon, ABS or polycarbonate which may have friction reducing fillers incorporated therein. The handle 14 is preferably made of nylon, ABS. polycarbonate, or a similar material. The knife blades 15 and 15A are conventional steel blades of the type commercially available for cutting all types of materials, by means of sharpened edges 16 and 16A.
The holding member 12 is made of an elongated strip of material having a continuous flat upper surface 17 and angled at its ends 18 and 19 inwardly toward flat lower surface 20 to form angled end surfaces 21 and 22. The angled surfaces are also tapered inwardly from one side surface 23 toward the other side surface 24 to form a tapered surface 25 at end 18, and tapered surface 26 at end 19. The amount of taper is approximately 20° at each end. However, the surface 25 and side 23 at end 18 form a tip 27 having a thickness of approximately 0.025 inch; and the surface 26 and side 23 at end 19 form a tip 28 which is approximately 0.050 inch. The holding member 13 is similar to member 12, except that it is a mirror image of member 12. Upon assembly of the tool the side surfaces 23 of each member will face each other, and the tapered surfaces 25 at the ends 18 of both holding members will be oppositely and outwardly facing. Similarly, the tapered surfaces 26 at the ends 19 of both holding members will also be oppositely and outwardly facing. The reference numbers applied to member 12 are also applicable to member 13.
When the tool 11 is assembled, the knife blade 15 is placed between the surfaces 23 of the holding members with the edge 16 facing downwardly, the end of the blade extending beyond the tips 27 of the end 18. A slotted opening 29 in the blade is aligned with openings in the holding member, which are aligned with each other. Similarly, the knife blade 15A is placed between the holding members with the end of the blade extending beyond tips 28 of end 19. Holding member 13 has four countersunk openings 30, 31, 32 and 33, which are aligned with four tapped and threaded openings 34, 35, 36 and 37 in holding member 13. In order to mount knife blade 15, a air of flat head machine screws 43 are inserted through openings 30 and 31, through slot 29, and threaded into the openings 34 and 35 to secure the blade between the holding members. Similarly, blade 45 is mounted by inserting another pair of screws 43 through openings 32 and 33, through slot 29, and threaded into openings 36 and 37 to secure that blade in the same manner.
The handle 14 is formed of two similar handle halves 47 and 48. Handle half 47 has openings 38 and 39, into which are pressed threaded inserts 40. Handle half 48 has two countersunk openings 41 and 42 which are aligned with these inserts. In order to assemble the tool, the handle halves are placed around the holding members, which fit within recesses 46. A flathead screw 45 is inserted through opening 41 of the handle, through central opening 44 of the holding members; and threaded into the insert 40 pressed into opening 38. The screw is tightly threaded so that its flat surface is flush with the outer surface of the handle half 48. The assembly is thus completed as shown in FIG. 1. The tips 27 of the ends 18 of the holding members are tapered to form an included angle of approximately 40°, and have a width of approximately 0.050 inch. In this position the knife blade 15A and ends 19 of the holding members are covered by the handle.
When it is desired to mount the knife blade at the other ends 19 of the holding members, the screw 45 is removed and the handle halves are slid toward ends 18 so that ends 19 are exposed, as well as the other knife blade 15A. The screw 45 is then inserted through openings 42 and 44 and threaded into insert 40 in opening 39 to provide the assembly shown in FIG. 3. In this arrangement, the tips 28 of ends 19 also provide an included angle of approximately 40°, but these tips have a width of approximately 0.100 inch, compared to 0.050 of ends 18. The knife blade 15 and ends 18 are now covered.
METHOD OF OPERATION
One of the important features of the novel cutting tool is its adaptability for use in separating belt bodies into belts of pre-determined widths after the bodies are shipped from the factory to a distributor, wholesaler, or even the eventual customer. In such establishments there will be no special machines for use in conjunction with cutting the bodies, so an individual must be able to cut the desired belt by hand. To do this, he must be able to support the belt body from at least two points within the inner periphery, and move the cutting tool around the groove to sever or slit the body between adjacent ribs.
A typical example of such an operation is illustrated in FIG. 4 wherein the operator utilizes a fork lift truck 55 having a fork 56 over which a length of pipe 57 preferably about five inches in diameter is placed. The belt body 51 is hung over the pipe to support the upper portion thereof, and the operator merely steps on the lower diametrically opposite portion to hold it taut. He then holds the cutting tool in one hand and places it into a selected groove and then manually passes the knife blade through the groove to cut completely through the body, using his other hand to rotate the body as required to make the cut along the entire length of the groove. If the belt body is sufficiently taut by virtue of its weight, the operator may not need to step on the lower portion. The relationship of the cutting tool is shown in detail in FIG. 5, wherein a segment of the belt body 5 is shown.
The integral part of the body is tie band 52, to which is secured alternating ribs 53 and grooves 54. The grooves are tapered inwardly toward the tie band, and have a minimum width W at the tie band.
The cutting tool is held in place by hand, preferably at an angle of about 45° to the band, and gradually forced upward into the selected groove 54 to cut the belt body apart at that groove, in order to provide a belt having the desired number of ribs. As indicated above, the end 18 forms tips 27 whose width is 0.050 inch, which conforms to width W of the belt body grooves. The width W conforms with Standard groove widths for belts designated by the Rubber Manufacturers Association and the Mechanical Power Transmission Association as R3V, R5V, RB and RC. The angled sides of the grooves are slightly less than the 40° taper angle of the holding member tips ranging from about 34° to 38°, but readily supporting the tips to provide accurate positioning of the cutting blade centrally of the groove. The tip width thus conforms with the groove width W when the tool is inserted into the grooves.
When the tool is placed into the FIG. 3 position, the cutting operation is the same, except that tips 28, having a width of 0.100 inch, are utilized. This time the belts designated as R8V and RD are cut, these grooves having dimension W which conforms to this width. The belt body 51 illustrated is a banded belt having only a common tie band 52 to provide the unitary construction. As discussed above, however, the cutting operation equally applies to ribbed belts formed from ribbed belt bodies; both ribbed belts and banded belts falling in the general category of multiple-element belts.
The operation shown in FIG. 4 will normally be used with large and heavy belt bodies so that the fork lift takes the weight of the body during cutting. However, if a belt body is smaller and lighter in construction, it may not be necessary to use the fork lift truck. Instead the operator holds the upper portion of the belt body with one hand, for example the left hand if he is right-handed; and steps on the inside of the body to hold it taut. He then operates the tool with his right hand to cut in the manner described above, and rotates the body with his left hand while continuing the cut through the selected groove.
The novel cutting tool thus provides manual holding means for selectively cutting a belt body into a plurality of endless belts, having selectively operative cutting blades at opposite ends thereof.
While present exemplary embodiments of this invention, and methods of practicing the same, have been illustrated and described, it will be recognized that this invention may be otherwise variously embodied and practiced within the scope of the following claims. | A manually held tool for cutting a polymeric endless power transmission belt body having alternating ribs and grooves; the tool comprising a pair of holding members for holding knife blades, and a handle around the holding members. The holding members are angled to fit within the grooves, and taper from the body to the tip, each end of the members have a different tip thickness and either end may hold a knife blade to fit belt body grooves of different thicknesses and permit cutting through selected grooves to form a plurality of endless belts having at least one rib. The tool is particularly adapted to cut belt bodies in an environment lacking in special machinery so that an operator can hold the body manually while performing the cutting operation. | 8 |
TECHNICAL FIELD
The present invention relates to a doll. More particularly, the present invention relates to a doll having an internal religious image.
FIELD OF THE INVENTION
Dolls, such as baby dolls, having internal images are known. For example, U.S. Pat. No. 5,439,407 to Friedel discloses a doll with an imaging heart. The doll includes a translucent heart-shaped area in the chest portion to allow viewing of the interior of the doll. The interior of the doll includes a silhouette portion of an inner child or soul. A lamp inside the doll is located behind the silhouette portion to create a silhouette of a child. The purpose of the doll in Friedel is to encourage a user thereof to get in touch with that which is referred to in psychiatric literature as the “inner child”.
Another example of a doll with an internal image is described in U.S. Pat. No. 5,324,201 to Friedel. This patent discloses a doll with an internal cavity for storing icons and includes features for dissuading a person from practicing a vice. The internal cavity is accessible through a front hatch in the doll. Icons that remind the user of a particular vice may be placed in the internal cavity. Example icons that may be placed inside the doll include a plastic liquor bottle, a plastic pill jar, a cardboard box with plastic candies, a paper bank envelope, a teddy bear, a baby doll, a parent doll, a book of instructions or affirmations, and a replica of the doll. Thus, the purpose of the doll described in Friedel is to provide psychotherapy for a person with substance dependency or other psychological/physiological problems.
A variety of other known dolls have either internal or external image projection systems. For example, in U.S. Pat. No. 4,878,873 to Yamaguchi et al. a doll toy in the shape of a man holding a gun is disclosed. The doll toy includes an interior light source that projects a desired pattern onto the trunk and head of the doll. The pattern is overlaid on a frame inside the doll. When the light source is activated, the pattern is projected on the inner surface of the head and trunk. The pattern is also projected outside of the doll. As illustrated in FIG. 2 of Yamaguchi et al., the pattern 19 appears to be an electronic circuit board.
Another doll toy capable of projecting patterns outside of the doll is disclosed in U.S. Pat. No. 5,545,072 to Arad et al. According to Arad et al., a doll toy embodying an action character from the popular “X-Men” comic series is disclosed. The doll includes an internal projection system that projects images stored on a disk inside the toy onto a surface outside the toy. As illustrated in FIG. 6 of Arad et al., example images that are projected include monsters and aliens.
Yet another doll with an internal projection system is disclosed in U.S. Pat. No. 5,118,319 to Smith et al. According to Smith et al., a toy doll includes a self-contained light show. The doll includes a plurality of lights located on the exterior surface of the doll. The lights are activated in a predetermined sequence to give the appearance of a light show.
U.S. Pat. No. 3,693,281 to Wolf discloses a viewing kit for a model such as a model airplane. The viewing kit includes a lens and an aperture that allows the user to view the inside of the model airplane, such as the cockpit.
Various dolls of religious figures are also known. For example, U.S. Pat. No. 5,456,625 to Dumond discloses a doll formed in the likeness of Jesus Christ with movable head and extremities. According to Dumond, the doll of Jesus is provided with electrically conductive nails, which when inserted through the apertures in the hands of the doll mount the doll to a cross and close an electrical circuit, which illuminates a cross.
Another example of a religious doll is disclosed in U.S. Pat. No. 5,957,747 to Liggit. According to the '747 Patent, a doll is formed in the likeness of Jesus Christ. The doll includes a heart-shaped locket attached to the chest of the doll. Liggett states that a photograph of the intended user can be placed inside the locket to indicate to the user that Jesus loves the user.
While the above-mentioned prior art discloses dolls having internal images of therapeutic value, toy dolls having interior or exterior projection systems, and religious dolls, none of these dolls are designed to impart the feeling to a child that Jesus Christ or God is inside of the child. Thus, there exists a need for a doll with an internal image that communicates to the child that God or Jesus Christ is inside of all children. Such a doll is preferably constructed in a manner that reduces the need for complex internal electrical circuitry for viewing the image.
DISCLOSURE OF THE INVENTION
The present invention includes a doll, such as a baby doll, having an internal religious image. In a preferred embodiment, the internal image comprises a hologram. The hologram is positioned inside the chest portion of the doll. An aperture is located in the body of the doll proximally to the internal image to provide illumination and to allow viewing of the image. The image may be an image of Jesus Christ or other religious figure or symbol.
Accordingly, it is an object of the invention of provide a novel doll with an internal religious image.
It is yet another object of the invention to provide a novel doll with an, internal religious hologram.
It is another object of the invention to provide a novel doll with an internal religious image that is easy to manufacture.
It is yet another object of the present invention to provide a method for communicating to children the presence of God or Jesus inside of all children.
Some of the objects of the invention having been stated hereinabove, other objects will be evident as the description proceeds, when taken in connection with the accompanying drawings as best described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be explained in detail with reference to the accompanying drawings of which:
FIG. 1 is a perspective view of a doll having an internal religious image according to an embodiment of the present invention;
FIG. 2 is a sectional view of a doll having an internal religious image according to an embodiment of the present invention; and
FIG. 3 illustrates an example of a religious image that may be included in a doll according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of a doll having an internal religious image according to an embodiment of the present invention. In FIG. 1, doll 100 is a baby doll. As such doll 100 includes a body including a head portion 102 , a torso portion 104 , arms 106 , and legs 108 . Torso portion 104 includes aperture 110 to allow illumination and viewing of religious image 112 located in the interior region of doll 100 . In a preferred embodiment of the invention, image 112 comprises a hologram. Doll 100 can be constructed of any suitable material, such as rubber, plastic, ceramic, wood, or any combination thereof.
FIG. 2 is a sectional view of the head and torso portion of doll 100 illustrated in FIG. 1 . In FIG. 2, arms 106 are omitted to facilitate explanation of the interior region of doll 100 . In the illustrated embodiment, doll 100 includes interior region 200 . Religious image 112 is located in interior region 200 . Support structure 202 holds image 112 proximally to aperture 110 . Support structure 202 also provides a passageway for light to illuminate image 112 and facilities viewing of image 112 from outside of doll 100 . In a Preferred embodiment of the invention, support structure 202 comprises a rigid cylinder. For example, support structure 202 may be made of hard plastic or other rigid material.
Aperture 110 is preferably covered by translucent member 204 . Translucent member 204 may be variously configured. For example, translucent member 204 may simply be a sheet of clear plastic that matches the contour of doll 100 . In an alternative embodiment, translucent member 204 may comprise a lens, such as a convex lens, to facilitate viewing of image 112 . In such an embodiment, image 112 may be located at the focal point of convex lens 204 . In yet another alternative embodiment, translucent member 204 may be omitted to allow maximum illumination of image 112 .
As stated above, according to a preferred embodiment of the invention, image 112 is preferably a hologram. A hologram is a light wave interference pattern recorded on photographic film or other suitable surface that can produce a three-dimensional image when illuminated properly. The hologram can be created by illuminating a three-dimensional model with a split beam, red krypton laser. One beam from the laser, referred to as the object beam, illuminates the model. The other beam, referred to as the reference beam, illuminates a specially coated glass plate. The laser beams meet to create a microscopic diffraction pattern, which is recorded on the glass plate and used to transfer the image onto a holographic film. The diffraction foil is created by cutting thousands of tiny grooves into an embossing plate. These closely spaced parallel grooves in an embossing plate reflect the light into all colors of the spectrum.
Using a religious hologram inside of the doll provides a number of advantages. First, no light source is required to illuminate the hologram from behind. A hologram can be completely illuminated by light entering from the front side of the image. Accordingly, in the present embodiment, there is no requirement of a light source, such as a battery-powered light source, inside of doll 100 . As a result, using a hologram decreases the manufacturing cost of doll 100 and increases child safety. However, the present invention is not limited to a doll without an interior light source. An interior light source, such as a battery-powered incandescent lamp, may be included inside the doll to provide additional illumination of image 112 .
Another advantage to using a hologram is that children will desire to hold doll 100 at different angles with respect to a light source to facilitate viewing of image 112 . The reflective properties of a hologram make the image maximally viewable when light rays impact the hologram at a predetermined angle. This angle depends on the relative positions of the doll and the light source. For example, when the hologram is viewed from the original direction of the reference beam, a three-dimensional image appears where the object was originally located. Because the user may be required to tilt or move the doll to enhance visibility of the image, a hologram encourages the user to play with the doll.
Yet another advantage of using a hologram for image 112 is that holograms are colorful and pleasing to the eye. For example, when a hologram is turned at an angle to the light source, the hologram appears to be three-dimensional. The combination of color and three-dimensional viewing make a hologram especially well suited for portraying a religious image such as an image of Jesus Christ.
FIG. 3 illustrates an example of a religious image suitable for use as image 112 . In the illustrated embodiment, image 112 comprises an image of Jesus Christ. Using an image of Jesus Christ is preferred because such an image is readily associated with a supreme being by Christian children. However, the present invention is not limited to using an image of Jesus Christ. For example, in an alternative embodiment, the image may be another Christian image, such as a cross or a fish. In yet another alternative, the image may be a Jewish image, such as the Star of David or a menorah. In yet another alternative the image may be an Islamic image such as an image of Mohammed or Allah. Any religious image that conveys to the doll user the presence of a supreme being inside of children is within the scope of the invention.
Although a hologram is preferred, the present invention is not limited to a hologram. Any two-dimensional or three-dimensional religious image is within the scope of the invention.
It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims. | A doll includes an internal religious image such as an image of Jesus Christ to convey to children the idea that God or Jesus Christ exists inside all children. The religious image is preferably a hologram. The image is located in the chest portion of the doll proximally to an aperture. The aperture provides a path for light to enter the doll and illuminate the image. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. national phase application filed under 35 U.S.C. §371 of International Application PCT/GB2008/000628, filed on Feb. 25, 2008, designating the United States, which claims priority from Great Britain Application 0703764.1, filed Feb. 27, 2007, which are hereby incorporated herein by reference in their entirety.
FIELD
The present invention relates to improvements in or relating to a machine for the preparation of beverages.
BACKGROUND
Beverage preparation systems for producing beverages such as coffee and tea are known in the art. One example is described in WO2004/064585 which teaches a beverage preparation system suitable for producing a wide range of beverages such as coffee, tea, hot chocolate, espresso and cappuccino.
Attempts have been made to produce alternative beverage preparation systems capable of dispensing both hot and cold beverages. However, such systems rely on the provision of a relatively high capacity, on-demand cooler, such as a flash cooler, for cooling relatively large volumes of water very quickly to a suitable temperature when a cold beverage is to be dispensed. Alternatively, the systems provide high capacity coolers for lowering the temperature of the water in the whole storage reservoir to the required temperature for cold beverages. High capacity coolers are those able to quickly cool either relatively large volumes of water by a moderate amount or to produce a relatively large temperature change in smaller volumes of water. These systems have disadvantages, including the problem that the high capacity coolers are large, noisy and contain a refrigerant gas as part of the cooling circuit. This makes the systems bulky, expensive and difficult to recycle. Thus they are unsuitable for use in a domestic setting.
SUMMARY
According to a the present invention there is provided a beverage preparation machine for dispensing beverages comprising:
a housing;
a first reservoir station;
a first reservoir for containing an aqueous medium, the first reservoir being connectable to said first reservoir station;
an auxiliary module station for receiving an auxiliary module.
An auxiliary module may be provided which is connectable to said auxiliary module station.
Advantageously the auxiliary module station is movable between first and second positions. The auxiliary module station may be movable from a storage position, in which the auxiliary module station is substantially hidden from external view, and an operating position in which the auxiliary module is connectable to the auxiliary module station. The auxiliary module station may be rotated between its first and second positions. Alternatively the auxiliary module station may be translated between its first and second positions. Alternatively, the auxiliary module station may be formed on a hinged panel which is rotatable between its first and second positions.
Optionally, the auxiliary module station is suitable for receiving a second reservoir for containing an aqueous medium. Optionally, an auxiliary module is connectable to the first reservoir station.
The machine may further comprise a second reservoir station and a second reservoir for containing an aqueous medium, the second reservoir being connectable to said second reservoir station.
Preferably, the first and second reservoirs are interchangeably connectable to the first and second reservoir stations.
Optionally, an auxiliary module is connectable to the second reservoir station.
The auxiliary module may be a chilling module. The chilling module may comprise a thermoelectric cooler (TEC) or peltier heat pump. The chilling module may comprise a recirculation mechanism for diverting aqueous medium cooled by the chilling module back to the reservoir.
The first reservoir preferably contains aqueous medium at ambient temperature. Ambient temperature is understood to mean the background temperature of the location in which the machine is utilised and may vary as the temperature of the location changes with time.
The second reservoir preferably contains aqueous medium at a temperature of between 5 and 30 degrees Celsius below ambient temperature. More preferably, the aqueous medium is at a temperature of between 5 and 15 degrees Celsius below ambient temperature. The second reservoir may contain aqueous medium at an absolute temperature of between 4 and 15 degrees Celsius depending on the local ambient temperature level.
Alternatively, the auxiliary module may be an aqueous medium filtration unit, a pre-heating module, a telemetry unit, a disinfection module or a reservoir for containing an aqueous medium.
The machine may comprise two or more auxiliary modules.
Where there are two auxiliary modules, a first auxiliary module may be connected to the auxiliary module station and a second auxiliary module may be connected to the first reservoir station.
Alternatively, where there are two auxiliary modules wherein a first auxiliary module may be connected to a first auxiliary module station and a second auxiliary module may be connected to a second auxiliary module station.
Alternatively, where there are two auxiliary modules a first auxiliary module may be connected to the auxiliary module station and a second auxiliary module may be connected to a second reservoir station.
In another aspect of the present invention there is provided a beverage preparation machine for dispensing beverages comprising:
a housing;
a first reservoir station;
a first reservoir for containing an aqueous medium, the first reservoir being connectable to said first reservoir station;
an auxiliary module, wherein the auxiliary module comprises a first interface for connecting the auxiliary module to the first reservoir station and a second interface for connecting the first reservoir to the auxiliary module such that, on assembly, the auxiliary module is located in between the first reservoir and the first reservoir station.
The machine may further comprise a second reservoir station and a second reservoir for containing an aqueous medium, the second reservoir being connectable to said second reservoir station.
The auxiliary module may be connected in between the second reservoir and second reservoir station.
The auxiliary module may be selected from a chilling module, a pre-heating module, an aqueous medium filtration unit, a disinfection module and a telemetry unit.
A heater may be provided in fluid communication with the first reservoir station and or the second reservoir station.
Preferably the first reservoir contains aqueous medium at ambient temperature.
Preferably the second reservoir contains aqueous medium at a temperature of between 5 and 30 degrees Celsius below ambient temperature. More preferably, the aqueous medium is at a temperature of between 5 and 15 degrees Celsius below ambient temperature. The ambient temperature will vary according to the local climate in which the machine is used. Preferably, the second reservoir contains aqueous medium at a temperature of between 4 and 15 degrees Celsius.
The chilling module may comprise a recirculation mechanism for diverting aqueous medium cooled by the chilling module back to the reservoir.
The second reservoir may be thermally insulated.
In another aspect of the present invention there is provided a beverage system for dispensing hot and cold beverages comprising:
a) a beverage preparation machine for dispensing beverages formed from one or more beverage ingredients by use of an aqueous medium, wherein the beverage preparation machine comprises:
a housing;
a first reservoir station;
a second reservoir station; and
a heater in fluid communication with the first station for heating aqueous medium;
b) a first reservoir containing an aqueous medium, the first reservoir being connectable to said first reservoir station so as to be in fluid communication with said heater; and
c) a removable second reservoir containing an aqueous medium at a temperature below ambient, the second reservoir being connectable to said second reservoir station.
Preferably the first reservoir contains aqueous medium at ambient temperature.
Preferably the second reservoir contains aqueous medium at a temperature of between 5 and 30 degrees Celsius below ambient temperature. More preferably, the aqueous medium is at a temperature of between 5 and 15 degrees Celsius below ambient temperature. 36. The second reservoir may contain aqueous medium at a temperature of between 4 and 15 degrees Celsius.
Preferably the second reservoir is thermally insulated.
The machine or system of the present invention may further comprise a recirculation mechanism for diverting aqueous medium from the first or second reservoirs back to the first or second reservoirs or from the auxiliary module back to the auxiliary module wherein the recirculation mechanism comprises a source of UV for disinfecting the aqueous medium as it circulates in the recirculation mechanism. Advantageously, using UV light to disinfect the aqueous medium as it recirculates allows for a lower power UV-emitter to be used as the total exposure time is increased.
Preferably, the source of UV are UV LEDs. Preferably, the UV LEDs have a wavelength of emitted light of between 250 and 320 nm. The extended exposure time of the aqueous medium to the UV light due to the recirculation of the water as well as the use of a small focus area for the LEDs allows a low power output to be used to provide effective disinfection.
The recirculation mechanism may also comprise a chilling mechanism. However, the UV disinfection may be used on any or all aqueous medium supplies forming part of the system.
In one embodiment a recirculation mechanism and a UV source are provided as part of a disinfection auxiliary module.
In another embodiment a recirculation mechanism, a chilling mechanism and a UV source are all provided as part of a chilling module.
Filtered UV light may be used to illuminate or fluoresce the reservoirs or medium contained therein.
The machine and system described is suitable for dispensing a range of hot and cold, extracted/infused or diluted beverages including, but not limited to, coffee, tea, cappuccino, hot chocolate, iced tea, fruit cordials, smoothies and frappes.
The present invention also provides a beverage system for dispensing hot and cold beverages comprising:
a) a beverage preparation machine for dispensing beverages formed from one or more beverage ingredients by use of an aqueous medium, wherein the beverage preparation machine comprises:
a first reservoir station; and
a heater in fluid communication with the first station for heating aqueous medium;
b) a first reservoir containing an aqueous medium, the first reservoir being connectable to said first reservoir station so as to be in fluid communication with said heater; and
c) a removable second reservoir containing an aqueous medium at a temperature below ambient, the second reservoir being connectable to said first reservoir station.
By using a single reservoir station and swapping in and out interchangeable reservoirs containing aqueous medium, such as water, of different temperatures a compact system is achieved that can efficiently dispense beverages that are either hot or cold.
Preferably the first reservoir contains aqueous medium at ambient temperature.
Preferably the second reservoir contains aqueous medium at a temperature of between 5 and 30 degrees Celsius below ambient temperature.
Optionally the aqueous medium is at a temperature of between 4 and 15 degrees Celsius.
Preferably the second reservoir is thermally insulated. Advantageously, the second reservoir can be stored in a fridge prior to attachment to the reservoir station to maintain the aqueous medium, such as water, at the required, chilled, temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a front perspective view of a first embodiment of beverage preparation machine according to the present invention;
FIG. 2 is a rear perspective view of the machine of FIG. 1 ;
FIG. 3 is a schematic representation of the machine of FIG. 1 ;
FIG. 4 a front perspective view of a second embodiment of beverage preparation machine according to the present invention;
FIG. 5 is a rear perspective view of the machine of FIG. 4 ;
FIG. 6 shows a series of perspective views of the machine of FIG. 4 illustrating the fitting of two auxiliary modules;
FIG. 7 is a schematic representation of the machine of FIG. 4 ;
FIG. 8 shows a series of perspective views of a third embodiment of beverage preparation machine according to the present invention illustrating the fitting of two water tanks and an auxiliary module;
FIG. 9 is a schematic representation of a disinfection system for us with the prior embodiments; and
FIG. 10 is a schematic representation of a fourth embodiment of beverage preparation system according to the present invention.
DETAILED DESCRIPTION
FIGS. 1 to 3 show a first embodiment of beverage preparation machine according to the present invention. The beverage preparation machine is of the general type described and shown in WO2004/064585 except for modifications as described below relating to the present invention as defined by the appended claims. WO2004/064585 describes fully the basic design and functioning of the beverage preparation machine and the design and function of the beverage cartridges used with the machine. These aspects will not be described in detail here except where relevant to the present invention. The contents of WO2004/064585 are incorporated herein by reference.
It will be appreciated that the invention may find application with other types of beverage preparation machine and for the purposes of the present invention there is no requirement for the beverage ingredients to be derived from cartridges or delivered in a single-dose format.
As shown in FIGS. 1 and 2 the beverage preparation machine 201 generally comprises a housing 210 containing a water heater 225 , a water pump 230 , a dispensing valve 235 with an air inlet 236 , a control processor, a user interface 240 and a cartridge head 250 . The cartridge head 250 in turn generally comprises a cartridge holder for holding, in use, the beverage cartridge, cartridge recognition means and inlet and outlet piercers, for forming, in use, an inlet and an outlet in the beverage cartridge.
The front half 211 of the housing 210 comprises a dispense station 270 where dispensation of the beverage takes place.
The machine user interface 240 is located on the front of the housing 210 and comprises a start/stop button 241 . The start/stop button 241 controls commencement of the operating cycle and is a manually operated push-button, switch or similar. The button 241 may also be used to manually stop the operating cycle.
A rear half 212 of the housing 210 provides a recess 214 for the attachment of first and second water tanks 220 , 280 .
The first water tank 220 may be made from a transparent or translucent material to allow a consumer to view the quantity of water remaining in the tank. Alternatively, the first water tank 220 may be made from an opaque material but have provided a viewing window therein. In addition, or in place of the above, the first water tank 220 may be provided with a low level sensor which prevents operation of the water pump 230 and optionally triggers a warning indicator, such as an LED, when the water level in the tank descends to a preselected level. The first water tank 220 preferably has an internal capacity of approximately 1.5 liters.
The first water tank 220 is connected in use to a first water tank station 120 . The first water tank 220 comprises a generally cylindrical body 221 which may be right circular or a frustum as desired for aesthetic reasons. The tank comprises an open upper end forming an inlet for filling the tank with water which is closed off in use by a manually removable lid 222 . An outlet is provided towards a lower end of the tank. The outlet contains a valve which is biased into a closed position when the first water tank is removed from the first water tank station 120 . The outlet may also be provided with a filter to prevent ingress of solid particulates into the internal parts of the machine. The first water tank station 120 comprises a base plate 121 shaped to receive a lower end of the first water tank 220 . The base plate 121 is provided with a valve connector 122 that matingly connects with the outlet valve of the first water tank 220 when the tank is placed on the base plate. Connection of the tank 220 to the station 120 opens the valve and allows for water flow therethrough.
As shown in FIG. 3 , a conduit 123 extending internally from the valve connector 122 communicates with the water heater 225 .
The beverage preparation machine 201 is provided with a second water tank station 180 . The second water tank station 180 comprises a base plate 181 having a valve connector 182 in the same manner as the first water tank station 120 . The second water tank 280 is locatable on the second water tank station 180 . The second water tank 280 is provided with an outlet valve of the same type as the first water tank and connects to the valve connector in the same manner as described above. The construction and materials of the second water tank 280 are preferable the same as those of the first water tank 220 .
The base plates 121 and 181 are preferable formed as one piece having separate indentations marking the locations of the first and second water tanks 220 , 280 .
A conduit 183 extends internally from the valve connector 182 of the second water tank station to the dispensing valve 235 .
The water pump 230 is a volumetric displacement pump that creates sufficient suction head to draw water from the tanks through the heater and the dispensing valve 250 . Preferably a peristaltic type pump is used such that each revolution delivers a known volume of water. The water pump 230 provides a maximum flow rate of 900 ml/min of water at a maximum pressure of 2.5 bar. Preferably, in normal use, the pressure will be limited to 2 bar. The flow rate of water through the machine can be controlled by the control processor to be a percentage of the maximum flow rate of the pump by speed control. Preferably the pump can be driven at any of 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 100% of the maximum rated flow rate. The accuracy of the volume of water pumped is preferably + or −5% leading to a + or −5% accuracy in the final volume of the dispensed beverage. Where a peristaltic pump is used the volume delivered can be determined by the number of revolutions. Alternatively, for example where a peristaltic pump is not used, a volumetric flow sensor (not shown) can be provided in the flow line either upstream or downstream of the water pump 230 . Preferably, the volumetric flow sensor would be a rotary sensor.
The dispensing valve, 235 preferably comprises an assembly of two electrically operated solenoid change-over valves with associated non-return valves as shown schematically in FIG. 3 . In order to correctly route water through the machine from the first or second water tanks to the cartridge head the respective solenoid valve of the dispensing valve 250 is selected by the control processor before flow commences.
The water heater 225 has a power rating of 1550 W and is able to heat water received from the water pump 230 from a starting temperature of approximately 20° C. to an operating temperature in the range of around 88 to 94° C. in under 1 minute. Preferably the dwell time between the end of one operating cycle and the heater 225 being able to commence a subsequent operating cycle is less than 10 seconds. The heater maintains the selected temperature to within + or −2° C. during the operating cycle. Preferably the water for the operating cycle may be delivered to the cartridge head 250 at 88° C., 91° C. or 94° C. The heater 225 is able to quickly adjust the delivery temperature within the range 88° C. or 94° C. The heater 225 comprises an over-temperature cut-off which shuts off the heater if the temperature exceeds 98° C.
The dispensing valve 235 receives water supply inlets from the water heater 225 and the second water tank 280 as shown in FIG. 3 . In addition, the air inlet 236 allows air to be pumped to the cartridge head 250 . If required a separate air compressor may be incorporated into the air supply route. The water/air outlet 237 from the dispensing valve 235 connects to the water pump 230 . In turn, the water pump 230 connects to the cartridge head 250 .
The control processor of the beverage preparation machine comprises a processing module and a memory. The control processor is operatively connected to, and controls operation of, the water heater 225 , water pump 230 , dispensing valve 235 and user interface 240 .
In use, the first water tank 220 is used to provide water for hot drinks and the water passes through the water heater 225 on the way to the cartridge head 250 . The second water tank 280 is used to provide water for cold drinks or drinks served at ambient temperature and the water does not pass through the water heater 225 . The water in the second water tank 280 may be chilled before it is poured into the tank. However, preferably, the tank, containing the water, may be chilled in a refrigerator. Preferably the water in the second water tank 280 when connected to the secondary water tank station is at between 5 and 30 degrees Celsius below ambient or room temperature, more preferably at between 5 and 15 degrees Celsius below ambient. The shape and size of the tank allows the tank to be fitted into a domestic refrigerator door when disconnected from the beverage preparation machine.
The first and second water tanks 220 , 280 may be interchangeable on the first and second water tank stations 120 , 180 . In other words, one design of tank may be used for fitting to the first and second water tank stations 120 , 180 .
FIGS. 4 to 7 show a second embodiment of beverage preparation machine 201 according to the present invention. As with the first embodiment, the machine comprises first and second water tanks 220 , 280 and first and second water tank stations 120 , 180 . As shown in FIG. 4 the design of the housing 210 is of a different shape but the function of the components of the machine is the same as that of the first embodiment described above except where noted differently below.
As shown in FIG. 6 the beverage preparation machine is provided with one or more auxiliary modules. In the illustrated embodiment two auxiliary modules are shown mounted to the first and second water tank stations 120 , 180 . A pre-heating module 320 is mounted on the first water tank station 120 between the first water tank 220 and the base plate 121 . A chilling module 380 is mounted on the second water tank station 180 between the second water tank 280 and the base plate 180 . It should also be noted that FIG. 6 shows an optional arrangement where the beverage preparation machine is provided with a single water tank 290 of double capacity which is located on both the first and second water tank stations.
The auxiliary modules 320 , 380 are mounted in line with the first and second water tanks. A lower face of each auxiliary module matches the interface of the water tanks stations, whilst an upper face of the auxiliary modules is shaped to receive the first or second water tanks. Both the upper and lower faces of the auxiliary module are provided with suitable valve connectors for mating with the valve connectors of the water tank stations and water tanks. This arrangement is particularly suitable where the auxiliary module comprises a chilling unit or a pre-heating unit. A filtration unit may also be used in this configuration.
FIG. 7 illustrates schematically the internal configuration of the second embodiment. The arrangement of the pump, water heater and dispensing valve are the same as in the first embodiment. As shown, the pre-heating module 320 comprises a heater 321 . The chilling module 380 comprises a thermoelectric cooler (TEC) 381 which receives water from the second tank 280 via a tank outlet 383 , cools the water and then re-circulates the water back to the second tank 280 via a tank inlet 384 . Motive force for the re-circulation is provided by a dedicated pump 382 within the chilling module 380 . When required water exits the chilling module 380 via valve 385 . Other types of peltier heat pump or similar device may be used instead of the TEC 381 .
In use, when a cold beverage is required, water is pumped from the second water tank 280 by the pump 230 to the cartridge head 250 . Due to the presence of the chilling module 380 the water in the second tank 280 is maintained in a chilled state.
The chilling module 380 may be used to chill water in the second tank 280 that is initially at ambient or room temperature or may be used to maintain the temperature of water in the second tank 280 which has previously been chilled in a refrigerator.
The pre-heating module 320 may be used to heat water taken from the first tank 220 at ambient temperature by a set amount before passing the water to the main heater 225 in the machine housing.
As an alternative, the second tank may itself comprise a chilling mechanism, such as a TEC, as an integral part of the tank.
FIG. 8 shows a third embodiment of the present invention wherein the beverage preparation machine 201 is provided with an auxiliary module station 300 as well as the first and second water tank stations 120 , 180 . The auxiliary module station 300 is used to mount auxiliary modules in parallel to the first and second water tanks rather than in line with the tanks.
The auxiliary module station 300 comprises power and fluid connections. The auxiliary module station 300 may be rotated in between a storage position, in which the station is hidden from view below the first and second water tank stations, and an operating position as shown in FIG. 8 in which the station is accessible and is position rearward of the first and second tank stations. In alternative, non-illustrated versions, the auxiliary module station 300 may be moved between storage and operating positions by means of a translational movement, such as a sliding motion, or by being located on a flip-down panel which is lowered when the auxiliary module is to be used.
The auxiliary module 300 may be any of a chilling module, a pre-heating module, a water filtration unit, a disinfection module, a telemetry device or similar as described above.
FIG. 9 illustrates a modification to the system which can be utilised in any of the above embodiments. An ultra-violet (UV) chamber 501 is provided as part of a water re-circulation system. As shown water is recirculated from the second tank 280 by means of pump 382 and three-way valve 500 back to the second tank 280 via the UV chamber 501 . This recirculation continues when water is not required to be transferred to the cartridge head 250 . When water is required to dispense a beverage then this is diverted to the cartridge head 250 by use of the three-way valve 500 .
The UV chamber 501 comprises a housing 503 and a plurality of UV emitting elements 502 which are focussed to illuminate the water passing through the chamber 501 with light in the UV range. Preferably, the piping used for conveying the water through the chamber 501 is formed from fluoroethylene polymer (FEP) to allow for good UV transmission across the piping. The UV emitting elements 502 comprises UV-emitting light emitting diodes (LEDs). The LEDs emit UV in a chosen wavelength between 250 and 320 nanometers (nm). The LEDs may have a relatively low power output compared with low-pressure mercury discharge UV lamps since the recirculation of the water through the chamber 501 many times increases the total UV exposure time of the water. In addition, the LEDs may be arranged to have a small focus area by the use of a suitable lens arrangement to enhance the disinfection effect. This allows less expensive and smaller UV LEDs to be utilised.
Preferably, the tank 280 or the water contained therein may be illuminated by a portion of the UV output of the LEDs which has been filtered. The tank 280 may be formed, or contain, a material which fluoresces when exposed to UV light.
The use of UV light to disinfect the water used in the system may be used for water recirculation in the first tank 220 and or the second water tank 280 irrespective of whether the water is also subject to chilling, heating or discharged at ambient temperature. The UV chamber 501 may be formed as part of the recirculation piping of a chilling module formed as part of the machine or as part of another auxiliary module connectable to one of the water or auxiliary module stations. Each reservoir station may be provided with an in-line UV chamber 501 if required.
The UV chamber 501 may be formed as part of the main housing of the machine or as part of a separate, connectable, auxiliary module. The UV chamber 501 and recirculation mechanism may be formed as part of a disinfection module per se or as part of a chilling module.
FIG. 10 illustrates a fourth embodiment of system. In this system the beverage preparation machine 201 comprises a single reservoir station and two water tanks. The first water tank 220 contains water at ambient temperature and is to be used to prepare hot beverages. The second tank 280 contains water 400 at below ambient temperature and is used to prepare cold beverages. The tanks 220 , 280 are interchangeable and swapped on and off the reservoir station as required. Advantageously, the second tank, when not mounted to the beverage preparation machine 201 is preferably stored in a refrigerator in order to create and maintain a chilled volume of water. In this way the system can quickly be used to make both hot and cold beverages without the necessity for chilling apparatus within the housing of the beverage preparation machine.
Preferably the second water tank 280 is thermally, insulated and may be provided with a carrying handle. It may also be suitably shaped to fit within standard compartments of a refrigerator such as a door pocket.
In use of any of the first to third embodiments described above, an auxiliary module as required is mounted to the auxiliary module station or the first or second water tank station as appropriate. In addition, one or other or both of the first and second water tanks are positioned on the respective first and second water tank stations as appropriate.
The water for the beverage is sourced from the first or second water tank depending on the type of beverage to be dispensed. For example, where a chilled beverage is required the water is sourced from the second tank which may contain water pre-chilled in a refrigerator, or contain water chilled by a chilling module or integrated TEC. Where a hot beverage is required the water is sourced from the first tank and the water is passed to the heater 225 , optionally via a pre-heating module.
The basic operational behaviour of the machine 201 thereafter for any of the embodiments set out above is described fully in WO2004/064585.
From the above it will be understood that in the present invention the auxiliary modules where present may be positioned in line or parallel to one or more tanks containing water for forming beverages. One, two or more auxiliary modules may be used in combination with one, two or more water tanks depending on the desired combination of functions. It will also be understood that the various types of auxiliary module described are given as examples only and may be used with one or more of the embodiments of beverage machine described above. The auxiliary modules and water tanks of the above embodiments may be used with beverage preparation machines having one, two or more reservoir stations. | A beverage preparation machine for dispensing beverages comprising: a housing; a first reservoir station; a first reservoir for containing an aqueous medium, the first reservoir being connectable to said first reservoir station; an auxiliary module station for receiving an auxiliary module. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of intermittent linear motors for use in combustion gas powered tools such as those used to drive fasteners.
2. Description of Related Art
The cycle of the intermittent linear motor is different from that of a continuous running engine. It does not continue automatically, as would be the case in a reciprocating internal combustion engine. Instead, the intermittent linear motor's power piston must be returned to, and remain in, a starting or rest position between each power stroke. Typically, a rod fitted to the power piston engages a fastener or other load and mechanical energy is transmitted through the rod to drive a fastener or perform other useful work during the power stroke.
The power piston is returned to its starting or rest position within a piston cylinder during a reciprocation stroke by a resilient member, vacuum draw, or return air pressure. This stroke is not generally used for compression purposes as in a conventional engine. Instead, the upper portion of the piston cylinder is vented during reciprocation so that the contents of the combustion chamber in the starting or rest position are at or near atmospheric pressure. This is primarily done because holding a compressed charge for what may be extended periods between cycles has not proven practical. However, as a result of the inherent thermal-to-mechanical output inefficiencies resulting from this lack of compression, the combustion chambers of intermittent linear motors are required to be fairly large for a given power output.
These relatively large uncompressed combustion chambers of intermittent linear motors, as well as being inherently inefficient, are especially sensitive to the presence of residual exhaust gases from previous cycles. Failure to remove such residual gases will result in a diluted charge and deterioration of burn speed, which is critical when driving a fastener. Thus, unless such gases can be substantially completely removed and replaced with a clean air/fuel mixture, subsequent cycles will deliver significantly less power.
It is, therefore, necessary to provide some type of efficient exhaust scavenging system in devices utilizing intermittent linear motors. Such systems should discharge exhaust gases from the tool as quickly as possible after combustion has been completed and useful work performed. This helps prevent the tool from overheating and can also minimize the amount of scavenging air required to completely clean out the remaining exhaust gases. There can be some variation due to the differing shapes and configurations of combustion chambers and their porting locations; however, it is generally necessary to pump clean air having a volume of at least 2.5 times the volume of the combustion chamber in order to adequately clean out (i.e. scavenge) exhaust gases prior to injecting fuel into the chamber. Representative prior art approaches the problem of rapidly and efficiently scavenging exhaust gases can be seen in U.S. Pat. Nos. 4,403,722; 4,712,379; and 4,759,318.
These patents generally rely on a temperature drop in the gases remaining in the combustion chamber after exhaust gases have been allowed to escape following a power stroke. This temperature drop forms a partial vacuum, causing scavenging air to be drawn in through check valves at the ignition end of the combustion chamber. A critical problem associated with these systems is the speed with which the scavenging operations of this type can be accomplished. As it takes time and temperature drop for a vacuum to be realized after the fastener has been driven, hot gases are allowed to stay in the tool for long periods of time up to 500 milliseconds. This causes the tool to heat up and lose power as well as severely limiting the operating speed of the tool.
SUMMARY OF THE INVENTION
In my current invention, a novel approach has been taken to address the problems described above, allowing rapid automatic operation in a simple device. Unlike my U.S. Pat. No. 4,712,379 and U.S. Pat. No. 4,403,722, which rely on a vacuum being set up and manual operations to complete their cycles, exhaust gases can be more completely scavenged within a much shorter time (e.g., 10 milliseconds) in the cycle of my invention. This allows for very rapid cycling rates and minimal heating of the tool. It shares the advantages of my U.S. Pat. Nos. 4,759,318 and 4,665,868 as its cycle can be initiated solely by electric signal without the need for manual pumps or valves, but does not require numerous complicated valves and seals. Thus, it represents a significant advance in efficiency and simplicity of operation over prior art devices.
The present invention features an improved scavenging system for a gas-powered intermittent motor having a power piston within a piston cylinder that divides the cylinder into a combustion chamber located above the power piston and an air chamber located below the power piston. A plenum chamber connects the air chamber to the combustion chamber. A first check valve located between the air chamber and the plenum chamber supports a flow of air from the air chamber into the plenum chamber. A second check valve located between the plenum chamber and the combustion chamber supports a flow of the air from the plenum chamber into the combustion chamber. The power piston is moveable in response to an ignition of combustion gas in the combustion chamber between a top or starting position at which a volume of the combustion chamber is minimized and a volume of the air chamber is maximized and a bottom position at which the volume of the combustion chamber is maximized and the volume of the air chamber is minimized. The first check valve supports the flow of air from the air chamber into the plenum chamber during the movement of the power piston toward the bottom position, and the second check valve supports the flow of air from the plenum chamber into the combustion chamber when the power piston is located in the vicinity of the bottom position to initiate a scavenging operation in the combustion chamber as pressure in the plenum chamber exceeds pressure in the combustion chamber.
The power piston is powered in a downward stroke by the ignition of combustion gas in the combustion chamber and is preferably biased to return to rest in an upward return stroke, when not powered by the ignition of gas. An exhaust valve associated with the combustion chamber opens to exhaust spent combustion gases and air from the combustion chamber after combustion. The plenum chamber is provided in fluid communication with both the air chamber below the power piston and the combustion chamber above the power piston. In addition, the plenum chamber can be provided in fluid communication with an actuator for the exhaust valve.
Air is compressed in the air chamber below the power piston during the downward movement of the power piston and this compressed air flows through the first check valve into the plenum chamber. The compressed air in the plenum chamber begins to flow through the second check valve into the combustion chamber when the power piston arrives the vicinity of the bottom position. Scavenging air flows from the plenum chamber into the combustion chamber after the pressure in the plenum chamber exceeds the pressure in the combustion chamber, which first occurs when the piston is in the vicinity of the bottom position (e.g., shortly before, at, or after the change in piston direction).
During operation, the motor is configured so that:
a. air is compressed in the air chamber below the power piston during the downward power stroke and this compressed air flows through the first check valve into the plenum chamber; b. then, as the combustion chamber pressure drops, the compressed air from the plenum chamber flows through the second check valve into the combustion chamber, and subsequently through the exhaust valve, scavenging the combustion chamber of spent combustion gases; c. as the plenum chamber pressure drops and the piston is on its upward return stroke, the piston draws in air through an air intake valve into the air chamber below the piston while exhaust gases above the piston are being forced out through the exhaust valve; and d. as the pressure in the combustion chamber and the plenum chamber return to substantially atmospheric pressure near the top position of the piston, the exhaust valve closes to ready the motor for fuel injection and ignition.
The first check valve preferably opens during the downward stroke of the power piston, while the intake valve is closed, to admit compressed air into the plenum chamber. The first check valve preferably closes in conjunction with (e.g., at or before) the opening of the intake valve to preserve the increased pressure of the plenum chamber. The second check valve preferably opens in conjunction with (e.g., at or after) the opening of the exhaust valve to provide for efficiently scavenging spent gases from the combustion chamber while also providing a charge of fresh air in the combustion chamber. The second check valve preferably closes in conjunction with (e.g., slightly before, at, or after) the closing of the exhaust valve in preparation for ignition of a fresh charge in the combustion chamber. Air pressure stored in the plenum chamber is preferably used for opening the exhaust valve. However, combustion air pressure from the combustion chamber can also be used for this purpose.
Preferably, the volume of the air chamber exceeds the volume of the combustion chamber at the start of the power piston's downward movement in response to the ignition of combustion gas by a ratio of at least 2.5 to 1.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the intermittent linear motor system for a fastening tool with the motor ready to fire.
FIG. 2 is a schematic view of the system with the combustible mixture being ignited and the power piston being driven down.
FIG. 3 is a schematic view of the system at the first stage of scavenging as the exhaust valve opens venting excess combustion pressure to atmosphere.
FIG. 4 is a schematic view of the system as the power piston begins to return to its top or starting position exhausting spent gases.
FIG. 5 is a schematic view of the system showing the power piston at rest in its top or starting position and the remaining valves closing.
FIG. 6 is a schematic view of an alternative embodiment of the system according to the present invention, in which the system is arranged so that the pressure to acuate the exhaust valve is sourced from combustion pressure.
FIG. 7 is a schematic view of an alternative embodiment of the system according to the present invention, in which a bypass vent is provided to enable compressed air within the air chamber beneath the piston to enter the combustion chamber above the piston.
While the invention will be described in conjunction with illustrated embodiments, it will be understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modification and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, similar features have been given similar reference numerals.
Turning to FIG. 1 , there is shown a schematic view of the intermittent linear motor system for a fastening tool ready for ignition. Fuel injection and starting means are not shown for clarity. At this point, a vapoured fuel such as Mapp gas or propane has been injected into the combustion chamber 2 in the correct proportion to create an explosive fuel/air charge, and the tool is ready to fire as a result of a spark from spark plug 6 . Typically, a manual starting pump is connected, preferably to the plenum chamber 4 , to provide fresh air to the combustion chamber in the event that unburned gases or inaccurate fueling has left a polluted atmosphere in the combustion chamber as my previous U.S. Pat. Nos. 4,759,318 and 4,665,868 more fully describe.
FIG. 2 shows the combustion mixture being ignited with a spark plug 6 and the power piston 8 being driven down along the piston cylinder through its power stroke, and a fastener is driven or other useful work performed. Air within the air chamber 10 below the power piston 8 is being compressed into the scavenging plenum chamber 4 through the plenum check valve 12 . Pressure building in the plenum chamber 4 is also being communicated through signal line 13 to the exhaust valve actuator 14 biasing the exhaust valve 16 to open. If desired to more fully control the opening and closing timing of the exhaust valve 16 , a check valve/orifice combination 18 (see FIG. 2 ) can be used to allow rapid opening of the valve whereby air flow to the actuator passes through an orifice 20 and past a check valve 22 during compression and only through the orifice as the pressure decreases during the cycle. (See FIG. 4 .) The pressure inside the combustion chamber at this time is relatively high, which holds the exhaust valve 16 closed. Also, the combustion chamber check valve 24 is held closed against the plenum pressure with combustion pressure, the remaining pressure in the combustion chamber 2 being higher than the pressure in the plenum chamber 4 .
FIG. 3 shows the first stage of scavenging as the power piston 8 arrives in the vicinity of its bottom position (i.e., is located near the bottom of its stroke shortly before, at, or after its change of direction) and as the exhaust valve 16 opens as a result of the high plenum pressure it references and lowered combustion chamber pressure. This vents the combustion chamber 2 , and as its pressure lowers towards atmospheric pressure, air begins flowing from the plenum chamber 4 through the combustion chamber 2 displacing exhaust gases from the combustion chamber 2 and out through the open exhaust valve 16 . There is also a spring 26 biasing the exhaust valve 16 to close, which is overcome by the plenum pressure on the diaphragm or actuation piston 14 of the actuator (not shown), and again as more fully described in my previous U.S. Pat. Nos. 4,759,318 and 4,665,868.
Simultaneously, the power piston 8 begins to return as the remaining combustion pressure falls and exhaust gases contained in the swept volume above the piston 8 are pushed out through the open exhaust valve 16 . In a preferred embodiment, the swept volume of the piston is roughly 2.5 or more times the volume of the combustion chamber 2 . Typically the combustion chamber 2 is of a shape and location whereby there is a passageway between the combustion chamber and the swept volume (expansion volume) such that substantially all the scavenging air from the plenum chamber 4 is used to displace exhaust gases from the combustion chamber 2 and substantially all of the gases present in the swept volume above the piston 8 are displaced by the piston 8 through the exhaust valve 16 .
As well as the spring 30 or other resilient means biasing the piston 8 upwards, a small amount of compressed air trapped in the air chamber 10 below the piston can add to the initial returning force applied to the piston 8 .
Alternately, as shown in the embodiment of FIG. 7 , the air compressed into the air chamber 10 below piston 8 can be bypassed as shown, into the volume of the combustion chamber above the piston as the piston reaches the bottom of its stroke, allowing this amount of otherwise unused air to assist in the cooling and scavenging process. This bypass vent 31 can be in the form of an external line as shown or simply be a channel cut into the cylinder wall at this location.
FIG. 4 shows the combustion chamber check valve 24 open during the return of the power piston 8 due to the accompanying pressure drop in the combustion chamber 2 . Air from the scavenging plenum chamber 4 passes through the open combustion chamber check valve 24 and flows through the combustion chamber 2 and out the exhaust valve 16 scavenging exhaust gases with it.
Simultaneously, the power piston 8 starts to return by spring 30 or other means to its top or starting position, drawing in air into the air chamber 10 below it through the air inlet valve 32 while forcing exhaust out of the combustion chamber 2 through the exhaust valve 16 above it. Pressure in the scavenging plenum chamber 4 is dropping at this time, and air is beginning to flow back from the exhaust valve actuator 14 . As previously stated, it may be desirable to place an orifice or check valve/orifice combination 18 to tailor the opening and closing profiles of the exhaust valve 16 , whereby the valve 16 would open quickly but close slowly so that pressure in the plenum chamber 4 could drop to atmospheric pressure before the exhaust valve 16 closes.
Air to be compressed in the next cycle is simultaneously drawn into the air chamber 10 below the power piston 8 through an inlet means such as a check valve 32 as the piston 8 returns. Once substantially all the pressure above atmospheric has been vented through the combustion chamber 2 , the exhaust valve 16 closes.
FIG. 5 shows the power piston 8 at rest in its top or starting position and the exhaust valve 16 and the combustion chamber valve 24 closing as the pressure in the plenum chamber 4 drops to near atmospheric. Once these valves 16 and 24 have closed, fuel can be injected and the cycle initiated again with a spark being delivered to the spark plug.
FIG. 6 shows an alternative embodiment of the motor according to the present invention wherein the combustion chamber 2 communicates with exhaust valve actuator 14 , preferably through a check valve/orifice combination 18 (similar to that of FIG. 2 ), so that exhaust valve 16 is actuated to move to an open position by combustion gases generated in combustion chamber 2 .
In operation, the very rapid cycling rates and minimal heating of the tool provides an efficient, effective intermittent linear motor. Similar details are supported in my U.S. Pat. No. 6,491,002, which is hereby incorporated by reference.
Thus, it is apparent that there has been provided in accordance with the invention an intermittent linear motor that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with illustrated embodiments thereof; it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention. | The intermittent linear motor of this invention incorporates features which enhance the exhaust scavenging and cooling processes, as well as simplifying overall construction including a compression plenum below the piston where air displaced during a power stroke by the piston is immediately transferred through the combustion chamber allowing said compressed air to immediately begin scavenging exhaust gases as the piston is returned further displacing spent gases from the motor. | 5 |
FIELD OF THE INVENTION
This invention relates to a plate type heat exchanger formed of individual heat exchanger plates stacked upon one another with the spaces between adjacent plates defining flow channels and with rows of aligned holes or apertures in the plates to define inlet and outlet connections to the various channels.
BACKGROUND OF THE INVENTION
Plate type heat exchangers have long been popular for a variety of heat transfer applications, particularly in the vehicular field. In the usual case, a series of plates are stacked in spaced relation. The spaces between adjacent plates define flow channels for the heat transfer fluids. Typically, aligned rows of holes are disposed in the plates and through the use of separators and/or baffles, are caused to provide fluid communication to only certain of the flow channels. In a typical case, for a two fluid plate type heat exchanger, every other channel from top to bottom of the stack will receive a heating/cooling fluid while the channels at the interface between the heating/coolant channels receives the fluid to be subject to the heat transfer operation. In typical vehicular applications, the heating/coolant fluid is typically engine coolant while the fluid being subject to the heat transfer operation will typically be some sort of oil as, for example, engine lubricating oil, transmission oil, oil used in other hydraulic systems, or retarder oil.
As vehicles become more and more complex, there is an increasing need to provide for cooling of the oil of each of the many vehicular systems that employs oil. Plate heat exchangers of the type described previously have only two separate circuits, one for the coolant and one for the oil. Consequently, in a vehicle having several sources of oil requiring cooling, it is necessary to employ a separate heat exchanger for each source of oil. This, of course, adds to the complexity of the fluid system of the vehicle and furthermore adds weight, which impacts on fuel economy. Furthermore, each separate heat exchanger adds to the cost of the heat exchange system. Moreover, the use of several heat exchangers in such a situation requires a greater space within the vehicle to house the heat exchangers.
In an attempt to alleviate the problem is disclosed in WO document 95/35474. According to this disclosure, three separate circuits for three different fluids are integrated into a single heat exchanger. In an especially preferred embodiment of such a heat exchanger, only two differently formed heat exchanger plates are required. These are inserted into one another in a certain way and forms three separate flow channels. However, they must be rotated by 180 degrees and failure to do so will result in a defective heat exchanger. Furthermore, all of the heat exchanger plates have a total of six openings for the passage of fluids. As a result of such a large number of openings, the potential for leakage at joints is increased.
The present invention is directed to overcoming one or more of the above problems.
SUMMARY OF THE INVENTION
It is the principal object of the invention to provide a new and improved plate type heat exchanger. More specifically, it is an object of the invention to provide a new and improved plate type heat exchanger which is capable of simultaneously performing heat exchange operations on three, and preferably four or more different fluid streams.
An exemplary embodiment achieves the foregoing object in a plate type heat exchanger for exchanging heat between a multiplicity of at least three heat exchange fluids. The plate type heat exchanger includes a plurality of spaced plates which are secured together to form a pack having a plurality of fluid flow channels extending between adjacent plates. The channels of the plurality are divided into at least three groups and the channels in a first of the groups are spaced from one another by the channels of the other groups. Separate inlets and outlets are connected to the channels of each of the groups and consist of a maximum of four rows of aligned holes in the plates.
In a preferred embodiment, the inlet and outlet of one of the groups are located in the holes of two of the sets defining the inlet and outlet for another of said groups.
In a highly preferred embodiment, a tube defines the holes of the one set and is located generally centrally within the holes of another set and extends at least partially through the pack.
In one embodiment, a disk is sealed to the exterior of the tube and to two adjacent plates in the holes defining another set.
In a highly preferred embodiment, the plates are drawn plates and at least some of the holes includes collars sealingly engaging an adjacent plate.
The invention also contemplates the provision of imperforate baffles sealed to certain of the holes of both of the sets of holes defining the inlet and outlet for the first group of channels at identical locations within the pack.
According to another facet of the invention, there is further provided at least one adapter unit defining at least one of the inlets or one of the outlets. The adapter unit includes a connecting plate mounted to the stack, a flow element entering the stack, and a separator element separating the flow element from the channels of the other group of channels.
In a preferred embodiment, the flow element is a conduit having its exterior sealed to both the connecting plate and to the separator element.
Preferably, the separator element is also sealed to two adjacent plates defining a channel of the first group.
Other objects and advantages will become apparent from the following specification taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a heat exchanger made according to the invention as it would appear in sections taken along either one of the lines 1--1 in FIG. 2;
FIG. 2 is a plan view of the heat exchanger of FIG. 1;
FIG. 3 is a bottom view of the heat exchanger of FIG. 1;
FIG. 4 is a view similar to FIG. 1 but of a modified embodiment of the invention;
FIG. 5 is a bottom view of the embodiment of FIG. 4; and
FIG. 6 is a sectional view similar to FIGS. 1 and 4 but of still a further modified embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-3, there is illustrated a plate type heat exchanger made up of a plurality of plates 10 and a plurality of plates 12. The plates are drawn or stamped in the configuration to be described and are assembled to form a stack, generally designated 13. Within the stack 13, the plates 10 and 12 are alternated with one of the plates 10 forming the top plate in the stack and one of the plates 12 forming the bottom plate in the stack.
As seen in FIG. 2, the plates 10 and 12 are generally rectangular and the construction at the upper right hand corner 14 is a mirror image of the construction at the lower left hand corner 16. Similarly, the construction at the upper left hand corner 18 is a mirror image of the construction shown at the lower right hand corner 20. As a consequence, only the constructions at the upper and lower left hand corners 18 and 16, respectively, will be described.
At the corner 16, a connecting flange 22 is located. The connecting flange 22 includes tapped bores by which any suitable fluid conducting fixture can be connected to the connecting flange 22. Generally centrally of the connecting flange 22 is a port 26 of circular shape. A groove 28 adapted to receive an 0-ring seal or the like surrounds the port 26.
Within the stack 13, each of the plates 10 and 12 includes respective openings 30 and 32 aligned with the port 26. The bottom most plate 12 in the stack includes an imperforate plug 34 in its opening 32.
The plates 10, about the openings 30, have downwardly and radially outwardly directed collars 36 which engage and seal against upwardly and radially inwardly directed collars 38 on the plates 12 surrounding the openings 32 therein. Further, the plates 10 have upwardly extending dimples 40 while the plates 12 have aligned, downwardly extending dimples 42. As can be readily appreciated, the collars 36 and 38 provide one means of spacing between the plates 10 and 12 while the dimples 40 and 42 engage each other and provide another means of spacing.
More specifically, the collars 30 and 32 provide spaces 44 between adjacent plates which are sealed from the port 26 by the interengagement of the collars 36 and 38. The dimples, on the other hand, provide spaces 46 which open to the holes 30, 32 in the plates 10, 12 and thus are open to the port 26. It will also be appreciated that the spaces 44, 46 alternate throughout the stack 13.
As mentioned previously, an identical construction is present at the corner 14. As a consequence, the connecting flange 22 at either location may be used as an inlet for a heat exchange fluid, typically an engine coolant, while the connecting flange 22 at the other corner may be used as an outlet. Fluid will flow into one of the ports 26 through the holes 30 and 32 to enter the spaces 46 and then flow between the plates 10 and 12 to the opposite corner where the connecting flange 22 serves as an outlet. During this flow, the spaces 44 are isolated by reason of the presence of the interengaging collars 36, 38.
Turning now to the corner 18, a connecting flange 50 is provided. The same includes a circular opening 52 that is aligned with holes 54 in the plates 10 and holes 56 in the plates 12. In the case of the holes 54 and 56, only the plates 10, about the holes 54, have collars 58 which project upwardly and somewhat radially inwardly.
Mounted within the opening 52 is a flow element in the form of a tube 60. The tube has an outside diameter somewhat smaller than the inside diameter of the collars 58 about the holes 54. Thus, a small gap 62 exists about the periphery of the tube 60 where it enters the stack 13.
At its lower end, tube 60 mounts a separator element 64 which extends radially outwardly to a location between two of the plates 10 and 12 at the space 46. A seal is established at this location during the assembly process as, for example, when the components are sealed or brazed together.
The connecting flange 50 also includes a port 70 which connects to a channel 72 which extends to the exterior of the tube 60. As a consequence, a heat exchange fluid may enter or leave the port 70 and flow through the channel 72 to or from the gap 62 to thereby enter the spaces 44 that are located above the separator element 64. Again, because the identical construction is employed at the corner 20, one of the ports 70 will serve as an inlet and the other may serve as an outlet for the two spaces 44 in the area designated A in FIG. 1.
The connecting flange 50 also includes a pair of tapped bores 74 for connection to a fixture as well as an O-ring receiving groove 76 concentric with the tube 60.
The openings 54 and 56 in the plates 10 and 1 2, near the bottom of the stack, are closed off by an imperforate baffle 80 having a periphery 82 that extends into one of the spaces 44 between the plates 10 and 12 and is sealed thereto to prevent fluid flow through the holes 54, 56 at its location. The baffle 80 isolates two of the spaces 44 from the remainder of the stack in an area designated "B" in FIG. 1. An annular disk 84 is located in the hole 56 in the lowermost plate 12 includes a central opening 86. An upwardly opening channel 88 has a peripheral flange 90 brazed to the bottom of the stack along with a port 92. The port 92 will thus be in fluid communication with the holes 54, 56 below the baffle 80, and thus with the spaces 44 at this location. Consequently, one of the ports 92 may be used as an inlet to the two spaces 44 in the zone "B" while the other may be used as an outlet.
If desired, annular disks or washers 96 may be located within the spaces 46 just radially outward of the collars 56. Turbulators are schematically shown at 98 and may be located within the spaces 44 if desired.
The heat exchanger is completed by a peripheral, upwardly and radially outwardly directed flange 100 about each of the plates 10 and 12. As is well known, the flanges 100 nest with one another as illustrated in FIG. 1 and seal against one another when the heat exchanger is assembled in a soldering or brazing operation.
For pressure resistance, relatively heavy gauge backing plates 102 at the top of the stack 13 and 104 at the bottom of the stack 13 may be employed. As can be appreciated from FIG. 1, the backing plates 102 may include apertures 106 adapted to receive the dimples 40 on the plate 10 to locate the components properly during assembly. Similarly, the plate 104 may include apertures 108 for receiving the dimples 42 on the lowermost plate 12 to perform the same function.
A consideration of the previously described structure will yield the conclusion that the heat exchanger shown in FIGS. 1-3 is capable of exchanging heat, simultaneously, between four different fluids. Although the heat exchanger is not restricted to vehicular use, it will find utility there and in such an environment, engine coolant will typically be flowed into and out of the ports 26 in the connecting flanges 22. As a consequence, coolant will be flowed to each of the spaces 46 within the stack 13.
Transmission oil, for example, may be flowed into and out of the tubes 60. As such, it will flow through the spaces 44 in all areas of the stack except those areas designated "A" and "B" by reason of the separating effect of the separator 64 and the baffle 80.
Retarder oil may be flowed through, for example, the ports 92 where it will pass into the spaces 44 between the plates in the region "B." Similarly, hydraulic fluid may be flowed into and out of the ports 70 to flow through the spaces 44 in the area "A."
In all cases, the oils will be in heat exchange relation with the engine coolant through the adjacent one of the plates 10 or 12 with isolation of the streams being maintained by the collars 36, 38, 58 or the washers 96 and/or separator 64 and the baffle 80.
FIG. 4 illustrates a similar embodiment but where the channels 88 are dispensed with in favor of a nipple 110 brazed to the bottom of the stack in alignment with the openings 54, 56. The nipple 110 includes an interior conduit 112 and a peripheral lip 114 surrounded by a radially outwardly opening peripheral groove 116. A hose may be fitted over the lip 114 to abut the base 118 of the nipple 110 and a hose clamp tightened within the groove 116 to hold the hose in place.
FIG. 6 illustrates an embodiment of the invention that is operative to perform heat exchange operations between as many as five different fluids. In this embodiment, at the top of the stack 13, the connecting flanges 22 and 50 are retained and the structure is identical to that previously described. However, the baffle 80 is moved upwardly in the stack to a point approximately mid-way in the stack 13. The channels 88 are dispensed with in favor of third and fourth connecting flanges of the type shown at 50. As a consequence, at the lower end of the stack 13, a connecting flange 50 is located at each of the corners 14 and 16 and each include a bore 120 aligned with the holes 54, 56 and the plates 10, 12 at a location below the baffle 80. A tube 122 is located within the bore 120 and is essentially identical to the tube 60. It extends upward to a separator element 124 identical to the separator element 64 which is located in and sealed to one of the spaces 44 between the plates 10 and 12. Again, the outer diameter of the tube 122 is less than the inner diameter of the holes 54 and 56 and the collars 58 so that a gap 126 similar to the gap 62 is formed. A port 128 is located in the connecting flange and extends to a channel 130 which goes to the outer diameter of the tube 122. As a consequence, the port 128 is in fluid communication with the gap 126.
In this embodiment, a fluid, typically a coolant, will flow between the ports 26, that is, through the spaces 44 within the stack 13. Another heat exchange fluid may enter and leave the tubes 60 and thus will flow through spaces 46 below the region "A" and above the baffle 80. This region is designated "C" in FIG. 6.
A third fluid may enter and leave through the ports 70 and will flow through the spaces 46 within the region designated "A." A fourth fluid may enter and depart through the tubes 122 and thus will flow through the spaces 46 above the region "B" and below the baffle 80. This region is designated "D." The fifth fluid may enter and depart at ports 128 and thus will flow through the spaces 46 in the region "B." Consequently, the four fluids flowing through the tubes 60 or 122, or the ports 70 or 128 will all exchange heat with the fluid being flowed through the ports 26.
It will thus be appreciated that a plate type heat exchanger made according to the invention is advantageous in that it provides for the exchange of heat between three or more fluids in a single structure. As a consequence, the expense of separate heat exchangers for each heat exchange operation is avoided. Furthermore, spacial requirements to house the heat exchangers is reduced because a single heat exchanger assembly can be employed. Because only two types of plates are utilized, assembly is readily simple and inasmuch as the orientation of one plate to the other does not change even when the plates are rotated, manufacturing problems are minimized.
It will also be appreciated that the unique construction of the connecting flange 50 with the tubes 60, 122 and the separator elements 64, 124 provides the unique means of achieving the separation of multiple heat exchange fluids in a single heat exchanger. | Space and weight constraints on heat exchangers performing heat exchange operations between three or more fluids are eliminated in a structure including a plurality of plates (10, 12) arranged in a stack (13). Collars (36, 38) about openings (30, 32) the plate (10, 12), divide the spaces between the plates (10, 12) into two different types of spaces (44, 46). A connecting flange (50) with a tube (46) and a separator element (64) cooperates with holes (54) and (56) within the plates that (10, 12) to isolate certain of the spaces (44) from other of the spaces (44) providing a means for flowing different heat exchange fluid through different ones of the spaces (44) while flowing still another heat exchange fluid through the spaces (46), all in a single structure. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to the pumps and compressors which incorporate adjustable inlet guide vanes for purpose of directing the fluid flow into the pump or the compressor rotating impeller.
Rotating fluid pumps and compressors are normally designed to operate best at specific fluid flow rate, pressure rise and rotating speed conditions. Process fluid flow systems often demand changes in the fluid flow rate, while maintaining relatively constant pressure rise. Such applications, very often employ pumps or compressors, operating at substantially constant rotating speed and include fluid flow control systems which bypass the excess fluid flow back to the pump or the compressor inlet by throttling of such fluid flow. Other control systems may utilize throttling of the entire pump flow, without the flow bypass. In such cases, a decrease in the fluid flow rate entering the pump or the compressor impeller causes a decrease in the axial fluid velocity while the rotational velocity of the impeller blades remain substantially constant. Such a condition causes higher relative inlet flow angle with respect to impeller blades, contributing to increase of blade inlet losses which negatively affect the pump efficiency and can produce unstable flow through the pump. Inlet guide vanes, producing pre rotation of the fluid flow in the direction of the impeller rotation, will decrease such high relative inlet flow angle, thus decreasing the blade inlet losses and increasing the impeller efficiency at such low flow conditions. Other applications, such as rotating air compressors used with turbochargers, boosting the pressure of internal combustion engines, are normally designed to achieve peak efficiency under pre-determined operating conditions. Change in the output power and rotating speed of internal combustion engine usually requires a cooresponding changes of charge air flow rate and the boost pressure delivered by the turbocharger to the engine. Such changes may result a decrease in the charge air flow rate, while the boost pressure demand remains disproportionally high. For instance, a reduction in the engine speed under high load conditions, usually decreases the ratio of the inlet air flow velocity relative to the rotatinal velocity of the turbocharger compressor blades, thereby producing higher inlet flow angle with respect to compressor impeller blades. Carefull matching of the turbocharger design to the specific engine requirements is needed, in order to avoid unstable compressor flows at such low flow conditions. Inlet guide vanes, causing pre-rotation of the air flow in the direction of the compressor rotation will, under such conditions, decrease the flow angle between the impeller blades and the air flow, thus allowing the turbocharger to achieve lower flow rates and increase its usefull flow range, while maintaining efficient compressor inlet flow conditions. Additionally, a fast responce of the inlet guide vanes system, when needed, during the engine and turbocharger acceleration, would be benefitial to the overall engine performance.
The use of inlet guide vanes in pumps and compressors to reduce the inlet flow angle for operating at conditions other than optimum is well known to the art. U.S. Pat No. 3,861,823 to George K. Serovy illustrates the use of inlet guide vanes,which are radially retractable in a linear fashion and which include automatic control system external to the fluid compressor. Such a control system, being connected to a system of ring gear, multiple pinion gears and rack members, inserts and retracts the guide vanes relative to the fluid flow.
Bladed turbine pump with adjustable guide vanes, in which the inlet guide vanes are linked to the second set of vanes located in the pump outlet, is described in the U.S. Pat. No. 4,484,857 to Pierre Patin. Such inlet guide vanes,being lengthwise pivotable, are continously submerged in the flow.
These approaches, while providing the desired inlet flow angle at part flow or at some other less than optimum conditions, use mechanical actuation systems, often employing ring gear, pinion gears, rack gears and levers. In order to maintain precise guide vanes alignment, such systems usually require a high degree of precision and minimum internal clearances between the mating parts, while at the same time allowing for manufacturing tolerances and thermal expansion differences that may occur in operation. Such mechanisms usually have relatively low tolerance toward particulate contamination between such mating parts. Repetitive cycling of such systems, with inlet guide vanes being subject to a great deal of turbulence generated by relatively high fluid velocities, tend to induce chatter and vibration into the guide vanes systems, which may lead to premature wear and malfunction of moving parts. Actuation systems, having multiple internal clearances in series, and which are required to transmit reversable motions, may also lag in responce when required to produce rapid and precise change of the inlet flow direction. Therefore, it would be desirable for such system to have a minimum mass inertia and no mechanical clearances between the individual parts.
It would be also desirable, for such guide vanes system, to be relatively insensitive to a particulate contamination in the fluid flow, with respect to its functional performance.
SUMMARY OF THE INVENTION
It is an object of this invention to provide, a guide vane assembly which guide the fluid flow in a desired direction only when required and to have a minimum interference with the fluid flow when not in use.
It is further object of this invention to provide a guide vane assembly which utilizes pump discharge pressure, acting on a single coaxial annular piston, to directly adjust the position of such inlet guide vanes, by pivoting said guide vanes into and out of the fluid flow.
It is still further object of this invention to provide a guide vane assembly which utilizes automatic control means to adjust the position of inlet guide vanes, to properly improve the inlet flow angle of the fluid under conditions other than the optimum design conditions.
It is still further object of this invention to provide a guide vane assembly which, while fulfilling the above objects, utilizes continous mechanical loading of such guide vanes, to maintain zero clearances between the actuation piston and the pivoting guide vanes.
It is still further object of this invention to provide a guide vane assembly which, while fulfilling the above objects, is simple and efficient in design.
An inlet guide vane assembly for a pump or a compressor having rotary blades is provided. The guide vanes of the assembly are pivotably disposed in a housing defining an fluid flow passageway so that a portion of the vanes can be inserted into or withdrawn from the passageway by pivoting the guide vanes about a pivot axis. Control means is provided for controling the degree of pivot.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the invention will become apparent from a study of the following specifications and drawings, in which:
FIG. 1 is a sectional elevation of the pump incorporating the invention, with the guide vanes removed from the fluid flow;
FIG. 2 is a sectional elevation of the pump incorporating the invention, with the guide vanes fully inserted into the fluid flow;
FIG. 3 is a sectional view taken along the line 3--3 of FIG. 2;
FIG. 4 is a developed sectional view taken along the line 4--4 of FIG. 1;
FIG. 5 is a developed sectional view taken along the line 5--5 of FIG. 2;
FIG. 6 is a vector diagram representing the fluid flow and the impeller blades velocities and relative flow angles, with the guide vanes removed from the fluid flow.
FIG. 7 is a vector diagram representing the fluid flow and the impeller blades velocities and relative flow angles, with the guide vanes fully inserted in the fluid flow.
FIG. 8 is a sectional view of a alternate automatic control means.
FIG. 9 is a diagram representing pressure rise as a function of flow, of a typical centrifugal pump and representing also the operating points of the alternate control means shown in FIG. 8.
FIG. 10 is a view of typical inlet guide vane sealing plate.
FIG. 11 is a sectional view taken along the line 11--11 of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With particular reference to FIGS. 1, 2, 3, 4 and 5, a pump incorporating the principles of the present invention is generally indicated by the reference numeral 8. Such pump 8 includes blades 11 being a part of the bladed impeller 10, which is rotatably mounted to the housing 9 and is further contained within pump housing 12. The central body 27 is fixed by stationary vanes 17 to inlet pipe 40 which provides the base for a plurality of bearing grooves 25 supporting the pivot axis 24 which are rigidly connected to the inlet guide vanes 23. The inlet pipe 40 together with the piston housing 31 are rigidly connected to the housing 9 with bolts 14. As shown on FIG. 5, the inlet guide vanes are configured as flat surfaces at the flow enterance and are curved at the trailing edges to a desired angle indicated by the letter A. Such angle A may vary along the radial lenght of the vanes 23 for a purpose which will be explained later. The relative position of individual vanes 23 is such, as to form together with the central body 27 and the inlet pipe 40, a series of efficient flow turning passages when the vanes are fully inserted into the fluid flow. The inlet pipe 40 includes radial slots 19, allowing the guide vanes 23 to pivot freely about the pivot axes 24, while being guided by the radial slots 19 in peripheral and axial directions, said slots 19 being configured in close proximity to the guide vanes 23, thus preventing excessive side-movement of such vanes, and at the same time preventing excessive fluid flow exchange between annular flow passage 41 and the cavities 38 and 39. A elastic band 30, being expanded peripherally over the ridges formed by guide vanes 23, and located substantially over the pivot centres formed by the guide vane pivot axes 24 and groves 25, is loading said guide vanes in a inward direction, thus resulting in a continous contact between pivot axes 24 and groves 25. A elastic band 36, being expanded peripherally over the ridges formed by the guide vanes and located substantially of center relative to pivot axes 24, is loading said guide vanes in a way to affect said guide vanes to pivot in the direction of retracting said guide vanes from the fluid flow. For reasons which will be described further on, the annular ridge 62, being a portion of the annular piston 20 is at all times in a sliding contact relationship with the guide vanes ridges 61 thus counterbalancing the moment causing by the action of said elastic band 36. The position of the guide vanes 23 is therefore, directly governed by the axial position of the annular piston 20, which is movable in axial direction, while compressing the spring 37 to a degree proportional to its axial motion.
A valve stem 54, configured with the flow passage 52 is rotatably mounted in the piston housing 31 and pump housing 12. By rotating the valve stem 54, the valve passage 52 can align to a varying degree with the passage 50 configured in the piston housing 31, thus selectively opening or closing said passages. Since the highest fluid pressure is in the pump discharge cavity 42, the change in the flow area of the valve 52, will pressurize to a varying degree cavity 38, thus directly affecting the pressure differential across the piston 20. The fluid pressure in the cavity 39 is nearly equal to the pressure in the annular passage 41 due to close communication of cavity 39 and the passage 41 through the slots 19, thus causing the pressure in the cavity 39 to be nearly the same as the pump inlet pressure. As shown on FIG. 1, the valve passage 52 is in a position of preventing fluid communication between the pump discharge cavity 42 and the cavity 38. Due to the annular gaps 64 and 65, between the piston 20 and piston housing 31 and the inlet pipe 40, the fluid pressure around the piston 20 is substantially equalized. Since the free length of the spring 37 is longer than the maximum allowable space, the force generated by the spring 37 holds the piston 20 in a solid contact with the piston housing 31, thus allowing the guide vanes to be fully retracted from the annular passage 41, by the action of elastic band 36. The force caused by the compression of spring 37, being linearly proportional to the axial displacement of said spring,is being counterbalanced by a fluid pressure difference between cavities 38 and 39. As described earlier, the valve passage 52 can prevent direct fluid communication between pump discharge cavity 42 and cavity 38 such as shown on FIG. 1, or it can be positioned to be aligned with the passage 50 as shown in the FIG. 2, allowing for direct and relatively unobstructed fluid flow communication between the cavities 42 and 38, in which case, the cavity 38 is being pressurized to a value higher than the cavity 39. The resulting pressure difference between the cavity 38 and cavity 39 is being counterbalanced by the force of the compressed spring 37 and by the axial component of the force acting on the countour 62 of the piston 20, due to the contact with the contour 61 of the guide vanes 23. A fluid flow relationship between the degree of opening of the valve passage 52 and the pressure in the cavity 38, is affected by the pressures in the cavity 42 and the inlet annulus 40, and by the fluid leakage through the gaps 64 and 65. By a suitable design choice of springs 37 and 36, shape of the guide vane ridge countour 61, frontal area of piston 20, size of gaps 64 and 65, and the flow area of the valve 52 with relation to the pump differential pressure, a desired balance can be achieved between the fluid and the spring forces, at all guide vanes postions, ranging from fully retracted position as shown in FIG. 1, to fully inserted position as shown on FIG. 2.
For the purpose of illustrating the operation of the present invention at optimum design conditions, FIG. 4, representing a section indicated by a broken line 4--4 on FIG. 1, shows the angle B of the impeller blades inlet edges and its relation to said blades tangential velocity U and the axial fluid inlet velocity V'.
FIG. 6 shows a conventional vector diagram of typical velocities associated with FIG. 4. To those skilled in the art, it becomes obvious from the vector diagram, that under such optimum conditions, the inlet flow velocity into the impeller blades, as represented by vector V', is in a purely axial direction. Said vector V', when compounded with the blades tangential velocity vector U, results in a relative velocity vector W, positioned at angle B relative to the axis of the blades rotation. Said angle B, being identical to the blades inlet angle B shown on FIG. 4, indicates the the relative flow vector is aligned with the blades, under said optimum flow conditions.
FIG. 5 shows a sectional view of the inlet guide vanes being fully inserted into the inlet flow, as indicated by the broken line 5--5 shown on FIG. 2. FIG. 7 shows a typical vector diagram associated with flow conditions shown on FIG. 5, where there was a substantial decrease in fluid flow rate as compared to the previously described optimum flow condition. The axial inlet flow velocity, being substantially lower than that at the optimum flow conditions, is being represented by the vector V', while at the same time the blades rotational velocity as represented by the tangential velocity vector U, has remained substantially constant. As it will be described later, such a low flow condition has called upon insertion of guide vanes 23, resulting in a change in the inlet flow direction, from purely axial to a flow rotated to a angle A relative to the axis, with the absolute inlet flow velocity represented bu the vector V. To those skilled in the art, it becomes obvious that such flow prerotation under certain low flow conditions and when the guide vanes inlet angles are designed properly, will result in the angle B, between the relative velocity vector W and the rotating axis direction shown on FIG. 7, to coincide with the blades inlet angle B as shown on FIG. 5, thus providing for a incidence angle free, improved inlet flow conditions.
Due to variation of the impeller blades tangential velocity along the impeller blades radius, the guide vanes 23, as shown on FIGS. 10 and 11, may be configured to generally provide less turning at the lower radial distance from the impeller center, indicated as hub profile on FIGS. 10 and 11, and more turning at the larger radial distance, indicated as tip profile on FIGS. 10 and 11, in order to match more properly the angle B of the relative velocity W with the generally varying blades angle B, along said blade radius. Due to a twist along the radial dimension, of the trailing edge of the guide vanes profile, shown as a difference between tip profile and the hub profile on FIG. 10, and considering that slot 19 must accomodate pivoting motion of said guide vanes, said slot 19 is enlarged in the area of said profile twist, and such enlargement indicated as extended slot 19 on FIG. 10. Since fluid flowing through turning vanes generally produces a pressure differential across the vane profiles, a sealing plate has been incorporated into the overall guide vane shape and shown as portion of the guide vane 23, such sealing plate being identified by a numeral 111 on FIGS. 10 and 11. Said sealing plate 111 contour is designed to fit a matching surface of the inlet pipe 40, so as to form a sealing surface indicated by a letter H on FIG. 11, thus preventing reciruclation of fluid in and out of the annular inlet passage 41 through said extended slot 19 area.
The principal control elements are shown schematically in FIGS. 1 and 2. A hydraulic cylinder 72 is anchored at one end to a pump or a compressor frame 84. Said hydraulic cylinder 72 includes piston 71 which is attached to a arm 55 of the valve stem 54 by a control rod 70. A control unit 82, interposes the cylinder 72 and the fluid source 83, receives an input signal such as pump discharge pressure or flow, designated by arrows DP and F, respectively. In response to the input signal, the control unit modulates the flow from the supply source to the hydraulic cylinder 72 by way of conduits 86 and 87, communicating respectively with internal chambers 80 and 81 located within cylinder 72.
Pump or the compressor performance may be easily measured by sensing the flow or the discharge pressure signals, which may be transmitted as a fluid pressure or as electrical signals to the control unit 82. For example, a decrease in the pump flow, transmitting such signal to the control unit 82, will cause the hydraulic fluid to enter the chamber 80 and proportinally to discharge the hydraulic fluid from the chamber 81, causing the piston 71 and control rod 70 to move arm 55 and rotate the valve stem 54, causing the passages 50 and 52 to open, allowing the pump discharge pressure to cause the fluid flow from cavity 40 to the cavity 38, causing the piston 20 to compress spring 37 and cause insertion of the guide vanes into the inlet flow annulus 41. A simmilar effect may be accomplished in principle by utilizing the discharge pressure signal or both signals, where the control unit is preprogrammed to compute the proper response of the hydraulic system acutating the piston 71.
A alternate guide vanes control system shown in FIG. 8, utilizes variation of the pump discharge pressure in the cavity 42, to cause a move of the inlet guide vanes 23 from a fully withdrawn position to a fully inserted position and vice versa. Control elements shown in FIG. 8 consist of a fluid cylinder 90 which includes an elongated piston 92 with stepped diameters, resulting a piston areas C, D and E, spring 93 and retaining screw 94. The fluid cylinder 90, together with the passages 97, 96 and 95 are configured within the body of the annular housing 91, which also houses the annular piston 20. The housing 91 is configured in the same fashion as the housing 31 shown in FIG. 1, 2 and 3, except for the details pertaining to the passages 52, 51 and the valve stem 54 which have been replaced by a alternate control system shown in the FIG. 8. All other features omitted on the FIG. 8 are the same as those shown on FIGS. 1, 2, 3, 4, 5, 6 and 7.
With the reference to FIG. 8, a piston 92 has a intermediate step, limiting its axial motion caused by a compressed spring 93 to a position shown by a broken line, whereas in this position, the largest diameter of the piston does not cover the passage 97, which allows fluid flow communication between the pump discharge cavity 42 and the cylinder chamber 98. Obviously, said position can be only achieved when the force generated by spring 93 is higher than the opposing difference in fluid pressures acting on piston 92, which right hand side is subject to a pump discharge pressure acting on the annular area D transmitted from cavity 42 via passage 97 into a cylinder chamber 98, plus the pressure acting on the area E transmitted from the cavity 38, which is nearly equalized with the annular inlet passage 41. The left hand side of the piston 92 is subject to the pump inlet pressure transmitted into chamber 99 via passages 88 and 89 from the pump inlet passage 43.
In said position, indicated by a broken line, the smallest piston diameter section is fully inserted into the passage 95, thus substantially blocking a flow communication between the pump discharge cavity 42 and the annular piston cavity 38, with the resulting pressure in the cavity 38 to be nearly equal to pressure in the annular inlet passage 41. As it has been explained earlier, under similar conditions, said pressures are nearly equal due to said cavity and the said passage close communication through the slots 19 and gaps 64 and 65. The inlet guide vanes, under such pressure conditions in the cavity 38 are fully withdrawn from the annular passage 41.
The pressure rise - flow relationship of a typical turbopump operating at constant rotating speed, is represented in FIG. 9 by a curve J for the inlet guide vanes fully withdrawn from the inlet flow passage, and by a curve K for said vanes fully inserted into the said flow passage. The nominal operating point assumes the pump operation to be with guide vanes fully withdrawn, and is for example indicated by a letter N. Typically, in the fluid flow systems utilizing discharge throttling to control the fluid flow, as the flow decreases, the pressure rise increases, thus for a pump operating nominally at the point N the pressure rise would be increasing from a value indicated by a letter Pn, toward the point O having the pressure rise value Po. At said point N, the balance between the force of the spring 93 and the force resulting from fluid pressures acting on stepped piston 92, areas C, D and E, is such, that said stepped piston smallest diameter is fully inserted into cavity 95 as indicated by a broken line. As the flow decreases and the pressure rise increases, and assuming for example, that the pump inlet pressure and the pressure in the chamber 99 remains relatively constant, the pressure in the cavities 42, passage 97 and chamber 98 increases, thus increasing the pressure difference across piston 92 in the direction of increasing the load on spring 93. By a suitable design choice of spring 93 and said spring preloading by a adjustable screw 94, and as the forces due to said pressure diference increase toward the value Po, repsented by the point O on FIG. 9, the spring 93 begins to compress, allowing the piston 92 to move leftwardly. As soon, as the right hand edge of piston 92 facing the cavity 38, begins to open the passage 96, the pressure in the cavity 38 begins to increase due to the fluid flow from the cavity 42 into the cavity 38, thus increasing the fluid pressure against the surface area E of the piston 92, which action causes still larger unballance force compressing the spring 93 even more, thus opening the passage 96 still further, which increases the fluid pressure in the cavity 38 still closer to the pump discharge pressure in the cavity 42, until the piston 92 is in the most leftward position. At this point, the passage 96 is fully open and the motion of the piston 92 is stoped by a extention of the screw 94. The force balance in this position of piston 92 is such, that the excess of fluid forces acting on areas C, D and E, against the spring 93, is being reacted by the extention of the screw 94. With passage 96 fully open, the cavity 38 is pressurized by the pump discharge pressure and the inlet guide vanes 23 are fully inserted. The pump operating point has been shifted from point O on the curve J to a point R on the curve K, indicating a substantial decrease in fluid flow caused by fluid dynamic action of fully inserted guide vanes, as it has been explained earlier using FIGS. 4, 5, 6 and 7. The most leftward position of piston 92 is being maintained as long as there is a force being reacted between the piston 92 and the extention of screw 94. As the pressure rise of the pump decreases from a value Pr toward a value Ps, as indicated on FIG. 9, the pressure forces acting on areas E and D decrease, and the excess force balancing the difference between the fluid forces and the force due to spring 93, that is being reacted by the extention of the screw 94, also decreases. At the point when the fluid forces acting on the piston 92 become lower than the force of the compressed spring 93, the piston 92 begins to move toward its rightward position, beginning to close the passage 96, thus generating a fluid flow restriction between cavities 42 and 38 and decreasing the fluid pressure in cavity 38, causing further decrease of pressure acting on the piston area E, thus causing a further force unbalance, moving the piston 92 further to the right, blocking the passage 96 more and decreasing the pressure acting on the area E still more, until the passage 96 is blocked and the pressure in the cavity 38 is nearly equalized to the pressure in the pump inlet passage 41 via slots 19 and piston gaps 64 and 65, causing the piston 92 to move into its most right position and causing the annular piston 20 to move into its most left position, thus causing the inlet guide vanes to retract from the fluid flow. At this point the pump operation has shifted from point S on curve K, to the point N on curve J. By a suitable design of the piston areas C, D and E, length of the piston travel, location of passage 96, the spring 93 and its preload, passage sizes and other parameters, a choice can be made relative to the specific pump characteristics as generally represented by curves J and K, of the points at which the guide vanes are to be inserted and retracted.
From the foregoing it will be appreciated that the present invention provides novel and improved inlet guide vane system. While a preffered embodiment of the invention is described and illustrated herein, there is no intent to limit the invention to this or any particular embodiment. | An inlet guide vane assembly for a pump or a compressor having rotary blades. The guide vanes are pivotably disposed so that a portion of the vanes can be inserted into or withdrawn from the inlet passageway of the pump or the compressor by pivoting the guide vanes about a pivot axes. A control is provided for controlling the degree of pivot. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefit of and incorporates by reference essential subject matter disclosed in German Patent Application No. 102 57130.9 filed on Dec. 5, 2002.
FIELD OF THE INVENTION
[0002] The invention concerns a fully hydraulic steering with a steering member, a steering unit that can be activated by the steering member, said steering unit comprising a supply connection arrangement with a pressure connection and a tank connection, and a working connection arrangement with two working connections, and a steering motor, which is connected with the working connection arrangement.
BACKGROUND OF THE INVENTION
[0003] In a fully hydraulic steering, a direct mechanical active connection does not exist between the steering member, for example a steering handwheel or a joystick, and the steered element, for example the steered wheels of a vehicle or the rudder of a ship. On the contrary, the steered element is controlled by a steering motor, which again is supplied via the steering unit. Usually, such a steering unit consists of a measuring motor section and a directional section, the latter usually having two mutually rotatable slides. The steering member rotates one slide, thus releasing a flow path from the pressure connection to one of the working connections, while another flow path is realised from the second working connection to the tank connection. The fluid flowing to the steering motor is led via the measuring motor, which again makes the other slide follow, so that when the desired fluid amount has flown through, the flow paths are closed again. In case of failure of the pump supplying the pressure connection, the measuring motor of the steering unit acts as emergency pump, that is, by activating the steering handwheel, the driver can pump the fluid to the steering motor, which is required to cause a change of direction.
[0004] When a steering unit is provided with a measuring motor, which also has to act as emergency steering pump, the measuring motor must not be too large. Otherwise, during emergency steering, the driver would have to provide substantial force to cause a position change of the steered element, for example to cause a change of direction. On the other hand, the measuring motor must not be too small. Otherwise, each steering activity would require a substantial movement of the steering element.
SUMMARY OF THE INVENTION
[0005] The invention is based on the task of increasing the opportunities during steering. With a fully hydraulic steering of the kind, this task is solved in that an auxiliary force operated steering valve is arranged in parallel to the steering unit between the supply connection arrangement and the working connection arrangement.
[0006] With a steering valve of this kind, it is possible to supply the steering motor with hydraulic fluid not only via the steering unit, but also via a parallel path. This can be utilised for a plurality of possibilities. For example, it is possible to use a measuring motor with a smaller tooth set, that is, a smaller displacement, in the steering unit. During emergency steering the vehicle can thus be steered with a relatively small force. During trouble-free operation, a further share of fluid can be supplied through the steering valve in addition to the fluid supplied through the steering unit with the smaller measuring motor section. The steering valve no longer has to be activated mechanically via the steering member. An auxiliary force can be used for adjusting the steering valve, for example a hydraulic pressure or an electrical power.
[0007] Preferably, the steering member acts upon a sensor, whose outlet is connected with a steering valve control device. This is a relatively simple possibility of controlling the steering valve. A sensor, which is arranged on the steering member, for example a steering handwheel or a joystick, determines the position of the steering member and then adjusts the steering valve so that the desired fluid amount can flow from the supply connection arrangement to the working connection arrangement without acting upon the steering unit to a corresponding extent. The steering member can also act upon the sensor indirectly, for example in that the sensor measures pressures or flows or something else, which are caused by the steering member.
[0008] Preferably, the sensor produces a proportional steering signal. A proportional signal, that is, a signal, whose dependence on the position of the steering member follows a linear function, is easy to process. No conversions have to be made, which depend on the position of the steering member.
[0009] Preferably, a share of the fluid supplied to the steering motor, originating from the steering valve, can be changed. This change can either be made from vehicle to vehicle or from series to series. In the same manner, it is possible to use the same steering for a plurality of vehicles, without the need for major design changes. However, it is also possible to change the share in dependence of the operation state or the work task of a vehicle, that is, when the steering has already been built into a vehicle. The driver can make the change, for example by means of a select switch or the like. It can also occur in dependence of the load state or another value to be measured by a sensor. Finally, during operation, it is also possible to change the share, that is, the relation between the fluid supplied via the steering unit and the fluid supplied via the steering valve. This can, for example, be done when going from street operation to building-site operation or the like.
[0010] Preferably, the steering valve is put together with the steering unit. This keeps lines short, which are required for connecting the supply connection arrangement and the working connection arrangement with the steering valve. In principle, the steering unit with the steering valve can be handled in exactly the same way as the steering unit alone.
[0011] In a preferred embodiment, it is ensured that the steering valve is flanged onto the steering unit. In another embodiment it may be ensured that the steering valve is built into the steering unit. In both cases, the steering valve and the steering unit are combined to a compact component.
[0012] Preferably, at least parts of a control electronics are arranged on the outside of the steering unit. This involves the advantage that the control electronics can be cooled by the surroundings, that is, the thermal load of the control electronics can be kept small.
[0013] It is also advantageous that a steering motor sensor is arranged on the steering motor, a leakage compensation device being provided, which contains the steering valve. A steering motor sensor monitors the position of the steering motor. This is particularly advantageous, when the steering valve must also be activated independently of the steering member, that is, via a remote control or a GPS (Global Positioning System). Particularly advantageous, however, is the fact that the steering valve can also be used to compensate for possibly occurring leakages in the steering. As soon as fluid has been lost, the accordance between the positions of steering member and steering motor is lost. This accordance can be restored by a supply of fluid, which can in a simple manner be controlled via the steering valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] In the following, the invention is explained in detail on the basis of a preferred embodiment in connection with the drawings, showing:
[0015] [0015]FIG. 1 is a schematic view of a hydraulic circuit of a fully hydraulic steering
[0016] [0016]FIG. 2 is a schematic view of the relation between the fluids supplied by the steering motor
[0017] [0017]FIG. 3 is a schematic external view of a steering unit
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] [0018]FIG. 1 is a schematic view of a fully hydraulic steering 1 with a steering member 2 , in the present case in the form of a steering handwheel 3 . Via a steering column 4 , the steering handwheel 3 is connected with a steering unit 5 . The steering motor 5 has a measuring motor section 6 with a measuring motor 15 and a directional section 7 . The mode of operation of such a steering unit is known per se. When the steering handwheel 3 is turned, one slide 8 is turned via the steering column in relation to another slide 9 , thus releasing a flow path from a pressure connection P to a working connection L, R. At the same time, a further flow path is established from the other working connection R, L to a tank connection. The measuring motor 15 in the measuring motor section 6 is activated by the fluid, which flows from the supply connection arrangement with the pressure connection P and the tank connection T to the working connection arrangement with the two working connections L, R, and turns the two slides 8 , 9 back to their neutral position, in which the flow paths are interrupted. The amount of hydraulic fluid flowing via the working connection arrangement L, R, reaches a steering motor 10 and activates it in the desired manner, that is, the deflection of the steering motor 10 is usually proportional to the rotary movement of the steering handwheel 3 . Here, the steering motor exists in the form of a steering cylinder.
[0019] Between the working connections L, R and the directional section 7 , pressure-reducing valves 11 , 12 , also called “shock valves”, and non-return valves 13 , 14 for anti-cavitation, can be arranged in a manner known per se.
[0020] Such a steering has proved its value for a long time. As a fully hydraulic steering is concerned, there is no direct mechanical connection between the steering member 2 and the steering motor 10 . The activation of the steering motor 10 occurs exclusively via hydraulic fluid, whose supply is controlled by the steering unit 5 .
[0021] When the pressure at the pressure connection P drops, for example when a drive motor of the vehicle provided with the steering 1 fails, said motor also driving a pump, which supplies the pressure, the vehicle can be steered anyway, as in this case, the measuring motor 15 of the measuring motor section 6 serves as emergency steering pump, that is, it is activated directly by the steering handwheel 3 and can transport the required fluid to the steering motor 10 .
[0022] When dimensioning the measuring motor 15 , however, certain compromises must be accepted. Firstly, the measuring motor 15 must not be too small, that is, the displacement should not fall short of a predetermined minimum size, as then a very large number of rotations would be required to cause a certain deflection of the steering motor 10 . When, on the other hand, the measuring motor 15 is too large, the driver will require a substantial body power to pump the required amount of fluid to the steering motor 10 during a failure of the pump, which supplies the pressure at the pressure connection P.
[0023] In the steering 1 is provided a steering valve 16 , which is connected in parallel with the steering unit 5 between the supply connection arrangement with the pressure connection P and the tank connection T, and the working connection arrangement with the working connections L, R. The steering valve 16 is auxiliary power operated. In the present case, it has a magnetic drive 17 . Other drives, for example hydraulic drives, can of course also be imagined.
[0024] By means of the steering valve 16 , fluid can be supplied from the supply connection arrangement P, T to the working connection arrangement L, R, thus driving the steering motor 10 , without requiring that the total amount of fluid must flow through the steering unit 5 , thus acting upon the measuring motor 15 . This is shown schematically in FIG. 2. The horizontal direction shows the rotational speed of the steering handwheel 3 , and the vertical direction shows the corresponding amount of fluid transported. A curve 18 shows the amount of fluid, which is supplied by the steering unit 5 alone. A curve 19 shows the amount, which is supplied to the steering motor by the steering unit 5 and the steering valve 16 in common. An arrow 20 shows that the amount of fluid, which is controlled by the steering valve 16 and the steering unit 5 in common, can be changed. As the amount of fluid, which can be controlled by the steering unit 5 , is constant, this means that the share of the fluid, which is controlled by the steering valve 16 , can be changed.
[0025] The change of this share can be used to adapt the steered vehicle to different operating conditions. The change can also occur on the vehicle, for example by the driver, who activates an adjustment device 21 connected with a control device 20 . The share, which is controlled by the steering valve 16 , can also be fixed, though being different from steering to steering. Thus, an adaptation to different vehicle types or series is possible.
[0026] The control of the steering valve 16 occurs via the control device 20 mentioned above. The control device 20 is connected with a sensor 22 , which generates a proportional signal in dependence of the position of the steering handwheel 3 . The sensor 22 can also be called steering member sensor.
[0027] Further, the control device 20 is connected with a steering motor sensor 23 . For example, the control device compares, if the positions, which are determined by the steering member sensor 22 and the steering motor sensor 23 , correspond to each other. If this is not the case, the steering valve 16 is opened, supplying oil to the steering motor 10 , until the correspondence has been achieved. Of course, this compensation of missing correspondence cannot only be made during idling, but also during steering.
[0028] Thus, the steering valve 16 definitely able to control the steering motor 10 proportionally to the steering unit 5 .
[0029] In many cases, it is not necessary at all for the steering unit 5 to be activated. This applies, for example, when the vehicle provided with the steering 1 is remote-controlled. Thus, the steering can also be used for a GPS steering and other kinds of electrical steerings.
[0030] [0030]FIG. 3 is a schematic external view of the steering unit 5 . The steering valve 16 is flanged onto the steering unit 5 . An alternative embodiment provides that the steering valve 16 is built into the steering unit 5 . At least parts of a control electrode 24 , by means of which the control device 20 is realised, are arranged on the outside of the steering unit 5 . The environment then cools the control electronics 24 , so that thermal overloading of the control electronics 24 can be avoided. Shown are merely the supply connection arrangement P, T and the working connection arrangement L, R, each with one line. It is obvious that, in relation to the drawing level, an additional line of these connection arrangements is arranged behind the line shown.
[0031] The steering valve 16 does not only control the amount of hydraulic fluid from the supply connection arrangement P, T to the steering motor 10 , but also its direction. | The invention concerns a fully hydraulic steering with a steering member, a steering unit that can be activated by the steering member, said steering unit comprising a supply connection arrangement (P, T) with a pressure connection (P) and a tank connection (T), and a working connection arrangement (L, R) with two working connections (L, R), and a steering motor, which is connected with the working connection arrangement (L, R). It is endeavoured to increase the possibilities of steering. For this purpose, it is ensured that an auxiliary force operated steering valve is arranged in parallel to the steering unit between the supply connection arrangement (P, T) and the working connection arrangement (L, R). | 1 |
CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority from U.S. Provisional Application No. 60/509,313, filed Oct. 7, 2003.
TECHNICAL FIELD
The invention relates generally to cleats and cleating systems for footwear.
BACKGROUND ART
Historically in the golfing industry, golfers have used shoes in which an array of screw holes were embedded into the shoe sole to accept an equivalent number of golf spikes. The golf spike tips are typically made of metal, such as tungsten or stainless steel, and are contained within a circular housing having a nub portion. These spikes are screwed into the screw holes and can be removed or replaced, as needed, using a special golf wrench tool. A standard golf shoe typically has between eight and eleven golf spikes for each shoe. These spikes provide traction for a golfer during a golf swing.
A major problem with these types of golf spikes is that the spikes and the nub portion can leave spike marks on the grass surface of a golf course, particularly on the putting surfaces (called the “green” or the “putting green”). A careless golfer who shuffles or twists his feet while walking across a putting green can damage the grass surface. Even a careful golfer can leave spike marks on a putting green, particularly when the putting green is wet.
Current golf rules permit the repair of golf ball marks on the putting green, such as the mark left when a golf ball hits the putting green. However, those current golf rules do not permit the repair of spike marks. It is well known that the spike marks that golf spikes make on the putting surface can dramatically affect the motion or path of a putted golf ball, and as a result, the golfer's overall score. Many golf courses have subsequently banned the use of traditional spiked golf shoes for these reasons.
Initially, some golf courses permitted the use of certain types of spikeless golf shoes, hoping to minimize the spike marks left by spiked golf shoes. Some versions of those spikeless golf shoes incorporated an array of circular rubber knobs, which were to provide the desired traction similar to the traditional spiked golf shoes, but tended to leave knob marks on the putting greens. In some instances, more severe marks were caused by these types of spikeless golf shoes. As a result, more golf courses have banned the use of the rubber knob type of spikeless golf shoes as well.
There are presently available golf shoes in which circular cleats (typically plastic) replace the traditional golf spikes, again using some form of golf wrench tool to remove the golf spikes and replace those golf spikes with the circular cleats. Each circular cleat typically has a series of pin-like projections or a circular array of triangular shaped nubs, which serve to provide traction during a golf swing. However, these circular types of spikeless golf cleats can still leave undesired marks on the putting surface, particularly in wet conditions. Another problem with these plastic cleats is they can fall out during a round and cause the threaded receptacle to become packed with mud and debris, making it very difficult to clean, so that a new cleat can be installed.
Another problem with existing golf shoes is that the outsole portion (the bottom) of the golf shoe tends to accumulate dirt and debris, especially during wet conditions. The accumulation of such dirt and debris requires frequent and tedious cleaning, as otherwise the desired traction during a golf swing can be affected.
In view of the foregoing, there is a need for an improved spikeless golf shoe which will eliminate or minimize the type of spike marks presently left on the grass surfaces and particularly the putting surfaces, while still providing the necessary traction during a golf swing and minimizing the accumulation of dirt and debris.
SUMMARY OF THE INVENTION
In the preferred embodiment, the flexible hinged cleat of the present invention is comprised of a base, a hinge section and a traction section, formed as a one-piece mechanism. When the hinge section is flexed, the traction section is extended to perform a cleating action. The traction section, when viewed cross sectionally, is substantially triangular in shape, having a first side and a second shorter side. The first side forms a first angle with respect to the base of the cleat and the second shorter side forms a second angle with respect to the base of the cleat. The hinge section is made of a flexible material which varies the first angle and second angle as required to perform the cleating action. A maximum cleating action is achieved when the second shorter side makes contact with the base. The hinge section is also capable of varying the first angle and second angle as required to achieve a walking position in which negligible cleating action is attained. A relaxed position may also be achieved. In the relaxed position, the hinge section is capable of sustaining the first angle and the second angle.
In one embodiment of the invention, a cleating system is provided as an outsole. The outsole has a front sole portion and a heel portion. The front sole portion and heel portion each have a lateral side and a medial side. A plurality of ridges is disposed at an outer periphery of both the lateral and medial sides of both the front sole portion and the heel portion.
A first row of flexible hinged cleats is disposed substantially parallel to the ridges on the lateral side of the front sole portion. A second row of flexible hinged cleats is disposed substantially parallel to ridges on the medial side of the front sole portion. A third row of flexible hinged cleats is disposed substantially parallel to the ridges on the medial side of the heel portion. Each of the flexible hinged cleats of the cleating system is configured to provide a cleating action. The cleating system also provides that when each flexible hinged cleat is in a walking position, negligible cleating action is occurring; thereby a putting surface is not altered. The cleating system is also configured such that each flexible hinged cleat can attain a relaxed position in the absence of an applied force.
This embodiment of the invention may also provide that a plurality of weight bearing structures is disposed amid the ridges of the front sole portion and heel portion. These weight bearing structures provide support when the flexible hinged cleats are in a walking or in a relaxed position. The support extends the life and durability of the flexible hinged cleats when walking on hard surfaces, such as asphalt or pavement. The durability is extended because the flexible hinged cleats do not extend beyond the apex of the weight bearing structures.
In another embodiment of the invention, a method of forming a spikeless golf shoe is provided. The method provides a midsole, flexible hinged cleat strips and an outsole. The midsole has a front sole portion and a heel portion. Both the front sole portion and heel portion have a lateral side and a medial side. The midsole is formed with cavities on the front sole portion lateral and medial sides and on the heel portion medial side. Each of the cavities is configured to accept a flexible hinged cleat strip. Each flexible hinged cleat strip is a unitary structure having a substructure formed with a plurality of flexible hinged cleats. The flexible hinged cleat strips are molded into a front sole lateral strip, a front sole medial strip and a heel medial strip by a means known to those of ordinary skill in the art. The present invention also provides an outsole configured to fit atop the midsole in a manner that allows each flexible hinged cleat to protrude through the outsole when the flexible hinged cleat strips are inserted into their respective cavities.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention:
FIG. 1A is a cross sectional view of a hinged cleat in a relaxed position with no force applied to it.
FIG. 1B is a cross sectional view of a hinged cleat in the cleating position during the golf swing
FIG. 1C is a cross sectional view of a hinged cleat in a position during walking or standing.
FIG. 2 is a bottom plan view of the outsole of a spikeless golf shoe, indicating section marks A-A, B-B and C-C.
FIG. 3 is a side elevation view of a right spikeless golf shoe according to the present invention, indicating section marks A-A, B-B and C-C.
FIG. 4 shows a cross sectional view of a right spikeless golf shoe of FIGS. 1 and 2 at section mark A-A and the arrangement of hinged cleats.
FIG. 4A is a cross sectional view of outsole 26 shown in the spikeless golf shoe in FIGS. 1 and 2 at section mark B-B and the arrangement of the hinged cleats.
FIG. 4B is a cross section of outsole 26 shown in FIG. 1 at section C-C and the arrangement of the hinged cleats.
FIG. 5 is a top view of a pre-molded flexible hinged cleat strip used in the front portion of a right shoe as in FIG. 2 .
FIG. 6A is a bottom view of the midsole with two cavities in the front sole portion and one cavity in the heel. These cavities accept the pre-molded hinged cleat strips.
FIG. 6B is a view of FIG. 6A after the pre-molded hinged cleat strips have been attached.
DETAILED DESCRIPTION
Referring now to the accompanying drawings, reference will now be made in detail to the preferred embodiments of the invention. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to those embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention.
In the preferred embodiment of the invention, FIG. 1A shows a cross-sectional view of the flexible hinged cleat 10 in a normal relaxed position. The flexible hinged cleat is comprised of a base 12 , a hinge section 14 and a traction section 16 . The base, hinge section and traction section are formed as a unitary mechanism. The traction section is configured to provide a cleating action when the hinge section, formed of a flexible material, is flexed to extend the traction section as shown in FIG. 1B . The traction section 16 , of FIG. 1A , is substantially triangular in shape, having a first side 18 forming a first angle 20 of approximately forty degrees with respect to the base 12 . The traction section also has a second shorter side 22 forming a second angle 24 of approximately twenty-two degrees with respect to the base 12 . The hinge section is capable of varying the first angle and second angle as required to perform a cleating action. FIG. 1B shows the hinge section has sufficient flexing capability to allow the second shorter side to make contact with the base. Making contact with the base prevents the traction section from extending beyond a substantially upright position, enabling a maximum cleating action to take place. FIG. 1C shows the hinge section 14 is capable of flexing in a manner that varies the first angle 20 and the second angle 24 so that a walking (or standing) position may be achieved. When in the walking position, negligible cleating action occurs.
In one embodiment, FIG. 2 shows the bottom view of an outsole 26 of a right shoe. The outsole 26 is comprised of front sole portion 28 and heel portion 30 . One or more ridges 32 are formed on the “outer periphery” of the outsole, along the lateral side of the front sole portion, and one or more ridges 34 are formed on the “outer periphery” of the outsole along the medial side of the front sole portion. The outsole also includes one or more ridges 36 along the medial and lateral sides of heel portion 30 . There are four flexible hinged cleats 38 , 40 , 42 and 44 in the front sole portion on the medial side facing in the lateral direction, and four flexible hinged cleats 46 , 48 , 50 and 52 in the front sole portion on the lateral side facing in the lateral direction. There are three flexible hinged cleats 54 , 56 and 58 in the heel portion on the medial side facing in the medial direction.
A series of individual widthwise placed weight bearing structures 60 , 62 , 64 , 66 and 68 is spaced apart from one another along the front sole portion 28 of outsole 26 . Another series of individual widthwise placed weight bearing structures 70 , 72 and 74 is spaced along the heel portion 30 of the outsole. The series of widthwise weight bearing structures in the front sole portion of the outsole has a rear face at approximately a ninety degree angle to the surface of the outsole and facing towards the rear of outsole, so as to provide traction to a golfer walking up an incline surface. The series of widthwise weight bearing structures in the heel portion 30 of the outsole has a front face at approximately a ninety degree angle to the surface of the outsole and facing towards the front sole portion of the outsole, so as to provide traction to a golfer walking down an inclined surface.
Referring now to FIG. 3 , a side view of a spikeless golf shoe 76 according to the present invention is shown. The upper portion 78 of the golf shoe is typically fabricated from stitched fabric, leather, canvas, or other types of synthetic or natural materials. In some embodiments, the upper portion of the golf shoe also includes a middle portion, or midsole 80 , typically made of a foam or rubber material. The spikeless golf shoe also includes a bottom outsole 26 which is attached to the midsole. Both the outsole portion and the midsole portion are attached to the upper portion. The outsole portion is the cleating system of FIG. 2 that includes ridges 32 and flexible hinged cleats 38 - 58 . The flexible hinged cleats, shown in FIG. 2 , provide the spikeless golf shoe with the ability to maintain traction during the golf swing, while minimizing the potential damage caused to the putting surface.
FIG. 4 shows a cross section of the outsole 26 shown in FIG. 2 at section A-A on a right golf shoe. The flexible hinged cleat 56 is placed on the medial side of the outsole facing the inside of the shoe. During the golf swing, the heel section 30 of a right handed golfer's feet tend to slide inward (clockwise), as the front sole portion 28 tends to slide outward (clockwise). In FIG. 4 , the flexible hinged cleat 56 is slightly taller than the ridges 36 , so as to allow the flexible hinged cleat to penetrate the grass surface and flex outwardly for increased traction during the golf swing.
FIG. 4A shows a cross section of outsole 26 shown in FIG. 3 at section B-B on a right spikeless golf shoe. The flexible hinged cleats 40 and 48 are positioned on the medial and lateral side of the front sole portion 28 . The flexible hinged cleats are facing in the lateral direction of the outsole. During the golf swing, the front sole portion of a right handed golfer tends to slide outward in a clockwise direction. As the foot starts to slide in this manner, the flexible hinged cleats will extend in length to further penetrate the grass surface and thus provide traction during the golf swing. In this extended position, the flexible hinged cleats become approximately 60% taller than the weight bearing structures 60 - 68 .
FIG. 4B is a cross section of the outsole 26 shown in FIG. 3 at section C-C. The ridges 32 , 34 and 36 , as shown in FIG. 2 , have an opening 82 along the outer periphery adjacent to the flexible hinged cleats 46 and 48 , so that the flexible hinged cleats can flex during the golf swing without any obstruction from the ridges. That is, openings should be properly positioned to allow the hinged cleats to operate properly.
In a further embodiment of the invention, FIGS. 5 , 6 A and 6 B show the method of construction of a spikeless golf shoe 76 . FIG. 5 shows a flexible hinged cleat strip 84 having a plurality of flexible hinged cleats 46 , 48 , 50 and 52 . The flexible hinged cleat strip is a unitary structure made of urethane and formed by an injection molding process. Midsole 80 is formed, by known means, with three cavities 90 , 92 and 94 . FIG. 6A shows a midsole having a front sole portion 28 and a heel portion 30 . The front sole portion has a lateral side cavity 90 and a medial side cavity 92 . The heel portion has a medial side cavity 94 . Each cavity is made to accept a flexible hinged cleat strip formed to fit into it. FIG. 6B depicts the midsole with the cavities filled with their respective flexible hinged cleat strip. In this embodiment, cavity 90 contains front sole lateral flexible hinged cleat strip 84 . Cavity 92 contains front sole medial flexible hinged cleat strip 86 , and cavity 94 contains heel medial flexible hinged cleat strip 88 . The flexible hinged cleats are attached to the cavity by a mean known in the art. An outsole 26 , formed to allow each flexible hinged cleat of the flexible hinged cleat strips to protrude through it, is fitted atop the midsole and attached by a known means. | A flexible hinged cleat for a shoe includes a base, a hinge section and a traction section formed as a one-piece mechanism. The flexible hinged cleat is capable of flexing upwardly or downwardly, depending on the direction of the applied force. The hinge section is configured such that the traction section is hinged for rotation relative to a generally fixed axis. Multiple flexible hinged cleats may be molded as parts of a strip and subsequently sandwiched between the outsole and midsole of a shoe. | 0 |
This application relates and claims priority to U.S. application Ser. No. 60/341,896, filed Dec. 19, 2001 now abandoned.
FIELD OF INVENTION
The invention relates to fabric specifications combining fibers of different modulus with particular fabrication techniques to produce reinforcement fabrics of compound modulus characteristics.
BACKGROUND
Definitions:
Fiber: unit of matter, either natural or manufactured, that forms the basic element of fabrics or textile structures. The fiber is characterized as having a length of at least 100 times its diameter or width.
Fibrous web: a unit of material in web form containing fiber components such as a woven fabric, knit fabric, laid-yarn products and spun bonded products.
Composite fiber: fiber composed of more than one polymer/fiber type, combined by ply-twisting, entangling or other means.
Intimate blend fiber: a technique of mixing two or more dissimilar staple fibers in a very uniform mixture. Usually the stock is mixed before or at the picker.
Crimp: the difference in distance between two points on a fiber in a fabric and the same two points on the fiber after it has been removed from the fabric and straightened under a specified tension, expressed as a percentage of the distance between the two points as it lies in the fabric; may be imparted to the yarn by several yarn processing methods including twisting, texturizing, knit-deknit, stuffer box method, and yarn entangling; may be imparted to the yarn several fabric formation processes such as weaving, knitting, braiding, etc.
Modulus: the ratio of the change in stress or force per unit length to the change in strain expressed as a fraction of the original length or percentage elongation, after crimp has been removed.
Fiber modulus: modulus of fiber.
Fabric modulus: modulus of fabric along test axis (warp/fill/bias) after crimp is removed.
Fabric crimp modulus: modulus of a fabric while crimp is being removed from the fibers as the fabric is loaded; initial part of modulus curve before fibers are under axial tension; significantly lower modulus than fiber/fabric modulus.
Low load elongation (LLE): elongation range over which fabric crimp modulus is measured; typically elongation value is based on a load limit less than 5 pounds per lineal inch (5 pli).
Shrinkage—change in fiber length due to a process mechanism such as dry heat, steam heat or chemistry.
Shrinkage tension—tension fiber/fabric exerts in fiber axis while shrinkage is performed.
Shrinkage crimp—amount of crimp imparted in the fabric/fiber as a result of shrinkage.
Differential shrinkage—difference in shrinkage between process fiber and reinforcement fiber.
Composite fabric—woven, braided or knitted substrate comprised of more than one fiber type.
Modulus is a characteristic of a material representing how much load (stress) is required to achieve a certain level of stretch (strain). As a result, a low modulus material requires less force than a high modulus material to achieve a given amount of elongation.
The modulus of a material may be constant in a material throughout a range of elongation values or quite variable, particularly for elastomeric composites. Homogeneous, non-reinforced elastomeric materials are generally considered low modulus and are also isotropic, or have the same properties in all directions. Textile fibers are medium or high modulus materials relative to elastomers and are not isotropic but rather have very different properties in the thread line direction vs. the transverse direction of the fiber.
Knit textiles are typically low modulus structures in that they stretch easily and have very high elongation to break. As a result of the knit structure, however, they tend to be inefficient materials on a strength/weight basis and may not always provide reasonable limits of elongation desired for certain component applications such as high pressure hoses and diaphragms.
Woven textile fabrics are typically lower stretch materials and have a modulus that is dependent on the angle of load relative to the orientation of the fabric and fiber. The modulus of the fabric will range from slightly lower than the fiber modulus in the thread-line direction to a much lower modulus at a 45° bias angle. The lower modulus on the bias angle is attributed to the ability of the fibers in the fabric to re-orient as load is applied.
The fabric modulus in the bias direction is typically much lower than the fabric modulus along the thread-line. Typical hose and diaphragm reinforcement fabrics have a thread-line modulus of 100-500 pli (0.9%-5.0% elongation @ 5 pli). Alternatively, the bias modulus of these same fabrics (@ 45°) is reduced to <16-25 pli (20-30% @ 5 pli).
Referring to prior art FIG. 1, there is shown a graph comparing the moduli of standard reinforcement fabric in the fill (1) direction versus 45 degree bias (2) direction. At a given elongation, the fill (weft) oriented material exhibits a higher load due to relatively high fiber stiffness and low weaving crimp. The bias oriented material exhibits a lower load elongation based on combination of warp and fill (weft) crimp as well as the fiber rotation. The low load elongation characteristics are utilized to enhance fabric processing and product characteristics.
Fabric reinforced elastomeric composites have modulus properties greater than the fabric but are still variable in direction due to the nature of the fabric reinforcement. Often, fabric orientation is controlled in the manufacture of fiber reinforced elastomer composites to achieve specific characteristics in the composite product in one or more directions.
Examples of fabric reinforced elastomer composites include hoses, belts, diaphragms and tires. In each of these applications, greater low load elongation is required in the manufacture of these parts than is available in the fabric along the threadline of the fiber. A common solution is to cut the fabric at a bias angle (e.g. 45°) and orient the fabric in the manufacturing process in the lower modulus direction to aid in the formation, assembly or performance of the composite product.
The bias modulus of 16-25 pli is adequate for many reinforced rubber and elastomer products. However, there remain problems with the prior art. The cost and productivity impact of utilizing fabrics at a bias angle, are non-trivial. Bias cutting the fabric requires special equipment, extra labor and increases waste costs of the process. Similar issues exist in apparel, glove and footwear manufacture.
What is needed is a fabric design which provides a lower fabric crimp modulus to deliver low load elongation in the thread-line direction greater than the 5% upper limit inherent in standard fabrics.
SUMMARY OF THE INVENTION
The invention encompasses a fabric system and manufacturing method that allows woven fabric to achieve a lower fabric crimp modulus (higher elongation) in the thread-line direction. The fabric system and method utilizes processing yarns of higher shrinkage than the product reinforcing yarns. The processing yarns are woven together with the reinforcing yarns in various patterns and combinations dependent on the desired fabric characteristics. The fabric is subsequently processed thermally to enable crimp to be imparted into the reinforcing yarns by the differential shrinkage of the processing yarns. By adjusting the ratio of reinforcing yarns to processing yarns, a unique set of characteristics in the fabric can be created, specifically lower modulus/higher initial elongation in the threadline direction of the reinforcing yarn.
These characteristics can be referred to as a compound fabric modulus, and the web or fabric referred to as a bi-modulus fabric; where there is a beneficially lower first modules low load elongation characteristic coupled with a beneficially higher second modules fabric stress limit, a combination not otherwise attainable along a threadline.
It is therefore among the objects of the invention to provide a product and a method for making the product from two different yarn types; where the product is a fibrous web, fabric, fabric-reinforced elastomeric product or part, component, or related article that benefits from having a compound fabric modulus along at least one thread line of the fabric weave. The feature in the fabric may be of benefit in the manufacture and/or the performance of the fabric, component or part.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a graph of the comparative moduli of standard reinforcement fabric in the fill direction versus 45 degree bias direction.
FIG. 2 is a graph of the load-elongation characteristics for a representative bi-modulus fabric of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Several fibers have very low shrinkage/shrinkage tension at elevated temperatures (from 150 to 500 F., <5%). Examples include:
a) acrylic
b) Liquid Crystal Polymer (Vectran™)
c) Low shrink polyester (Trevira™)
d) Low shrink aramid (Nylon™)
e) Melamine (Basofil™)
f) Meta-aramid (Nomex™, Conex™)
g) Para-aramid (Kevlar™, Twaron™, Technora™)
h) UHMW Polyethylene (Spectra™, Dyneema™)
Applicant makes no claim to the trademarks referenced here and elsewhere; references are provided as examples of brand names well-known in the industry, which are associated with the related materials.
Other fibers have very high shrinkage/shrinkage tension at normal processing temperatures (150-400 F., >15%). Examples include:
a) Nylon
b) Polyester (T52 Dacron™)
c) Polypropylene
Although the shrinkage process is the preferred embodiment for manipulating the processing yarn as described, non-thermal mechanisms may be used to produce this effect as well, including but not limited to chemical treatments, elastic contraction of elastomeric yarns or fiber filling or fiber felting of natural cotton or wool fibers. In both cases, these yarns act as the processing yarn imparting crimp in the reinforcing yarn by their reduction in length.
Referring to FIG. 2, there is shown a graph of the load-elongation characteristics for a representative bi-modulus fabric of the invention. Low load elongation characteristic similar to the bias results shown in prior art FIG. 1 are achieved in this new fabric in the filling direction, thus eliminating the need to bias cut the fabric to achieve extra stretch.
The compound fabric modulus or bi-modulus fabric properties of the invention, as exhibited in FIG. 2, extend to and include a fabric that has three principle characteristics. There is more than one distinct fabric modulus beyond at least 5% and preferably beyond 10% elongation in at least one fiber direction. There is exhibited relatively high elongation in the fiber direction, at least 5% and preferably greater than 10%, at low load of either 5-10 pounds per linear inch or about 25% of the breaking strength or stress limit of the fabric in the fiber direction, whichever is greater. And it is constructed of yarn which is not crimped by special means other than by typical twisting or spinning prior to weaving or knitting, in other words, the yarn did not need to be subjected to knit-deknit, gear crimping, stuffer box crimping, or other such pre-weaving conditioning.
The application for reinforcement fabrics with controlled bi-modulus properties with higher low load elongation in one or more fiber directions includes fiber reinforced elastomer materials such as hoses, diaphragms, belts, seals, gaskets, and tires, as well as other flexible composite materials for use in spinnaker sails, inflated structures, inflatable craft, storage tanks, floatation devices, and devices intended to reduce shock and vibration. In addition there is broad application in apparel goods including outerwear, innerwear, glove and footwear. This disclosure is directed to a material system that can be tailored and applied to any of these and similar products. This disclosure is intended to cover the use of this material system in these and related products and hybrids. This disclosure is intended to include the integration of these fabrics into these products by means of stitching, adhesives, lamination, calendaring, mechanical assembly, molding by pressure and/or heat in single part and/or multipart molds or mandrels or by autoclaving or other known means. The inventors are well aware of the application of these technologies to produce the listed products.
The invention in all embodiments contains a fabric with a least one fiber direction having the bi-modulus properties defined above. This direction is intended as the primary loading axis where additional stretch is desirable for manufacturing of the product and/or in the product itself. To maximize stretch retention, the cross machine direction (CM) of the fabric is the preferred direction to contain the bi-modulus properties. This embodiment preserves the higher stretch in the CM direction, while allowing processing in the machine direction. It is very desirable to have bi-modulus properties in the MD as well as long as it can be retained through processing as it lends to additional manufacturing simplification for some products.
The principles of the invention have been put into practice with several fabrics using greater than 10% processing fiber (P-Fiber) by weight in the bi-modulus direction. A preferred embodiment includes a woven fabric with warp material made of a low shrink spun meta-aramid fiber woven with weft yarns where 75% of the weft fiber by weight is a spun meta-aramid fiber and 25% of the weft fiber by weight is high shrinkage filament nylon fiber. Anyone skilled in the art of weaving and informed by this disclosure can create such a fabrics. Fabric finishing includes a minimum of one heat setting pass to create the differential crimp by differential shrinkage of the weft fibers and may or may not include a scouring process to clean the fabric and may or may not include the application of adhesion promoters such as silanes or RFLs or other coatings determined appropriate to the application. Anyone skilled in the art of finishing and informed by this disclosure can create such fabric properties with standard finishing equipment.
The application of the preferred embodiment to mandrel wrapped hose manufacturing is significant for several reasons, particularly for hose parts that have sections of differential diameters. While non-reinforced rubber parts can easily deform to slide over the various geometric sections of a mandrel, reinforced rubber parts need the reinforcement fabric to expand in these areas to allow for part removal from the mandrel as part of the manufacturing process. The bi-modulus fabric allows for this expansion. The extent of the allowable expansion is determinable using an appropriate percentage of processing fiber vs. reinforcing fibers based on hose strength requirements and cost parameters.
For sheet molded rubber parts which are molded, stamped or drawn by other process methods to a part depth greater than 15% of the diameter of the part (or the smallest dimension in the initial plane direction of the sheet), a bi-modulus reinforcement fabric allows for deeper parts to be fabricated with fibers which cannot be reliably processed by a pre-crimping method including fibers such as spun fibers or high modulus fibers, including para-aramid, UHMW or liquid crystal polymer fibers.
For molded rubber parts using a fabric pre-form, such as deep draw diaphragms, where greater part depth is desired relative to sheet molded parts, a bi-modulus fabric can be used to increase part depth further by providing extra fabric elongation in the MD and/or CM direction as compared to standard woven materials while providing significant improvement in part strength as compared to knit fabrics.
Also, a fabric reinforcement made with high modulus fibers such as para-aramid (Kevlar™), liquid crystal polymer (Vectran™), UMW polyethylene (Spectra™) or equivalent fibers can be produced with processing fibers to create a bi-modulus reinforcement which allows for an increase in pre-form depth over what was previously limited by the lack of stretch in the fabric due to the high modulus fibers.
Other and various embodiments within the scope of the invention and the appended claims will be apparent to those skilled in the art from the description and figures provided. For example, there is within the scope of the invention, a fibrous web with a compound fabric modulus in at least one of warp and fill directions consisting of at least a first yarn type and a second yarn type woven together in at least one of the warp and fill directions, where the second yarn type has a higher fiber modulus and greater fiber shrinkage crimp than the first yarn type imparted by processing of the fibrous web.
The compound modulus of the fibrous web consists of a first modulus low load elongation of greater than 5% @ 5 pli, and a second modulus fibrous web stress limit of at least 15 pli. The compound modulus may have a first modulus low load elongation of greater than 10% @ the greater of 5 pli or 25% of the fibrous web stress limit, and a second modulus fibrous web stress limit of at least 15 pli. The first yarn type may be greater than 10% by weight of yarn used in the selected direction. The second yarn type may consist of fibers from among the group of fibers consisting of para-aramid, liquid crystal polymer, and UMW polyethylene.
As another example, there is a fibrous web with a compound fabric modulus in each of both warp and fill directions consisting of at least a first yarn type and a second yarn type woven together in each direction, where the second yarn type has a higher fiber modulus and greater fiber shrinkage crimp after processing than the first yarn type, and where the compound modulus in each direction has a first modulus low load elongation of greater than 5% @ 5 pli, and a second modulus fibrous web stress limit of at least 15 pli.
As yet another example, there is a woven fabric with a compound fabric modulus in the weft direction consisting of a warp material woven with weft yarns, where the weft yarns consist of greater than 10% of weft fiber by weight of a high shrinkage filament nylon fiber and less than 90% of weft fiber by weight of an aramid type fiber such as a spun meta-aramid fiber, and the woven fabric has been thermally processed for shrinkage of the nylon fibers. The nylon fibers may be 25% by weight, and the aramid type fiber may be 75%.
As a further example, there is a woven fabric with a compound modulus in the CM (cross machine, weft, or fill) direction, consisting of one yarn type in the MD (warp or machine direction) and at least two yarn types in the CM direction, the second yarn type of the two yarn types having a higher fiber modulus and greater fiber shrinkage crimp, due to having a lower fiber shrinkage, than the first yarn type after shrinkage processing, and the compound moduli comprising a first modulus low load elongation of greater than 5% @ 5 pli, and a second modulus fabric stress limit of at least 15 pli.
Another example of the invention is a fiber reinforced elastomeric material consisting of a fibrous web with a compound fabric modulus in at least one of warp and fill directions, where the fibrous web is made up of at least a first yarn type and a second yarn type woven together in a common one of the two directions, and the second yarn type has a higher fiber modulus and greater shrinkage crimp after shrinkage processing than the first yarn type.
The compound modulus may have a first modulus low load elongation of greater than 5% @ 5 pli, and a second modulus fabric stress limit of at least 15 pli. The second yarn type made use fibers from among the group of fibers consisting of para-aramid, liquid crystal polymer, and UMW polyethylene fibers.
The invention contemplates, discloses and claims methods as well as products. For example, there is a method for making a woven fabric with a compound modulus in at least one of the warp and weft directions, consisting of the steps of weaving a fibrous web with at least two yarn types in at least one of the warp and weft directions, where the two yarn types have different fiber shrinkage characteristics and different fiber moduli, and then processing the fibrous web for fiber shrinkage so as to achieve the shrinkage differential between the two yarn types.
The fiber shrinkage characteristics may be thermal, the second yarn type have a higher fiber modulus and lower thermal shrinkage characteristic than the first yarn, and the processing may be thermal processing at a temperature greater than 100 F. The at least one of warp and weft directions can be both warp and weft directions. The second yarn type may have a fiber modulus of at least 100 pli and a thermal fiber shrinkage characteristic of less than 5%, and the first yarn type may have a fiber modulus low load elongation of greater than 5% @ 5 pli and a thermal fiber shrinkage characteristic of greater than 15%. Furthermore, the compound modulus of the fibrous web after the step of thermal processing may have a first modulus low load elongation of at least 5% @ 5 pli, and a second modulus fabric stress limit of at least 15 pli. The yarn type may come from the group consisting of filament, spun, and intimate blend yarns. The weaving may be of a plain, basket, or pattern weave construction.
Another method for making a woven fabric of a plain, basket or pattern weave with a compound modulus in the weft direction includes the steps of weaving two or more yarn types having uniform thermal fiber shrinkage characteristics in the warp direction with two or more yarn types having different thermal fiber shrinkage characteristics and different fiber moduli into a woven web; and processing the woven web at a temperature greater than 100 F. until a differential fiber shrinkage is obtained in the weft direction.
Other and various embodiments and equivalent constructions within the scope of the invention and the claims that follow will be apparent to those skilled in the art from the specifications and attached figures. | A fabric system and manufacturing method for achieving higher fiber crimp in selected fibers to reduce initial fabric modulus (gain higher elongation) in the thread-line direction. The fabric system and method utilizes processing yarns of higher shrinkage than the product reinforcing yarns. The processing yarns are woven together with the reinforcing yarns in various patterns and combinations dependent on the desired fabric characteristics. The fabric is processed thermally or otherwise to impart crimp into the reinforcing yarns by the differential shrinkage of the processing yarns. By adjusting the ratio of reinforcing yarns to processing yarns, a unique set of characteristics in the fabric is created, specifically a lower modulus, higher initial elongation in the thread-line direction of the reinforcing yarn. | 3 |
BACKGROUND
The present invention relates to reverse cementing operations useful in subterranean formations, and more particularly, to the use of ball operated back pressure valves in reverse circulation operations.
After a well for the production of oil and/or gas has been drilled, casing may be run into the wellbore and cemented. In conventional cementing operations, a cement composition is displaced down the inner diameter of the casing. The cement composition is displaced downwardly into the casing until it exits the bottom of the casing into the annular space between the outer diameter of the casing and the wellbore. It is then pumped up the annulus until a desired portion of the annulus is filled.
The casing may also be cemented into a wellbore by utilizing what is known as a reverse-cementing method. The reverse-cementing method comprises displacing a cement composition into the annulus at the surface. As the cement is pumped down the annulus, drilling fluids ahead of the cement composition around the lower end of the casing string are displaced up the inner diameter of the casing string and out at the surface. The fluids ahead of the cement composition may also be displaced upwardly through a work string that has been run into the inner diameter of the casing string and sealed off at its lower end. Because the work string by definition has a smaller inner diameter, fluid velocities in a work string configuration may be higher and may more efficiently transfer the cuttings washed out of the annulus during cementing operations.
The reverse circulation cementing process, as opposed to the conventional method, may provide a number of advantages. For example, cementing pressures may be much lower than those experienced with conventional methods. Cement composition introduced in the annulus falls down the annulus so as to produce little or no pressure on the formation. Fluids in the wellbore ahead of the cement composition may be bled off through the casing at the surface. When the reverse-circulating method is used, less fluid may be handled at the surface and cement retarders may be utilized more efficiently.
In reverse circulation methods, it may be desirable to stop the flow of the cement composition when the leading edge of the cement composition slurry is at or just inside the casing shoe. In order to determine when to cease the reverse circulation fluid flow, the leading edge of the slurry is typically monitored to determine when it arrives at the casing shoe. Logging tools and tagged fluids (by density and/or radioactive sources) have been used monitor the position of the leading edge of the cement slurry. If a significant volume of the cement slurry enters the casing shoe, clean-out operations may need to be conducted to ensure that cement inside the casing has not covered targeted production zones. Position information provided by tagged fluids is typically available to the operator only after a considerable delay. Thus, even with tagged fluids, the operator is unable to stop the flow of the cement slurry into the casing through the casing shoe until a significant volume of cement has entered the casing. Imprecise monitoring of the position of the leading edge of the cement slurry can result in a column of cement in the casing 100 feet to 500 feet long. This unwanted cement may then be drilled out of the casing at a significant cost.
SUMMARY
The present invention relates to reverse cementing operations useful in subterranean formations, and more particularly, to the use of ball operated back pressure valves in reverse circulation operations.
According to one aspect of the invention, there is provided a method for selectively closing a downhole one way check valve, the method having the following steps: attaching the valve to a casing; locking the valve in an open configuration; running the casing and the valve into the wellbore; reverse circulating a composition down an annulus defined between the casing and the wellbore; injecting a plurality of balls into the annulus; unlocking the valve with the plurality of balls; and closing the valve.
A further aspect of the invention provides a valve having a variety of components including: a plug removably connected to a housing; a plug seat; and a baffle having a plurality of holes. When the plug is connected to the housing, the valve is in an open position, and fluid may flow through the valve. When the holes in the baffle become plugged, the plug becomes disconnected from the housing and moves into the plug seat, restricting flow through the valve. Another aspect of the invention provides a system for reverse-circulation cementing a casing in a wellbore, wherein the system has a valve and a plurality of balls. The valve may have a plug removably connected to a housing, a plug seat, and a baffle having a plurality of holes. The plug may be connected to the housing, the valve may be in an open position, and fluid may flow through the valve. When the holes in the baffle become plugged, the plug may become disconnected from the housing and move into the plug seat, restricting flow through the valve. The balls may be sized to cause the holes in the baffle to become plugged.
The objects, features, and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present disclosure and advantages thereof may be acquired by referring to the following description of non-limitative embodiments with reference to the attached drawings, wherein like parts of each of the several figures are identified by the same referenced characters, and which are briefly described as follows.
FIG. 1A is a cross-sectional, side view of a valve having a plug suspended outside of a plug seat, such that the valve is in an open position.
FIG. 1B is a perspective view of the valve of FIG. 1A .
FIG. 2A is a cross-sectional, side view of the valve of FIG. 1A , as a cement composition and balls flow through the valve.
FIG. 2B is a cross-sectional, side view of the valve of FIG. 1A , showing the plug within the plug seat, such that the valve is in a closed position.
FIG. 3A is a cross-sectional, side view of an alternate embodiment of a valve having a plug suspended outside of a plug seat, such that the valve is in an open position.
FIG. 3B is a perspective view of the valve of FIG. 3A .
FIG. 4A is a cross-sectional, side view of an alternate embodiment of a valve showing a plug within a plug seat, such that the valve is in an open position.
FIG. 4B is a perspective view of the valve of FIG. 4A .
FIG. 5A is a cross-sectional, side view of an alternate embodiment of a valve showing a plug within a plug seat, such that the valve is in an open position
FIG. 5B is a perspective view of the valve of FIG. 5A .
FIG. 6 is a cross-sectional side view of a valve and casing run into a wellbore, wherein a cementing plug is in the casing above the valve.
FIG. 7A is a cross-sectional, side view of a portion of a wall of a baffle section of a plug, wherein the wall has a cylindrical hole and a spherical ball is stuck in the hole.
FIG. 7B is a cross-sectional, side view of a portion of a wall of a baffle section of a plug, wherein the wall has a cylindrical hole and an ellipsoidal ball is stuck in the hole.
FIG. 8A is a cross-sectional, side view of a portion of a wall of a baffle section of a plug, wherein the wall has a conical hole and a spherical ball is stuck in the hole.
FIG. 8B is a cross-sectional, side view of a portion of a wall of a baffle section of a plug, wherein the wall has a conical hole and an ellipsoidal ball is stuck in the hole.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, as the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION
The present invention relates to reverse cementing operations useful in subterranean formations, and more particularly, to the use of ball operated back pressure valves in reverse circulation operations.
FIG. 1A illustrates a cross-sectional side view of a valve 1 . This embodiment of the valve 1 has a plug seat 2 , which is a cylindrical structure positioned within the inner diameter of a sleeve 3 . A seal 4 closes the interface between the outer diameter of the plug seat 2 and the inner diameter of the sleeve 3 . The seal 4 may be an O-ring seal, Halliburton Weld A™ Thread-Locking Compound, or any other seal. The plug seat 2 has an inner bore 5 for passing fluid through the plug seat 2 . At the mouth of the inner bore 5 , the plug seat 2 has a conical lip 6 for receiving a plug 7 when the valve is in a closed position.
The valve 1 also has a housing 8 that suspends the plug 7 outside the plug seat 2 . The housing 8 has a baffle section 9 (shown more clearly in FIG. 1B ). In the illustrated embodiment, the plug 7 has a cylindrical structure having an outside diameter larger than an inside diameter of the inner bore 5 of the plug seat 2 , but slightly smaller than an inside diameter of an inner wall 10 of the housing 8 . This leaves a flow conduit 11 extending between an outer wall 12 of the housing 8 and the inner wall 10 , which abuts the plug 7 .
When the plug 7 is suspended outside the plug seat 2 of the valve 1 , as illustrated in FIG. 1A , the valve 1 is locked in an open configuration. The plug 7 may be suspended outside the plug seat 2 by a shear pin or pins 13 , which may connect the plug 7 to the inner wall 10 of the housing 8 .
Referring now to FIG. 1B , the flow conduit 11 extends through the housing 8 , between the inner wall 10 and the outer wall 12 . The baffle section 9 is an opening to the flow conduit 11 . The baffle section 9 has a plurality of holes 14 . The holes 14 may have a radial pattern around the baffle section 9 . The holes 14 and the flow conduit 11 allow for fluid passage around the plug 7 .
FIGS. 2A and 2B illustrate cross-sectional side views of a valve similar to that illustrated in FIG. 1A , wherein FIG. 2A shows the valve in a locked, open configuration and FIG. 2B shows the valve in an unlocked, closed configuration. In FIG. 2A , the plug 7 is suspended outside of the plug seat 2 to hold the valve 1 in an open position. Pins 13 retain the plug 7 outside of the plug seat 2 . In FIG. 2B , the plug 7 is seated in the plug seat 2 , within the conical lip 6 of the plug seat 2 to close the valve 1 .
An example of a reverse cementing process of the present invention is described with reference to FIGS. 2A and 2B . The valve 1 is run into the wellbore in the configuration shown in FIG. 2A . With the plug 7 held outside of the plug seat 2 , such that the valve 1 is in an open position, fluid from the wellbore is allowed to flow freely up through the valve 1 , wherein it passes through the holes 14 of the baffle section 9 and through the flow conduit 11 of the housing 8 . As casing 26 is run into the wellbore, the wellbore fluids flow through the open valve 1 to fill the inner diameter of the casing 26 above the valve 1 . After the casing 26 is run into the wellbore to its target depth, a cement operation may be performed on the wellbore. In particular, a cement composition slurry may be pumped in the reverse-circulation direction, down the annulus defined between the casing 26 and the wellbore. Returns from the inner diameter of the casing 26 may be taken at the surface. The wellbore fluid enters the sleeve 3 at its lower end below the valve 1 illustrated in 3 A and flows up through the valve 1 as the cement composition flows down the annulus.
Balls 15 may be used to close the valve 1 , when a leading edge 16 of cement composition 17 reaches the valve 1 . Balls 15 may be inserted ahead of the cement composition 17 when the cement composition is injected into the annulus at the surface. These balls 15 may be located in a fluid that is just ahead of the cement, or even at the leading edge 16 of the cement. The balls 15 flow down the annulus, around the bottom of the casing 26 , and back up into the valve 1 to close it. As shown in FIG. 2A , the balls 15 may be pumped at the leading edge 16 of the cement composition 17 until the leading edge 16 passes through the flow conduit 11 of the housing 8 of the valve 1 . When the leading edge 16 of the cement composition 17 passes through baffle section 9 of the housing 8 , the balls 15 seat and seal off in the holes 14 , preventing any further flow through the holes 14 . At this point, hydrostatic pressure from the column of cement begins to build up underneath the housing 8 . This pressure works across an O-ring 18 on the outer diameter of the plug 7 . As the differential pressure created between the cement and lighter fluid above the valve 1 increases, the pins 13 may shear, allowing the plug 7 to shift upward into the plug seat 2 so that the plug 7 extends into the conical lip 6 . The shear pins 13 may shear at any predetermined shear value. The shear value may change from one application to the next. If the predetermined shear value is low enough, the shear pins 13 may shear without a complete seal between the balls 15 and the holes 14 . In fact, when desired, the shear pins 13 may shear when only a portion of the holes 14 are occupied by balls 15 . In the instances where the shear pins 13 shear without a complete seal, the back pressure buildup created by the reduced flow of some balls 15 may create the pressure necessary to shear the pins 13 . The end of the plug 7 contains a seal 19 that seals inside the plug seat 2 . This seal 19 is a back up seal to the balls 15 that are sealing flow through the holes 14 in the event the balls 15 do not create a complete positive seal.
The plug seat 2 and the housing 8 may be attached to a sleeve 3 that will make-up into the casing 26 as an integral part of the casing 26 . This allows for casing 26 to be attached below it. The plug seat 2 , the housing 8 , and the plug 7 may be made of drillable material such as aluminum to facilitate drilling out these components with a roller-cone rock bit if required.
FIG. 2B illustrates a configuration of the valve 1 after the plug 7 has been pumped into the plug seat 2 . The plug 7 then prevents flow through the inner bore 5 of the valve 1 , effectively closing the valve 1 . The closed valve 1 prevents the cement composition 17 from flowing up through the valve 1 into the inner diameter of the casing 26 above the valve 1 . The plug 7 may be locked in place using a locking ring 27 (shown only in FIG. 2B ) or any other locking device. This allows the valve 1 to be locked in a closed position with or without the presence of continued pressure. Once the valve 1 is closed, casing head pressure can be removed from the well. However, the locking ring 27 or other locking device may not be necessary to maintain the plug 7 in position. The valve 1 will remain in a closed position so long as adequate pressure is maintained.
Referring to FIGS. 3A and 3B , an alternate embodiment is shown. This embodiment allows the valve 1 to be screwed between two joints of casing as an insert. To do so, a valve seat 20 with a casing thread on the outer diameter may be provided. This would allow the valve 1 to be screwed into a casing collar. The thread may be coated with Halliburton Weld A™ Thread-Locking Compound to create a seal around the valve seat 20 .
The valve 1 may accept a cementing plug 21 in the upper end of the plug seat 2 . The cementing plug 21 is illustrated in FIGS. 4A and 4B . This allows for cementing the casing in place by conventional cementing operations, where the cement is pumped down the inside of the casing and back up the wellbore-to-casing annulus. While a latch-down cementing plug is illustrated, the cementing plug 21 may be a standard cementing plug that lands and seals on top of the valve 1 , as illustrated in FIGS. 5A and 5B .
Referring to FIG. 6 , a cross-sectional side view of a valve similar to that illustrated in FIGS. 2A and 2B is illustrated. The valve 1 and casing 26 are shown in a wellbore 22 , wherein an annulus 23 is defined between the casing 26 and the wellbore 22 . In this embodiment, a standard cementing plug or a latch-down plug is run into the inner diameter of the casing 26 to a position immediately above the valve 1 . The valve 1 can be secured to the bottom joint of casing as a guide shoe or located above the bottom of the casing 26 similar to where a float collar would be located.
FIGS. 7A and 7B illustrate cross-sectional, side views of a portion of the baffle section 9 of the plug 7 . In particular, a hole 14 is shown extending through the baffle section 9 . In this embodiment, the hole 14 is cylindrical. In FIG. 7A , the illustrated ball 15 is a sphere having an outside diameter slightly larger than the diameter of the hole 14 . The ball 15 plugs the hole 14 when a portion of the ball 15 is pushed into the hole 14 as fluid flows through the hole 14 . In FIG. 7B , the illustrated ball 15 is an ellipsoid wherein the greatest outside circular diameter is slightly larger than the diameter of the hole 14 . The ellipsoidal ball 15 plugs the hole 14 when a portion of the ball 15 is pushed into the hole 14 as fluid flows through the hole 14 .
FIGS. 8A and 8B illustrate cross-sectional, side views of a portion of the baffle section 9 of the plug 7 . In particular, a hole 14 is shown extending through the baffle section 9 . In this embodiment, the hole 14 is conical. In FIG. 8A , the illustrated ball 15 is a sphere having an outside diameter slightly smaller than the diameter of the conical hole 14 at an exterior surface 24 of the baffle section 9 and slightly larger than the diameter of the conical hole 14 at an interior surface 25 of the baffle section 9 . The spherical ball 15 plugs the hole 14 when at least a portion of the ball 15 is pushed into the hole 14 as fluid flows through the hole 14 . In FIG. 8B , the illustrated ball 15 is an ellipsoid wherein the greatest outside circular diameter is slightly smaller than the diameter of the conical hole 14 at the exterior surface 24 of the baffle section 9 and slightly larger than the diameter of the conical hole 14 at the interior surface 25 of the baffle section 9 . The ellipsoidal ball 15 plugs the conical hole 14 when at least a portion of the ball 15 is pushed into the hole 14 as fluid flows through the hole 14 .
In one embodiment of the invention, the valve 1 is made, at least in part, of the same material as the sleeve 3 . Alternative materials, such as steel, composites, cast-iron, plastic, cement, and aluminum, also may be used for the valve so long as the construction is rugged to endure the run-in procedure and environmental conditions of the wellbore.
According to one embodiment of the invention, the balls 15 may have an outside diameter of approximately 0.75 inches so that the balls 15 may clear the annular clearance of the casing collar and wellbore (e.g., 7.875 inches×6.05 inches). The composition of the balls 15 may be of sufficient structural integrity so that downhole pressures and temperatures do not cause the balls 15 to deform and pass through the holes 14 . The balls 15 may be constructed of plastic, rubber, phenolic, steel, neoprene plastics, rubber coated steel, rubber coated nylon, or any other material known to persons of skill in the art.
The present invention does not require that pressure be applied to the casing to deactivate the valve to the closed position after completion of reverse cementing. There may be instances when pumping equipment may not be able to lift the weight of the cement in order to operate a pressure operated float collar or float shoe.
Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. | A method for selectively closing a downhole one way check valve, the method having the following steps: attaching the valve to a casing; locking the valve in an open configuration; running the casing and the valve into the wellbore; reverse circulating a composition down an annulus defined between the casing and the wellbore; injecting a plurality of balls into the annulus; unlocking the valve with the plurality of balls; and closing the valve. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/DE01/02136 filed Jun. 7, 2001, which designates the United States.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a method for testing a capacitive actuator or actuating element, particularly an actuating element for a fuel injection valve in an internal combustion engine, for correct operation.
[0003] DE 199 10 388, which is not a prior publication and has earlier priority, describes a method for testing a piezo-electric actuating element, particularly one for a fuel injection valve, in which the actuating element's open period, ascertained from the charging and discharge currents on the actuating element by comparison with threshold values, is compared with the duration of the control signal and this comparison is used to diagnose correct operation of the actuating element. This method can be applied when the charging period and discharging period are the same length, since otherwise the actuating element's open period is not equal to the duration of the control signal.
[0004] To open, by way of example, a fuel injection valve in an internal combustion engine, an electric charge needs to be applied to the actuating element and must be removed from the actuating element again in order to close the injection valve. For a constant fuel pressure, for example in a common rail fuel injection system, the injected quantity of fuel is primarily dependent on the length of the injection period.
[0005] When any capacitive actuating element is charged, a charging current flows into the actuating element; the latter is charged when the charging current becomes zero again. During the charging operation, the actuating element voltage drop across the actuating element rises to a particular value. In the charged state, no current flows, and the actuating clement voltage remains approximately constant. During discharge, a discharge current flows out of the actuating element; the latter is discharged when the discharge current becomes zero again. During the discharging operation, the actuating element voltage which is on the actuating element falls to zero volts again.
[0006] DE 198 45 042 A1 discloses a method for diagnosing a capacitive actuator, where the actuator is supplied with a prescribable amount of energy, and incorrect operating states of the actuator are inferred by comparing measured values for the actuator current, actuator voltage or actuator charge with prescribed comparative values.
[0007] DE 199 44 734, which is not a prior publication and has earlier priority, describes a method for driving a capacitive actuating element with different charging and discharging periods. The shorter the charging and discharging operations are, the more noise intensive they become.
[0008] The control operations can be disrupted by internal or external influences such that the charge applied to the actuating element remains on the actuating element for longer than prescribed by the control signals output by an engine control system, and the fuel injection valve remains open for an undefined period, which results in too much fuel being injected.
SUMMARY OF THE INVENTION
[0009] It is an object of the invention to specify a method for driving a capacitive actuating element which provides a simple way of monitoring the operation of the actuating element even for driving operations in which the charging period and discharging period are of unequal length. P The invention achieves this object by a method for testing a capacitive actuating element, particularly one for operating a fuel injection valve in an internal combustion engine, which is controlled by means of a control signal, for correct operation, wherein the controlled variables
[0010] duration T 1 of the control signal,
[0011] actuating element's charging period T 2 ,
[0012] actuating element's discharging period T 3 , and the measured variable
[0013] open period T 4 * for a valve operated by the actuating element are related to one another in accordance with the formula (T 1 +T 3 −T 2 −T 4 *)≦|X|, where |X| is a prescribed magnitude (limit value), and wherein a fault in the operation of the actuating element is diagnosed if this formula is not satisfied.
[0014] The actuating element's prescribed charging period (T 2 ) may start when the control signal (st) starts (time t 1 ). The actuating element's prescribed discharging period (T 3 ) may start when the control signal (st) ends (t 4 ), and the measured variable ‘open period (T 4 *) for a valve operated by the actuating element’ may start (t 3 ) when the actuating element's charging current (+Ip) falls below a first current threshold value (S 1 ) or when the actuating element voltage (Up) exceeds an upper voltage threshold value (S 4 ), and may end (t 6 ) when the discharge current (−Ip) exceeds a second current threshold value (S 2 ) or when the actuating element voltage (Up) falls below the lower voltage threshold value (S 3 ).
[0015] Another method according to the present invention for testing a capacitive actuating element, particularly one for operating a fuel injection valve in an internal combustion engine, which is controlled by means of a control signal, for correct operation, provides that the controlled variable duration T 1 of the control signal and the measured variables
[0016] actuating element's charging period T 2 *,
[0017] actuating element's discharging period T 3 *, and
[0018] open period T 4 * for a valve operated by the actuating element are related to one another in accordance with the formula (T 1 +T 3 *−T 2 *−T 4 *)≦|X|, where |X| is a prescribed magnitude (limit value), and in that a fault in the operation of the actuating element is diagnosed if this formula is not satisfied.
[0019] The actuating element's measured charging period (T 2 *) may start (t 2 ) when the actuating element's charging current (+Ip) exceeds a first current threshold value (S 1 ) or when the actuating element voltage (Up) exceeds a lower voltage threshold value (S 3 ), and may end (t 3 ) when the charging current (+Ip) falls below the first current threshold value (S 1 ) again or when the actuating element voltage (Up) exceeds an upper voltage threshold value (S 4 ). The actuating element's measured discharging period (T 3 *) may start (t 5 ) when the actuating element's discharge current (−Ip) falls below a second current threshold value (S 2 ) or when the actuating element voltage (Up) falls below an upper voltage threshold value (S 4 ), and may end (t 6 ) when the discharge current (−Ip) exceeds the second current threshold value (S 2 ) or when the actuating element voltage (Up) falls below the lower voltage threshold value (S 3 ). The measured open period (T 4 *) for a valve operated by the actuating element may start (t 3 ) when the actuating element's charging current (+Ip) falls below a first current threshold value (S 1 ) or when the actuating element voltage (Up) exceeds an upper voltage threshold value (S 4 ), and may end (t 6 ) when the discharge current (−Ip) exceeds a second current threshold value (S 2 ) or when the actuating element voltage (Up) falls below the lower voltage threshold value (S 3 ). The measured variables ‘charging period (T 2 *)’ and ‘discharging period (T 3 *)’ may be compared with the corresponding, controlled variables (T 2 , T 3 ), and a fault in the operation of the actuating element can be diagnosed if the measured variables differ from the controlled variables by more than a prescribed magnitude.
[0020] The methods may include that a fault occurring repeatedly on an actuating element results in this actuating element being turned off. Furthermore, a fault occurring on an actuating element can result in an entry being made in a fault log. A warning lamp may be turned on when an actuating element is turned off.
[0021] The charging current +Ip supplied to the actuating element and the discharge current −Ip dissipated by it or the actuating element voltage drop Up across the actuating element are measured and are compared with threshold values. According to the invention, prescribed or ascertained times (periods) for the control signal, charging, discharging, and actuating element operation are related to one another and are compared with a prescribed limit value. The result of the comparison is used to infer correct or faulty operation of the actuating element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] A plurality of exemplary embodiments of the invention are described in more detail below with reference to the single figure of a schematic drawing. In the drawing:
[0023] [0023]FIG. 1 a shows the timing of a control signal st,
[0024] [0024]FIG. 1 b shows the profile of the charging current and discharge current while an actuating element is being driven,
[0025] [0025]FIG. 1 c shows the profile of the actuating element voltage while an actuating element is being driven,
[0026] [0026]FIG. 1 d shows the durations of control signal, charging time, discharging time and opening time while an actuating element is being driven in a first and a third exemplary embodiment, and
[0027] [0027]FIG. 1 e shows the durations of control signal, charging time, discharging time and opening time while an actuating element is being driven in a second and a fourth exemplary embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] [0028]FIG. 1 a shows the profile of a control signal st for a capacitive actuating element (not shown) for a fuel injection valve in an internal combustion engine for a fuel injection operation. These control signals st are ascertained by an engine control unit (not shown) as the result of a plurality of input parameters, such as engine speed, load, temperature etc.
[0029] The control signal st starts at a time t 1 and ends at a time t 4 . The difference t 4 −t 1 is equivalent to the duration T 1 of this control signal st. The drawing shows times or instants; normally, such times for the start or end of signals are output by the engine control unit, but in crankshaft angles (°KW).
[0030] In line with FIG. 1 b , the actuating element is charged with a charging current +Ip from the time t 1 . This charging current +Ip exceeds a prescribed, first current threshold value S 1 at the time t 2 , falls below it at the time t 3 and then becomes zero. From the end of the control signal st at the time t 4 , the actuating element is discharged with a discharge current Ip−. The discharge current −Ip falls below a prescribed, second current threshold value S 2 at the time t 5 , exceeds it again at the time t 6 and then becomes zero.
[0031] [0031]FIG. 1 c shows the actuating element voltage Up which is on the actuating element during a driving operation. This voltage rises from the start of the control signal st at the time t 1 , exceeds a prescribed, lower voltage threshold value S 3 at the time t 2 and exceeds a prescribed, upper voltage threshold value S 4 at the time t 3 . It then reaches its maximum, which is maintained up to the end of the control signal st at the time t 4 . At the end of the control signal st, the actuating element voltage Up falls again, falls below the upper voltage threshold value S 4 at the time t 5 and falls below the lower voltage threshold value S 3 at the time t 6 before becoming zero again.
[0032] A first exemplary embodiment, in line with FIGS. 1 b and 1 d , describes a method for monitoring a capacitive actuating element using “controlled” variables of charging period T 2 and discharging period T 3 , derived from the charging and discharge currents Ip. The text below denotes controlled variables to be variables which are measured from the start or end of the control signal st onward. In all cases, this is the variable T 1 itself, and in this exemplary embodiment also the charging period T 2 and the discharging period T 3 . All other variables, measured either after exceeding or falling below a threshold value, are called “measured” variables and have been provided with an asterisk. In this exemplary embodiment, this is just the variable T 4 * (the open period of the valve operated by the actuating element), since it starts when the charging current +Ip falls below the first current threshold value S 1 . It ends at the time t 6 , at which the discharge current −Ip exceeds the second current threshold value S 2 .
[0033] The charging period T 2 extends from the start of the control signal st at the time t 1 up to the time t 3 , at which the charging current +Ip falls below the first current threshold value S 1 . Accordingly, the discharging period T 3 extends from the end of the control signal st at the time t 4 up to the time t 6 , at which the discharge current −Ip exceeds the second current threshold value S 2 .
[0034] As can be seen in FIG. 1 d , the following relationship applies to the variables T 1 to T 4 * when the actuating element is in an operational state:
T 2 +T 4 *=T 1 +T 3 .
[0035] If the sum of the periods T 2 +T 4 does not differ from the sum of the periods T 1 +T 3 by more than a prescribed limit value X:
(T 2 +T 4 *−T 1 −T 3 )≦|X|,
[0036] it is assumed that the actuating element and hence the fuel injection valve are operating correctly. In the event of a fault occurring—for example if the discharge starts after a delay or does not start at all—the periods T 3 and T 4 * would change by the same magnitude; the equilibrium T 2 +T 4 *=T 1 +T 3 would be maintained and the fault would not be identified.
[0037] The charging period T 2 and the discharging period T 3 are also calculated and prescribed by the engine controller on the basis of various parameters, however; these variables are calculated and stored and are therefore known. This is the reason why, in this exemplary embodiment, these calculated values for the charging period T 2 and the discharging period T 3 are used to establish operating faults in the actuating element.
[0038] In the case of the fault described above, only the period T 4 * then changes, whereas the other periods T 1 , T 2 and T 3 have been prescribed; the following occurs:
(T 2 +T 4 *)>(T 1 +T 3 )→(T 2 +T 4 *−T 1 −T 3 )>|X|.
[0039] In this way, the fault can now be identified.
[0040] A second exemplary embodiment, in line with FIGS. 1 b and 1 e , likewise describes a method for monitoring a capacitive actuating element using variables which are derived from the charging and discharge currents Ip but which are “measured” (charging period T 2 *, discharging period T 3 * and valve open period T 4 *).
[0041] The charging period T 2 * starts when the charging current +Ip exceeds the first threshold value S 1 , that is to say at the time t 2 ; it ends at the time t 3 , when the charging current +Ip falls below the first threshold value S 1 again.
[0042] The discharging period T 3 * starts when the discharge current −Ip falls below the second threshold value S 2 , that is to say at the time t 5 ; it ends at the time t 6 , when the discharge current −Ip exceeds the second threshold value S 2 again.
[0043] For this exemplary embodiment, and for the fourth exemplary embodiment described further below, it can be assumed that, in a first approximation, t 2 −t 1 =t 5 −t 4 .
[0044] For the fault described above, only the period T 4 * changes in this case too, and the fault can be identified:
(T 2 *+T 4 *)>(T 1 +T 3 *)→(T 2 *+T 4 *−T 1 −T 3 *)>|X|.
[0045] A third exemplary embodiment, in line with FIGS. 1 c and 1 d , describes a method for monitoring a capacitive actuating element using “controlled” variables, derived from the actuating element voltage Up, of charging period T 2 and discharging period T 3 .
[0046] The charging period T 2 extends from the start of the control signal st at the time t 1 up to the time t 3 , at which the actuating element voltage Up exceeds the upper voltage threshold value S 3 . Accordingly, the discharging period T 3 extends from the end of the control signal st at the time t 4 up to the time t 6 , at which the discharge current −Ip falls below the lower voltage threshold value S 3 again.
[0047] The open period T 4 * for the valve operated by the actuating element starts when the actuating element voltage Up exceeds the upper voltage threshold value S 4 . It ends at the time t 6 , at which the actuating element voltage Up falls below the lower voltage threshold value S 3 again.
[0048] In this exemplary embodiment too, the prescribed, stored values are again used for the charging and discharging periods. In the case of the fault mentioned in the first exemplary embodiment, the method in accordance with this third exemplary embodiment proceeds in exactly the same way as the method in accordance with the first exemplary embodiment.
[0049] Finally, a fourth exemplary embodiment, in line with FIGS. 1 c and 1 e , describes the method using variables which are derived from the actuating element voltage Up but which are “measured” (charging period T 2 *, discharging period T 3 * and valve open period T 4 *).
[0050] The charging period T 2 * extends from the time t 2 , at which the actuating element voltage Up exceeds the lower voltage threshold value S 3 , up to the time t 3 , at which the actuating element voltage Up exceeds the upper voltage threshold value S 4 . Accordingly, the discharging period T 3 * extends from the time t 5 , at which the actuating element voltage Up falls below the upper voltage threshold value S 4 , up to the time t 6 , at which the actuating element voltage Up falls below the lower voltage threshold value S 3 again.
[0051] In this exemplary embodiment too, the open period T 4 * for the valve operated by the actuating element starts when the actuating element voltage Up exceeds the upper voltage threshold value S 4 , and ends at the time t 6 , at which the actuating element voltage Up falls below the lower voltage threshold value S 3 again. In this fourth exemplary embodiment too, as in the second exemplary embodiment, only the period T 4 * changes for the fault described above, and the fault can be identified:
(T 2 *+T 4 *)>(T 1 +T 3 *)→(T 2 *+T 4 *−T 1 −T 3 *)>|X|.
[0052] The faults which can be identified using the described method are as follows:
[0053] The first method, in line with the first or third exemplary embodiment, in which T 1 , T 2 and T 3 are “controlled” (calculated and stored) variables and T 4 is measured, can be used to establish the following faults:
[0054] the charging current +Ip or the discharge current −Ip starts to flow too early or too late;
[0055] the charging period T 2 or the discharging period T 3 becomes longer or shorter than the prescribed value.
[0056] In these four cases, the prescribed values of the variables T 1 , T 2 and T 3 remain unchanged, but T 4 becomes longer or shorter):
(T 2 +T 4 *)>(T 1 +T 3 )→(T 2 +T 4 *−T 1 −T 3 )>|X|.
[0057] The second method, in line with the second or fourth exemplary embodiment, in which T 1 is a “controlled” variable and T 2 *, T 3 * and T 4 * are measured, can be used to establish the following faults:
[0058] a) with a level of accuracy as in the first method:
[0059] all faults which can be detected on the basis of the first method when the measured values T 2 * and T 3 * are additionally compared with the controlled variables T 2 and T 3 ; if there is no match, then this is rated as a fault;
[0060] b) with a better level of accuracy than in the first method:
[0061] the charging current +Ip or the discharge current −Ip starts to flow too early or too late; in this case, the charging period T 2 * or the discharging period T 3 * remains the same length and is merely shifted forward or backward; only the variable T 4 * changes in this case:
(T 2 *+T 4 *)>(T 1 +T 3 *)→(T 2 *+T 4 *−T 1 −T 3 *)>|X|.
[0062] It is also possible to establish a plurality of faults occurring simultaneously, but these would result in too long a list on account of the large number of combinations for them.
[0063] When one of the listed faults arises, then in the event of it arising once, for example, no reaction is triggered. If it arises a plurality of times, then this actuating element (and, in the case of an internal combustion engine, at least the associated cylinder) needs to be turned off. If there is an OBD system (On-Board Diagnosis) available, an entry is then made in a fault log, for example whenever a fault arises, and a warning lamp can additionally be turned on. | A capacitive actuating element is driven using a control signal of duration T 1. This duration T 1 is related to prescribed or measured values for charging, discharging and open periods T 2, T 3 and T 4:
(T 1 +T 3 −T 2 −T 4 )≦|X| and is compared with a magnitude (limit value |X|). If a magnitude greater than |X| is obtained, then a fault is inferred. | 5 |
[0001] The work leading to this invention was supported in part by Grant Nos. DK08753 and RO1DK48042 from the National Institutes of Health. The U.S. Government may have certain rights to this invention.
FIELD OF THE INVENTION
[0002] This invention is directed to specific antagonists of glucose-dependent insulinotropic polypeptide (GIP). This invention is also directed to treatment of non-insulin dependent diabetes through increasing glucose tolerance without requirement for increased serum insulin, the treatment of obesity by the administration of a GIP antagonist, the development of nonpeptide GIP antagonist compounds, and compositions.
BACKGROUND
[0003] Insulin release induced by the ingestion of glucose and other nutrients is due part to both hormonal and neural factors (Creutzfeldt, et al., 1985, Diabetologia 28:565-573). Several gastrointestinal regulatory peptides have been proposed as incretins, the substance(s) believed to mediate the enteroinsular axis and that may play a physiological role in maintaining glucose homeostasis (Unger, et al., 1969, Arch. Intern. Med, 123:261-266; Ebert R., et al. 1987, Diab. Metab. Rev., 3:1-16; Dupré J., 1991, “The Endocrine Pancreas.” Raven Press, New York, p 253). Among these candidates, only glucose-dependent insulinotropic polypeptide (GIP) and glucagon like peptide-1 (7-36)(GLP-1) appear to fulfill the requirements to be considered physiological stimulants of postprandial insulin release (Dupre, et al. 1973, J. Clin. Endocrinol. Metab., 37:826-828; Nauck, et al., 1989, J. Clin. Endocrinol. Metab., 69:6540662; Kreymann, et al. 1987, Lancet, 2:1300-1304; Mojsov, et al., 1987, J. Clin. Invest., 79:616-619).
[0004] Following oral glucose administration, serum GIP levels increase several fold (see Cleator, et al., 1975, Am. J. Surg., 130:128-135; Nauck, et al. 1986, J. Clin. Endocrinol. Metab., 63:492-498; Nauck, et al., 1986, Diabetologia, 29:46-52; Salera, et al., 1983, Metabolism, 32:21-24; Kreymann, et al., 1987, Lancet, 2:1300-1304), and although the increment in plasma GLP-1 concentration in response to glucose is also significant, it is far smaller in magnitude (Kreymann, et al., 1987, Lancet, 2:1300-1304; Orskov, et al., 1987, Scand. J Clin. Lab. Invest., 47:165-174; Ørskov, et al., 1991, J. Clin. Invest., 87:415-423; Shuster, et al., 1988, Mayo Clin. Proc., 63:794-800). In human volunteers, Nauck et al. (1993, J. Clin. Endocrinol. Metab., 76:912-917) showed that GIP was a major contributor in the incretin effect after oral glucose, whereas GLP-1 appeared to play a major role. Shuster et al. (1988) also suggested that GIP was the most important, but not the sole, mediator of the incretin effect in humans.
[0005] Some studies have demonstrated that GIP and GLP-1 are equally potent in their capacity to stimulate insulin release (Schmid, et al., 1990, Z. Gastroenterol., 28:280-284; Suzuki, et al., 1990, Diabetes, 39:1320-1325), whereas others have suggested that GLP-1 possesses greater insulinotropic properties (Siegel, et al. 1992, Eur. J. Clin. Invest. 22:154-157; Shima, et al. 1988, Regul. Pept., 22:245-252). Recently, using a putative specific antagonist to the GLP-1 receptor, exendin (9-39), Wang et al. have demonstrated that exenden reduced postprandial insulin release by 48% and thus concluded that GLP-1 might contribute substantially to postprandial stimulation of insulin secretion (Wang, et al. 1995, J. Clin. Invest., 95:417-421). More recent studies, however, have shown that exendin might also displace GIP binding from its receptor and thereby reduce GIP-stimulated cyclic adenosine monophosphate (cAMP) generation (Wheeler, et al. 1995, Endocrinology, 136:4629-4639; Gremlich, et al. 1995, Diabetes, 44:1202-1208). Therefore, the antagonist properties of exendin (9-39) might not be limited to GLP-1.
[0006] The availability of a GIP-specific receptor antagonist would be invaluable for determining the precise roles of these peptides in mediating postprandial insulin secretion.
SUMMARY OF THE INVENTION
[0007] It is an object of this invention to provide specific antagonists of glucose-dependent insulinotropic polypeptide (GIP).
[0008] It is another object of this invention to provide alternative methods for treatment of non-insulin dependent diabetes which increase glucose tolerance without requirement for increased serum insulin, for treatment of obesity with a GIP antagonist which inhibits, blocks or reduces glucose absorption from the intestine of an animal, and for development of nonpeptide GIP antagonist compounds.
[0009] In one embodiment, this invention provides an antagonist of glucose-dependent insulinotropic polypeptide (GIP) consisting essentially of a 24-amino acid polypeptide corresponding to positions 7-30 of the sequence of GIP.
[0010] In another embodiment, this invention provides a method of treating non-insulin dependent diabetes mellitus in a patient comprising administering to the patient an antagonist of glucose-dependent insulinotropic polypeptide (GIP).
[0011] In yet another embodiment, this invention provides a method of improving glucose tolerance in a mammal comprising administering to the mammal an antagonist of glucose-dependent insulinotropic polypeptide (GIP).
[0012] Using a reporter L-cell line stably transfected with rat GIP receptor cDNA (LGIPR2), the inventors have identified a fragment of GIP [GIP (7-30)-NH 2 ] as a specific GIP receptor antagonist. This antagonist (referred to as ANTGIP) inhibited GIP-stimulated intracellular CAMP production in vitro, and ANTGIP competed with GIP for binding to cellular receptors, but did not complete with GLP-1. ANTGIP inhibited the GIP-dependent release of insulin in vivo, but ANTGIP had no effect on glucose-, GLP-1-, GIP-, and arginine-induced insulin release in anesthetized rats. In conscious rats, ANTGIP inhibited postprandial insulin release, without significantly affecting the serum glucose concentration. However, despite its inhibiting effect on insulin release, ANTGIP has been discovered to enhance glucose tolerance in an oral glucose tolerance test.
BRIEF DESCRIPTION OF THE FIGURES
[0013] [0013]FIGS. 1A and 1B show cAMP-dependent β-galactosidase production by LGIPR2 cells in the presence of GIP or various GIP fragments.
[0014] [0014]FIG. 2 shows dose-dependent inhibition of ANTGIP on GIP-included cAMP-dependent β-galactosidase production in LGIPR2 cells.
[0015] [0015]FIG. 3 shows competition of 125 I-GIP and 125 I GLP-1(inset) binding by GIP, GLP-1 and ANTGIP.
[0016] [0016]FIG. 4 shows plasma insulin concentrations (±SE) in fasted anesthetized rats after 30 min of GIP, ANTGIP, or 0.9 NaCl infusion.
[0017] [0017]FIG. 5 shows plasma insulin concentrations (±SE) in fasted anesthetized rats after a 30-min infusion of GLP-1 (0.4 nmol/kg), glucose (0.8 g/kg), or arginine (375 mg/kg) with (open bars) or without (solid bars) ANTGIP (100 nmol/kg) (n=6 for each group).
[0018] [0018]FIG. 6 shows postprandial plasma insulin and serum glucose levels (±SE) in conscious trained rats.
[0019] [0019]FIG. 7 shows plasma insulin level following oral glucose administration to rats with or without ANTGIP injection.
[0020] [0020]FIG. 8 shows plasma glucose level following oral glucose administration to rats with and without ANTGIP injection.
[0021] [0021]FIG. 9 shows the effects of the GIP receptor antagonist, ANTGIIP, on the absorption of free D-glucose from the lumen of the jejunal test segment.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Glucose-dependent insulinotropic polypeptide (GIP) is 42-amino acid hormone that was originally described as a inhibitor of acid secretion. More recently, however, it has been shown to be potent stimulant for the release of insulin from the endocrine pancreas.
[0023] The inventors have confirmed previous studies (Rossowski, et al., 1992, Regul. Pep., 39:9-17) indicating that truncated GIP [GIP (1-30)-NH 2 ] might be one of the biologically active forms of mature GIP. As shown in FIG. 1, GIP (1-30)-NH 2 was nearly equipotent to GIP (1-42) in stimulating cAMP dependent β-galactosidase production in LGIPR2 cells. These findings are consistent with the observations of Wheeler, et al. (1995), reported that both GIP(1-42) and GIP(1-30) exhibited similar stimulatory properties for cAMP production in COS-7 cell transiently expressing GIP receptor cDNA. Moreover, Kieffer et al. (1993, Can. J. Physiol. Pharmacol., 71:917-922) found that GIP (1-30) competitively inhibited binding of GIP (1-42) to the GIP receptor in βTC3 cells. These data suggest the possibility of cellular processing of GIP (1-42) to yield biologically-active α-amidated GIP (1-30).
[0024] Physiological Effects of GIP Antagonists
[0025] Insulin release induced by the ingestion of glucose and other nutrients is due in part to both hormonal and neural factors (see, e.g., Creutzfeldt, et al., 1985). Although a number of gastrointestinal regulatory peptides have been proposed as putative incretins, GIP and GLP-1 are the most likely physiological insulinotropic peptides. Although both GIP and GLP-1 possess significant insulinotropic properties, controversy exists regarding their relative physiological roles in stimulating insulin release.
[0026] Using a GLP-1 receptor antagonist exendin (9-39), Wang et al. (1995) detected a 50% decrease in postprandial insulin secretion in exendin-treated rats. Administration of exendin also reduced 70% of insulin release following intraduodenal glucose infusion (Kolligs, et al., 1995, Diabetes, 44:16-19). Recent studies, however, have demonstrated that exendin also displaced GIP binding from its receptor, and inhibits cAMP generation in response to GIP stimulation (Wheeler, et al. 1995; Gremlich, et al. 1995). Therefore, the antagonist properties of exendin do not appear to be GLP-1 specific.
[0027] Successful synthesis by the present inventors of a specific GIP receptor antagonist greatly facilitates investigation of the relative contribution of GIP in mediating the enteroinsular axis. The GIP fragment ANTGIP [GIP (7-30)-NH 2 ] specifically inhibits various GIP-dependent effects. In LGIPR2 cells, ANTGIP inhibited the cAMP response to GIP in a concentration-dependent manner (see FIG. 2), and in βTC3 cells, the antagonist displaced GIP binding from its receptor (see FIG. 3). Furthermore, ANTGIP completely abolished the insulinotropic properties of GIP in fasted anesthetized rats, while not affecting GLP-1, glucose-, or arginine-stimulated insulin release indicating that this antagonist is GIP-specific. ANTGIP alone demonstrated no stimulatory effect on insulin release or cAMP generation in either intact rats or LGIPR2 cells, indicating the absence of any agonist properties. Studies demonstrated that even at a concentration as high as 10 −4 M, ANTGIP did not stimulate a detectable increase in cAMP-dependent β-galactosidase level in LGIPR2 cells.
[0028] The inventors have observed a 72% decrease in postprandial insulin release in response to the administration of ANTGIP to rats. ANTGIP did not affect GLP-1 binding to its receptor, and the insulinotropic effect of GLP-1 is preserved in vivo in the presence of ANTGIP. Furthermore, postprandial GLP-1 levels were not affected by ANTGIP. These findings are consistent with a dominant role for GLP in mediating the enteroinsular axis.
[0029] Wang et al. demonstrated an approximate 50% reduction in postprandial insulin levels in exendin-treated rats, whereas plasma glucose levels increased minimally from 7.5 to 8.7 mmol/l. The physiological significance of this minor increment in glucose level was not clear to Wang, et al. The inventors found that serum glucose concentrations remained largely unchanged despite a marked decrease in serum insulin levels in ANTGIP-treated rats. The results of the present study are consistent with the notion that insulin is not the sole mediator of glucose homeostasis, but that glucose maintenance is dependent on numerous neurohumoral factors. These factors include hormones, such as pancreatic glucagon, cortisol, and growth hormone, and physiological events, including peripheral and hepatic glucose uptake.
[0030] The results of the present studies demonstrate that GIP (7-30)-NH 2 is a specific receptor antagonist of naturally occurring GIP. GIP (7-30)-NH 2 inhibits GIP-induced cAMP generation and insulin release, but does not affect the insulinotropic effects of other secretagogues such as glucose, arginine, and GLP-1. Furthermore, circulating insulin levels decreased by 72% in response to the concomitant administration of GIP (7-30)-NH 2 to chow-fed rats, indicating that GIP plays a dominant role in mediating postprandial insulin secretion.
[0031] Strikingly, although GIP (7-30)-NH 2 reverses the insulin stimulatory properties of the parent compound, when the GIP antagonist was administered to rats (injected intraperitoneally), oral glucose tolerance was improved: a significant decrease in serum glucose levels was detected at all time points in all rats. In addition, plasma insulin levels were also diminished in these same rats. These results are surprising—with the decrease in insulin release, one would expect an increase in serum glucose. However, GIP has several other peripheral effects which may include an affect of GIP on peripheral glucose utilization, and the decrease in serum glucose levels seen with GIP might be due to such an effect.
[0032] The effect of GIP antagonists on serum glucose levels in the absence of increased serum insulin suggests their use in patients with noninsulin dependent diabetes mellitus (NIDDM). With the aging of the United States population, an increase in the number of cases of NIDDM has been predicted. In the past forty years, very few new forms of therapy for this most prevalent disease have been developed. GIP antagonists enhance tolerance to oral glucose, as demonstrated herein, and therefore treatment of NIDDM patients with these compounds is indicated.
[0033] GIP Antagonists
[0034] A GIP antagonist according to this invention is any composition which interferes with biological action of GIP. Such compositions include antibodies specific for either GIP or GIP receptors, antisense RNA which hybridizes with mRNA encoding GIP or GIP receptor, or other genetic controls which knock out expression of GIP or GIP receptor. GIP antagonists also include peptides or other small molecules which bind to the GIP receptor and block the cAMP response to GIP. Suitable assays for antagonist activity are exemplified in Examples 1 and 2 below:
[0035] As described herein (see Example 1 below), the inventors have now discovered a polypeptide fragment of GIP that is a specific GIP receptor antagonist. While the 30-amino acid N-terminal fragment [GIP (1-30)-NH 2 ] was as effective in stimulating cAMP increase through GIP receptors as the parent hormone, a fragment missing the most N-terminal six amino acids [GIP (7-30)-NH 2 ] did not stimulate cAMP release in the same system. Thus, the N-terminal hexamer appears to be important for functional GIP signaling. GIP fragments missing the N-terminal 15 amino acids (e.g., GIP (16-30)-NH 2 ) did not mimic GIP, but neither did they inhibit GIP-dependent effects. Thus, the segment from amino acids 7-15 appears to be especially important in signaling through the GIP receptor. Fragment GIP (10-30)-NH 2 was less effective as an antagonist, but retained some ability to affect GIP receptor activation, as indicated by partial agonist activity. Thus, peptide antagonists would appear to require the segment from amino acids 7-9 of the GIP sequence, and some or all of the amino acids from 10-30 or effective alternative amino acids thereto are likely to promote binding to the receptor. It should therefore be understood by those of skill in this art that the present invention contemplates any polypeptide sequence which effectively prevents GIP activation of its native receptor, such as the sequence containing amino acids in positions 7-30 of the sequence of the GIP sequence and polypeptides based upon sequences containing amino acids in positions 7-30 of the sequence of the GIP that include additional, deleted or alternative amino acids to form effective GIP polypeptide antagonist. Polypeptides based on this sequence may be designed for use as GIP antagonists according to this invention by the skilled artisan, who will routinely confirm that the resultant peptides exhibit antagonist function by testing the peptides in in vitro and in vivo assays such as those described in Examples 1 and 3-5 below.
[0036] Immunologic components specific for GIP or GIP receptors can be employed as GIP antagonists. Such antagonists include with specific monoclonal antibodies (either naked or conjugated to cytotoxic agents) or specific activated cytotoxic immune cells. Such antibodies or immune cells may be generated as reagents outside the body, or may be generated inside the body by vaccines which target GIP or GIP receptors.
[0037] Antibodies which are specifically reactive with GIP or the hormone binding domain of GIP receptor, or antigenic recombinant peptide fragments of either of those proteins, may be obtained in a number of ways which will be readily apparent to those skilled in the art. The known sequences of GIP (see Takeda, et al. 1987, Proc. Natl. Acad. Sci USA, B84:7005-7008, and Genbank Accession No. M18185), and GIP receptor (see Bonner, T. I., and Usdin, T. B., 1995, Genbank Accession No U39231) can be used in conjunction with standard recombinant DNA technology to produce the desired antigenic peptides in recombinant systems (see, e.g., Sanbrook et al.). Antigenic fragments of GIP or GIP receptor can be injected into an animal as a immunogen to elicit polyclonal antibody production. Purification of the antibodies can be accomplished by selective binding from the serum, for instance by using cells transformed with DNA sequence encoding the respective proteins. The resultant polyclonal antisera may be used directly or may be purified by, for example, affinity absorption using recombinantly produced protein coupled to an insoluble support.
[0038] In another alternative, monoclonal antibodies specifically immunoreactive with either GIP or the hormone binding domain of GIP receptor may be prepared according to well known methods (See, e.g., Kohler and Milstein, 1976, Eur. J. Immunol., 6:611), using the proteins or antigenic fragments described above as immunogen(s), using them for selection or using them for both functions. These and other methods for preparing antibodies or immune cells that are specifically immunoreactive with GIP or GIP receptor are easily within the skill of the ordinary worker in the art.
[0039] Immunogenic compositions according to this invention for use in active immunotherapy include recombinant antigenic fragments of GIP or GIP receptor prepared as described above and expression vectors (particularly recombinant viral vectors) which express antigenic fragments of GIP or GIP receptor. Such expression vectors can be prepared as described in Baschang, et al., U.S. Pat. No. 4,446,128, incorporated herein by reference, or Axel, et al., Pastan, et al., or Davis, et al., using the known sequences of GIP or GIP receptor.
[0040] Still another GIP antagonist according to this invention is an expression vector containing an antisense sequence corresponding to all or part of an mRNA sequence encoding GIP or GIP receptor, inserted in opposite orientation into the vector after a promoter. As a result, the inserted DNA will be transcribed to produce an RNA which is complementary to and capable of binding or hybridizing to the mRNA. Upon binding to the GIP or GIP receptor mRNA, translation of the mRNA is prevented, and consequently the protein coded for by the mRNA is not produced. Suitable antisense sequences can be readily selected by the skilled artisan from the sequences of GIP or GIP receptor cited above. Production and use of antisense expression vectors is described in more detail in U.S. Pat. No. 5,107,065 and U.S. Pat. No. 5,190,931, both of which are incorporated herein by reference.
[0041] Alternative materials within the contemplation of the skilled artisan which function as antagonists of GIP in the procedures described in Examples 1 and 3-5 below may also be used in the therapeutic methods according to this invention.
[0042] Therapeutic Use of GIP Antagonists
[0043] GIP (7-30)-NH 2 acts as a receptor antagonist of GIP, but also improves glucose tolerance contrary to the expected consequence of blocking GIP-dependent insulin secretion. In addition, a GIP receptor antagonist in accordance with the present invention inhibits, blocks or reduces glucose absorption from the intestine of an animal. In accordance with this observation, therapeutic compositions containing GIP antagonists may be used in patients with noninsulin dependent diabetes mellitus (NIDDM) to improve tolerance to oral glucose or in animals, such as humans, to prevent, inhibit or reduce obesity by inhibiting, blocking or reducing glucose absorption from the intestine of the animal, as demonstrated herein.
[0044] Therapeutic compositions according to this invention are preferably formulated in pharmaceutical compositions containing one or more GIP antagonists and a pharmaceutically acceptable carrier. The pharmaceutical composition may contain other components so long as the other components do not reduce the effectiveness of the GIP antagonist according to this invention so much that the therapy is negated. Examples of such components include sweetening, flavoring, coloring, dispersing, disintegrating, binding, granulating, suspending, wetting, preservative and demulcent agents and the like. Pharmaceutically acceptable carriers are well known, and one skilled in the pharmaceutical art can easily select carriers suitable for particular routes for administration ( Remington's Pharmaceutical Sciences, Mack Publishing Co., Easton, Pa., 1985).
[0045] Also in accordance with the present invention, the GIP receptor antagonist of the present invention may be lyophilized using standard techniques known to those in this art. The lyophilized GIP receptor antagonists may then be reconstituted with, for example, suitable diluents such as normal saline, sterile water, glacial acetic acid, sodium acetate, combinations thereof and the like. The reconstituted GIP receptor antagonists in accordance with the present invention may be administered parenterally or orally and may further include preservatives or other acceptable inert components as mentioned hereinbefore.
[0046] The pharmaceutical compositions containing any of the GIP antagonists according to this invention may be administered by parenteral (subcutaneously, intramuscularly, intravenously, intraperitoneally, intrapleurally, intravesicularly or intrathecally, topical, oral, rectal, or nasal route, as necessitated by choice of drug and disease. The dose used in a particular formulation or application will be determined by the requirements of the particular state of disease and the constraints imposed by the characteristics of capacities of the carrier materials. The concentrations of the active agent in pharmaceutically acceptable carriers may range from 0.1 nM to 100 μM. The compositions described above may be combined or used together or in coordination with another therapeutic substance.
[0047] Dose will depend on a variety of factors, including the therapeutic index of the drugs, disease type, patient age, patient weight, and tolerance of toxicity. Dose will generally be chosen to achieve serum concentrations fro about 0.1 μg/ml to about 100 μg/ml. Preferably, initial dose levels will be selected based on their ability to achieve ambient concentrations shown to be effective in in-vitro models, such as that used to determine therapeutic index, and in-vivo models and in clinical trials, up to maximum tolerated levels. Standard clinical procedure prefers that chemotherapy be tailored to the individual patient and the sytemic concentration of the chemotherapeutic agent be monitored regularly. The dose of a particular patient can be determined by the skilled clinician using standard pharmacological approaches in view of the above factors. The response to treatment may be monitored by analysis of blood or body fluid levels of the glucose or GIP or GIP antagonist according to this invention, measurement of activity if the antagonist or its levels in relevant tissues or monitoring disease state of the patient. The skilled clinician will adjust the dose based on the response to treatment revealed by these measurements.
[0048] One approach to therapy of NIDDM is to introduce vector expressing antisense sequences to block expression of GIP and/or GIP receptor. In one embodiment of this invention, a method is provided which comprises obtaining a DNA expression vector containing a cDNA sequence having the sequence of human GIP or GIP receptor mRNA which is operably linked to a promoter such that it will be expressed in antisense orientation, and transforming cells which express GIP or GIP receptor, respectively, with the DNA vector. The expression vector material is generally produced by culture of recombinant or transfected cells and formulated in a pharmacologically acceptable solution or suspension, which is usually a physiologically-compatible aqueous solution, or in coated tablets, tablets, capsules, suppositories, inhalation aerosols, or ampules, as described in the art, for example in U.S. Pat. No. 4,446,128, incorporated herein by reference.
[0049] The vector-containing composition is administered to a mammal exhibiting NIDDM in an amount sufficient to transect a substantial portion of the target cells of the mammal. Administration may be any suitable route, including oral, rectal, intranasal or by intravesicular (e.g. bladder) instillation or injection where injection may be, for example, transdermal, subcutaneous, intramuscular in intravenous. Preferably, the expression vector is administered to the mammal so that the target cells of the mammal are preferentially transfected. Determination of the amount to be administered will involve consideration of infectivity of the vector, transection efficiency in vitro, immune response of the patient, etc. A typical initial dose for administration would be 10-1000 micrograms when administered intravenously, intramuscularly, subcutaneously, intravesicularly, or in inhalation aerosol, 100 to 1000 micrograms by mouth, 10 5 to 10 10 plaque forming units of a recombinant vector, although this amount may be adjusted by a clinician doing the administration as commonly occurs in the administration of other pharmacological agents. A single administration may usually be sufficient to produce a therapeutic effect, but multiple administrations may be necessary to assure continued response over a substantial period of time.
[0050] Further description of suitable methods of formulation and administration according to this invention may be found in U.S. Pat. Nos. 4,592,002 and 4,920,209, which are incorporated herein by reference in their entireties.
[0051] The present invention also contemplates the use of the GIP antagonists and/or its properties to develop nonpeptide compounds which exhibit antagonist properties similar to the GIP polypeptide antagonists as herein described using techniques known those versed in the pharmaceutical industry.
EXAMPLES
[0052] In order to facilitate a more complete understanding of the invention, a number of Examples are provided below. However, the scope of the invention is not limited to specific embodiments disclosed in these Examples, which are for purposes of illustration only.
Example 1
Effects of Various Peptide Fragments on cAMP Production
[0053] To define the biologically active region of GIP, the effects of several peptide fragments of GIP on stimulating cAMP-dependent β-galactosidase production in LGIPR2 cells were examined. LGIPR2 cells are stably transfected with a cAMP-dependent promoter from the VIP gene fused to the bacterial lac Z gene. When intracellular cAMP increases within these cells, lac Z gene transcription is activated, resulting in the accumulation of its product, β-galactosidase. The measurement of β-galactosidase in this system provided a convenient, inexpensive, and nonradioactive method for detecting changes in the levels of intracellular cAMP.
[0054] LGIPR2 cells were grown in Dulbecco's Modified Eagle's Medium (DMEM) containing 4.5 g/L of glucose and 10% fetal calf serum. For each assay, 10 5 cells/well were seeded onto 24-well plates. After incubation overnight, peptides were added in various concentrations to the wells in the absence of 3-isobutyl-methylxanthine (IBMX) for 4 h, at which time maximal stimulation of β-galactosidase was determined. The medium was then removed and wells rinsed once with phosphate-buffered saline (PBS). The plates were then blotted briefly and frozen overnight at −70° C., and, after the addition of chlorophenol red-β-D-galactopyranoside, accumulated β-galactosidase was detected using a calorimetric assay, as described previously (Usdin, et al., 1993, Endocrinology, 133:2861-2870).
[0055] Preliminary studies using LGIPR2 cells demonstrated that GIP(1-42) stimulated β-galactosidase production in a concentration-dependent manner, with the maximum effect observed at 4 h with 10 −8 M. Various peptide fragments of GIP, including GIP(21-30)NH 2 , GIP (16-30)-NH 2 , GIP (7-30)-NH 2 , GIP (1-30)-NH 2 , GIP (10-30)-NH 2 , and GIP (31-44), were synthesized at the Biopolymer Laboratory, Harvard Medical School, based on previously published rat GIP cDNA sequence (Tseng, et al., 1993, Proc. Natl. Acad. Sci. USA, 90:1992-1996). LGIPR2 cells were incubated in the presence of 10 −8 M GIP or different GIP fragments for 4 h, and β-galactosidase was measured as described herein and expressed in optical density (O.D.) units. FIG. 1A and 1B show cyclic AMP-dependent β-galactosidase generation in LGIPR2 cells in response to incubation with different fragments of GIP. Values are expressed as the mean±SE of quadruplicate measurements (*p<0.01, compared to control).
[0056] As demonstrated in FIG. 1A, 10 −8 M GIP (1-30)-NH 2 stimulated β-galactosidase production to a similar degree, while none of the other peptide fragments tested, including GIP (7-30)-NH 2 , GIP (16-3 0)-NH 2 , GIP (21-30)-NH 2 , and GIP (31-44), stimulated β-galactosidase generation above control levels. Furthermore, no changes in cAMP-dependent-β-galactosidase levels were detected when LGIPR2 cells were incubated in the presence of higher concentrations of the smaller peptide fragments.
[0057] To examine whether any of these fragments might serve as an antagonist to GIP, LGIPR2 cells were incubated with 10 −8 M GIP (1-42) and one of the peptide fragments at two different concentrations (10 −8 M or 10 −6 M ) for 4 h. LGIPR2 cells were cultured in the presence of 10 −8 M GIP and various concentrations of ANTGIP, as depicted on the horizontal axis if FIG. 2. Values are expressed as the mean±SE of quadruplicate measurements. Only GIP (7-30)-NH 2 (ANTGIP) was found to attenuate the cAMP stimulatory effects exhibited by GIP (1-42); the inhibition was concentration-dependent, with half-maximal inhibition occurring at 10 −7 M (FIG. 2).
[0058] [0058]FIG. 1B shows that peptide GIP (10-30)-NH 2 is an antagonist, albeit a weak one, as demonstrated by the reduction in GIP-stimulated β-gal levels when GIP (10-3 0)-NH 2 is present with GIP (1-42) compared to GIP (1-42) alone. On the other hand, GIP (10-30)-NH 2 also has agonist properties, as demonstrated by β-gal level of 0.39 O.D. +0.03 stimulated by GIP (10-30)-NH 2 alone, compared to 0.95+0.04 for GIP (1-42).
Example 2
Receptor Binding Studies
[0059] Binding studies were performed in either LGIPR2 or βTC3 cells to determine the relative affinities of GIP, ANTGIP, and GLP-1 for both GIP and GLP-1 receptors. GLP(7-37) and porcine GIP (5 μg each) were iodinated by the chloramine-T method and were purified using C-18 cartridges (Sep-Pak®, Millipore, Milford, Mass.) using an acetonitrile gradient of 30-45%. The specific activity of radiolabeled peptides was 10-50 μCi/mg (Hunter, et al., 1962, Nature, 194:495-498; Kieffer, et al., 1993, Can. J. Physiol. Pharmacol., 71:917-922). Aliquots were lyophilized and reconstituted in assay buffer at 4° C. to a concentration of 3×105 cpm/100 μl. Binding studies was performed in desegrated LGIPR2 or βTC2 cells, the latter a generous gift from Dr. S. Efrat (Diabetes Center, Albert Einstein College of Medicine, New York). The βTC2 cell line originally arose in a lineage of transgenic mice expressing an insulin promoted, SV40 T-antigen hybrid oncogene in pancreatic β-cells (Efrat, et al., 1988, Proc. Natl. Acad. Sci. U.S.A., 85:9037-9041) and has previously been demonstrated to be responsive to both GIP and GLP (Kieffer, et al., 1993, Can. J. Physiol. Pharmacol., 71:917-922). The receptor binding buffer contained 138 mM NaCl, 5.6 mM KCl, 1.2 mM MgCl 2 , 2.6 mM CaCl 2 , 10 mM Hepes, 10 mM glucose, and 1% bovine serum albumin (BSA, fraction V, protease free, Sigma). For binding assays, LGIPR2 (GIP binding) or βTC3 (GLP-1 binding) cells were cultured in DMEM containing 4.5 g/L of glucose and 10% fetal bovine serum until 70% confluent. Cells were washed once with PBS and then harvested with PBS-EDTA solution. βTC3 cells were then suspended in assay buffer at a density of 2×1 06 cells/ml, and LGIPR2 cells were used at a density of 2.5×10 5 cells/mil. Binding was performed at room temperature in the presence of 3×10 5 cpm/ml of [ 125 I]-GIP and -GLP. Nonsaturable binding was determined by the amount of radioactivity associated with cells when incubated in the presence of unlabeled 10 6 M GIP, GLP, or 10 −4 M ANTGIP. Specific binding was defined as the difference between counts in the absence and presence of unlabeled peptide. GIP binding was examined using LGIRP2 cells, and GLP-1 binding was assessed using βTC3 cells, and the results are shown in FIG. 3. Values are expressed as a percentage of maximum specific binding and are the mean±SE, with assays performed in duplicate.
[0060] GIP and ANTGIP displaced the binding of [ 125 I]GIP to LGIPR2 cells in a concentration-dependent manner (FIG. 3), with an IC 50 of 7 nM for GIP (n=5) and 200 nM for ANTGIP (n=4). Binding of [ 125 I]GLP-1 to its βTC3 cell receptor was displaced fully by GLP-1, but negligibly by ANTGIP, with an IC 50 of 4 nM and 80 μM, respectively (n=7; FIG. 3).
Example 3
Intravenous Infusion of Peptides in Fasting Anesthetized Rats
[0061] Adult male Sprague-Dawley rats (250-350 g) were purchased from Charles River Co. (Kingston, Mass.). For infusion studies, rats were fasted overnight and then anesthetized using intraperitoneal sodium pentobarbital. The right jugular vein was cannulated with silicon polymer tubing (0.025 in I.D., 0.047 in O.D., Dow Corning Corporation, Midland, Mich.), as described by Xu and Melethil (21). The tubing was then connected to an infusion pump (Harvard Apparatus Co., Inc., Millis, Mass.), and freshly made 0.9% NaCl, 5% glucose, arginine, GIP, or GLP-1 (peptides and arginine dissolved in 0.9% NaCl) was infused at a rate of 0.1 ml/min. Blood (0.5 ml each) was obtained at 0, 10, 20, and 30 min by translumbar vena cava puncture, as described by Winsett et al. (1985, Am. J. Physiol., 249:G145-146), and samples were centrifuged at 2,000 g for 10 min. Serum samples were separated and stored at −20° C. until assayed for insulin using a radioimmunoassay kit (ICN Biochemicals, Costa Mesa, Calif.), and glucose, using a One Touch lip glucose meter (Lifescan, INS., Milpitas, Calif.).
[0062] To examine the insulinotropic effect of GIP in vivo, fasted anesthetized rats were perfused continuously with three different concentrations of GIP (0.5, 1.0, and 1.5 nmol/kg) at a rate of 0.1 ml/min for 30 min (10 −8 M equivalent to 1 nmol/kg/30 min). Significant increases in plasma insulin levels were first detected at 15 min, and after completion of the GIP infusion, insulin levels were elevated with all three GIP concentrations (43.5±2.7, 61.6±4.2, and 72.4±3.5 μIU/ml, respectively) compared to control (32.2±3.3 μIU/m, p<0.05, FIG. 4). The concomitant administration of ANTGIP (100 nmol/kg) completely abolished the insulinotropic properties of GIP (1.5 nmol/kg), with plasma insulin returning to control values (FIG. 4). GIP was infused at 0.5, 1.0, and 1.5 nmol/kg, with the largest insulin stimulatory response seen with 1.5 nmol/kg. ANTGIP (100 nmol/kg) administered concomitantly with GIP 1.5 nmol/kg completely abolished its insulinotropic effect, whereas ANTGIP and 0.9% NaCl infusion had no effect on insulin secretion (n=6 for each group, *p<0.05, compared with basal levels).
[0063] To examine whether ANTGIP exerted a nonspecific effect on β-cell function, GLP-1 (0.4 nmol/kg), glucose (0.8 g/kg), or arginine (375 mg/kg) was infused, in the presence or absence of the antagonist for 30 min, as described by Wang et al. (13). FIG. 5 shows plasma insulin concentrations (±SE) in fasted anesthetized rats after a 30-min infusion of GLP-1 (0.4 nmol/kg), glucose (0.8 g/kg), or arginine (375 mg/kg) with (open bars) or without (solid bars) ANTGIP (100 nmol per kg) (n=6 for each group, *p<0.05, compared with basal levels). GLP-1, glucose, and arginine alone each significantly increased insulin levels after 15 min of infusion, and by 30 min, the insulin levels in GLP-1-, glucose-, and arginine-infused rats were 50.3±3.7, 63.1±2.5, 69.7±5.8μIU/ml respectively (p<0.01, compared with control rats, 29.1±2.9 μIU/ml, FIG. 5). No significant change in the insulin response was detected when ANTGIP was administered concomitantly (FIG. 5).
Example 4
Insulinotropic Effect of GIP in Trained Conscious Fed Rats
[0064] Postprandial plasma insulin and serum glucose levels were studied in conscious trained rats. Previous reports have indicated that the stress response to injection in untrained rats might alter their feeding and subsequently glucose and insulin levels (13). To avoid such a response, rats were trained for 10 d before experimentation. They were fasted from 17:00 to 08:00, and 0.9% NaCl (0.3 ml) was injected subcutaneously at 08:00 before feeding. After the injection of 0.9% NaCl, animals were given rat chow for 30 min, after which it was removed. At the end often days, the rats were accustomed to the injection and ate quickly (consuming 4-6 g of rat chow within 30 min).
[0065] On the day of the experiment, after fasting from 17:00 the night before, trained rats were injected subcutaneously at 08:00 with 0.3 ml of either 0.9% NaCl or ANTGIP (100 nmol/kg). This dose was chosen to approximately the amount of peptide used in the anesthetized animal studies of Example 3. After injection, six of the fasted control rats were killed to obtain baseline serum glucose and insulin levels. ANTGIP- or 0.9% NaCl-treated rats (n-6 in each group) were exposed to chow for 30 min, after which food was withdrawn. Rats were then anesthetized by intraperitoneal sodium pentobarbital, and blood was collected by translumber vena cava puncture at 20 and 40 min for the subsequent measurement of plasma insulin, glucose, and GLP-1.
[0066] [0066]FIG. 6 shows postprandial plasma insulin and serum glucose levels (±SE) in conscious trained rats (*p<0.01 compared to ANTGIP injection). In response to consuming chow, serum glucose and plasma insulin levels increased significantly, with insulin levels of 38.7±5.3 and 58.9±3.7 μIU/ml at 20 and 40 min, respectively (p<0.05, FIG. 6A). These increases in plasma insulin level were nearly abolished by ANTGIP pretreatment; at 20 and 40 min, the plasma insulin concentrations were 25.3±4.7 and 27.1±2.6 μIU/ml, respectively (p<0.01). Postprandial serum glucose concentrations were similar in both saline- and ANTGIP-treated rats (FIG. 6B). To determine whether the effects of the GIP receptor antagonist were mediated through changes in GLP-1 release into the circulation, postprandial serum GLP-1 levels were measured in both control and ANTGIP-treated animals. Meal-stimulated serum GLP-1 concentrations were not affected by ANTGIP administration. Following the ingestion of rat chow, serum GLP-1 levels at 20 min were 280±20 and 290±10 pg/ml in control and ANTGIP-treated rats, respectively; at 40 min, serum GLP-1 concentrations were 320±10 and 330±20 pg/mgl, respectively.
Example 5
Effect of ANTGIP on Glucose Tolerance and Plasma Insulin Levels
[0067] Oral glucose tolerance tests were performed on rats injected intraperitoneally with ANTGIP (300 ng/kg) or 0.9% saline solution. After the intraperitoneal injection of 0.9% NaCl or ANTGIP, an oral glucose tolerance test was performed. The test was done by administering a 40% glucose solution by oral gavage at a dose of 1 g per kg. The volume administered to each rat was approximately 0.5 ml. Blood was obtained at various time points for subsequent measurement of plasma insulin and glucose levels.
[0068] As expected in view of the experiment in Example 4, rats treated with ANTGIP showed reduced the plasma insulin levels (FIG. 7). Surprisingly, plasma glucose was diminished at all time points in rats treated with ANTGIP, compared to control rats (FIG. 8). Thus, ANTGIP increases glucose tolerance, despite its negative effect on the insulinotropic response to GIP shown in Examples 3 and 4.
Example 6
Effect of GIP Receptor Antagonist on Intestinal Glucose Absorption
[0069] Male Sprague-Dawley rats weighing about 200-250 g are fasted overnight and anesthetized using intraperitoneal urethane (about 1.25 g per kg body weight). After midline laparotomy, an about 30-cm segment of jejunum, starting at about 5 cm distal to the ligament of Treitz, is isolated and flushed with approximately 20 ml of about 0.9% NaCl. The jejunal test segments are each perfused twice, initially with control buffer and then once again with control buffer or with the test solution. The test solution consists of Krebs-Ringer-bicarbonate buffer containing about 5 mmol/L [ 14 C]D-glucose, and 3 H-labeled polyethylene glycol is included in the luminal perfusate to correct for fluid movement. The test or control solution is perfused through the jejunal segment without recirculation at a flow rate of about 1.6 ml/min, using a Harvard PHD 2000 syringe pump (Harvard Apparatus, Millis, Mass.). The effluent from the luminal segment is collected at about 5-min intervals for about 30 min. After the initial period of perfusion, the luminal contents in the jejunum are flushed with about 20 ml of about 0.9% NaCl prior to the initiation of the second period of perfusion. In all experiments, animals are administered either about 0.9% NaCl (control) or ANTGIP (10 nmol/kg body weight) though the inferior vena cava by single injection at about time 0 min.
[0070] The enclosed FIG. 9 depicts the effects of the GIP receptor antagonist, ANTGIP, on the absorption of free D-glucose from the lumen of the jejunal test segment. Data points are believed to represent the rate of glucose disappearance from the luminal perfusate corrected for fluid movement. Results are expressed as the mean±SE of five experiments. Statistical significance (*) is assigned if P<0.05. As seen in the figure, a ANTGIP is believed to significantly reduce the absorption of D-glucose from the jejunal test segment throughout the entire 30-mini period of perfusion. Thus, it is believed that one of the mechanisms by which GIP receptor antagonism may improve glucose tolerance is by decreasing intestinal glucose absorption.
[0071] For purposes of clarity of understanding, the foregoing invention has been described in some detail by way of illustration and example in conjunction with specific embodiments, although other aspects, advantages and modifications will be apparent to those skilled in the art to which the invention pertains. The foregoing description and examples are intended to illustrate, but not limit the scope of the invention. Modifications of the above-described modes for carrying out the invention that are apparent to persons of skill in medicine, molecular biology, pharmacology, and/or related fields are intended to be within the scope of the invention, which is limited only by the appended claims.
[0072] All publications and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. Al publications and patent applications are herein incorporated by reference in their entireties to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference. | In one embodiment, this invention provides an antagonist of glucose-dependent insulinotropic polypeptide (GIP) consisting essentially of a 24 amino acid polypeptide corresponding to positions 7-30 of the sequence of GIP. In another embodiment, this invention provides a method of treating non-insulin dependent diabetes mellitus in a patient comprising administering to the patient an antagonist of glucose-dependent insulinotropic polypeptide (GIP). In yet another embodiment, this invention provides a method of improving glucose tolerance in a mammal comprising administering to the mammal an antagonist of glucose-dependent insulinotropic polypeptide (GIP). | 2 |
[0001] The present invention relates to a method for the generation of single chain immunoglobulins in a mammal. In particular, the present invention relates to a method for the generation of single chain camelid VIM antibodies in a mammal. Single chain antibodies generated using the method of the present invention and the uses thereof are also described.
BACKGROUND TO THE INVENTION
[0002] The antigen binding domain of an antibody comprises two separate regions: a heavy chain variable domain (VH) and a light chain variable domain (V L : which can be either V kappa or V lambda ). The antigen binding site itself is formed by six polypeptide loops: three from VII domain (H1, H2 and H3) and three from V L domain (L1, L2 and L3). A diverse primary repertoire of V genes that encode the VH and V L domains is produced by the combinatorial rearrangement of gene segments. The VH gene is produced by the recombination of three gene segments, VH, D and J H . In humans, there are approximately 51 functional VH segments (Cook and Tomlinson (1995) Immunol Today, 16: 237), 25 functional D segments (Corbett et al. (1997) J. Mol. Biol., 268: 69) and 6 functional J H segments (Ravetch et al. (1981) Cell, 27: 583), depending on the haplotype. The VH segment encodes the region of the polypeptide chain which forms the first and second antigen binding loops of the VH domain (H1 and H2), whilst the VH, D and J H segments combine to form the third antigen binding loop of the VH domain (H3). The V L gene is produced by the recombination of only two gene segments, V L and J L . In humans, there are approximately 40 functional V k segments (Schäble and Zachau (1993) Biol. Chem. Hoppe - Seyler, 374: 1001), 31 functional Vλ segments (Williams et al. (1996) J. Mol. Biol., 264: 220; Kawasaki et al. (1997) Genome Res., 7: 250), 5 functional J K segments (Hieter et al. (1982) J. Biol. Chem., 257: 1516) and 4 functional J λ segments (Vasicek and Leder (1990) J. Exp. Med., 172: 609), depending on the haplotype. The V L segment encodes the region of the polypeptide chain which forms the first and second antigen binding loops of the V L domain (L1 and L2), whilst the V L and J L segments combine to form the third antigen binding loop of the V L domain (L3). Antibodies selected from this primary repertoire are believed to be sufficiently diverse to bind almost all antigens with at least moderate affinity. High affinity antibodies are produced by “affinity maturation” of the rearranged genes, in which point mutations are generated and selected by the immune system on the basis of improved binding.
[0003] The heavy chain locus contains a large number of variable chain genes (VH; in fact not complete genes but comprising a first coding exon plus transcriptional start site) that are recombined onto two short coding regions D and J (known as VDJ recombination) which procede the exons that code for the constant region of the heavy chain Cμ to give a complete antibody heavy chain gene known as IgM. Subsequently a class switch takes place where the variable part is recombined with another constant region that is located downstream of the IgM constant region to give IgD, IgG, IgA and IgE (coded for by the exons of the various Cδ,Cγ,Cα,Cε located downstream of the gene for Cμ. The intervening constant regions are deleted in the process. A similar process takes place in the light gene loci, first the κ locus, and when this does not lead to a productive antibody in the λ locus (for review see Rajewski, K., Nature 381, p 751-758, 1996; for an extensive review, see the textbook Immunobiology, Janeway, C., Travers, P., Walport, M., Capra. J., Current Biology Publications/Churchill Livingstone/Garland Publishing, fourth edition, 1999, ISBN 0-8153-3217-3).
[0004] Camelids (camels, dromedary and llamas) contain, in addition to normal heavy and light chain antibodies (2 light chains and 2 heavy chains in one antibody), single chain antibodies (containing only heavy chains). These are coded for by a distinct set of VH segments referred to as VHH genes. Antigen binding for single chain antibodies is different from that seen with conventional antibodies, but high affinity is achieved the same way, i.e. through hypermutation of the variable region and selection of the cells expressing such high affinity antibodies (affinity maturation). The VH and VHH are interspersed in the genome (i.e. they appear mixed in between each other). The identification of an identical D segment in a VH and VHH cDNA suggests the common use of the D segment for VH and VHH. Natural VHH containing antibodies are missing the entire C H 1 domain of the constant region of the heavy chain. The exon coding for the C H 1 domain is present in the genome but is spliced out due to the loss of a functional splice acceptor sequence at the 5′ side of the C H 1 exon. As a result the VDJ region is spliced onto the C H 2 exon. When a VHH is recombined onto such constant regions (C H 2 , C H 3) an antibody is produced that acts as a single chain antibody (i.e. an antibody of two heavy chains without a light chain interaction). Binding of an antigen is different from that seen with a conventional antibody, but high affinity is achieved the same way, i.e. through hypermutation of the variable region and selection of the cells expressing such high affinity antibodies.
[0005] The structure of isolated VH domains has been determined using NMR and X-ray crystallography techniques (Spinell et al, (1996), Nat Structural biol. 3, 752). Data show that the Immunoglobulin fold is well preserved in Camelid VHH domains. Two beta sheets (one with four and one with five beta-strands) are packed against each other and stabilised by a conserved intradomain disulphide bond between C22 and C92. The side of the camel VHH domain corresponding to the VL interface of the normal VH in an Fv has a quite different architecture. Compared to the human VH, four amino acid substitutions are located in this region.
[0006] From a survey of all human and mouse VH antigen binding loop structures, it is apparent that there are only a restricted number of possible conformations. Three and four different conformations are described for the first and second antigen binding loop respectively. These canonical structures are determined by the length of the loop and the presence of particular residues at key positions. The H3 loop is extremely variable in length and sequence (Wu et al (1993) Proteins: structure, funct and genet., 16, 1). Surprisingly, the antigen binding loop of camel VH domains deviate from the canonical loop definitions of human and mouse VHH domains. This deviation could not be predicted as the loop length and the residues at the key positions are very similar between camel VH and human VH. The additional canonical loop structures in camel VH domains make the structural repertoire of their paratope larger than that of VH domains in Fv fragments from conventional antibodies. Moreover, the hypervariable region around the first antigen binding loop is enlarged compared with human or mouse antibodies. It is thought that the extension of the first hypervariable region and concomitant enlarged antigen binding surface compared to that of a VH in a conventional antibody compensates in part for the absence of a V L domain (Riechmann, L. & Muyldermans, S (1999), 231 25-38).
[0007] A single domain camelid VHH antibody as well as being more suitable for structural analysis than the larger heavy and light chain antibody molecules, also provides a small and efficient antigen binding unit. Such an antibody has many and varied therapeutic potential. In addition, it has been found that camelid single chain antibodies can bind antigens which are inaccessible to antibodies possessing both heavy and light chains. It is thought that this ability is due to the presence of a large protruding third hypervariable loop of 10 amino acids or more which can insert into cavities of antigen surfaces. This is especially significant as the catalytic site of an enzyme is often located at the largest cavity on their protein surface. (Ladowski, R. A (1996). Protein Science 5, 2438). Such sites are not normally immunogenic for conventional antibodies (Novotny, J et al, (1986) Proc Nat Acad Sci USA, 83, 226). In the structure of the camel VHH cAb-Lys3, the 24 residue H3 loop penetrates deeply into the active site of lysozyme (Transue, T. R et al (1998) Prot: Structure, Funct and Genet, 32, 515), showing that Camel heavy chain antibodies have the potential to form specific enzyme inhibitors.
[0008] Recently, isolated Camelid VHH domains have been generated in bacteria (Riechmann, L et al. Journal of Immunological Methods 231 (1999), 25-38). However bacterial expression systems have the disadvantage that they do not perform post-translational modifications. Such modifications, in particular glycosylation events, are crucial for the effective functioning of antibodies, particularly in an in vivo environment.
[0009] In the same study, the genes for Camel VHH domains were inserted into expression vectors and expressed in Cos cells to generate multi-domain proteins. In one example, an intact single heavy chain only antibody was generated by cloning a particular camel VHH in front of the hinge and effector function domains of human IgG1. The expression in Cos cells has the advantage over bacterial expression systems that post-translational modification events occur in these cells. Consistent with this was the finding that these antibodies were fully active in antigen binding. The DNA for the generation of these constructs is generally isolated from mature (ie those which have undergone affinity maturation) antibodies generated from B cells. Although these single chain antibodies expressed in mammalian cells in an in vitro environment can bind to one or more antigens, they cannot undergo the processes of class (isotype) switching and affinity maturation (hypermutation). Thus the single chain antibodies expressed in Cos cells do not undergo the process of antibody evolution as those naturally occurring antibodies generated within a mammal. It is this process of antibody evolution which results in the production of specific antibodies which bind with high affinity. Thus, there remains a need in the art for a method allowing the generation of single chain VHH antibodies in a mammal such that the normal processes of antibody evolution can take place.
[0010] In addition Camelid single chain antibodies have also been selected and expressed using phage display technology. (Riechmann, L. & Davies, S. J. Biomol. NMR, 6, 141). Again though, the antibody constructs are generated from nucleic acid isolated from mature B cells or spleen, and therefore as with the case above, the antibodies expressed do not undergo class switching and somatic hypermutation (affinity maturation) which is necessary for the production of specific antibodies which bind to their antigen with selectivity and high affinity.
[0011] The present inventors realised that if they could understand the mechanism by which camelid single chain antibody molecules evolve (by class-switching and affinity maturation) during early antibody development in B cells, then this system may be recreated in vivo. This would allow the generation of vast quantities of an evolved single chain antibody for structural, therapeutic and diagnostic applications.
SUMMARY OF THE INVENTION
[0012] Antibody molecules which comprise both heavy and light chains switch classes during B-cell development. Developing B cells in the bone marrow first express membrane bound IgM. During development secretory IgG is expressed. In the case of antibodies possessing both light and heavy chains, a J region is recombined onto a Cμ region to produce an IgM comprising VH, D and J regions. The IgM producing cell further matures by switching to a different heavy chain constant region to produce IgA for example. The mechanism of recombination involves a pseudo light chain which recombines with the VH part of IgM, the pseudo-light chain being present during the early B cell lineage.
[0013] The present inventors realised that understanding the mechanism by which single chain antibodies switch classes and/or undergo affinity maturation (antibody evolution) during pre B-cell development would allow a VHH locus as herein defined to be generated which resulted in the production of a specific single chain VHH antibody which undergoes a process of evolution similar or the same as that of camelid antibodies produced in their native environment.
[0014] Thus, in a first aspect the present invention provides a method for the production of a VHH single heavy chain antibody in a mammal comprising the step of expressing a heterologous VHH heavy chain locus in that mammal.
[0015] Preferably the VHH heavy chain locus comprises:
(a) at least one VHH region each comprising one VHH exon, at least one D region each comprising one D exon and at least one J region each comprising one J exon, wherein the VHH region, the D region and the J region are capable of recombining to form VDJ coding sequence, (b) a constant heavy chain region comprising at least one Cγ constant heavy chain gene, and which when expressed does not express a functional CH1 domain nor a functional CH4 domain, (c) at least one recombination sequence (rss) capable of recombining a J region of step (a) directly with a Cγ constant heavy chain gene of step (b). and which locus when expressed is capable of forming a complete single heavy chain IgG molecule (scIgG).
[0020] In a further aspect, the present invention provides a method for the production of a camelised VH single heavy chain antibody in a mammal comprising the step of expressing a camelised VH heavy chain locus in that mammal
[0021] Preferably, the camelised VH heavy chain locus comprises:
(a) a VH region each comprising one VH exon which is mutated such that the nucleic acid sequence is the same as a camelid VHH exon (a ‘camelised VH exon’), a D region comprising one D exon and a J region comprising one J exon, wherein the VH region, the D region and the J region are capable of recombining to form VDJ coding sequence, and (b) a constant heavy chain region comprising at least one Cγ constant heavy chain gene, and which when expressed does not express a functional CH1 domain nor a functional CH4 domain, (c) at least one recombination sequence (rss) capable of recombining a J region of step (a) directly with a Cγ constant heavy chain gene of step (b).
and which locus when expressed is capable of forming a complete single heavy chain IgG molecule (scIgG).
[0025] The present inventors have shown that in the case of single heavy chain antibodies, class switching occurs to form scAb (a complete single heavy chain antibody polypeptide chain). This mechanism involves recombining the J region of step (a) directly with a Cγ heavy chain region gene of the constant heavy chain region of step (b), preferably in the bone marrow resulting in the generation of a scIgG (single chain IgG molecule). The presence of the recombination signal sequence (rss) in the construct, therefore permits the connection of the J region of step (a) directly to the Cγ gene of step (b).
[0026] In the context of the present invention, the mammal is not a human. The transgenic mammal is advantageously smaller than a camelid and easier to maintain and immunise with desired antigens. Ideally, the transgenic mammal is a rodent, such as a rabbit, guinea pig, rat or mouse. Mice are especially preferred. Alternative mammals, including goats, sheep, cats, dogs and other domestic or wild mammals, may also be employed.
[0027] Advantageously heavy chain loci endogenous to the mammal are deleted or silenced when a single chain antibody is expressed according to the method of the present invention. Suitable techniques for the later are described in WO00/26373 or WO96/33266 and (Li and Baker (2000) Genetics 156(2): 809-821; Kitamura and Rajewsky (1992); Kitamura and Rajewsky, (1992) Nature 356, 154-156).
[0028] The term a ‘VHH single heavy chain antibody’ according to the present invention means an antibody molecule which is composed only of heavy chains (generally two) and does not comprise any light chains. Each heavy chain comprises a variable region (encoded by VHH, D and J exons) and a constant region. The constant region further comprises a number of CH (constant heavy chain domains), advantageously it comprises two: one CH2 domain and one CH3 domain encoded by a constant region gene. A VHH single chain antibody as herein defined does not possess a functional CH1 domain and also lacks a functional CH4 domain. It is the lack of a functional CH1 domain (which in conventional antibodies possesses the anchoring place for the constant domain of the light chain) which accounts for the inability of the heavy chain antibodies according to the present invention to associate with light chains to form conventional antibodies.
[0029] The term ‘a camelised VH single heavy chain antibody’ according to the present invention means an antibody molecule which is composed only of heavy chains (generally two) and does not comprise any light chains. Each heavy chain comprises a variable region (encoded by ‘a camelised VH exon/s’, D and J exon/s) and a constant region. The constant region comprises at least one constant region gene. Each constant region gene comprises a number of constant region exons, each exon encoding a constant region CH domain. Generally, the constant region comprises two CH domains: one CH2 domain and one CH3 domain. A camelised VH single chain antibody as herein defined does not possess a functional CH1 domain, in addition it also lacks a functional CH4 domain. It is the lack of a functional CH1 domain (which in conventional antibodies possesses the anchoring place for the constant domain of the light chain) which accounts for the inability of the heavy chain antibodies according to the present invention to associate with light chains to form conventional antibodies.
[0030] In the context of the present invention, the term ‘heterologous’ means a VHH heavy chain locus as herein described which is not endogenous to that mammal. That is in the case where the mammal is a camelid ie a camel or a llama, then the expression is of a VHH locus which is not normally found within a camel or llama respectively.
[0031] A ‘VHH heavy chain locus’ according to the present invention is comprised of a ‘VHH region’, a ‘J region’, a ‘D region’ and a ‘constant heavy chain region’. Each VHH region comprises one VHH exon, each J region one J exon and each D region one D exon, and each heavy chain constant region comprises one or more heavy chain constant region genes. In addition each VHH region essentially does not comprise one or more functional VH exons.
[0032] A ‘VHH exon/region’ in the context of the present invention describes a naturally occurring VHH coding sequence such as those found in Camelids and any homologue, derivative or fragment thereof as long as the resultant exon/region recombine with a D exon/region, a J exon/region and a constant heavy chain region (which comprises several exons) according to the present invention to generate a VHH single chain antibody as herein defined, when the nucleic acid is expressed.
[0033] A ‘camelised VH heavy chain locus’ according to the present invention is comprised of a ‘a camelised VH region’ as herein defined, a ‘J region’, a ‘D region’ and a ‘constant heavy chain region’. Each camelised VH region comprises one camelised VH exon, each J region one J exon and each D region one D exon and each heavy chain constant region comprises one or more heavy chain constant region exons.
[0034] A ‘camelised VH exon/region’ in the context of the present invention describes a naturally occurring VH coding sequence derived from mammals other than Camelids for example a human which has been mutated such that the sequence is the same as that of a Camelid exon. A camelised VH exon according to the present invention also includes within its scope any homologue, derivative or fragment of the exon as long as the exon/region can recombine with a D region/exon, a J region/exon and a constant heavy chain region comprising one or more exons according to the present invention to generate a camelised VH single chain antibody as herein defined.
[0035] VHH and VH exons may be derived from naturally occurring sources or they may be synthesised using methods familiar to those skilled in the art and described herein.
[0036] Likewise in the context of the present invention the terms ‘a D exon’ and ‘a J exon’ include naturally occurring sequences of D and J exons which are found in Camelids or other species of mammals. The terms D exon and J exon also include within their scope derivatives, homologues and fragments thereof as the resultant exon can recombine with the remaining components of a heavy chain antibody locus as herein described (either camelised VH or VHH) to generate a single chain antibody as herein described. D and J exons/regions may be derived from naturally occurring sources or they may be synthesised using methods familiar to those skilled in the art and described herein.
[0037] In addition, a heavy chain antibody locus according to the present invention (either VHH or camelised VH) comprises a region of DNA encoding a constant heavy chain polypeptide (a constant heavy chain region).
[0038] Each constant heavy chain region essentially comprises at least one constant region heavy chain gene which is Cγ, so that generation of single chain IgG can occur. Each constant heavy chain gene comprises one or more constant heavy chain exons which may be of Camelid or non-Camelid origin and are selected from the group consisting of Cδ, Cγ 1-4 , Cε and Cα 1-2 . Preferably, at least one heavy chain constant region exon in a heavy chain antibody locus according to the present invention is of human, mouse or rabbit origin. Advantageously, at least one Cγ heavy chain exon is of human origin. When expressed the constant heavy chain region lacks a functional CH1 and CH4 domain which are present in dual chain antibodies. Advantageously, only one or more Cγ2 and/or Cγ3 genes with modified (non-functional) CH1 domains are present in the constant heavy chain region of the present invention.
[0039] A ‘constant heavy chain region exon’ (‘C H exon’) as herein defined includes the sequences of naturally occurring C H exons such as those found in camelids or humans or other mammals including rabbits and mice. The term ‘C H exon’ also includes within its scope derivatives, homologues and fragments thereof in so far as the C H exon is able to form a functional single heavy chain antibody (comprising either regions encoded by VHH exons or camelised VH exons) as herein defined when it is a component of a constant heavy chain region.
[0040] Generally, C H genes comprise three or four exons (C H 1-C H 4) that encode different domains of each constant heavy chain polypeptide, with generally two polypeptides constituting a single heavy chain antibody as herein described. However, as discussed previously, VHH and camelised VH single chain antibodies do not possess an functional CH1 (containing the light chain domain anchoring region) or CH4. Thus, single heavy chain antibody loci according to the present invention possess one or more genes which do not express functional CH1 or CH4 domains. This may occur by mutation, deletion substituted or other treatment of the CH1 and CH4 exons of the constant heavy region gene.
[0041] In a preferred embodiment of the invention a single chain VHH locus comprises at least one constant heavy chain gene wherein the nucleic acid encoding the CH1 and the CH4 domain is mutated, deleted or substituted or otherwise treated so that the constant heavy chain of expressed VHH single chain antibodies as herein defined does not contain a functional CH1 domain and a CH4 domain.
[0042] For the avoidance of doubt, the term ‘rabbit origin’ or ‘human origin’ as referred to above, means that the nucleic acid sequence of one or more exons comprising a heavy chain antibody locus (either camelised VH or VHH) according to the present invention is the same as one or more naturally occurring rabbit or human antibody locus exons. One skilled in the art will appreciate that these exons may be derived from natural sources or may be synthesised using methods familiar to those skilled in the art and described herein.
[0043] Each VHH or ‘camelised VH region’ comprises one VHH exon or ‘camelised VH exon’ respectively. Each J region and D region comprises one J and D exon respectively. Preferably, each heavy chain locus comprises more than one, more than 2, more than 3, more than 4, more than 5, more than 6 J and/or D regions/exons. Most preferably, a VHH locus or camelised VH locus according to the present invention comprises the same number of VHH exons/regions and/or D exons/regions and/or J exons/regions as those found in a Camelid.
[0044] Advantageously, the method of this aspect of the present invention is for the production of a single chain antibody by the expression of a VHH heavy chain locus or camelised VH heavy chain locus comprising one or more constant heavy chain exons of human, rabbit or mouse origin as herein defined. That is, preferably a single heavy chain antibody of the present invention is generated by the expression of a hybrid camelid/human locus or a hybrid camelid/rabbit locus or a hybrid camelid/mouse locus. In an especially preferred embodiment of this aspect of the invention, the single heavy chain locus expressed according to the method of the present invention comprises all VHH exons of Camelid origin and all D, J and constant heavy chain region exons of human origin, rabbit or mouse origin. In a further preferred embodiment of this aspect of the invention, the single heavy chain locus expressed according to the method of the present invention comprises all camelised VH exons and all D, J and constant heavy chain region exons of human origin, or rabbit or mouse origin.
[0045] In a preferred embodiments of the above aspects of the invention, the heavy chain locus further comprises one or more cassette sites enabling the direct cassetting of the locus from one vector to another. Advantageously, one or more cassette sites are located in the 5′ leader sequence of the locus and/or the 3′ untranslated region of the locus. Preferably, one or more cassettes sites are located in both the 5′ leader sequence of the locus and the 3′ untranslated region of the locus. The direct cassetting permits, for example, movement of nucleic acid into a bacterial expression vector for the addition of tags, signals and the like.
[0046] This approach of generating hybrid single heavy chain antibodies as described above maybe of particular use in the generation of antibodies for human therapeutic use as often the administration of antibodies to a species of vertebrate which is of different origin from the source of the antibodies results in the onset of an immune response against those administered antibodies. Hybrid camelid/human single chain antibodies are therefore potentially less immunogenic than Camelid single chain antibodies when administered to a human.
[0047] In the context of the present invention, the same includes substantially the same. Substantially the same means greater than 80% homologous, preferably greater than 85%, 90%, 95% homologous. More preferably greater than 96, 97, 98% homologous. Most preferably, substantially the same means that the mutated human VH region is greater than 99% homologous with a Camelid VHH region
[0048] In a further aspect, the present invention provides a VHH single heavy chain antibody obtainable according to the method of the present invention wherein that part of the antibody encoded by a VHH exon is encoded by an exon of camelid origin and the remainder of the antibody molecule is encoded by exons of human origin.
[0049] In yet a further aspect, the present invention provides a VHH single heavy chain antibody obtainable according to the method of the present invention, wherein that part of the antibody encoded by a VHH exon is encoded by an exon of camelid origin and the constant heavy chain region is encoded by one or more exon/s of rabbit origin.
[0050] In a further aspect still, the present invention provides a VHH single heavy chain antibody obtainable according to the method of the present invention wherein that part of the antibody encoded by a VHH exon is encoded by an exon of camelid origin and the constant heavy chain region is encoded by one or more exon/s of mouse origin.
[0051] In yet a further aspect, the present invention provides a camelised single heavy chain antibody obtainable by the method of the present invention
[0052] Advantageously, a camelised VH single heavy chain antibody according to this aspect of the present invention is entirely encoded by exons of human origin as herein defined.
[0053] In a further preferred embodiment of this aspect of the invention, a camelised VH single heavy chain antibody comprises a constant heavy chain region encoded by one or more exon/s of rabbit origin.
[0054] In a further embodiment still, a camelised VH single heavy chain antibody according to this aspect of the invention comprises a constant heavy chain region encoded by one or more exon/s of mouse origin.
[0055] Antibodies produced according to the method of the present invention have the advantage over those of the prior art in that they undergo a process of class switching which is similar or the same as that of a single chain Camelid antibody generated in its normal environment. Antibodies obtainable according to the methods of the present invention may be monoclonal or polyclonal antibodies. Advantageously, they are monoclonal antibodies. Antibodies may be generated using methods known to those skilled in the art. Advantageously hybridomas may be used for generating monocloanl antibodies. Techniques will be familiar to those skilled in the art and are described herein.
[0056] In yet a further aspect, the present invention provides a vector comprising a VHH heavy chain locus according to the present invention.
[0057] In a further aspect still, the present invention provides a vector comprising a camelised VH heavy chain locus according to the present invention.
[0058] Suitable vectors will be familiar to those skilled in the art. Advantageously, a vector suitable of inserting large amounts of nucleic acid, sufficient to encode an entire immunoglobulin heavy chain locus are preferred. Suitable vectors include yeast and bacterial artificial chromosomes such as YACs and BACs. Advantageously, the vectors are constructed so that direct cassetting of nucleic acid encoding a single heavy chain antibody locus as herein defined into a different vector can be performed. For example the reverse transcribed cDNA coding for a single heavy chain antibody may be ‘cassetted’ into a bacterial expression vector allowing for the addition of tags, signals or epitopes and the like.
[0059] In yet a further aspect, the present invention provides a host cell transformed with a VHH locus according to the present invention.
[0060] In a further aspect still, the present invention provides a transgenic mammal expressing a heterologous VHH heavy chain locus according to the present invention.
[0061] In yet a further aspect, the present invention provides a transgenic mammal expressing a camelised VH heavy chain locus according to the present invention.
[0062] In the context of the present invention, the term ‘a transgenic mammal’ does not include within its scope a transgenic human. Preferably a transgenic mammal according to the present invention is smaller than a Camelid. Preferably it is selected from the group consisting of: a mouse, rat, guinea-pig, hamster, monkey and rabbit. Advantageously, it is a mouse.
[0063] Advantageously heavy chain loci endogenous to the transgenic animal are deleted or silenced in a transgenic mammal according to the present invention. Suitable techniques for the later are described in WO00/26373 or WO96/33266 and (Li and Baker (2000) Genetics 156(2): 809-821; Kitamura and Rajewsky (1992); Kitamura and Rajewsky, (1992) Nature 356, 154-156).
[0064] Antibody producing cells may be derived from transgenic animals according to the present invention and used for example in the preparation of hybridomas for the production of VHH single chain antibodies as herein defined. In addition or alternatively, nucleic acid sequences may be isolated from transgenic mammals according to the present invention and used to produce single chain antibodies, using recombinant DNA techniques which are familiar to those skilled in the art. Alternatively or in addition, specific single chain antibodies may be generated by immunising a transgenic animal according to the present invention.
[0065] Thus in a further aspect, the present invention provides a method for the production of single chain antibodies by immunising a transgenic mammal according to the present invention with an antigen.
[0066] In a preferred embodiment of this aspect of the invention, the mammal is a mouse.
[0067] In the context of the present invention, the term ‘immunising’ a mammal means administering to a transgenic mammal of the present invention an antigen such that an immune response is elicted against that antigen. Suitable methods for the immunisation of mammals will be familiar to those skilled in the art and are described herein. Suitable antigens may be naturally occurring or synthetic. Naturally occurring antigens include proteins which may be for example enzymes or cofactors, peptides and nucleic acid molecules. One skilled in the art will appreciate that this list is not intended to be exhaustive.
[0068] In a further aspect, the present invention provides the use of a single heavy chain antibody as herein described as an intracellular binding reagent.
[0069] In a further aspect, the present invention provides, the use of a single chain antibody according to the present invention as an enzyme inhibitor.
[0070] In a further aspect still, the present invention provides the use of an antibody obtainable by the method of the present invention in the preparation of a medicament for the prophylaxis and/or treatment of disease.
[0071] In a final aspect, the present invention provides the use of a heavy chain antibody locus according to the present invention in the prophylaxis or treatment of disease.
BRIEF DESCRIPTION OF THE FIGURES
[0072] FIG. 1 shows a preferred single chain antibody locus according to the present invention.
DEFINITIONS
[0073] ‘A gene’ comprises one or more exons coding for a complete mRNA. An ‘antibody gene’ comprises V, D, J exons which recombine to form a VDJ coding region and which then further recombine with a constant heavy chain region comprising one or more constant heavy chain exons. There are many sub-groups of V, D J and C exons. One particular V region has one exon, one D region has one exon, one J region has one exon and one C region has several exons. Together they from a complete gene after recombination when one V exon, one D exon, one J exon and one C region have been selected.
[0074] ‘Exon’ and ‘intron’. An Exon is a coding or messenger sequence of deoxynucleotides. That is, it is any sequence of DNA in eukaryotes that will be ultimately expressed in mature mRNA or rRNA molecules. Exons are commonly interspersed with introns. Introns are non-coding DNA sequences. That is they are DNA sequences which are not ultimately expressed in a mature RNA molecule.
[0075] Introns are spliced out from newly transcribed RNA to order to generate mature mRNA.
[0076] A ‘VHH heavy chain locus’ according to the present invention is comprised of a ‘VHH region’, a ‘J region/exon’, a ‘D region/exon’ and a ‘constant heavy chain region’. Each VHH region comprises one VHH exon, each J region one J exon and each D region one D exon and each heavy chain constant region comprises one or more heavy chain constant region exons.
[0077] A ‘VHH exon’ in the context of the present invention describes a naturally occurring VHH coding sequence such as those found in Camelids and any homologue, derivitive or fragment thereof as long as the resultant exon can when a constituent of a VHH region as herein defined recombine with at least one D region, at least one J region and at least one constant heavy chain region according to the present invention to generate a VHH single chain antibody as herein defined, when the nucleic acid is expressed.
[0078] A ‘camelised VH heavy chain locus’ according to the present invention is comprised of one or more ‘camelised VH region/s’ as herein defined, one or more ‘J region/s’, one or more ‘D region/s’ and a ‘constant heavy chain region’. Each camelised VH region comprises one camelised VH exon, each J region one J exon and each D region one D exon and each heavy chain constant region comprises one or more heavy chain constant region genes.
[0079] A ‘camelised VH exon’ in the context of the present invention describes a naturally occurring VH coding sequence derived from mammals other than Camelids for example a human which has been mutated such that the sequence is the same as that of a Camelid exon. A camelised VH exon according to the present invention also includes within its scope any homologue, derivative or fragment of the exon as long as the resultant exon can, when a constituent of a camelised VH region as herein defined recombine with at least one D region, one J region and one constant heavy chain region according to the present invention to generate a camelised VH single chain antibody as herein defined.
[0080] A ‘constant heavy chain region exon’ (‘C H exon’) as herein defined includes the sequences of naturally occurring C H exons such as those found in camelids or humans or other mammals including rabbits and mice. The term ‘C H exon’ also includes within its scope derivatives, homologues and fragments thereof in so far as the C H exon is able to form a functional single heavy chain antibody as herein defined when it is a component of a constant heavy chain region. Generally, C H exons are of four different types (C H 1-C H 4) that encode different portions (domains) of each constant heavy chain polypeptide. However, VHH and camelised VH single chain antibodies according to the present invention do not possess a functional CH1 domain (containing the light chain domain anchoring region) nor do they possess a functional CH4 domain. There are a number of sub-groups of constant heavy chain region exons. Different antibody classes possess different CH exons for instance, IgM molecules possess one or more Cμ constant region exons and IgG molecules possess one or more Cγ exons.
[0081] The term a ‘VHH single heavy chain antibody’ according to the present invention means an antibody molecule which is composed only of heavy chains (generally two) and does not comprise any light chains. Each heavy chain comprises a variable region (encoded by VHH, D and J exons) and a constant region. The constant region further comprises a number of CH domains encoded by constant heavy region exons, generally it comprises two: one CH2 domain and one CH3 domain. A VHH single chain antibody as herein defined does not possess a functional CH1 domain nor a functional CH4 domain. It is the lack of a functional CH1 domain (which in conventional antibodies possesses the anchoring place for the constant domain of the light chain) which accounts for the inability of the heavy chain antibodies according to the present invention to associate with light chains to form conventional antibodies. The sub-class of antibodies known as scIgG2 and/or scIgG3 comprise only Cγ2 and/or Cγ3 genes.
[0082] The term ‘a camelised VH single heavy chain antibody’ according to the present invention means an antibody molecule which is composed only of heavy chains (generally two) and does not comprise any light chains. Each heavy chain comprises a variable region (encoded by ‘a camelised VH exon’, D and J exon/s) and a constant region. The constant region encoded by constant region exons further encodes a number of CH domains, generally it comprises two: one CH2 domain and one CH3 domain. A camelised VH single chain antibody as herein defined does not possess a functional CH1 domain or a functional CH4 domain. It is the lack of a functional CH1 domain (which in conventional antibodies possesses the anchoring place for the constant domain of the light chain) which accounts for the inability of the heavy chain antibodies according to the present invention to associate with light chains to form conventional antibodies.
[0083] ‘Antibodies’ as used herein, refers to antibodies or antibody fragments capable of binding to a selected target, and includes monoclonal and polyclonal antibodies, engineered antibodies including chimeric, CDR-grafted and humanised antibodies, and artificially selected antibodies produced using phage display or alternative techniques. Small antibody fragments possess advantageous properties for diagnostic and therapeutic applications on account of their small size and consequent superior tissue distribution.
[0084] ‘Antibody evolution’ describes the process of class switching and affinity maturation (somatic hypermutation) which occurs during antibody development and which results in the generation of antibodies which bind selectively and with high affinity.
DETAILED DESCRIPTION OF THE INVENTION
[0085] General Techniques
[0086] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art (e.g., in cell culture, molecular genetics, nucleic acid chemistry, hybridisation techniques and biochemistry). Standard techniques are used for molecular, genetic and biochemical methods (see generally, Sambrook et al., Molecular Cloning: A Laboratory Manual, 2d ed. (1989) Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. and Ausubel et al., Short Protocols in Molecular Biology (1999) 4 th Ed, John Wiley & Sons, Inc. which are incorporated herein by reference) and chemical methods. In addition Harlow & Lane., A Laboratory Manual Cold Spring Harbor, N.Y, is referred to for standard Immunological Techniques.
[0087] VH/h Heavy Chain Loci of the Present Invention
[0088] In a first aspect, the present invention provides a method for the production of a VHH single heavy chain antibody in a mammal comprising the step of expressing a heterologous VHH heavy chain locus in that mammal.
[0089] In a further aspect, the present invention provides a method for the production of a camelised VH single heavy chain antibody in a mammal comprising the step of expressing a camelised VH heavy chain locus in that mammal.
[0090] The construction of the various VHH heavy chain loci according to the present invention are as described in the summary of the invention.
[0091] Advantageously, a locus of the invention comprises one or more FRT (flp recombination target) sites (http://www.esb.utexus.edu), and two or more LoxP sites (which consists of two thirteen by inverted repeats separated by an 8 bp asymmetric spacer region (Brian Sauer, Methods of Enzymology; 1993, Vol 225, 890-900).
[0092] Preferably, there are at least two loxP sites in a locus according to the present invention. The presence of the FRT site/s in the locus allows the production of single copy transgenics, whilst the presence of the Lox sites allows the deletion of IgM and IgD heavy chain genes if required.
[0093] (A) Vectors
[0094] The present invention also provides vectors including a construct of the present invention. Essentially two types of vectors are provided, replication vectors and transformation vectors.
[0095] (I) Replication Vectors
[0096] Constructs of the invention can be incorporated into a recombinant replicable vector such as a BAC vector. The vector may be used to replicate the construct in a compatible host cell. Thus, in a further embodiment, the invention provides a method of making constructs of the invention by introducing a construct of the invention into a replicable vector, introducing the vector into a compatible host cell, and growing the host cell under conditions which bring about replication of the construct. The construct may be recovered from the host cell. Suitable host cells include bacteria such as E. coli, yeast, mammalian cell lines and other eukaryotic cell lines, for example insect Sf9 cells (baculovirus).
[0097] (II) Transformation Vectors
[0098] The constructs of the present invention may also be incorporated into a vector capable of inserting the construct into a recipient genome and thus achieving transformation. In addition to the construct of the present invention such transformation vectors may include one or more of the following components.
[0099] Promoters
[0100] The promoter is typically selected from promoters which are functional in mammalian cells, although prokaryotic promoters and promoters functional in other eukaryotic cells may be used. The promoter is typically derived from promoter sequences of viral or eukaryotic genes. For example, it may be a promoter derived from the genome of a cell in which expression is to occur. With respect to eukaryotic promoters, they may be promoters that function in a ubiquitous manner (such as promoters of alpha-actin, beta-actin, tubulin) or, alternatively, a tissue-specific manner (such as promoters of immunoglobulin genes). They may also be promoters that respond to specific stimuli, for example promoters that bind steroid hormone receptors. Viral promoters may also be used, for example the Moloney murine leukaemia virus long terminal repeat (MMLV LTR) promoter, the Rous sarcoma virus (RSV) LTR promoter or the human cytomegalovirus (CMV) IE promoter. It may also be advantageous for the promoters to be inducible so that the levels of expression of the heterologous gene can be regulated during the life-time of the cell. Inducible means that the levels of expression obtained using the promoter can be regulated.
[0101] In addition, any of these promoters may be modified by the addition of further regulatory sequences, for example enhancer sequences. Tissue-specific enhancers capable of regulating expression in antibody-producing cells are preferred. In to particular, the heavy-chain enhancer required for the successful activation of the antibody gene locus in vivo (Serwe, M., and Sablitzky, F., EMBO J. 12, p 2321-2321, 1993) may be included. Locus control regions (LCRs), particularly the immunoglobulin LCR, may also be used. Chimeric promoters may also be used comprising sequence elements from two or more different promoters.
[0102] Other Vector Components
[0103] In addition to a promoter and the construct, vectors of the present invention preferably contain other elements useful for optimal functioning of the vector in the mammal into which the vector is inserted. These elements are well known to those of ordinary skill in the art, and are described, for example in Sambrook et al., Molecular Cloning:. A Laboratory Manual Cold Spring Harbor Laboratory Press, 1989.
[0104] Construction of Vectors
[0105] Vectors used for transforming mammalian embryos are constructed using methods well known in the art, including, without limitation, the standard techniques of restriction endonuclease digestion, ligation, plasmid and DNA and RNA purification, DNA sequencing, and the like as described, for example in Sambrook, Fritsch, and Maniatis, eds., Molecular Cloning: A Laboratory Manual., (Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. [1989]). In general, vector construction will include the following steps:
[0106] a) The endogenous mouse locus is inactivated, for example using one of the published knockout procedures (eg. Kitamara, D and Rajewski K., Nature 352, p 154-156, 1992).
[0107] b) The DJ and IgM region of a suitable heavy chain region as herein described is localised as a recombinant DNA from a human PAC, BAC or YAC library and cloned as a restriction enzyme fragment, for instance a Sal1 fragment. This region also contains the heavy chain enhancer required for the successful activation of the antibody gene locus in vivo (see Serwe, M., Sablitzky, F., EMBO J. 12, p 2321-2321, 1993).
[0108] c) A number of VHH or ‘camelised VH exons’ are first cloned as cosmids through the construction of a suitable genomic DNA library by conventional techniques. Since the VHH exons are located among VH exons as herein described they are subsequently cloned along with the VHH exons. Thus an array of VH and VHH exons is made. This array of genes can be isolated as a MluI (or other restriction enzyme) fragment.
[0109] d) The 3′ human immunoglobulin heavy chain LCR, a regulatory region required for the expression of the locus, is cloned as an SceI restriction fragment.
[0110] e) The constant region heavy chain exons are cloned as a separate restriction fragment. The C H 1 and/or C H 4 domains encoded by their respective exons are rendered non-functional by homologous recombination in bacteria (Imam et al., 2000) by removing the splice acceptor sequences of the C H 1 exon and/or C H 4 exon (Nguyen et al., ibid,).
[0111] Steps b-e provide the pieces for a ‘VHH heavy chain locus’ or ‘a camelised VH heavy chain locus’ ( FIG. 3 ) that should take over the function of the inactivated mouse locus described under a). These loci are constructed by cloning each of the fragments in the appropriate order into a suitable vector, for example a BAC vector containing a linker region with all of the restriction sites described above ( FIG. 1 ). Loci created according to the method of the present invention are generally in the order of 200-250 kB in size. They can be isolated and purified away from the vector by standard laboratory techniques which will be familiar to those skilled in the art. The purified nucleic acid encoding the ‘VHH heavy chain locus’ or ‘a camelised VH heavy chain locus’ according to the present invention ( FIG. 3 ) may be subsequently introduced into fertilised mouse eggs derived from the knock-out mice described in a) by standard techniques to obtain transgenic mice expressing one or more loci according to the present invention.
[0112] Single Chain Antibodies According to the Present Invention
[0113] It will be understood that term ‘a single heavy chain antibody’ and ‘VHH heavy chain loci’ according to the present invention also include homologous polypeptide and nucleic acid sequences obtained from any source, for example related cellular homologues, homologues from other species and variants or derivatives thereof.
[0114] Thus, the present invention encompasses variants, homologues or derivatives of the single heavy chain antibodies and VHH heavy chain loci as herein described.
[0115] In the context of the present invention, a homologous sequence is taken to include an amino acid sequence which is at least 80, 85, 90, 95, 96, 97, 98, 99, 99.5, 99.6, 99.7, 99.8, 99.9% identical, preferably at least 98 or 99% identical at the amino acid level over at least 30, preferably 50, 70, 90 or 100 amino acids. Although homology can also be considered in terms of similarity (i.e. amino acid residues having similar chemical properties/functions), in the context of the present invention it is preferred to express homology in terms of sequence identity.
[0116] Homology comparisons can be conducted by eye, or more usually, with the aid of readily available sequence comparison programs. These commercially available computer programs can calculate % homology between two or more sequences.
[0117] % homology may be calculated over contiguous sequences, i.e. one sequence is aligned with the other sequence and each amino acid in one sequence directly compared with the corresponding amino acid in the other sequence, one residue at a time. This is called an “ungapped” alignment. Typically, such ungapped alignments are performed only over a relatively short number of residues (for example less than 50 contiguous amino acids).
[0118] Although this is a very simple and consistent method, it fails to take into consideration that, for example, in an otherwise identical pair of sequences, one insertion or deletion will cause the following amino acid residues to be put out of alignment, thus potentially resulting in a large reduction in % homology when a global alignment is performed. Consequently, most sequence comparison methods are designed to produce optimal alignments that take into consideration possible insertions and deletions without penalising unduly the overall homology score. This is achieved by inserting “gaps” in the sequence alignment to try to maximise local homology.
[0119] However, these more complex methods assign “gap penalties” to each gap that occurs in the alignment so that, for the same number of identical amino acids, a sequence alignment with as few gaps as possible—reflecting higher relatedness between the two compared sequences—will achieve a higher score than one with many gaps. “Affine gap costs” are typically used that charge a relatively high cost for the existence of a gap and a smaller penalty for each subsequent residue in the gap. This is the most commonly used gap scoring system. High gap penalties will of course produce optimised alignments with fewer gaps. Most alignment programs allow the gap penalties to be modified. However, it is preferred to use the default values when using such software for sequence comparisons. For example when using the GCG Wisconsin Bestfit package (see below) the default gap penalty for amino acid sequences is −12 for a gap and −4 for each extension.
[0120] Calculation of maximum % homology therefore firstly requires the production of an optimal alignment, taking into consideration gap penalties. A suitable computer program for carrying out such an alignment is the GCG Wisconsin Bestafit package (University of Wisconsin, U.S.A.; Devereux et al., 1984, Nucleic Acids Research 12:387). Examples of other software than can perform sequence comparisons include, but are not limited to, the BLAST package (see Ausubel et al., 1999 ibid—Chapter 18), FASTA (Atschul et al., 1990, J. Mol. Biol., 403-410) and the GENEWORKS suite of comparison tools. Both BLAST and FASTA are available for offline and online searching (see Ausubel et al., 1999 ibid, pages 7-58 to 7-60). However it is preferred to use the GCG Bestfit program.
[0121] Although the final % homology can be measured in terms of identity, the alignment process itself is typically not based on an all-or-nothing pair comparison. Instead, a scaled similarity score matrix is generally used that assigns scores to each pairwise comparison based on chemical similarity or evolutionary distance. An example of such a matrix commonly used is the BLOSUM62 matrix—the default matrix for the BLAST suite of programs. GCG Wisconsin programs generally use either the public default values or a custom symbol comparison table if supplied (see user manual for further details). It is preferred to use the public default values for the GCG package, or in the case of other software, the default matrix, such as BLOSUM62.
[0122] Once the software has produced an optimal alignment, it is possible to calculate % homology, preferably % sequence identity. The software typically does this as part of the sequence comparison and generates a numerical result.
[0123] Methods for the Production of Single Chain Antibodies According to the Present Invention
[0124] (A) Transgenic Animals
[0125] The loci and vectors of the present invention may be introduced into an animal to produce a transgenic animal. Thus, the present invention also provides a transgenic animal including a construct described herein.
[0126] Inserting the loci into the genome of a recipient animal may be achieved using any technique apparent to those skilled in the art, for example, microinjection. Following introduction of nucleic acid into a fertilised egg, reimplantation is accomplished using standard methods which will be familiar to those skilled in the art. Usually, the surrogate host is anaesthetised, and the eggs are inserted into the oviduct. The number of eggs implanted into a particular host will vary, but will usually be comparable to the number of offspring the species naturally produces.
[0127] Alternatively, the DNA may be introduced into embryonic stem cells (ES) cells which can be inserted into a host embryo to derive transgenic mice by standard technology.
[0128] In a further embodiment the DNA can be introduced into any cell. The nuclei of these cells are used to replace the nucleus of a fertilised egg which may be of any species to give rise to transgenic animals. This technique of nuclear transfer is familiar to those skilled in the art.
[0129] Transgenic offspring of the surrogate host may be screened for the presence of the transgene by any suitable method. Screening is often accomplished by Southern or Northern analysis, using a probe that is complementary to at least a portion of the transgene. Western blot analysis using a ligand specific for the antibody encoded by the transgene may be employed as an alternative or additional method for screening. Typically, the tissues or cells believed to express the transgene at the highest levels are tested, although any tissues or cell types may be used for this analysis.
[0130] Progeny of the transgenic mammals may be obtained by mating the transgenic mammal with a suitable partner, or by in vitro fertilisation of eggs and/or sperm obtained from the transgenic mammal. Where in vitro fertilisation is used, the fertilised embryo may be implanted into a surrogate host or incubated in vitro, or both. Where mating is used to produce transgenic progeny, the transgenic mammal may be backcrossed to a parental line. Using either method, the progeny may be evaluated for the presence of the transgene using methods described above, or other appropriate methods.
[0131] The animal may be varied provided it is a mammal. Preferably, the animal is a non-human mammal such as a rodent and even more preferably a rat or mouse. In this regard, it is also preferred that the recipient animal is incapable of producing antibodies that include light chains or at the very least has a reduced capacity to produce such antibodies. To achieve this end the recipient animal may be a “knock out” animal that is capable of having one or more of the genes required for the production of antibodies with light chains turned off or suppressed.
[0132] By using recipient animals incapable of producing antibodies that include light chains or at the very least with only a reduced capacity to produce such antibodies, the method of the present invention enables the efficient production of large quantities of single chain antibodies and antibody producing cells from a transgenic animal according to the present invention upon challenge with a given antigen.
[0133] (B) Phage Display Technology
[0134] Vectors for phage display fuse the encoded polypeptide to, e.g., the gene III protein (pIII) or gene VIII protein (pVIII) for display on the surface of filamentous phage, such as M13. See Barbas et al., Phage Display: A Laboratory Manual, Cold Spring Harbor Laboratory Press (2001) (ISBN 0-87969-546-3); Kay et al. (eds.), Phage Display of Peptides and Proteins: A Laboratory Manual, San Diego: Academic Press, Inc., 1996; Abelson et al. (eds.), Combinatorial Chemistry, Methods in Enzymology vol. 267, Academic Press (May 1996).
[0135] Prokaryotic hosts are particularly useful for producing phage displayed antibodies of the present invention. The technology of phage-displayed antibodies, in which antibody variable region fragments are fused, for example, to the gene III protein (pIII) or gene VIII protein (pVIII) for display on the surface of filamentous phage, such as M13, is by now well-established, Sidhu, Curr. Opin. Biotechnol. 11(6):610-6 (2000); Griffiths et al., Curr. Opin. Biotechnol. 9(1):102-8 (1998); Hoogenboom et al., Immunotechnology, 4(1):1-20 (1998); Rader et al., Current Opinion in Biotechnology 8:503-508 (1997); Aujame et al., Human Antibodies 8:155-168 (1997); Hoogenboom, Trends in Biotechnol. 15:62-70 (1997); de Kruif et al., 17:453-455 (1996); Barbas et al., Trends in Biotechnol. 14:230-234 (1996); Winter et al., Ann. Rev. Immunol. 433-455 (1994), and techniques and protocols required to generate, propagate, screen (pan), and use the antibody fragments from such libraries have recently been compiled, Barbas et al., Phage Display: A Laboratory Manual, Cold Spring Harbor Laboratory Press (2001) (ISBN 0-87969-546-3); Kay et al. (eds.), Phage Display of Peptides and Proteins: A Laboratory Manual, Academic Press, Inc. (1996); Abelson et al. (eds.), Combinatorial Chemistry, Methods in Enzymology vol. 267, Academic Press (May 1996), the disclosures of which are incorporated herein by reference in their entireties.
[0136] For the phage display of antibodies as herein described including fragments thereof, advantageously, they are fused to the phage g3p protein.
[0137] (C) Hybridomas
[0138] Recombinant DNA technology may be used to produce single chain antibodies according to the present invention using an established procedure, in bacterial or preferably mammalian cell culture. The selected cell culture system preferably secretes the single chain antibody product.
[0139] Multiplication of hybridoma cells or mammalian host cells in vitro is carried out in suitable culture media, which are the customary standard culture media, for example Dulbecco's Modified Eagle Medium (DMEM) or RPMI 1640 medium, optionally replenished by a mammalian serum, e.g. foetal calf serum, or trace elements and growth sustaining supplements, e.g. feeder cells such as normal mouse peritoneal exudate cells, spleen cells, bone marrow macrophages, 2-aminoethanol, insulin, transferrin, low density lipoprotein, oleic acid, or the like. Multiplication of host cells which are bacterial cells or yeast cells is likewise carried out in suitable culture media known in the art, for example for bacteria in medium LB, NZCYM, NZYM, NZM, Terrific Broth, SOB, SOC, 2× YT, or M9 Minimal Medium, and for yeast in medium YPD, YEPD, Minimal Medium, or Complete Minimal Dropout Medium.
[0140] In vitro production provides relatively pure immunoglobulin preparations and allows scale-up to give large amounts of the desired immunoglobulins. Techniques for bacterial cell, yeast or mammalian cell cultivation are known in the art and include homogeneous suspension culture, e.g. in an airlift reactor or in a continuous stirrer reactor, or immobilised or entrapped cell culture, e.g. in hollow fibres, microcapsules, on agarose microbeads or ceramic cartridges.
[0141] Large quantities of the desired immunoglobulins can also be obtained by multiplying mammalian cells in vivo. For this purpose, hybridoma cells producing the desired immunoglobulins are injected into histocompatible mammals to cause growth of antibody-producing tumours. Optionally, the animals are primed with a hydrocarbon, especially mineral oils such as pristane (tetramethyl-pentadecane), prior to the injection. After one to three weeks, the immunoglobulins are isolated from the body fluids of those mammals. For example, hybridoma cells obtained by fusion of suitable myeloma cells with antibody-producing spleen cells from Balb/c mice, or transfected cells derived from hybridoma cell line Sp2/0 that produce the desired antibodies are injected intraperitoneally into Balb/c mice optionally pre-treated with pristane, and, after one to two weeks, ascitic fluid is taken from the animals.
[0142] The foregoing, and other, techniques are discussed in, for example, Kohler and Milstein, (1975) Nature 256:495-497; U.S. Pat. No. 4,376,110; Harlow and Lane, Antibodies: a Laboratory Manual, (1988) Cold Spring Harbor, incorporated herein by reference. Techniques for the preparation of recombinant antibody molecules is described in the above references and also in, for example, EP 0623679; EP 0368684 and EP 0436597, which are incorporated herein by reference.
[0143] The cell culture supernatants are screened for the desired antibodies, preferentially by immunofluorescent staining of cells expressing the desired target by immunoblotting, by an enzyme immunoassay, e.g. a sandwich assay or a dot-assay, or a radioimmunoassay.
[0144] For isolation of the antibodies, those present in the culture supernatants or in the ascitic fluid may be concentrated, e.g. by precipitation with ammonium sulphate, dialysis against hygroscopic material such as polyethylene glycol, filtration through selective membranes, or the like. If necessary and/or desired, the antibodies are purified by the customary chromatography methods, for example gel filtration, ion-exchange chromatography, chromatography over DEAE-cellulose and/or (immuno-)affinity chromatography, e.g. affinity chromatography with the target molecule or with Protein-A.
[0145] (3) Immunisation of a Transgenic Animal
[0146] In a further aspect, the present invention provides a method for the production of single chain antibodies according to the present invention comprising administering an antigen to a transgenic animal according to the present invention.
[0147] The single chain antibodies produced from transgenic animals of the present invention include polyclonal and monoclonal single chain antibodies and fragments thereof. If polyclonal antibodies are desired, the transgenic animal (e.g., mouse, rabbit, goat, horse, etc.) may be immunised with an antigen and serum from the immunised animal collected and treated according to known procedures. If serum containing polyclonal antibodies contains antibodies to other antigens, the polyclonal antibodies of interest can be purified by immunoaffinity chromatography and such like techniques which will be familiar to those skilled in the art. Techniques for producing and processing polyclonal antisera are also known in the art.
[0148] Uses of Single Chain Antibodies According to the Present Invention
[0149] Single chain antibodies including fragments thereof according to the present invention may be employed in in vivo therapeutic and prophylactic applications, in vitro and in vivo diagnostic applications, in vitro assay and reagent applications, and the like.
[0150] Therapeutic and prophylactic uses of single chain antibodies according to the invention involve the administration of the above to a recipient mammal, such as a human.
[0151] ‘Camelised VH single chain heavy chain antibodies’ possess several advantages over camelid VHH single chain antibody molecules in the treatment of humans. For example camelised VH single chain antibodies possess a protein A binding site in the case of antibodies based on the VH3 gene family. In addition, camelised VH single chain antibodies are expected to show lower immunogenicity than camelid VHH single chain antibodies when administered to humans.
[0152] It will also be appreciated that ‘camelised VH single heavy chain antibodies’ and ‘camelid VHH single heavy chain antibodies’ have some different physical characteristics than conventional dual chain antibodies. For example, due to the lack of a functional CH1 heavy domain, antibodies of the present invention do not bind complement molecule C1q which is involved in activation of the classical pathway of complement.
[0153] Substantially pure single chain antibodies including fragments thereof of at least 90 to 95% homogeneity are preferred for administration to a mammal, and 98 to 99% or more homogeneity is most preferred for pharmaceutical uses, especially when the mammal is a human. Once purified, partially or to homogeneity as desired, the single to chain antibodies as herein described may be used diagnostically or therapeutically (including extracorporeally) or in developing and performing assay procedures using methods known to those skilled in the art.
[0154] The selected single chain antibodies of the present invention will typically find use in preventing, suppressing or treating inflammatory states, allergic hypersensitivity, cancer, bacterial or viral infection, and autoimmune disorders (which include, but are not limited to, Type I diabetes, multiple sclerosis, rheumatoid arthritis, systemic lupus erythematosus, Crohn's disease and myasthenia gravis), and in preventing transplant rejection. For instance, depletion of the regulatory T cells or interference with their recruitment may result in an enhanced immune response which may be of particular use in the treatment of infections which otherwise escape a normal immune response.
[0155] In addition, the selected single chain antibodies including fragments thereof maybe useful for modulating an immune response in regions of a vertebrate where they are not normally located. For example, one or more antibodies used as herein described may be perfused, injected, into a tissue of a vertebrate, using techniques known to those skilled in the art. The presence of an antibody as described herein, in such an ectopic environment may be useful in the modulation of an immune response during for example, transplant rejection and the like.
[0156] In the instant application, the term “prevention” involves administration of the protective composition prior to the induction of the disease. “Suppression” refers to administration of the composition after an inductive event, but prior to the clinical appearance of the disease. “Treatment” involves administration of the protective composition after disease symptoms become manifest.
[0157] Animal model systems which can be used to screen the effectiveness of the selected antibodies of the present invention in protecting against or treating the disease are available. Methods for the testing of systemic lupus erythematosus (SLE) in susceptible mice are known in the art (Knight et al. (1978) J. Exp. Med., 147: 1653; Reinersten et al. (1978) New Eng. J. Med., 299: 515). Myasthenia Gravis (MG) is tested in SJL/J female mice by inducing the disease with soluble AchR protein from another species (Lindstrom et al. (1988) Adv. Immunol., 42: 233). Arthritis is induced in a susceptible strain of mice by injection of Type II collagen (Stuart et al. (1984) Ann. Rev. Immunol., 42: 233). A model by which adjuvant arthritis is induced in susceptible rats by injection of mycobacterial heat shock protein has been described (Van Eden et al. (1988) Nature, 331: 171). Thyroiditis is induced in mice by administration of thyroglobulin as described (Maron et al. (1980) J. Exp. Med., 152: 1115). Insulin dependent diabetes mellitus (IDDM) occurs naturally or can be induced in certain strains of mice such as those described by Kanasawa et al. (1984) Diabetologia, 27: 113. EAE in mouse and rat serves as a model for MS in human. In this model, the demyelinating disease is induced by administration of myelin basic protein (see Paterson (1986) Textbook of Immunopathology, Mischer et al., eds., Grune and Stratton, New York, pp. 179-213; McFarlin et al. (1973) Science, 179: 478: and Satoh et al. (1987) J. Immunol., 138: 179).
[0158] Generally, the selected single chain antibodies of the present invention will be utilised in purified form together with pharmacologically appropriate carriers. Typically, these carriers include aqueous or alcoholic/aqueous solutions, emulsions or suspensions, any including saline and/or buffered media. Parenteral vehicles include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride and lactated Ringer's. Suitable physiologically-acceptable adjuvants, if necessary to keep a polypeptide complex in suspension, may be chosen from thickeners such as carboxymethylcellulose, polyvinylpyrrolidone, gelatin and alginates.
[0159] Intravenous vehicles include fluid and nutrient replenishers and electrolyte replenishers, such as those based on Ringer's dextrose. Preservatives and other additives, such as antimicrobials, antioxidants, chelating agents and inert gases, may also be present (Mack (1982) Remington's Pharmaceutical Sciences, 16th Edition).
[0160] The selected single chain antibodies including fragments thereof, of the present invention may be used as separately administered compositions or in conjunction with other agents. These can include various immunotherapeutic drugs, such as cyclosporine, methotrexate, adriamycin or cisplatinum, and immunotoxins. Pharmaceutical compositions can include “cocktails” of various cytotoxic or other agents in conjunction with the selected antibodies, or T-cells of the present invention or even combinations of the selected antibodies according to the present invention.
[0161] The route of administration of pharmaceutical compositions according to the invention may be any of those commonly known to those of ordinary skill in the art. For therapy, including without limitation immunotherapy, the selected antibodies, receptors or binding proteins thereof of the invention can be administered to any patient in accordance with standard techniques. The administration can be by any appropriate mode, including parenterally, intravenously, intramuscularly, intraperitoneally, transdermally, via the pulmonary route, or also, appropriately, by direct infusion with a catheter. The dosage and frequency of administration will depend on the age, sex and condition of the patient, concurrent administration of other drugs, counterindications and other parameters to be taken into account by the clinician.
[0162] The selected antibodies, of this invention can be lyophilised for storage and reconstituted in a suitable carrier prior to use. Known lyophilisation and reconstitution techniques can be employed. It will be appreciated by those skilled in the art that lyophilisation and reconstitution can lead to varying degrees of functional activity loss and that use levels may have to be adjusted upward to compensate.
[0163] In addition, antibodies according to the present invention may be used for diagnostic purposes. For example antibodies as herein described may be generated or raised against antigens which are specifically expressed during disease states or whose levels change during a given disease states.
[0164] For certain purposes such as diagnostic or tracing purposes labels may be added. Suitable labels include but are not limited to any of the following, radioactive labels, NMR spin labels and fluorescent labels. Means for the detection of the labels will be to familiar to those skilled in the art.
[0165] Examples of suitable radioactive labels include technetium 99m ( 99m Tc) or iodine-123 ( 123 I). Labels such as iodine-123, iodine-313, indium-111, fluorine-19, carbon-13, nitrogen-15, oxygen-17, gadolinium, manganese or iron allow detection of the label using NMR. Labels such as 11C methionine and FDG are suitable for use in the technique of positron emission tomography. Descriptions of procedures and protocols for using PET are familiar to those skilled in the art.
[0166] A suitable fluorophore is GFP or a mutant thereof. GFP and its mutants may be synthesised together with the antibodies of the present invention or target molecule by expression therewith as a fusion polypeptide, according to methods well known in the art. For example, a transcription unit may be constructed as an in-frame fusion of the desired GFP and the immunoglobulin or target, and inserted into a vector as described above, using conventional PCR cloning and ligation techniques.
[0167] Antibodies according to the present invention may be labelled with any agent capable of generating a signal. The signal may be any detectable signal, such as the induction of the expression of a detectable gene product. Examples of detectable gene products include bioluminescent polypeptides, such as luciferase and GFP, polypeptides detectable by specific assays, such as beta-galactosidase and CAT, and polypeptides which modulate the growth characteristics of the host cell, such as enzymes required for metabolism such as HIS3, or antibiotic resistance genes such as G418.
[0168] The compositions containing the present selected antibodies of the present invention or a cocktail thereof can be administered for prophylactic and/or therapeutic treatments. In certain therapeutic applications, an adequate amount to accomplish at least partial inhibition, suppression, modulation, killing, or some other measurable parameter, of a population of selected cells is defined as a “therapeutically-effective dose”. Amounts needed to achieve this dosage will depend upon the severity of the disease and the general state of the patient's own immune system, but generally range from 0.00005 to 5.0 mg of selected single chain antibody per kilogram of body weight, with doses of 0.0005 to 2.0 mg/kg/dose being more commonly used. For prophylactic applications, compositions containing the present selected polypeptides or cocktails thereof may also be administered in similar or slightly lower dosages.
[0169] A composition containing one or more selected antibodies according to the present invention may be utilised in prophylactic and therapeutic settings to aid in the alteration, inactivation, killing or removal of a select target cell population in a mammal. In addition, the selected repertoires of polypeptides described herein may be used extracorporeally or in vitro selectively to kill, deplete or otherwise effectively remove a target cell population from a heterogeneous collection of cells. Blood from a mammal may be combined extracorporeally with the selected antibodies, cell-surface receptors or binding proteins thereof whereby the undesired cells are killed or otherwise removed from the blood for return to the mammal in accordance with standard techniques.
[0170] In a further aspect, the present invention provides the use of a single heavy chain antibody as herein described as an intracellular binding reagent.
[0171] Antibodies of the present invention can be expressed in any cell type and may bind to and affect the function of any intracellular component. Intracellular components may be for example components of the cytoskeleton, molecules involved in gene expression and/or the regulation of expression, enzymes or molecules involved in the regulation of the function of cellular components. One skilled in the art will appreciate that this list is not intended to be exhaustive. Where for example the component is an enzyme inhibitor, an antibody of the present invention may increase or decrease the activity of the enzyme. The active site of enzymes is often located in the largest cavity on the protein surface. Such sites are not normally immunogenic for conventional antibodies (Novotny et al, (1986) Proc. Nat. Acad USA, 83, 226). The long H3 loop of single chain antibodies according to the present invention penetrates deeply into the active site of enzymes, allowing them to act as efficient enzyme inhibitors.
[0172] In particular the single chain antibodies, and/or fragments and/or compositions thereof to of the present invention may be of particular use as anti-viral and/or antibacterials in external applications, for instance in the form of creams for skin, vaginal application and so on. In addition, antibodies fragments and compositions according to the present invention may find use in treating equipment, such as places where opportunistic infections are prevalent. For example, antibodies, fragments thereof and compositions may be of particular use in hospital environments, and in particular intensive care units. Furthermore, the antibodies, fragments thereof, and compositions of the present invention may find use in the treatment of transplantation material either artificial or natural tissue. For example stents or bone marrow infected with CMV or other viruses.
[0173] In addition, other functions may be added to antibodies of the present invention such as transport peptides and/or functional moieties providing an enzymic activity, for example kinases, proteases, phosphatases, de-acetylases, acetylases, ubiquitinylation enzymes, sumolation enzymes, methylases etc. Furthermore, other antibodies may be attached to the single chain antibodies, or fragments thereof according to the present invention. Those skilled in the art will appreciate that this list is not intended to be exhaustive.
[0174] All publications mentioned in the above specification are herein incorporated by reference. Various modifications and variations of the described methods and system of the present invention will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. Although the present invention has been described in connection with specific preferred embodiments, it should be | The present invention relates to a method for the generation of single chain immunoglobulins in a mammal. In particular, the present invention relates to a method for the generation of single chain camelid VHH antibodies in a mammal which undergo the process of class-switching and affinity maturation found within antibody producing B cells. Single chain antibodies generated using the method of the present invention and the uses thereof are also described. | 2 |
RELATED APPLICATIONS
This is a continuation-in-part application of Ser. No. 770,411, filed Feb. 18, 1977, now abandoned, which is a continuation of Ser. No. 635,217, filed Nov. 25, 1975, now abandoned, which in turn is a continuation-in-part of Ser. No. 620,566, filed Oct. 8, 1975 and now abandoned.
BACKGROUND OF THE INVENTION
A search has disclosed various types of locking thread designs wherein a binding pressure is provided between the threads of male and female elements to produce a positive lock. Such prior art designs, for example, are shown in U.S. Pat. Nos. 1,657,244; 1,697,118; 1,798,604; 1,817,295 and 1,828,856 and in French Pat. No. 40,199 of 1932. These prior art locking thread designs are believed to operate satisfactorily in theory, but from a practical and commercial standpoint, are unacceptable due to the tolerance limitations under which modern thread forming equipment must operate. The locking thread design of the present invention on the other hand, may be readily formed with conveniently available equipment and in accordance with current tolerance limitations. More importantly, the thread forms of the present invention are not intended to lock by binding action, as is the case with the thread forms of the aforementioned prior art patents but instead, locking action is achieved by preventing relative motion between the mating parts and results in a locking action between the threaded elements that appears to be at least as good as, if not superior to the locking performance of the aforesaid prior art locking thread designs.
SUMMARY OF THE INVENTION
The locking thread form of the present invention is illustrated, by way of example, as embodied on a nut and bolt which are employed to clamp a pair of elements in tight secured engagement with each other. The subject thread form may be operatively associated with both Standard and buttress-type threads and utilizes a flat area or ramp at the thread root of either or both of the bolt and nut threads. In the case where the locking thread form is used on both elements having buttress-type threads, the ramp at the thread root on the bolt is disposed at an angle of approximately 30° from the bolt's axis, while the ramp at the thread root of the nut is disposed at an angle of approximately 221/2° to the nut axis. The purpose of the angles at the thread roots is to allow the threads to be manufactured to normal commercial tolerances and still always make contact with the crown of the mating thread and thereby prevent lateral movement between the threaded members and thus prevent loosening under vibration or other adverse conditions. In the case where the ramp is utilized on one of a pair of elements provided with Standard-type threads, the angle of the ramp may be varied within limits in accordance with the class fit, size threaded elements and acceptable tolerance ranges to provide for optimum locking ability with commercially available equipment and technology. It is to be noted that the aforesaid angles for buttress-type threads are given by way of example and apply particularly when the nut (female element) is fabricated of a relatively softer material than the bolt or male element, and that the angles may be the same or relatively larger or smaller on the male and female elements depending upon the relative degree of hardness of the materials from which these elements are formed.
The thread design of the present invention is free running under non-loaded or lightly loaded conditions; however, at such time as the degree of loading reaches a predetermined magnitude, the thread crown or crowns move into contact with the ramp or ramps of the opposing threaded element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in elevation of a bolt clamping two elements together on a thread embodying features of the present invention;
FIG. 2 is an enlarged broken view of the bolt thread illustrated in FIG. 1;
FIG. 3 is an enlarged broken sectional view of the thread of the nut and bolt when in free-running relation to each other;
FIG. 4 is a view of the structure illustrated in FIG. 3 after the bolt has clamped the two elements illustrated in FIG. 1, with a minimum of holding force;
FIG. 5 is a view of the structure illustrated in FIG. 4, when a substantial pressure has been applied on the nut to cause the thread of the nut to advance to the right until thread engagement occurs;
FIG. 6 is a view of structure, similar to that illustrated in FIG. 3, with only the bolt having the root of the thread provided with a sloping surface;
FIG. 7 is a view of structure, similar to that illustrated in FIG. 6, with only the nut having the root of its thread provided with a flat surface;
FIG. 8 is a view of a chart showing the substantial holding force provided by the thread structure herein illustrated and described;
FIG. 9 is an enlarged fragmentary cross-sectional view of an alternate construction of the locking thread form of the present invention, as shown in a free-running condition;
FIG. 10 is an enlarged fragmentary cross-sectional view of the thread form shown in FIG. 9 after a partial loading has been applied thereto;
FIG. 11 is an enlarged fragmentary cross-sectional view of the thread form shown in FIGS. 9 and 10 after substantially complete loading has been applied thereto;
FIG. 12 is an enlarged fragmentary cross-sectional view, similar to FIG. 9 of still another alternate embodiment of the present invention; and
FIG. 13 is a graphic representation similar to FIG. 8 and illustrates the comparative locking characteristics of the locking thread form shown in FIGS. 9-11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-8 illustrate embodiments of the present invention wherein the locking thread form is associated with buttress-type threads. In particular, a bolt or male threaded element 11 is shown as comprising a shank portion at one end thereof which is formed with a thread 12, and with an enlarged head 13 being provided at the opposite end from the thread 12. The bolt, as illustrated in FIG. 1, extends through a pair of elements 14 which are to be clamped together by a nut or female threaded element 15 having an internal thread 10 which is normally freely running on the thread 12 of the bolt. The bolt 11 is preferably, although not necessarily, constructed from a hardenable steel, such as 1335, 1441 or 1340, while the nut 15 is constructed from a relatively softer or more deformable steel than the bolt 11, such as 1008 or 1010. It is to be understood that the bolt could also be constructed from a soft steel but is preferably constructed of a hardenable steel. As is conventional with threads of the buttress type, threads 10, 12 have one flank thereof at a substantial angle while the opposing flanks thereof have very small angle relative to the axis of the bolt or nut. As illustrated in FIGS. 2-5 inclusive, the thread of both the bolt 11 and nut 15 has the root flattened in a manner to provide a flat surface or ramp which slopes relative to the thread axis; the flat 16 at the root of the nut 15 is disposed at an angle of approximately 221/2° relative to the thread axis, while the flat 17 at the root of the bolt thread 12 is disposed at an angle of approximately 30° from the axis of the thread.
It is to be noted that the aforesaid angles will vary with the degree of hardness of the material from which the bolt 11 and nut 15 are fabricated, and that when these elements are fabricated so as to be of similar or identical hardness, the angles of the flats or ramps 16 and 17 are preferably equal or approximately equal.
When the nut 15 is in the position illustrated in FIG. 3 with the crown 19 of its thread 10 disposed adjacent to the corner 21 of the bolt 11 between the flat surface 17 and the sloping face 22, the nut 15 is free running on the thread 12 and is freely rotatable toward the left until the nut 15 strikes the adjacent element 14, whereupon the continued rotation of the nut 15 will cause the crowns 19 and flat 16 to move to the right engaging the flat sloping surface 17 and crown 23, respectively, and causing the softer metal of the crown 19 to deform. In FIG. 4, the crown 23 is illustrated as contacting the sloping flat 16 of the nut 15, as would occur when an approximately 50 foot-pound force is exerted on a one-half inch bolt, thereby providing a substantial degree of contact between the threads which locks the nut 15 in position along the bolt shank. When an increased torsional force is applied to the nut 15, an even greater degree of contact will occur between the ramps 16, 17 and the crowns 19, 23 until the faces of the nut thread engages the faces of the bolt thread, as shown in FIG. 5, which would occur, for example, when a one-half inch bolt is subjected to a 90 foot-pound load. This provides an even greater degree of contact between the crowns 19 and 23 and the flat sloping surfaces 17 and 16, and under these conditions, any relative lateral movement between the nut 15 and bolt 11 is positively prevented so as to assure against loosening thereof, which locked condition will exist until such time as a positive force is applied to unscrew the nut thread 10 from the thread 12 of the bolt 11 and thereby cause the respective threads to reach the position illustrated in FIG. 3, whereupon the nut 15 is again free running toward the end of the bolt thread 12.
Referring to FIG. 6, the bolt 11 is the same as the bolt above described with regard to FIGS. 1-5 while the nut 25 has no flat areas 16 in the thread root thereof. As a result, the crown 19 of the nut will contact the flat sloping surface 17 at the root of the bolt to provide the locking of the nut on the bolt when sufficient pressure has been applied to the nut after the elements 14 have been clamped together.
A similar result is obtained when the relationship of the threads is that illustrated in FIG. 7. In this arrangement, the thread 10 of the nut 15 has the flat 16 thereon while bolt 26 has no flat in the root area. When the nut 15 is subjected to a predetermined degree of axial loading, such as when it is being tightened against the element 14, further rotation of the nut 15 will cause the crown 23 of the bolt thread to contact flat surface 16 of the nut thread 10, thereby producing distortion or penetration of the ramp 16 of the soft nut metal to a degree commensurate with the amount of pressure (torque) which is applied to clamp the element 14. When a substantial pressure is applied, the faces of the nut thread will advance into engagement with the facing surfaces of the thread of the bolt 26, as described above. In any of the examples herein illustrated, it will be noted that the engagement of the crowns of one or both threads with the sloping ramp or ramps at the roots of the opposing threads will produce the deformation or distortion of the soft metal of the nut or both the nut and bolt, with the result that no lateral movement between the nut and bolt will occur, which in turn assures against loosening of the bolt and nut after assembly thereof.
The chart or graph of FIG. 8 shows the result of the same test made on four different nut and bolt combinations on a Junkers testing machine which vibrates the tightened nut and bolt supported thereon. The first graph line 27 represents a test performed on a Standard-type of bolt and nut having a 7/16 inch diameter after it was drawn up to approximately 7,000 pounds axial force. The shaking of this bolt and nut rapidly loosened the nut and the holding force quickly decreased to substantially below 1,000 pounds. Each square represents approximately two seconds of time so that this test occurred in practically ten seconds. The graph line 28 represents a test run on a 7/16 inch nut and bolt of the present invention in which it will be noted that under a clamping force of 6,500 pounds the vibration caused an initial Brinelling of the nut and seating of the thread form (although no rotation of the nut), but which thereafter maintained a clamping force of between approximately three and four thousand pounds. The third graph line 29 was the result of a test on a 7/16 inch prior art-type lock nut and associated bolt, the lock nut being triangular in this particular test, and as illustrated, a rapid drop from the 6,500 pounds applied force occurred on to the bottom of the chart. Graph line 30 discloses a subsequent or second test of the identical nut and bolt tested in connection with the graph line 28 and illustrates the fact that the superior locking characteristics of the present invention are not lessened even during reuse of the nut and bolt. The reason that the bolt and nut lessened to a greater degree during the original test depicted by line 28, as compared to the "reuse" test depicted by line 30, is believed to be attributed to a certain amount of thread seating and a protective coating on the nut and bolt elements which caused an artificially low reading of the original test data.
FIGS. 9-12 illustrate alternate embodiments of the locking thread form of the present invention wherein the thread form is operatively associated with Standard, i.e., American or Unified, type threads, and wherein the thread form may be provided on either of two threaded elements and operatively associated with the other threaded element which may be of conventional construction. In particular, FIGS. 9-11 illustrate a locking thread form 100 shown in association with a pair of threaded elements 102 and 104. By way of example, the threaded element 102 may consist of a nut, while the threaded element 104 may consist of a bolt. The threaded element 102 is formed with a Standard thread form 106, each thread of which comprises converging flanks 108, 110 defining a crest 112 and having a root area 114. Similarly, the threaded element 104 is formed with a Standard thread form 116, each thread of which comprises flanks 118, 120, a crest 122 and a root area 124.
In accordance with the principles of the present invention, each of the root areas on the threaded member 104 is formed with an inclined ramp 126 which is analogous to the aforedescribed ramps 16. The ramps 126 are oriented at an angle with respect to the axis of the threaded elements 102, 104, which angle is selected so as to assure positive engagement of the crest 112 therewith upon application of loading to the elements 102, 104 and consistent with modern manufacturing tolerances.
More particularly, it has been found that optimum locking ability of the elements 102, 104 can be achieved without sacrificing any strip strength thereof by making the axial length of the ramps 126 equal to approximately 0.020 inches and designing the angle thereof relative to the axis of the elements 102, 104 such that approximately one-half the maximum tolerance between the elements 102 and 104, plus a safety factor of approximately 0.002, is taken up in the aforesaid axial distance of 0.020 inches.
By way of example, for a Standard 3/8 inch nut and bolt having 16 threads per inch, the maximum acceptable diameter limit is 0.3750 inches and the minimum acceptable diameter limit is 0.3595 inches. Taking the difference between these limits, i.e., 0.3750-0.3595 results in 0.0155 which, when added to the aforementioned safety factor of 0.002 (which accommodates for tool wear, etc.) equals 0.0175, and one-half of 0.0175 equals 0.0087. The angle a whose tangent equals 0.0087÷0.020 is 23.5°. Therefore, the optimum angle at which the ramps 126 should be located relative to axis of the elements 102, 104 where it is desired to take up approximately one-half the total maximum tolerance between the aforementioned size and class threaded elements in a distance of 0.020 is 23.5°. It will be appreciated, of course, that such angle a will vary in accordance with changes in either the safety factor, class threads, number of threads per inch, or diameter of threaded elements. The following chart sets forth acceptable angles of the ramps 126 for the respective size threaded elements, thread class and number of threads per inch, as calculated in accordance with the above example:
______________________________________STANDARD SERIES SCREW THREADSSize CLASS 1 CLASS 2 CLASS 3Threaded Threads Angle Angle AngleElements Per Inch Required Required Required______________________________________3/8 16 23.5 ± .5° 17.6 ± .5° 15.9 ± .5° 7/16 14 25.2 ± .5° 18.9 ± .5° 17.0 ± .5°1/2 13 26.3 ± .5° 19.7 ±.0 .5° 17.8 ± .5° 9/16 12 27.4 ± .5° 20.5 ± .5° 18.5 ± .5°5/8 11 28.5 ± .5° 21.4 ± .5° 19.4 ± .5°11/16 12 -- 20.5 ± .5° 18.5 ± .5°3/4 10 30.1 ± .5° 22.6 ± .5° 20.4 ± .5°______________________________________
By selecting the angles of the ramps 126 in accordance with the above, lateral movement between the elements 102, 104 upon applying preselected loading thereto is effectively precluded, thereby assuring that the elements 102, 104 will remain in their respective locked positions once they are moved from their free-running relation shown in FIG. 9 to either the partially loaded position shown in FIG. 10 or the completely loaded position shown in FIG. 11. While the angles given in the table above are preferred for the indicated applications, it has been found that angles up to and in excess of 35° are effective in many combinations. It is believed that the practical upper limit is about 45°.
FIG. 12 illustrates a slightly modified embodiment of the thread form shown in FIGS. 9-11 wherein the inclined ramps are located on the female element (nut) instead of the male element, as is the case with the thread form shown in FIGS. 9-11. In particular, the locking thread form shown in FIG. 13 is generally designated by the numeral 150 and is shown in operative association with threaded elements 152 and 154 which may consist of a nut and bolt, respectively. The elements 152, 154 are provided with Standard threads 156 and 158, respectively, with the root area of the thread 156 being formed with inclined ramps 160, as hereinabove described. The angles at which the ramps 160 are inclined relative to the axis of the elements 152, 154 are selected in accordance with the above example of the angle of the ramp 126 so as to minimize relative lateral movement between the elements 152, 154 and hence provide for optimum locking ability within the range of acceptable commercial tolerances. Thus, it will be seen that the principles of the present invention are applicable when either the male or female member is provided with the locking thread form, and that the other member need not have any special form other than the Standard form, thereby providing for universality of application. The embodiments shown in FIGS. 3-7 may be considered to be preferable to the embodiments shown in FIGS. 9-12 insofar as strip strength is concerned, although the strip strength of Standard thread forms can be improved by slightly increasing the length of the threads.
FIG. 13 is a graphic illustration similar to FIG. 8 and depicts the performance of the locking thread form shown in FIG. 12 as compared to conventional thread designs. The illustration shown in FIG. 13 represents tests on a 7/16 inch grade five bolt having a Standard thread form with three different nuts, as performed on the Junkers testing machine hereinabove described. The curve 162 represents a test performed on a Standard nut and bolt that had no type of locking means, and it will be noted that the effective locking ability drops to nearly zero in less than 14 seconds. The curve represented by the numeral 164 represents the results of a test of a Standard thread form on a bolt and associated with a conventional lock nut of the crimp or deformed type. This particular locking arrangement, while superior to the arrangement shown by the curve 162, also loses its locking ability rapidly, with the result that the locking ability thereof is effectively nonexistent after approximately 26 seconds. Graph line 166 represents a test run with the thread form illustrated in FIG. 12 wherein the bolt has a Standard thread form and the nut is provided with the aforementioned ramps 126. It will be readily apparent that the locking performance of this thread form is highly superior to those associated with the curves 162 and 164 and that the locking ability of the thread form of the present invention remains at a highly acceptable level for the duration of the testing procedure.
While it will be apparent that the embodiments illustrated herein are well calculated to fulfill the objects above stated, it will be appreciated that the present invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims. | A locking thread design which may be incorporated in various types of male and female threaded elements, for example, a bolt and nut, or a bolt and casting, forging or similar member having a threaded bore therein. The thread design may be of the Standard, i.e., American or Unified Standard, or buttress type and is free running until a predetermined magnitude of loading is applied thereto, at which time the locking action of the thread occurs so as to prevent relative lateral movement between the nut and bolt and hence positively resist loosening thereof under vibration and similar adverse operating conditions. The locking thread may be embodied on either one or both of the threaded elements, and will operate effectively when the locking thread is operatively associated with threaded members having conventional threads thereon. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. Ser. No. 12/902,523, filed Oct. 12, 2010, now U.S. Pat. No. 8,069,608.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The field of the invention is mushroom compost compacting systems, and particularly those systems for composting Phase II or Phase III mushroom composts.
[0004] 2. Background
[0005] Mushroom farming comprises generally six steps: (1) Phase I composting; (2) Phase II composting; (3) spawning; or (2a/3a) Phase III composting; (4) casing; (5) pinning; and (6) cropping. The most used and least expensive mushroom compost is straw-bedded horse manure to which nitrogen supplements and a conditioning agent, such as gypsum, are added. After the compost ingredients have been mixed, watered and aerated in Phase I for a requisite number of days, the compost is pasteurized in Phase II. Pasteurization kills insects, unwanted fungi or other pests that may be present in the compost.
[0006] Preparing Phase II mushroom compost can be difficult. One reason for the apparent difficulty with this phase is that pasteurization can last up to two weeks, depending upon the production system used. The time required, as well as other difficulties in maintaining temperature control and eliminating pests during this phase have led many mushroom farmers to purchase pre-pasteurized compost. In many cases, the Phase II compost is pre-mixed with mushroom spawn. Alternatively, Phase III compost is pasteurized, pre-mixed with mushroom spawn and spawn run.
[0007] When commercial mushroom farmers purchase pre-pasteurized Phase II or Phase III composts, proper compaction of mushroom beds is still necessary to spawn and grow mushrooms. Moreover, regardless the type of receptacle in which the compost is stored during processing, uniform compaction and density of the compost is beneficial for mushroom cultivation. For maximum yield, mushroom beds should have Phase II and Phase III compost density and compaction that fosters gas exchange, keeps compost temperatures sufficiently low, and prevents spawn kill in the next phase of processing.
[0008] Presently, commercial mushroom farmers who purchase pre-pasteurized compost introduce the Phase II or Phase III compost into beds by conveyor and attempt to use spawning machines to compact the compost. These machines, however, are not designed to compact to the degree desired for mushroom cultivation. Furthermore, these machines are less than desirable for commercial mushroom farmers because during operation they also chop up the spawn incorporated into the compost, potentially interfering with the next step in mushroom farming.
[0009] Other known compacting systems and methods are impractical for commercial use. One such system uses an assembly with rollers and smoothing plates. In this system, mushroom compost is partially compacted after placement into the mushroom bed. The assembly is then horizontally positioned over the bed and manually guided by two operators located on each side of the bed. This system tends to compact only a surface layer portion of the bed. Compaction to some degree has also been performed by hand after placement of compost in the bed. These time-consuming manual systems and methods make clear the need for improved mushroom compaction systems.
[0010] While certain aspects of prior art mushroom compacting systems have been discussed, aspects of these systems are in no way disclaimed and it is contemplated that the claimed invention may encompass one or more aspects of the prior art devices discussed herein.
SUMMARY OF THE INVENTION
[0011] The present invention is directed toward a mushroom compost compacting system and method. In one embodiment, the system comprises a roller assembly mounted to a compost receptacle, and a web, all of which are configured to compact mushroom compost from an initial compost height to a final compost height. The compost receptacle is configured to receive mushroom compost from any source.
[0012] The roller assembly includes a roller, a shaft, and two fixtures to removably mount or affix the roller and shaft to the compost receptacle. The roller is mounted for rotation on the shaft, such as by a through-hole for receiving the shaft. The fixtures are coupled to the shaft for height adjustment of the roller and the shaft in relation to the floor portion of the compost receptacle. Each fixture has (a) a first end that is coupled to one respective end of the shaft, (b) a mid-section that is coupled to a sleeve that seats over a sidewall of the compost receptacle, and (c) a second end that is adapted to mount to a support onto the compost receptacle. The sleeve that is coupled to the mid-section of the fixture is adapted to removably mount onto the sidewalls of the compost receptacle.
[0013] The web or liner or conveyor included in the mushroom compacting system is adapted to move under the roller to convey compost to the nip. As the web or liner or conveyor moves under the roller, the mushroom compost is compacted from an initial compost height to a final desired compost height.
[0014] Accordingly, a mushroom compacting system and method are disclosed. Advantages of the system and method will appear from the drawings and following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention described above will be explained in greater detail below on the basis of embodiments and with reference to the accompanying drawings in which:
[0016] FIG. 1 is a top perspective view of a mushroom compost bed with a mushroom composting system;
[0017] FIG. 2 is a cross-sectional view of the mushroom composting system shown in FIG. 1 taken along line 2 - 2 in FIG. 1 ;
[0018] FIG. 3 is a left side partial perspective view of a roller assembly;
[0019] FIG. 4 is a right side partial perspective view of the roller assembly of FIG. 3 ;
[0020] FIG. 5 is a right side view of the roller assembly;
[0021] FIG. 6 is a broken front elevation view of the roller assembly;
[0022] FIG. 7 is a right side view of two roller assemblies operably attached to two mushroom compost beds; and
[0023] FIG. 8 is a right side view of an alternative fixture for a roller assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Turning in detail to the drawings, FIG. 1 . illustrates a mushroom compost bed 10 that includes a series of trays or shelves, herein compost receptacles 12 , into each of which mushroom compost 8 is deposited or laid. The mushroom compost 8 may be Phase I, Phase II or Phase III compost. Phase II compost may be pre-spawned, and Phase III compost may be spawn run. The compost receptacle 12 may be any geometric configuration suitable to house mushroom compost 8 . In one configuration as shown in FIG. 1 , the compost receptacle 12 is an elongated bin, tray, or shelf that has two endwalls 18 (not shown), two sidewalls 20 , and a bottom 22 . The bottom may be a series of slats or decking running generally lengthwise. Each compost receptacle 12 is supported by vertical posts or members 24 positioned at each corner of the compost receptacle 12 and optionally at intervals along the length of the compost receptacle 12 . The vertical posts or members 24 may act as supporting legs for one or more compost receptacles 12 . As shown in FIG. 1 , the vertical posts or members 24 extend vertically to support other compost receptacles (three tiers shown in FIG. 1 ). These types of multi-tiered compost receptacles are typical in commercial mushroom farming. For additional support, some compost receptacles also have horizontal members or joists 26 that may be mounted to or connected to the vertical members 24 and extend under the floor portion of the compost receptacle 12 . Typically, the compost receptacles 12 are wooden, although any suitable material may be used, including, but not limited to plastic, metal, and composite materials.
[0025] The mushroom compost 8 is initially placed into the compost receptacle 12 from any suitable source. Preferably, the mushroom compost 8 is distributed inside the compost receptacle 12 along the length of the compost receptacle using a conveyor system (not shown) that acts on the web or conveyor or liner 28 . In one type of conveyor system, at one end of the compost receptacle 12 , compost is placed on top of the flexible web or conveyor or liner 28 in the bottom 22 of the compost receptacle 12 at a proximal end thereof. The liner 28 is then pulled from the opposite distal end of the compost receptacle 12 , such that the compost 8 is distributed or spread along the length of the compost receptacle 12 . Examples of suitable materials for the liner include woven fabrics with a plastic or Teflon coating, or may be polyester.
[0026] A mushroom compost compacting system 11 includes a roller assembly 14 that is removably affixed to the compost receptacle 12 . Each roller assembly 14 comprises a roller 32 , a shaft 34 , and two fixtures 36 , 36 ′. The shaft 34 and roller 32 extend laterally over the tray portion of the compost receptacle 12 . The roller 32 may be made from a lightweight material such as plastic or aluminum, or may be made of another metal lined on its outer surface with a nylon or Teflon or other sheeting. The roller surface is smooth such that the mushroom compost to be compacted by the roller may move easily under the roller 32 . In one embodiment, the diameter of roller 32 is from about 8 to 20 inches. The shaft 34 may be formed of steel; however, any material suitable to support the weight of the roller 32 may be used.
[0027] As shown in FIGS. 3 , 5 and 6 , the first fixture 36 includes a first end 40 , a mid-section 42 coupled to a sleeve 44 , and a second end 46 . The first fixture 36 is coupled at one end 40 to one shaft end 38 at pillow block bearing 50 and is coupled at the opposite end 62 to a support 58 , such as a channel member. The pillow block bearing 50 is then mounted onto a mounting bracket or plate 52 , using bolts 53 or other suitable fasteners. The mounting bracket or plate 52 is then welded to a first mounting element 54 which is threaded to the mid-section 42 . Disposed within the first mounting element 54 is a pin 56 which may be rotated for adjustment of the first end 40 , such that height adjustment of the roller 32 and shaft 34 is possible for compaction of the mushroom compost. As an example, the nip height between the outer circumferential surface of the roller and the floor of the compost receptacle may be from about 2 to about 8 inches. The nip height is set at a distance that is less than the desired compacted height of the mushroom compost.
[0028] The mid-section 42 of first fixture 36 may be joined by a spacer 48 or may bewelded to a sleeve 44 that is removably mounted or seated or engaged onto a first sidewall 20 of the compost receptacle 12 . The second end 42 of the first fixture 36 is threaded to engage the mid-section 42 and to mount onto the compost receptacle 12 . Preferably, the second end or opposite end of the first fixture 36 is joined to or mounted to a support, such as channel member 58 , that abuts joist or horizontal member 26 . In one embodiment, the channel member 58 is a square hollow pipe with a length sufficient to extend under the compost receptacle, and the dimensions of such square may be from 2 inches to 6 inches. In another embodiment, the support may also comprise a solid pipe of suitable cross-sectional shape as desired. The second end 46 is further coupled to a handle element 60 to allow for adjustment of the second end 46 . For additional adjustment of the second end 42 , washer(s) 63 may be placed between the channel member 58 and the handle element 60 .
[0029] Referring next to FIGS. 4 and 6 , the second fixture 36 ′ may be joined by spacer 48 ′ or may be welded to a sleeve 44 ′. The second fixture 36 ′ is coupled at one end 40 ′ to one shaft end 38 at pillow block bearing 50 ′ and is coupled at the opposite end 62 ′ to a support 58 , such as a channel member. The pillow block bearing 50 ′ is then mounted onto a mounting bracket or plate 52 ′, using bolts 53 or other suitable fasteners. The plate 52 ′ is then welded to a first mounting element 54 ′ which is threaded to the mid-section 42 ′. Disposed within the first mounting element 54 ′ is a pin 56 ′ which may be rotated for adjustment of the first end 40 ′.
[0030] In an alternative embodiment, however, the second end of the first fixture 36 and the second end of the second fixture 36 ′ are mounted directly to the compost receptacle 12 , such as to post 24 or to joist 26 (not shown).
[0031] The roller shaft may be turned by hand. Preferably, the first end of the shaft 34 is coupled to a motor 64 for rotation of the roller 32 . As shown in FIG. 3 , the motor 64 is mounted to a vertical post 24 of the compost receptacle 12 using a mounting plate 66 . Adjustment of the mounting plate 66 is achieved through use of a pin 68 that is threaded to the mounting plate 66 . Suitable motors include electric and hydraulic motors rated at 1 to 5 HP, or higher HP, although any motor with sufficient capacity to rotate shaft 34 may be used.
[0032] The first and second fixtures 36 , 36 ′ may be formed from shaped metal, such as steel; however, other materials with sufficient strength to support the roller 32 and shaft 34 may be used.
[0033] Once installed, the mushroom compacting system 11 compacts mushroom compost from a first height A to a compacted height B as illustrated in FIG. 2 . Gauge boards (not shown) can be inserted adjacent to the side walls of the compost receptacle 12 to help workers place a quantity of mushroom compost onto the conveyor, web or liner 28 at a desired height at one end of the compost receptacle. The roller 32 is rotated in the direction of arrow 9 and the conveyor, web or liner 28 conveys mushroom compost laid thereon to the nip between the roller 32 and the floor portion of the compost receptacle 12 . The mushroom compost compacting system 11 can be used with pre-spawned Phase II compost or spawn run Phase III compost without adversely impacting the mushroom crop. As one example, the height A may be about 15 to 16 inches and the height B may be about 6 to 9 inches. A successful degree of compaction is determined at the mushroom grower's discretion. The mushroom compacting system 11 provides means to obtain a more uniform compaction of the mushroom compost at the top, middle and bottom portions of the compacted compost bed.
[0034] Upon completing compaction of compost to a desired thickness within a first bin or tray of a mushroom compost bed 10 , the mushroom compacting system 11 may be detached from the sidewalls 20 of the compost receptacle 12 and attached to another bin or tray.
[0035] As shown in FIG. 7 , the mushroom compacting system 11 can include multiple roller assemblies 14 operating concurrently on separate trays or shelves or compost receptacles 12 of one or more compost beds 10 , 10 ′. Each roller assembly 14 is portable, and may be easily disassembled and re-installed to other areas along the length of a compost receptacle 12 or to other trays positioned above or below a first compost receptacle 12 of a compost bed 10 . Compost beds may include six or seven compost receptacles 12 mounted in stacked relation. After a lower compost receptacle is prepared and compacted, the next highest compost receptacle may be installed and prepared and compacted for growing mushrooms.
[0036] An alternative construction of a fixture 76 is shown in FIG. 8 . The fixture 76 is welded at weld seam 78 to the sleeve 44 . The fixture 76 may be formed with thicker sidewalls than the fixtures 36 , 36 ′ in FIGS. 1-7 , and has a generally square configuration in cross-section.
[0037] A properly compacted mushroom compost bed using the mushroom compacting system according to the invention can shorten the mushroom grow time cycle by one or two days. The system not only expedites mushroom bed preparation with Phase II or Phase III compost, but also produces a more consistent compost compaction that can lead to enhanced yield in a shorter grow time cycle.
[0038] While embodiments of this invention have been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the following claims. | A mushroom compost compacting system and method includes a roller assembly mounted to a compost receptacle to form a nip, and a web or conveyor to convey mushroom compost to the nip. Mushroom compost is compacted at the nip from an initial compost height to a final compost height. The roller assembly has a roller, a shaft, and fixtures coupled to each end of the shaft. The fixtures are adjustable to define the roller nip height. In one embodiment, the fixtures are mounted to sleeves that engage the sidewalls of the compost receptacle. In another embodiment, the ends of the fixtures are mounted to a support, which may be a joist or a separate channel extending under the floor portion of the compost receptacle, or which may be a post that forms support structure for the compost receptacle. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] N/A
BACKGROUND
[0002] Union Cycliste Internationale (UCI)—a.k.a. in English as the International Cycling Union—is the world governing body for sports cycling and oversees international competitive cycling events. Among its various duties, the UCI manages the classification of races and the points ranking system in various cycling disciplines including mountain biking, road and track cycling, for both men and women, amateur and professional. It also oversees the World Championships.
[0003] One of the more controversial roles of the UCI resides in the technical regulations it establishes and enforces with regard to the eligibility of bicycles used in the varying types of racing discipline. Although many feel that the rules arbitrarily restrict riders from achieving faster times, the UCI counters that strict adherence to these rules “guarantees sporting fairness and safety during competition.” As such, racers' bikes must conform to the standards set when wishing to compete in most any UCI sponsored event; and especially those in the three disciplines of: road events, track events and cyclo-cross. Each discipline has its own technical characteristics and each may have variants depending on the type of event.
[0004] For example, in massed-start road races and cyclo-cross, Article 1.3.020 of the UCI technical regulations states that the frame elements shall be tubular without excessive curvature (a straight line along the element's longitudinal axis must remain inside the element). Further, the regulations state that the elements shall have a maximum transverse dimension of 8 cm and a minimum transverse dimension of 2.5 cm (reduced to 1 cm for the seat stays, chain stays and forks).
[0005] The above max/min traverse dimensions are further limited to a “1:3 ratio”, which applies to the shapes of bicycle elements, with the exception of moving parts (wheels and chainsets1) and the saddle. Likewise, Article 1.3.024 establishes that aerodynamic assemblies and protuberances on the head tube are prohibited. More specifically, the Regulations do not allow for protective screens, aerodynamic shapes, fairings or any other device added or forming part of the structure, which is destined or has the effect of reducing wind resistance. Nevertheless, this regulation does not apply to the pedals, front or rear derailleur bodies or wheel brake mechanisms. The regulation does, however, apply to all elements making up the frame architecture as well as frame accessories (stem, handlebars, handlebar extension, seat post).
[0006] Notwithstanding any of the above, the subject of the shape of bicycle elements (1:3 ratio) does not exempt manufacturers from complying with the official “racing bicycle” standards when concerning uncovered projections, which, e.g., must be rounded for safety. Further, the 1:3 ratio does not limit other items including: brake levers, gear levers, bottle cages and other items; however, such elements with “knife-edge profile” shapes are not allowed.
[0007] To illustrate Regulation 1.3.024 (1:3 ratio), when using the maximum transverse dimension authorized for an element, namely 8 cm, the associated minimum transverse dimension is 8/3=2.66 cm. Likewise, when using the minimum transverse dimension authorized for an element, namely 2.5 cm, the associated maximum transverse dimension is 2.5×3=7.50 cm. For all intermediate options, the maximum to minimum transverse dimension ratio cannot exceed three.
[0008] Except for individual and team pursuit (kilometer and 500 time trials), only the traditional type of handlebars are authorized for use in massed-start road races, cyclo-cross and track competitions (under Article 1.3.022). Further, additional handlebar components or extension attachments are prohibited.
[0009] In contrast, for time trials on the road and track competitions the elements making up the frame are not restricted provided they fit freely inside a defined template (see regulations) and comply with the 1:3 ratio described above. (See comments on Article 1.3.021 and Article 1.3.020). Further, the bicycles may be fitted with an “additional handlebar” (extension) upon which elbow or forearm rests are authorized without these representing supplementary points of support (in contradiction of Regulation 1.3.008). The extension, as the name indicates, extends the handlebars in the horizontal plane and needs to be fitted with handgrips, which may be located on the handlebar extension horizontally, inclined or vertically. Nevertheless, the profile of the extension must conform to the 1:3 ratio in accordance with Article 1.3.024. Further, the extension must be fixed and not feature a system that would allow a change of length or angle during the race.
[0010] Although the use of handlebar extensions puts the rider in a more aerodynamic position for the road and track competitions, such position has unintended consequences. For example, because the rider's arms remain tightly held under the chest of the rider and slightly extended in a somewhat “superman” position, it becomes difficult for the rider to change this position or take her hands off the handle bar section without creating unwanted drag. Accordingly, when the rider needs water or other nutritional fuels during a race, the rider must shift their weight in order to reach for a bottle in a rack typically below their seat. Such shifting and reaching not only adds unwanted drag from the body's position, but may also cause a change in balance on the bike, resulting in stability issues. Further, because one must typically look in the direction of the water bottle to reach for it, the rider's attention is drawn away from the race and obstacles on the course—obviously increasing the risk for a serious accident due to any number of changed circumstances or unexpected events that require the rider's immediate attention. Although the odds of such unforeseen accident are low when a rider tries t reach for such items, even the most skilled rider will (at a minimum) experience a reduction in speed due to: (i) unwanted drag from change in optimal aerodynamic body position or angle; and (ii) decrease in pedaling momentum due to, e.g., lack in focus from sight diversion and/or changed bicycle stability from body movement.
[0011] Due to these inherent problems of current bicycle water bottle systems, there remains a need for a hydration and/or nutritional system that allows a rider to easily obtain the needed fuel with minimal movement and distraction. As an added consideration, the system should preferably improve aerodynamic performance; however, if necessary, it can still comply with the 1:3 ratio and other international bicycling regulations as outlined above by the UCI and other similar regulatory agencies.
BRIEF SUMMARY
[0012] Example embodiments of the present invention overcome the above-identified deficiencies and drawbacks of current bicycle hydration and nutrition systems. For example, embodiments described herein provide for an integrated hydration and nutrition container with the handlebars of a cycling system (e.g., a bicycle). Such integration allows a rider easy access to the nutritional value necessary for high performance competition with little to no movement required, thereby allowing the rider to maintain focus, balance, speed, aerodynamic efficiency. Further, embodiments provide for an aerodynamic hydration and nutritional center, which although integrated with the handlebars of a bicycle may conform to the international regulatory schemes, but can also be easily removed with, and if, the regulating authority does not allow such systems. Typically, the system is easily removable, if desired; yet holds firmly in place on the desired handlebar positioning during a ride.
[0013] Note that this Summary simply introduces a selection of concepts in a simplified form that are further described below in the Detailed Description. Accordingly, this Summary does not necessarily identify key features or essential aspects of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0014] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the invention. The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In order to describe the manner in which the above-recited and other advantageous features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0016] FIG. 1 illustrates an integrated handlebar and hydration/nutrition containment system with a suction tub used for ease in extracting the contents of the unit in accordance with example embodiments of the present invention;
[0017] FIG. 2 illustrates a top view of a extended handlebar system with a water/food container attached thereto and a alternative content access mechanism in accordance with other example embodiments described herein;
[0018] FIG. 3 is a side or front directional view of an integrated water/food storage unit and handlebar system in accordance with example embodiments described herein;
[0019] FIGS. 4-7 illustrate various views of example storage containment units, there attachment mechanisms, and international regulatory compliance considerations in accordance with varying exemplary embodiments described herein;
[0020] FIG. 10 illustrates an alternative attachment and design consideration of the handlebar storage containment system and content extraction system in accordance with other example embodiments described herein;
[0021] FIGS. 11 and 12 illustrate top and front views, respectively, of a varying design for a integrated handlebar containment unit in accordance with example embodiments of he present invention;
[0022] FIG. 13 illustrates an alternative handlebar system that can also utilize the integrated containment system as described in example embodiments herein;
[0023] FIG. 14 illustrates a integrated handlebar and containment unit that does not comply with a 3:1 ratio according the UCI standards, but still includes other advantageous aerodynamic and other properties described herein and in accordance with example embodiments;
[0024] In contrast, FIG. 15 illustrates a hydration/nutritional supplement container, which complies with the 3:1 ratio; yet still has added aerodynamic and other advantageous features described herein according to exemplary embodiments; and
[0025] FIG. 16 illustrates a fully integrated arm rest system, fuel container, and handlebars in accordance with exemplary embodiments described herein.
DETAILED DESCRIPTION
[0026] The present invention extends to methods, systems, and devices for a removable, yet integrated, storage container for a bicycle handlebar system. The storage container can hold most anything; however, embodiments generally consider its use as a water bottle, feed system, nutritional supplement, or other fuel resource holder. Although the following embodiments generally refer to the storage container as a water bottle or nutritional supplement storage container, any specific use of the contents of the storage container are used herein for illustrative purposes only and are not meant to limit or otherwise narrow the scope of the present invention unless otherwise explicitly claimed.
[0027] Turning now to the various Figures, e.g., as shown in FIG. 1 , example embodiments provide for a handlebar 120 configured to accept an improved handlebar section that provides an integrated, removable bicycle handlebar storage container system 100 , with storage unit(s) 105 for holding various items needed during a bicycle ride. As noted above, the storage unit(s) may hold any number of items, but typically hold water or fuel for human consumption. As such, in accordance with one example embodiment, the storage system 100 further includes a content extraction mechanism 112 , which connects to the storage unit(s) for ease in consuming the contents of the container(s) 105 with little or no movement.
[0028] For example, as shown in FIG. 1 , the extraction mechanism, may be a suction device such as a straw for sucking out the contents of the container(s) without the need for removal of the unit(s) from the bars themselves. Such suction unit may take the form of a straw or other plastic item. The item may be connected in any number of desired ways for proper ease in extracting the substance from the containment unit(s) 105 . For instance, the suction tube 112 may be connected to the bottom 125 of the storage device 105 , as shown in FIG. 1 . In such case, the tubing 112 will need to be securely fastened to the under portion 125 of the unit(s) 105 with leak proof seals as needed. Of course, there may be any number of places to connect such extraction mechanisms. For instance, the suction unit 125 may be included through the top of the units, similar to putting a straw in a lid of a drink. Alternatively, or in combination, the extraction unit or tubing 112 may be connected through the side of the bottle or units 105 with appropriate extensions there from, thus allowing a rider to consume the contents of the container(s) 105 while remaining in the desired aerodynamic position on the bicycle.
[0029] Of course, other example embodiments contemplate that the storage container or unit 105 may be accessed through alternative mechanisms. For example, as shown in FIG. 2 , the bottles 105 may include caps or lids 102 as a mechanism for accessing the contents of the containers 105 . Such lids may be any type of well known lid that attaches to the bottle 105 and seals the contents therein. For example, lids 102 may be snap on caps, screw caps, plug caps, or any other type of lid for securing the contents from inadvertent or unintentional leakage. In any event, the caps 102 will typically be of a form that provides easy access to the contents of the container 105 to ensure that the rider's discretion from her performance is minimal. Further, the lid will typically include some type of attachment mechanism to the bottle in order to not loose it when opening it on a ride.
[0030] Of course, other types of access mechanisms other than caps or straws are also contemplated herein. For instance, the access mechanism may be in the form of a lid for accessing contents of the container 105 other than liquid contents. For example, not shown in the current Figures, example embodiments consider that a lid may be formed in the top of the containers that flip open to allow one to get fuel or food supplements or any other items that one might wish to carry on a ride. In fact, example embodiments further contemplate a combination of access mechanisms. For example, as described in greater detail below, when the storage container resides internally within the handlebars, a combination of lid and suction member may be needed for access. For instance, the lid may allow access to a bladder that holds the contents of the actual container, and the suction device further provides a mechanism for easy extraction while operating the cycling unit. Accordingly, any specific type of lid or access mechanism for extracting the storage container or its contents as described herein is for illustrative purposes only and is not meant to limit or otherwise narrow the scope of the present invention unless otherwise specifically claimed.
[0031] FIG. 3 illustrates the potential aerodynamic features of the storage container 105 in accordance with other example embodiments. As previously noted, one advantageous feature of one embodiment is the ability to extend the handlebar shape to a more aerodynamic shape; yet still remain in compliance with UCI and other regulatory authorities. For example, as shown in FIGS. 4-9 , 14 and 15 , the shape of the bottle (especially when combined with the bars) may be of a toroidal shape to form a substantially elliptical cross section. Generally, the forward facing part of the container 105 will form a narrow part of the ellipsis, gradually increasing in depth to a width diameter or distance (e.g., the distance formed by the lines 7 or 8 in FIGS. 5 and 6 , respectively, or the width D or C shown in FIGS. 14 and 15 , respectively), which will typically be larger than the widest part of the handlebars (see, e.g., FIG. 9 , which shows a cusp) for forming fitting around the handlebar 120 itself and providing an aerodynamic flow of air or airfoil shape around therein. Of course, other types of shapes are also contemplated herein.
[0032] For example, the front of the bottle or container may be more rounded, e.g., as shown for example in FIG. 15 , than narrowly tapered one shown in, e.g., FIG. 6 . Further, the front of the bottle may vary or change in form, especially as it may form around other sections or parts of the handlebars 120 system. For instance, as illustrate in FIGS. 10 , 11 , 12 , the containment unit 105 may form as a single piece formed around the several parts of a bicycle steering section, e.g., the handlebars 120 and gooseneck as shown in these figures. Moreover, the shape, style, and width of the various portions may vary across the length of the containers 105 depending on the desired airflow and form fitting needs when integrated into the handlebar 120 system. Although not preferred (or shown in the diagrams), the front of the bottle can even take on a blunt or square shape or form. In fact, in one embodiment, the shape of the storage container resembles that of typical water bottles. Although this may not gain the advantage of the desired aerodynamic features described herein, it does allow the rider to still easily consume the content with little movement from the riding position. In other words, example embodiments contemplate most any shape, style, form or number of sections for a storage container 105 as integrated into a handlebar 120 system; and therefore, any specific shape, style, form or number as described herein is for illustrative purposes only and is not meant to limit or otherwise narrow the scope of the present invention unless otherwise specifically claimed.
[0033] As previously noted, regardless of the shape, style, form or number of the storage container 105 units, the container(s) 105 will generally form an integral part of the handlebar 120 system. As such, example embodiments contemplate an aspect ratio (i.e., width to length diameter) of the integrated container 105 and handlebars 120 to range from about 2:1 to 6:1—and preferably about 3:1 or 3 in order to comply with UCI standards. As noted, however, the integrated storage containment 105 and handlebar 120 system may take on other aspect ratios and should not be limited to those noted above unless otherwise specifically claimed.
[0034] For example, FIGS. 14 and 15 illustrate two cross sectional views of integrated storage containment unit(s) 105 and handlebar 120 system in accordance with two varying example embodiments. As shown in FIG. 14 , the aspect ratio of the width to length of the integrated system (i.e., storage unit 105 with the handlebars 120 ) may be non-UCI compliant (i.e., larger than 3:1 or 3). On the other hand, as shown in FIG. 15 , the aspect ratio of the integrated storage containment unit 105 with the handlebar system 120 may preferably comply with UCI regulations, i.e., be less than about 3. Further, while not wishing to be bound by theory, it is believed that good aerodynamic efficiency is achieved with the integrated storage container 104 and the handlebar system by countervailing aerodynamic factors of minimum frontal area and laminar or smooth airflow are balanced.
[0035] In fact, other example embodiments further contemplate other aerodynamic enhancements the overall integrated storage containment and handlebar system described herein. For example, the handlebars 120 may be specifically designed for the storage containment unit 105 and or vise versa. As such, the system will form a tightly integrated feature with optimal aerodynamic properties. Further, this also allows for tighter control and optimization of the overall integrated structure with varying considerations such as: the desired ratio of the width to length in order to meet UCI and other requirements; the amount of storage space in the container; the rigidity of the handlebars; optimal aerodynamic properties of the combination; etc.
[0036] As mentioned above, one example embodiment contemplates the incorporation of the storage unit 105 directly into the handlebar unit 120 . In this embodiment, the storage unit may comprise a bladder of sorts made from a malleable material such as rubber, plastic, cloth, animal or other organic material, or any combination thereof. The contents of the storage unit 105 may further be accessed by any well know mechanism such previously described such as a zip-lock sealer, zipper, cap, suction device, etc. On the other hand, accessing the storage unit within the handlebar section 120 may be done by a flap or door within the handlebar unit, or through access by one of the ends of the handlebars. Alternatively, the storage container 105 might be accessed through a sliding section of the bar that reveals the storage container therein. Of course, many other well know ways of incorporating a storage device within a generally solid unit are contemplated herein and the above gives merely some examples of mechanisms used in accessing the storage container and its contents when integrated internally within a handlebar system. For example, the storage unit may not necessarily have a separate bladder part as described above, but simply be formed within the handlebar section. As such, the above description of the storage unit internally formed within the handlebar system and the mechanisms for accessing such is used for illustrative purposes only and is not meant to limit or otherwise narrow the scope of the present invention unless otherwise explicitly claimed.
[0037] Further, other embodiments compensate or reduce the appearance of the discontinuity formed between the storage containment unit 105 and the handlebar 120 section by using aerodynamic trip edges or cusps formed in the container unit, handlebars system, or both. A correctly shaped trip edge or cusp, encourages a standing vortex, which advantageously creates a virtual surface of continuity between the storage container and the handlebars. For example, the use of a trip edge at the training edge of the containment unit promotes a favorable pressure gradient that acts as the extension of the container, further integrating it with the handlebar system. Similarly, the s cusp shape can be used like a flow trip to promote flow reattachment in a favorable pressure gradient, which will make the container less sensitive to changes in handlebar diameters or changes in wind conditions with varied levels of turbulence.
[0038] In other words, by making forming a trip edge or cusp at the trailing or other desired section of the containment unit, a trip flow causes a circulation or vortex in the area of discontinuity, which forms a smoother virtual surface for the flow field. This generates a low pressure, which will help flow attachment and reduce drag. Further, the virtual profiled integrated storage container and handlebar system helps control flow without the necessity of designed integration and manufacturing of either the storage container with the handlebar unit, or vise versa. In other words, the ability to provide a virtual or seamless integration of the storage container and handlebars enhances the desirability of the use of described embodiments of the present without regard to the type of handlebar system used. As such, example embodiments contemplate using any standard form of handlebars, e.g., those shown in FIG. 13 . More generally, example embodiments also consider the ability to provide a range of integrated units from universal systems (e.g., where one storage container can easily integrate with multiple handlebars, or vise versa) to highly specialized units (e.g., where the container is manufactured as a single unit within the handlebars, as described in more detail below with regards to other example embodiments.
[0039] Other embodiments also consider other design factors in optimizing performance with UCI and non-UCI regulations. For example, as shown in FIGS. 16 and 17 , the trailing edge 135 of the storage container 105 is slanted or tapered relative to the inside (gooseneck side) to outside (handlebar grip side) edges of the container. This may provide various advantageous including a more aerodynamic design, stability in holding the storage container 105 in place, or even merely for aesthetic purposes. Of course, other similar design considerations and varying shapes and edge forms are considered herein. For example, the storage containers may take almost any form that allows for ease in integration with the handlebar system. As such, any specific shape, size, form or other physical feature of the storage containment unit and integration system as described herein is for illustrative purposes only and is not meant to limit or otherwise narrow the scope of the present invention unless otherwise explicitly claimed.
[0040] Without regard to other design considerations noted herein, other example embodiments provide for various forms of attachment mechanisms for securing the storage container 105 to the handlebar 120 system. Although example embodiments generally consider attachment types for easy removal and reattachment of the storage container 105 to the handlebar system 120 , other example embodiments allow for more tightly affix the container to the handlebar unit.
[0041] For example, as shown in FIGS. 1 and 10 , when the containers use a straw or other suction device for extraction of the contents, ease in removal of the containment units may not matter as much as a desire to minimize the overall movement. In such instances, example embodiments consider more stable attachment mechanism, which usually do not allow for ease or quick removal. Such attachment mechanisms may include, without limitation: screws; bolts; pins; clamps; clips; straps; or other similar hardware.
[0042] On the other hand, example embodiments also consider the case were frequent removal of the storage container is preferred, which generally means less secure or stable attachment. For instance, if he storage unit are water bottles with flip caps or other opening mechanisms for drinking the contents thereof, then ease in removing (and reattaching) the bottle will generally be desirable. Accordingly, such attachment mechanisms may include, without limitation: magnets; Velcro; clips; snaps; grooved guides or channels; adhesive tape or glue; prongs; or other hardware. Of course, any combination of the attachment mechanisms is also contemplated herein.
[0043] In yet another example embodiment, the storage container may be adjustable relative to the handlebar unit in order to divert airflow as desired. For example, the storage container 105 may be fitted at an angle to allow airflow around the handlebar unit. In such embodiment, the rotation of the storage unit provides essentially a turning vane to move the flow of air towards or away from a rider or other parts of the cycling unit. Such airfoil adjustment allows for the reduction of the overall system drag or may serve to simply provide a rider with additional air-cooling when needed.
[0044] Still other example embodiment provide for the integration of the attachment mechanism with the storage container, handlebar system, or both. For example, as illustrated in FIG. 9 , the cusp shape area that joins or abuts the storage container with the handlebars may include a clamping feature, not shown, that snaps the water bottle or fuel container to the bars. Further, such mechanism may be integrated within the molding or manufacturing operation of the storage container, the handlebars, or both. Further, other embodiments consider the use of molding and or hardware combinations that secure the storage containers onto the handlebar unit. Of course, the attachment mechanism can also be partially or fully machined into the integrated system, e.g., pegs on the storage container that fit into holes drilled into the handlebar units. In addition, as mentioned above, the shape of the bottle itself or other external hardware or integrated pieces may also aid in the attachment and stability of the storage container into the handlebar system. For example, as shown in FIGS. 16 and 17 , the added length of the storage container unit as it extends onto the handle bar system may be used in aiding the rotational stability of the storage unit—especially for higher aspect ratios that will cause added potential energy or force in the rotational direction of the container around the handlebars. Of course, other hardware and formed features for assisting in the stability and ease in removal (and attachment) of the water bottle to the handlebar system are also contemplated herein; and therefore, any specific use of attachment mechanism, design shape, or hardware mechanism in describing such embodiments is used herein for illustrative purpose only and is not meant to limit or otherwise narrow the scope of the present invention unless otherwise explicitly claimed.
[0045] Note that many types of materials and combinations thereof are considered in forming the integrated storage container and handlebar system herein described. For example, the storage container may be made from polyurethane or other plastic materials, fiberglass material, metals and alloys, carbon fiber, or any other suitable material and combinations thereof. Further, the materials may be of a disposable form for a single use, or a more durable, long lasting material. Of course, the above gives a brief example of the many types of materials used in forming example embodiments described herein; and therefore, it is not meant to limit or otherwise narrow the scope of the present invention unless otherwise specifically claimed.
[0046] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | Embodiments described herein provide for an integrated hydration and nutrition container with or within the handlebars of a cycling system (e.g., a bicycle). Such integration allows a rider easy access to the nutritional value necessary for high performance competition with little to no movement required, thereby allowing the rider to maintain focus, balance, speed, and aerodynamic efficiency. In one embodiment, the system is easily removable, if desired; yet holds firmly in place (with also available airfoil adjustments) on the desired handlebar positioning during a ride. In another embodiment, the container resides within the handlebar unit itself. | 8 |
This is continuation-in-part of application Ser. No. 07/766,327, filed Sep. 26, 1991, now U.S. Pat. No. 5,188,417
BACKGROUND OF THE INVENTION
This invention pertains to an improved vehicle cover and more particularly to such a cover including storage means which also serve to anchor an end of the cover to the vehicle and which are useful with a variety of vehicles and in various locations within the vehicles.
It is known that sunlight damages the exposed surfaces of the interior of a vehicle. It is also known that when parked under direct sunlight, the vehicle's interior temperature rises due to the familiar greenhouse effect. This rise in temperature further damages the vehicle's interior. Furthermore, the hot air and the hot surfaces of the interior can prove uncomfortable for a person staying in or returning to the vehicle. Some articles in the vehicle such as magnetic media and electronic equipment can sometimes suffer from the elevated temperature as well.
In addition, when a vehicle is left to stand outside all night exposed to the elements, the finish on the vehicle will be dulled.
The general object of this invention is to provide sun protection for the interior of a vehicle by means of a highly effective, low cost, durable, easy to use, theft resistant and reflective sun protection cover to be deployed over the cabin of the vehicle.
The cover, its storage bag or pouch, and its attachment means for securing an end of the cover to an end of the vehicle are designed as a single integrated unit which significantly reduces the cost of the unit. It further makes the unit easier to use.
As shown herein the pouch is held firmly inside the trunk of the vehicle by plastic dipped hooks which engage openings in the trunk lid. The cover is deployed by being taken out of the trunk through the opening which is created between the trunk lid and the rear windshield or body of the vehicle when the trunk lid is opened. Accordingly, the deployment and storage of the cover can readily be handled by a single person requiring no special tools or the like. Since the cover is anchored or remains anchored securely at the trunk end thereof, it remains stable during deployment as well as during storage.
According to another feature of the invention, the cover uses the vehicle's own body parts to hold it in place when pulled over the cabin. At least one door of the vehicle is used to hold the cover in place by being closed onto it whereby the cover will fit underneath the upper portion of the door containing the window frame. The leading portion of the cover can be held in place by being tucked under the windshield wipers of the vehicle.
According to a further embodiment, the cover employs elastic strings disposed to be wrapped about the side view mirrors of the vehicle.
The foregoing design of the cover makes it substantially theft proof without requiring any specific tie-down or locks or alarms or the like. In the deployed position, the cover is firmly anchored to the interior of the trunk. With the trunk lid closed and locked it would be extremely difficult if not impossible to tamper or remove the cover from the vehicle. When the cover is stowed, the cover is safely locked within the trunk, concealed and out of sight.
SUMMARY OF THE INVENTION AND OBJECTS
In general as disclosed herein a storable vehicle cover for covering at least the cabin portion of a vehicle carries a storage means or pouch secured thereto to be disposed in the trunk of the vehicle in a manner anchoring the trailing edge of the cover when the cover is disposed onto the vehicle. The storage means or pouch remains affixed firmly inside the trunk of the vehicle. By opening the trunk lid of the vehicle the cover is in position to be readily removed from its associated pouch and fed from the trunk through the opening which is created between the raised trunk lid and the rear windshield or body of the vehicle.
In general it is an object of the present invention to provide an improved car cover for a variety of vehicles, including sedans, vans, and hatchbacks.
A protective vehicle cover according to the invention includes a sheet of strong, flexible, pliant material sufficient to overlay a substantial portion of the front windshield, rear windshield, and the side windows of a vehicle to be covered. The sheet carries a storage unit at one end thereof with the storage unit being anchored within a compartment of said vehicle. The compartment has a closure moveable between open and closed positions so that the sheet is clamped between the closure and the body of the vehicle when the closure is in its closed position.
The storage unit comprises a pair of panels joined together along a forward edge of each. One of the panels is movable between a first and a second position with respect to the other panel to form an open space therebetween for receiving the cover for storage therein.
The storage unit for the protective vehicle cover is mounted in a variety of vehicles and locations within the vehicles. For a sedan these locations include the floor of the trunk compartment of a vehicle and the rear sill of the trunk compartment of a vehicle. For a van, the location for the storage units include the rear closure door, where the protective sheet is disposed to be clamped between said rear closure door of the van and the body of said vehicle when said rear closure doors is in its closed position. For a hatchback, the storage unit is mounted in a rear storage compartment of a hatchback vehicle in locations such as the inside of the hatch door, the floor, the protective internal cover, and the rear sill.
A protective vehicle cover includes a sheet of strong, flexible, compliant material sufficient to overlay the front windshield, rear windshield and side windows of a vehicle to be covered. The sheet carries a storage pouch at one end thereof to be disposed within a compartment of the vehicle. The compartment has a closure member moveable between an open and a closed position. Means are provided for mounting the pouch from the interior surface of the compartment. The pouch has an opening thereto which is accessible for storing the sheet within the pouch.
The invention provides a method of protecting the interior and exterior of a vehicle of a type having a compartment accessible via a movable closure carried on a pair of laterally spaced hinges connected to the vehicle body. The method includes the steps of forming a sheet of material which is sufficient to overlay the front windshield, rear windshield and side windows of the vehicle, forming at one end of said sheet a storage pouch having top and bottom surface portions, yieldingly retaining said surface portions to be carried within the compartment of the vehicle, opening said compartment, removing said sheet from the pouch, feeding the sheet from the compartment onto the roof of the vehicle via an opening formed between the vehicle body and an edge of the closure between the hinges, clamping the sheet between the closure and the vehicle body to retain an end edge of said cover anchored inplace.
The method further includes the step of closing a side door in a manner to clamp a portion of the sheet covering the side window of the door between the vehicle body and the door to retain the sheet in a covering relation to the side window.
It is yet a further object of the invention to provide a car cover of the kind described having a reflective outer surface to minimize transmittal of heat into the vehicle.
It is yet an additional object of the invention to provide pie-shaped slits at the rear corners of the car cover associated with elastic strings bounding the space between the open end of the slits and extending further along the bottom edge of the cover whereby the cover assembly can accommodate a variety of sizes of vehicles.
Yet an additional object of the invention is the provision of a car cover having a relatively large open central region to permit wind to readily escape from beneath when it is being deployed.
Yet a further object of the invention is the provision of an improved method of deployment of a car cover onto a vehicle.
The foregoing and other objects of the invention shall become more readily evident from the following detailed description of preferred embodiments when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of a car cover according to the invention;
FIG. 2 shows the rear of a vehicle with its trunk raised and a storage pouch portion of the car cover disposed in place;
FIG. 3 shows a side elevation of a vehicle trunk containing a car cover stored therein;
FIG. 4 shows a side elevation showing the removal of the car cover from the pouch carried by the closure of the trunk;
FIG. 5 shows a perspective view showing how the car cover can be fed through the opening between the trunk lid and the body of the vehicle;
FIG. 6 shows a side elevation view of the construction shown in FIG. 5 illustrating the feeding of the car cover through the opening formed between the trunk lid and the vehicle body;
FIG. 7 shows a vehicle covered and protected by a car cover of the kind described according to another embodiment of the invention;
FIG. 8 shows a car cover disposed in place on a vehicle according to the first embodiment; and
FIG. 9 shows an enlarged detail in side elevation of another embodiment of the invention.
FIG. 10 shows a side sectional elevation view of a sedan with a car cover stored in a pouch on the rear sill of the trunk compartment.
FIG. 11 shows a side sectional elevation view of a sedan with a car cover stored in a pouch on the rear sill of the trunk compartment
FIG. 12 shows a side elevation view of a van with a car cover stored in a pouch located on the inside surface of the rear hatch door and threaded through the opening between the bottom of the hatch door and the body of the van.
FIG. 13 shows a side elevation of a van with a car cover stored in a pouch located on the inside surface of the rear hatch door and threaded through the opening between the top of the hatch door and the rear edge of the roof of the van.
FIG. 14 shows a side sectional elevation view of a van or hatchback vehicle with a car cover stored in a pound located on the floor surface of the rear cargo area thereof.
FIG. 15 shows a side sectional elevation view of a hatchback vehicle with a car cover stored in a pouch located on the inside surface of a privacy screen for the rear cargo area thereof.
FIG. 16 shows a side sectional elevation view of a hatchback vehicle with a car cover stored in a pouch located on the outside rear sill of the rear cargo area thereof.
FIG. 17 shows a side sectional elevation view of a hatchback vehicle with a car cover stored in a pouch located on the inside surface of the rear hatch door.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferably the nature of the material employed in the car cover 10 should be chosen to be wear and tear resistant, weather resistant, lightweight, thin, foldable, stain resistant, washable, non-shrinking and able to hold print. One such material which provides the foregoing qualifications includes nylon.
Of the foregoing characteristics the sheet of material forming cover 10 should primarily be strong, flexible, and pliant. Cover 10 carries a storage unit or pouch 11 at the trailing end thereof as shown in FIG. 1. Storage unit 11 comprises a pair of fabric panels 12, 13. Panels 12, 13 are mutually joined together along a forward edge of each panel. One of panels 12, 13 is movable between raised and lowered positions with respect to the other said panel to form an open space therebetween for receiving the car cover 10 to be stored therein. Preferable, the trailing edge of both panels 12, 13 carries a flexible reinforcing material 16 sewn into the edge margin thereof so as to both reinforce the edge margin of panels 12, 13 and to permit the edge margin to flex when removing cover 10 therefrom.
Cover 10 includes a tail piece 17 of essentially flat material captured between the leading edge margins of panels 12, 13 of storage unit 11. Thus the leading edge margins 14 of panels 12, 13 are sewn together therealong and capture tail piece 17 therebetween.
Cover 10 has a sufficient scope so as to cover the trailing windshield, the leading windshield, and side windows of the vehicle to which it is to be employed.
Finally, storage unit 11 includes a plurality of plastic dipped hooks 18, 19 to be connected to the underside of trunk lid 21.
Thus, trunk lid 21 has been provided with the usual strengthening or reinforcing bars 22. Bars 22 as shown have been formed with a number of openings 23 therein which can be engaged by the ends of hooks 18, 19. As thus arranged, a storage pouch for use in a vehicle has been provided comprising confronting flexible side panels 12, 13 wherein the side panels are joined along a given edge 14 while an opening is formed along the opposite edge of pouch 11. A plurality of hooks 18, 19 coupled to pouch 11 serve to support same from the underside of the interior of a compartment of the vehicle. Hooks 19 each support the trailing edge of a pair of edges 16 of pouch 11 by means of an elastic band 24. Thus band 24 serves to pull the trailing corners of panels 12, 13 together while hook 19 supports both of the trailing edges.
A pair of spaced apart hinges 26 serves to support trunk lid 21 for movement between lowered and raised positions.
As shown in FIGS. 3 and 4 with trunk lid 21 in its raised position an opening 27 is defined between the leading edge of trunk lid 21 and the body of the vehicle.
As shown FIG. 3, the tail piece 17 joins the balance of the cover 10 to pouch 11. Accordingly a very small length 10a of cover 10 will underlie pouch 11 when the cover has been stored therein. When it is desired to employ cover 10 to protect the interior and exterior of a vehicle of a type having a compartment such as the trunk accessible via a moveable closure carried one pair of laterally spaced hinges connected to the vehicle body, the method of installing the cover comprises the steps of forming a sheet of reflective material such as cover 10 which is sufficient to overlay the front windshield, rear windshield and side windows of the vehicle. The next step is to form at one end of the sheet a storage pouch having a top and bottom surface portions. Next the surface portions are yieldingly retained to be carried within the compartment of the vehicle from the underside of the closure thereof. The next step is to open the compartment, then remove the sheet of material forming cover 10 from the pouch 11. Next the sheet of material forming cover 10 is fed from the trunk compartment onto the roof of the vehicle via opening 27 formed between the vehicle body and an edge of the closure 21 and defined between hinges 26. The next step is to clamp the sheet of material forming cover 10 between closure 21 and the vehicle body to retain an end of the wheel opening for a vehicle. (See FIG. 7.)
As mentioned above, in order to avoid capturing the substantial gust of air beneath cover 10 as it is being applied to the vehicle and thereby make it difficult to handle, a relatively large opening 33 has been formed in the top of cover 10.
Means for anchoring the forward end of cover 10 to cover with the leading windshield of the vehicle includes the step of simply tucking the leading end edge margin of cover 10 beneath the windshield wiper blades 34 as shown in FIG. 8.
The embodiment shown in FIG. 8 also shows the concept of closing and locking the side doors 36 of the vehicle out to the downwardly depending portion of cover 10 so as to cover the door windows from the inside.
According to another embodiment as shown in FIG. 7, the leading end of cover 10 can be secured by means of elastic straps 37 disposed to be hooked about the outside mirrors on opposite sides of the vehicle such as mirror 39.
Thus cover 10 can be clamped by the side doors of the vehicle and locked, whereby the sides serve to cover the side windows while the vehicle remains locked.
From the foregoing it will be readily evident that there has been provided an improved car cover capable of being locked securely to the vehicle and in which the car cover carries its own storage pouch within a compartment of the vehicle.
In addition to the above, it will be evident that the number of appropriate openings such as for antenna and the like can be located variously through the cover.
The side edges of cover 10 further include elastic drawstring bands 30, 35 serving to accommodate variations in the size of the cabin portion of various vehicles.
In addition, it will be evident that pouch 11 can also be provided by employing a single panel 12 located closely in confronting relation to the underside of trunk lid 21.
Thus, as shown in FIG. 9, a single panel 12' hung from hooks 18', 19' disposes panel 12' in confronting relation with respect to the underside of trunk lid 21'. The trailing edge margin 16' can flex away from trunk lid 21' to accommodate the storage of a car cover therebetween.
FIGS. 10-17 illustrate a number of examples of a car cover being used with a variety of vehicles and locations within each type of vehicle. For example, the vehicles include sedan-type vehicles as described herein above, vans, and hatchbacks. The pouch for containing the cover can be mounted in a variety of places within a vehicle. For example, in a sedan, the pouch can be mounted to the inside surface of the truck lid or to various other places within the trunk on the trunk deck and rear sill. Similarly, the pouch can be mounted in various places within a hatchback or a van vehicle, as described herein below. Mounting of the pouch to the various locations is accomplished, for example, using a plurality of straps and hooks as discussed previously. Deployment and storage of the car cover is similar to that described herein above.
FIG. 10 shows a sedan 50 with a car cover 52 stored in a pouch 54 located on the deck 56 of the trunk compartment 58. The car cover is threaded between the rear edge of the truck lid 60 and the body of the vehicle.
FIG. 11 shows a sedan 60 with a car cover 62 stored in a pouch 64 located on the rear sill 66 of the trunk compartment 68.
FIG. 12 show a van-type of vehicle 70 with a car cover 72 stored in a pouch 74 located on the inside surface of the rear hatch door 76 and threaded through the opening between the bottom of the hatch door 76 and the lower body of the van 70. The sheet of material forming the cover 72 is fed from the pouch in the van compartment onto the roof of the vehicle in several ways. As illustrated one way is to feed the cover through the opening formed between the vehicle body and the bottom of the rear hatch door closure with the cover being held between the rear hatch door and the lower body of the van 70.
FIG. 13 shows a van 80 with a car cover 82 stored in a pouch 84 located on the inside surface of the rear hatch door 86 and threaded through the opening between the top of the hatch door 86 and the rear edge of the roof of the van 82.
FIG. 14 shows a van or hatchback-type vehicle 90 with a car cover 92 stored in a pouch 94 located on the floor or rear deck surface 96 of the rear cargo area 98 of the vehicle.
FIG. 15 shows a hatchback-type vehicle 100 with a car cover 102 stored in a pouch 104 located on the inside surface of a privacy screen 106 for covering the rear cargo area 108 of the hatchback.
FIG. 16 shows a hatchback vehicle 110 with a car cover 112 stored in a pouch 114 located on inside surface of the rear sill 116 of the rear cargo area 118 of the hatchback.
FIG. 17 shows a hatchback vehicle 120 with a car cover 122 stored in a pouch 124 located on the inside surface of the rear hatch door 126 of the vehicle. The cover 122 is deployed through the space between the top of the door 126 and the rear edge of the roof of the vehicle, as illustrated.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A storable cover for covering the cabin portion of a variety of vehicles, such as sedans, vans, and hatchbacks, carries storage means secured thereto to be disposed in a suitable compartment of the vehicle. The trailing edge of the cover is anchored inside the vehicle when the cover is disposed onto the vehicle. The storage means is affixed firmly inside the trunk or other rear compartment of the various vehicles, such as for example, sedans, hatchbacks, and vans so as to locate part of the over assembly within a locked compartment. The cover is deployed by being taken out of the storage means and fed from the trunk through the opening which is created between the raised closure member for the compartment and the body of the vehicle. | 1 |
FIELD OF THE INVENTION
The present invention relates to a valve especially a throttle valve, as well as to a method of operating the valve, a method of manufacturing the valve and to use of the valve in the field of weaving, e.g. in jet weaving. The present invention also relates to a weaving loom comprising the valve and a method of weaving using the valve.
BACKGROUND TO THE INVENTION
In an air jet weaving system, compressed air is used to draw weft threads from supply spools and to blow them into the shed of an air jet loom. A set of relay nozzles is used to support the movement of the weft thread across the shed, which may be several meters in width. Additional nozzles at the far end of the shed may stretch an inserted thread during a weaving operation. An example air jet loom is described in U.S. Pat. No. 4,534,387.
It is known to adjust the airflow to the main or to the relay nozzles according to the kind of weft thread to be woven. For example, a smooth and strong filament yarn can be woven with a high airflow at the relay nozzles while a weak spun yarn, or a spun yarn with several irregularities, can be woven only with a lower airflow at the relay nozzles. In order to successively insert two or more kinds of weft threads, the airflow of the relay nozzles can be set at a value required by the weakest type of weft yarn so that the weft yarn is not blown apart, broken or damaged.
U.S. Pat. No. 4,534,387 provides two airflow rates for the relay nozzles and selects the correct airflow such that a yarn will not be blown apart and such that the yarn will be inserted across the shed to arrive timely at the other side or far end of the shed. The weaving machine speed is adapted to suit to the slowest yarn. This machine requires a separate pressure-reducing valve for each required airflow rate.
U.S. Pat. No. 6,062,273 describes an electrically actuated throttle valve for an insertion nozzle. The throttle valve comprises a plunger which is movable, in a linear direction, within a bore hole. The plunger can be positioned at a desired distance from a valve seat. This type of valve is relatively slow to operate. In situations where the airflow rate needs to be varied for each insertion, the valve has to operate in a period of less than 35 msec. A second problem with this type of valve is that it has a rubber sealing ring which surrounds the plunger to prevent compressed air from escaping from the valve. This sealing ring is prone to wear and thus this type of valve has a limited life time when used in situations where the airflow rate needs to be varied for each insertion.
It is desirable to have a reduced number of valves as these valves are expensive and are volume/area consuming items. It is also desirable to provide a valve which has a long life time and which does not wear so rapidly. Further, it is also desirable to have a rapidly operating valve.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved valve as well as a method of operating the valve, a method of manufacturing the valve, use of the valve in the field of weaving, e.g. in jet weaving, a weaving loom comprising the valve and a method of weaving using the valve. An advantage of the present invention is rapid speed of operation allowing airflow rate to be varied for each insertion and even during an insertion of a weft thread in a weaving loom.
A first aspect of the present invention provides a valve comprising:
a housing having a fluid inlet for receiving a flow of compressed fluid and a fluid outlet;
a flow duct movably mounted with respect to the housing, the duct having a fluid inlet for receiving a flow of compressed fluid and a fluid outlet, the fluid outlet being positioned around at least a part of the circumference of the duct and being dimensioned to provide a different flow rate at different sections or positions around the circumference of the duct;
the fluid outlet of the housing being alignable with a portion of the fluid outlet of the duct to provide a flow rate related to the relative position of the portion of the fluid outlet of the duct and the fluid outlet of the housing; and,
a drive element for moving the duct with respect to the housing such that a desired portion of the fluid outlet of the duct aligns with the fluid outlet of the housing. The valve may operate as a so-called throttle valve.
A valve of this kind has an advantage of being quickly movable into a desired relative position in order to regulate fluid flow through the valve. The duct can be formed with a thin tubular wall which makes the duct lightweight and with low inertia. A valve having a tubular duct having a fluid outlet allowing a different fluid flow around the circumference of the duct allows to dimension the outlet of the duct in a simple manner to provide a different fluid flow rate through the valve. The rapid speed of operation allows a fluid flow rate to be varied at each insertion and even during the insertion of a weft thread. The valve is designed to have a long operational lifetime as, even if the outer surface of the duct wears, the outlet will not substantially change in size and the throttling effect will remain substantially the same.
It is preferred that the valve comprises a flow duct mounted rotatably with respect to the housing and a drive element for rotating the duct with respect to the housing. The duct of such a valve only needs to be rotated by a small angular distance, which can be achieved rapidly and reliably. Such a movement can normally be done more quickly than a movement in a valve which operates by linear movement along a borehole.
It is preferred that the valve is not provided with a seal with moving parts which could wear and become unreliable. Particularly, there is no seal provided with respect to the flow duct. The valve can have a means for impeding fluid flow by an amount determined by the position of the fluid outlet of a duct. To this end or in applications where an on-off function is required, a shut-off valve can be positioned downstream of the throttle valve.
It is preferred that the drive element, such as a motor and coupling device, is positioned within the flow path through the valve. This has an advantage of avoiding the need for a seal between a moving valve element and the housing to prevent fluid escaping from the housing. It also has an advantage of cooling the drive element.
Preferably, the drive means, such as a motor, has a drive shaft which is mounted coaxially with the longitudinal axis of the duct.
The fluid inlet of the duct can be located in an end face of the duct. More particularly, the inlet may be positioned around the circumference of the duct at a position spaced along the duct from the fluid outlet and can take the form of a set of apertures, e.g. holes or slots in the wall of the duct. This allows the drive element to connect to the end face of the duct and to use a duct with a small the diameter, which further reduces the weight of the duct and its moment of inertia. This improves the ability to quickly move into a desired angular position.
The fluid outlet of the duct can comprise a slot around a part of the circumference of the duct or a set of holes, with the size of individual holes and/or the density of holes in the set differing around the circumference of the duct.
In order that the outlet of the duct can maintain a simple fitting to the fluid outlet of the housing through a range of angular positions, it is preferred that both the flow duct and the part of the housing in the region of the fluid outlet are cylindrical. The remainder of the duct can be of a different shape although, for ease of manufacture and cost, it is preferred that the entire duct is substantially cylindrical.
The invention has a particularly advantageous application in the field of air jet weaving but the invention is not limited to this application.
The use of valves according to the invention in an airjet loom also allows use of one air tank for all the relay nozzles and also for the main nozzles. Of course a limited number of air tanks may still be used that can supply air at a given pressure to a respective relay or to a respective main nozzle via a valve according to the invention.
Further aspects of the invention provide a controller for controlling operation of a valve according to the invention. The control functionality described here can be implemented in software, hardware or a combination of these. Accordingly, another aspect of the invention provides software for controlling operation of the valve. The software may be stored on an electronic memory device, hard disk, optical disk or other machine-readable storage medium. The software may be delivered as a computer program product on a machine-readable carrier or it may be downloaded directly to the controller via a network. Further aspects of the invention include a manufacturing method for such a valve, a weaving loom comprising such a valve and a method of operating such a valve.
A further aspect of the invention provides a valve assembly comprising:
a housing having a fluid inlet for receiving a flow of compressed fluid, a fluid outlet and a flow path joining the inlet and the outlet;
a valve member comprising a tubular flow duct movably mounted within the flow path which is operable to regulate flow along the flow path by positioning the fluid outlet of the duct, more particularly by aligning a portion of the fluid outlet, with respect to the outlet of the housing; and,
a drive element for operating the valve member, the drive element being mounted in the flow path.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be described with reference to the accompanying drawings in which:
FIG. 1 schematically shows a jet weaving machine in which the invention can be used;
FIG. 2 shows a first embodiment of a throttle valve for use in the machine of FIG. 1 ;
FIG. 3 shows a second embodiment of a throttle valve for use in the machine of FIG. 1 ;
FIG. 4 shows a cross-section of a variant of a duct as in FIG. 3 near its outlet;
FIG. 5 shows the outlet of the valve shown in FIG. 3 in more detail, and;
FIG. 6 shows a third embodiment of a throttle valve for use in the machine of FIG. 1 .
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but the invention is only limited by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. Where the term “comprising” is used in the present description and claims, it does not exclude other elements or steps. Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.
The present invention will mainly be described with reference to the use of a throttle valve in a weaving loom. Other applications of such a valve are in textile machines whereby a different fluid flow through the valve is required to provide a different fluid flow through a nozzle or similar device of the textile machine. In addition, the term “throttle valve” should not be interpreted as including any limitations other than those in the attached claims.
FIG. 1 shows an overall schematic view of a weft insertion system of an air jet weaving loom. Three main jet nozzles 2 a , 2 b , 2 c and three additional main jet nozzles 2 d , 2 e , 2 f are shown. Each main nozzle 2 a , 2 b , 2 c , 2 d , 2 e , 2 f is supplied with air from a reservoir 5 via an adjustable throttle valve 11 a , 11 b , 11 c , 11 d , 11 e , 11 f and a shut-off valve 10 a , l 0 b , 10 c , 10 d , 10 e , 10 f which are described more fully below. The reservoir 5 comprises pressurised air at a given pressure. A weft preparation device 7 a , 7 b , 7 c draws off a weft thread 8 a , 8 b , 8 c from a corresponding yarn supply spool 9 a , 9 b , 9 c . Each supply spool 9 a , 9 b , 9 c may be provided with a different kind of weft thread, e.g. weft threads having different properties, such as e.g colour or thickness. The weft preparation device 7 a , 7 b , 7 c stores the weft thread 8 a , 8 b , 8 c on a winding drum and releases the required length of the weft thread 8 a , 8 b , 8 c at the proper moment in the weaving cycle to be inserted into the shed 1 by means of the associated jet nozzles 2 a , 2 d , the associated jet nozzles 2 b , 2 e or the associated jet nozzles 2 d , 2 f . The shed 1 is formed in a known manner between two planes of warp threads. The weft threads 8 a , 8 b , 8 c may be inserted in the warp shed 1 according to a predefined sequence which is programmed in controller 20 . Several sets of relay nozzles 4 a , 4 b , . . . , 4 x are positioned across the shed 1 , and serve to carry a weft thread 8 a , 8 b , 8 c across the shed 1 . The relay nozzles 4 a , 4 b , . . . , 4 x are supplied with air from reservoir 5 via a further throttle valve 13 a , 13 b , . . . , 13 x and shut-off valve 12 a , 12 b , . . . , 12 x . At the far end of the shed 1 there is a so-called stretching nozzle 3 which serves to stretch an inserted weft thread 8 a , 8 b , 8 c . This nozzle 3 is also supplied with air from reservoir 5 via a further throttle valve 15 and shut-off valve 14 . Controller 20 operates the throttle valves 11 a , 11 b , 11 c , 11 d , 11 e , 11 f , 13 a , 13 b , . . . , 13 x , 15 and shut-off valves 10 a , 10 b , 10 c , 10 d , 10 e , 10 f , 12 a , 12 b , . . . , 12 x , 14 to provide a required air flow rate at each moment in the weaving cycle during the weaving operation. For a desired weaving pattern, controller 20 has a set of instructions which determine, amongst others, the required weft threads 8 a , 8 b , 8 c , airflow rates for the nozzles, and also valve settings and timings for the throttle valves 11 a , 11 b , 11 c , 11 d , 11 e , 11 f , 13 a , 13 b , . . . , 13 x , 15 and the shut-off valves 10 a , 10 b , 10 c , 10 d , 10 e , 10 f , 12 a , 12 b , . . . , 12 x , 14 . Further a weft thread detector 6 is provided at the far end of the shed 1 in order to determine the arrival of the weft thread 8 a , 8 b , 8 c.
FIG. 2 shows a first embodiment of the throttle valve 13 a according to the present invention and shut-off valve 12 a in more detail. The throttle valve 13 a comprises a housing 50 which connects, in a fluid-tight manner, to an air reservoir 5 . The housing 50 comprises a fluid inlet 54 for receiving a flow of compressed air and a fluid outlet 55 . The fluid-tight seal is provided by bolts 52 and a sealing ring 57 . Housing 50 has a channel 51 , e.g. a bore hole in which a tubular duct 60 is mounted. In this embodiment, duct 60 comprises a thin-walled tube which is cylindrical along its entire length, although other shapes are possible. In a preferred embodiment the tube is formed of metal with a wall thickness of about 0.2 mm or more particularly with a wall thickness less than 1 mm. A drive element, more particularly a motor 70 is mounted between the air reservoir 5 and channel 51 of the housing 50 . A drive shaft 72 extends from the motor 70 and the drive shaft 72 is connected, via a coupling device 74 , to the upstream end of the duct 60 . The drive shaft 72 is aligned with the longitudinal axis 61 of the duct 60 . Duct 60 is supported at the upstream end by the drive shaft 72 and coupling device 74 , and at the downstream end by a sleeve or bearing 58 which fits between the duct 60 and housing 50 . The bearing 58 is formed as a tubular element that is fixed, e.g. glued, into the channel 51 of the housing 50 . The housing 50 has a fluid outlet 55 near the upper face of the housing 50 , e.g. a circular bore hole or a slot-like opening. The fluid outlet 55 comprises an opening in the bearing 58 which is situated in the prolongation of an opening 55 in the housing 50 . The air reservoir 5 can be connected in a known manner to an air supply line (not shown). The housing 50 can be mounted to the frame 53 at a place adjacent to an associated nozzle of the loom.
Duct 60 has a set of inlet holes 62 at its upstream end. Each of the holes 62 extends from the outer surface of the wall of the duct 60 to the hollow interior of the duct 60 . In this embodiment the holes 62 are located around the entire circumference of the duct, along a band which is almost 50% of the total length of the duct 60 . The number of holes 62 is chosen so as to permit, in use, a good flow of air into the interior of the flow duct 60 , while maintaining sufficient strength of the duct 60 to withstand air pressure and rapid movement of the duct 60 . At the downstream end of the duct 60 , a V-shaped slot 65 is defined in the duct 60 . The slot 65 extends from the outer surface of the wall of the duct 60 through to the hollow interior. The slot 65 extends partially around the circumference of the duct 60 . Clearly, the circumferential length of the slot 65 is limited to a part of the circumference of the duct 60 , otherwise it would dissect the duct 60 . The V-shaped slot 65 aligns with the outlet 55 of the housing 50 . The outlet 55 is dimensioned such that it overlaps only a portion of the slot 65 . As noted above, duct 60 is rotatable about longitudinal axis 61 . In use, motor 70 turns drive shaft 72 , and thus tube 60 , into a particular angular position. The position of the slot 65 with respect to the outlet 55 defines what part or portion of the slot 65 is aligned with the outlet 55 and thus regulates how much air can flow from the air reservoir 5 , through the duct 60 and through the outlet 55 . In this way it may be possible to regulate the air flow through the outlet 55 between almost no air flow and maximum air flow, e.g. creating a flow through opening from the duct 60 to the opening 55 between 0% or 100% of the opening of the outlet 55 . Of course, according to a variant the flow through opening may also be between for example 20% and 100% of the opening of the outlet 55 . The duct 60 is shaped or dimensioned to provide a different flow rate at different sections around the circumference of the duct 60 , e.g. by the shape of the slot 65 around the circumference of the duct 60 .
A shut-off valve 12 a (shown schematically) is mounted downstream of the throttle valve 13 a . A plunger 83 and valve member 82 act on a valve seat and are normally biased into a closed position (as shown) by a spring 84 . The valve member 82 can be moved, e.g. electromagnetically, against the bias of spring 84 into an open position to allow air to flow from the outlet 55 to the outlet 88 . Outlet 88 connects to a main nozzle or to a relay nozzle as shown in FIG. 1 .
FIGS. 3-5 show a second embodiment of the throttle valve 13 b and shut-off valve 12 b . The main differences are in the design of the inlet and outlet of the duct 60 . In this embodiment the inlet comprises a series of slots 62 A. As shown more fully in FIG. 3 , adjacent rings of slots 62 A are offset from one another. For example, in this embodiment the housing 50 does not include a separate bearing element and the downstream end of the duct 60 is guided directly into the housing 50 .
The outlet 65 A of the duct 60 comprises a set of holes which form a band around part of the circumference of the duct 60 . The set of holes 65 A are arranged such that the achievable flow rate gradually increases at different sections around the circumference of the duct 60 , thus allowing to achieve a different flow rate or flow through opening of the valve by rotating the duct 60 with respect to the outlet 55 of the housing 50 , from one end of the outlet 65 A to the other. FIGS. 4 and 5 each show a set of holes 65 A in more detail. It will be appreciated that the pattern of FIG. 5 , which is shown as a plan view, would be wrapped around the outer wall of the duct 60 . At a first end of the outlet 65 A of the duct 60 , the holes have a small diameter. In this example a sub-set 91 have a small diameter (e.g. 0.25 mm). As one moves towards the second end of the outlet the diameter of each hole increases and the number of holes increases. A second sub-set of the holes has a larger diameter (e.g. 0.5 mm.) A sub-set 92 A of the holes at this diameter are aligned in a linear manner while a second sub-set 92 B of the holes at this diameter are staggered about a centre-line. This staggering increases the achievable flow compared to the linear alignment, while maintaining the strength of the duct 60 . A third sub-set 93 of holes have a larger diameter (e.g. 1.1 mm) and a final sub-set 94 of holes have the largest diameter (e.g. 1.5 mm). In this final sub-set 94 the holes are arranged so that, as one moves in the direction 98 by rotating the duct 60 , there is an increasing number of holes in each row that in use will be arranged in alignment with the outlet 55 of the housing 50 . This modified form of outlet 65 A of the duct 60 has an advantage in that it maintains the strength of the duct 60 better than a slot 65 and can be provided around a greater portion of the total circumference of the duct 60 . Furthermore, the outlet 65 of the duct 60 can be manufactured precisely, more particularly the holes of the outlet 65 A can be manufactured more precisely than the slot 65 in FIG. 2 .
In FIG. 5 also possible positions of the outlet 55 of the housing 50 are shown with respect to the outlet 65 A of the duct 60 . As shown in full lines the outlet 55 of the housing 50 is arranged with respect to the holes of the outlet 65 A of the duct 60 in such a way that the flow through the duct 60 and the outlet 55 of the housing 50 is almost 100% of the flow through a free outlet 55 , while in the position shown in dashed lines the outlet 55 of the housing 50 is arranged in such a way that the flow through the duct 60 and the outlet 55 of the housing 50 is only a fraction of the flow through a free outlet 55 .
Although FIGS. 2 and 3 show a different inlet and a different outlet, either of these modifications can be used independently of the other, e.g. combinations of embodiments of FIGS. 2 and 3 are possible.
FIG. 6 shows a further embodiment of the invention. In FIG. 6 the duct 160 has a conical shape, with a wide mouth 161 at the upstream end and a narrower, cylindrical section 162 at the downstream end. The downstream end 162 and outlet 65 A operate in the same manner as described above. This alternative form of inlet has the effect of funnelling airflow towards the section 162 . The mouth 161 provides an easy path for airflow into the interior of the duct 160 and thus there is no need for any holes or slots ( 62 , 62 A) in the wall of the duct 160 . As in the other embodiments, duct 160 is rotatable about its longitudinal axis 61 . A motor 70 has a drive shaft 72 which is aligned with the longitudinal axis 61 . A set of arms forming a coupling device 73 connect the drive shaft 72 to the duct 160 . There can be two, preferably three or more arms 73 . Air can freely flow between the set of arms into the interior of duct 160 . It can be seen that this embodiment is more complex to manufacture compared to a cylindrical tube 60 shown in the previous embodiments.
As described above, the entire motor 70 , drive shaft 72 , coupling device 73 , 74 , and duct 60 , 160 are mounted in the air flow path between the air reservoir 5 and outlet 55 of the housing 50 . This has the advantage that a flow of air through the valve cools these parts and prevents overheating. It also means that no seal is required between the moving valve member, more particularly duct 60 , 160 and the external atmosphere.
According to an alternative (not shown) the air flow can also flow through the motor 70 itself instead of around the motor 70 as shown in FIGS. 2 , 3 and 6 . To this end, the drive shaft 72 of the motor 70 may be made of a hollow shaft or the motor 70 may contain channels to allow the flow of air to pass along the motor 70 .
It is necessary to provide power and a control signal to the motor 70 via a control cable 40 and a connector 41 . This control cable 40 can be fitted through a borehole in the wall of the housing 50 . The borehole should be sealed against air escape, such as by a fluid-tight seal. The sealing requirements are simple since the control cable 40 is arranged stationary. This control cable 40 can according to an alternative embodiment be fitted through a borehole (not shown) in the wall of the reservoir 5 .
Friction between the duct 60 and the portion of the housing 50 in the region of the outlet 65 can be minimised by a copper or polymer bearing ring 58 in which the duct 60 will rotate. The bearing ring 58 comprises an opening 59 arranged mainly in the prolongation of the opening 55 of the housing 50 . Even if friction occurs, the heat generated due to this friction will be taken up by the airflow passing through the throttle valve 13 a , 13 b . Although it is not expected that the throttle valve 13 a , 13 b will unduly increase temperature, warm air has been found to have a beneficial effect of aiding weft insertion. It is possible that an airflow can flow between the bearing ring 58 and the duct 60 . This airflow will not be disadvantageous because normally this airflow will be small with respect to the airflow through the outlet 65 of the duct 60 and will not or only slowly change in time.
The position of the duct 60 of the throttle valve 13 a , 13 b is determined by motor 70 . Motor 70 can be a stepper motor with a suitable number of steps to permit a required degree of control of the airflow rate. Alternatively the motor 70 can be a servomotor, e.g. a DC servomotor. Feedback of the angular position of duct 60 can be provided from an encoder attached to the duct or to the drive shaft 72 of the motor 70 , e.g. an optical encoder (not shown). It is also possible to use an air flow sensor at the valve outlet 88 or at the outlet 55 of the housing 50 to generate a feedback signal for the air flow. It is also possible to use a pressure sensor at the outlet 88 or at the outlet 55 of the housing 50 .
An embodiment has been operated with a stepper motor having a total of 80 steps, with 20 steps for high airflow and 60 steps for low airflow. A controller 20 is programmed with the relationship between, on the one hand, the angular position of the drive shaft 72 or the timing of the insertion cycle, and hence angular position of the duct 60 , 160 , and, on the other hand, the flow rate that this achieves. The position of the throttle valve 13 a , 13 b is operated in coordination with the main controller 20 for the air jet loom to set the air flow to a desired rate at a desired time. A control function 22 for the motor 70 , e.g. the different motors 70 of the throttle valves 13 a , 13 b , can form part of the overall controller 20 of the machine. The control function 22 can receive an input indicative of the required airflow rate, e.g. from the set of instructions 21 for the current textile design, and outputs a control signal which causes the at least one motor 70 at a particular throttle valve 13 a , 13 b to move into an angular position which will cause the valve to achieve the desired flow rate. The control function 22 may alternatively reside locally with each motor 70 . In this case, the control signal applied to each motor controller will indicate the required flow rate. Of course, the control of the motors 70 can also occur in dependence of signals of a weft detector 6 , in other words as a function of the arrival of the respective weft thread 8 a , 8 b , 8 c at the weft detector 6 .
Consider an example weaving operation, which uses three different yarns 8 a , 8 b and 8 c , further named A, B and C, each requiring a different airflow rate. With a yarn insertion sequence of ABCABC the throttle valve will normally be operated for each insertion. With a weaving rate of 1200 insertions per minute, it is necessary to operate the throttle valve twenty times every second, i.e. each 50 msec. As is known, in each weaving cycle the insertion time interval is substantially half of the time interval available for one weaving cycle, i.e. the time interval for one insertion and the time interval for beating up the inserted weft against the fell line. If one chooses for moving the duct 60 between two insertions, e.g. during the time interval for beating up, there is about 20 msec to bring the throttle valve in readiness for the next insertion. Even if one chooses to use the practically whole insertion cycle for moving the duct 60 there will only be available 50 msec for moving the duct 60 . Of course other yarn insertion sequences can be used, depending on the desired pattern to be woven. With a yarn insertion sequence of AABBCC it is only necessary to change the throttle valve after every two insertions, as the same yarn, with almost the same properties, is inserted in two consecutive weaving machine cycles.
Referring again to FIG. 1 , the throttle valve 13 a , 13 b , . . . , 13 x can be positioned between an air tank or air reservoir 5 and a group of relay nozzles 4 a , 4 b , . . . , 4 x or between a reservoir 5 and a main nozzle 2 a , 2 b , 2 c , 2 d , 2 e , 2 f . The shut-off valve 10 a to 10 f , 12 a to 12 x , 14 is not essential but is preferable. FIG. 1 shows each time a number of the relay nozzles 4 a , 4 b , . . . , 4 x fed from the same throttle valve 13 a , 13 b , . . . , 13 x . Different relay nozzles 4 a , 4 b , . . . , 4 x along the loom may operate at a different airflow rate. For example, the last group of relay nozzles 4 x may be controlled at a higher airflow than the ones at the beginning of the shed in order to hold the weft at the end of the insertion. The throttle valve according to the invention can be used to select whatever airflow rate is required. Any other function of airflow rates along the shed can be chosen with, for example, a high airflow for some of the relay nozzles and a lower airflow for some of the other relay nozzles. The use of the throttle valve allows to use one main reservoir 5 for all the relay nozzles and possibly also for all the main nozzles. In FIG. 1 each throttle valve supplies a group of three relay nozzles 4 a , 4 b , . . . , 4 x with air. According to an alternative, each relay nozzle or groups having two, four or more relay nozzles may be supplied with air via a same throttle valve.
The throttle valve according to the invention can also be used to optimise the airflow through each relay nozzle, which will lead to less airflow and less use of pressure air for the insertion. Using a throttle valve according to the invention an airflow reduction of up to 30% is possible. Another use of the throttle valve is to vary, e.g. increase or reduce the airflow during the insertion, such that for example a large airflow is generated as the weft passes the relay nozzle while a reduced airflow is generated when the weft is farther away from the relay nozzle. Another possibility is to vary the airflow cyclically during an insertion as known from U.S. Pat. No. 3,672,406.
If the throttle valve is used to provide airflow to a main insertion nozzle, it is desirable to set the throttle valve to a required throttle position before opening corresponding shut-off valve 11 a to 11 f . If the throttle valve is used to provide airflow to a relay nozzle, the throttle valve can preferably be set to a required throttle position before opening corresponding shut-off valve 12 a to 12 x . Further advantages can be gained by changing the throttle position while a weft thread 8 a , 8 b , 8 c is being inserted.
The flow duct 60 that is movable with respect to the housing 50 or with respect to the flow path of the compressed fluid, is in the preferred embodiments shown in the drawings mounted rotatably within the housing 50 . According to an alternative not shown the duct 60 is mounted movable in the direction of the longitudinal axis 61 such that a particular portion of the outlet of the duct 60 will be aligned with the outlet 55 of the housing 50 in order to regulate the fluid flow through the valve. In this embodiment the holes of the outlet 65 A may be arranged longitudinally with respect to the duct 60 , instead of circumferentially as shown in FIG. 5 . According to a further alternative the duct 60 is movable with respect to the housing 50 both rotatable and longitudinally, for example such that the outlet of the duct 60 moves along a screw line and particular portions of the outlet of the duct 60 will be aligned with the outlet 55 of the housing 50 to regulate the fluid flow through the valve.
It is also possible that a throttle valve according to the invention is situated downstream of a shut off valve.
The invention is not limited to the embodiments described herein, which may be modified or varied without departing from the scope of the invention. It is possible to use throttle valves having the same construction or to use, for example, throttle valves having a different construction, more particularly throttle valves having a different construction for feeding an airflow to the main nozzles or to the relay nozzles or to the stretching nozzles. | A valve ( 13 a ) is described comprising: a housing ( 50 ) having a fluid inlet for ( 54 ) receiving a flow of compressed fluid and a fluid outlet ( 55 ); a flow duct ( 60 ) movably mounted with respect to the housing, the duct ( 62 ) having a fluid inlet ( 62 ) for receiving a flow of compressed fluid and a fluid outlet ( 65 ), the fluid outlet being positioned around at least a part of the circumference of the duct and being dimensioned to provide a different flow rate at different sections or positions around the circumference of the duct; the fluid outlet of the housing being alignable with a portion of the fluid outlet of the duct to provide a flow rate related to the relative position of the portion of the fluid outlet of the duct and the fluid outlet of the housing; and, a drive element ( 70 ) for moving, e.g. rotating, the duct with respect to the housing such that a desired portion of the fluid outlet of the duct aligns with the fluid outlet of the housing. The valve may operate as a so-called throttle valve. It is an advantage that the valve is quickly movable into a desired relative position in order to regulate fluid flow through the valve. The valve is designed to have a long operational lifetime as, even if the outer surface of the duct wears, the outlet will not substantially change in size and the throttling effect will remain substantially the same. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119 of German Patent Application No. 10 2015 014 355.7, filed Nov. 6, 2015, and German Patent Application No. 10 2015 016 678.6, filed Dec. 21, 2015, the disclosures of which are hereby incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to methods for mounting and/or changing a milling unit of a ground milling machine, as well as to a ground milling machine comprising a dismountable and mountable or exchangeable milling unit according to the independent claims.
BACKGROUND OF THE INVENTION
[0003] Essential elements of a generic ground milling machine are a machine part having a machine frame, an operator platform, a drive engine as well as travelling devices driven by the drive engine, such as wheels and/or crawler tracks. The travelling devices are connected to the machine frame via height-adjustable lifting columns so that the distance of the machine frame to the ground in the vertical direction can be adjusted by adjusting the lifting columns. Furthermore, a generic ground milling machine comprises a milling unit having a milling drum for milling ground material and a milling drum box for covering the milling drum to the sides and upward. The milling unit can be detachably fastened via a fastening device fastening the milling drum box to the ground milling machine. Such a ground milling machine is known from DE 10 2011 018 222 A1, for example. The invention described therein particularly relates to road milling machines.
[0004] Generic ground milling machines are usually used in road and pathway construction. Ground milling machines of the road cold milling machine type are used for milling off a road surface layer for road renewal. An essential aspect for the application range of such a ground milling machine is the width of the milling drum arranged on said ground milling machine, the milling drum usually being a hollow-cylindrical unit with a plurality of milling tools being arranged in a known manner on the outer jacket surface of said unit. The milling drum is usually supplied with drive energy by the drive unit of the ground milling machine, for example, via a mechanic or hydraulic drive train. The milling drum rotates inside a milling drum box about a horizontal rotation axis extending transversely to the working direction and mills off ground material when in a state immersed in the ground. Here, the milling drum box relates to a housing-like entirety with the milling drum being arranged therein and protruding toward the ground. The milling drum box prevents milled material from being thrown around in an uncontrolled manner during working operation and additionally provides a compartment for controlled guidance of milled material. In other words, the milling drum box, while being open toward the ground, surrounds the milling drum partially in the horizontal direction and in the vertical direction upwards. It is known to design the milling unit as a demountable entirety, comprising the milling drum and the milling drum box, at the machine part of the ground milling machine. For example, demounting the milling unit may be desired when the ground milling machine is to be lightened, for example, for transport purposes. Working times required for dismounting and mounting the milling unit from/to the machine part are, of course, desired to be as short as possible. Furthermore, there is often a need for being able to mill various milling widths with one and the same ground milling machine. To that end, it is preferred if various milling units can be mounted and quickly exchanged amongst one another on one and the same ground milling machine. In particular, this relates to the use of so-called large-scale milling machines having a milling unit arranged between the front and rear travelling devices. The option of dismounting the milling unit as an entirety from the machine part is described in DE 10 2011 018 222 A1, for example. To that end, the milling drum box is connected to the machine part in a detachable manner via massive fastening screws and corresponding lock nuts. The disadvantage of said configuration lies with the fact that the fastening screws are oftentimes hardly accessible, which is why other parts of the ground milling machine need to be removed first in order to allow access to the fastening screws. Moreover, the screws are comparatively large screws, so that a great force must be applied for mounting and dismounting. This is a challenge particularly in constricted space. Furthermore, in this alternative, time expenditure for the mounting and dismounting or changing of the milling unit is comparatively high as well. When referring to the dismounting and mounting of the milling unit hereinafter, this is to be understood as equally comprising mounting and dismounting one and the same milling unit as well as changing the milling unit, i.e., dismounting a first milling unit and mounting a second milling unit.
SUMMARY OF THE INVENTION
[0005] A principle of the present invention is to provide a method and a ground milling machine which enable, compared to known options of the prior art, mounting the milling unit to the machine part or machine frame more rapidly and more simple for an operator.
[0006] The method according to the present invention thus relates to a method for mounting/changing a milling unit of a ground milling machine and for aligning a releasable milling unit relative to a machine frame of a ground milling machine. Generally, the challenge of mounting the milling unit to the ground milling machine lies with bringing the milling unit into a position relative to the ground milling machine in which the fastening means have a relative position to one another in which the milling unit can be fastened to the ground milling machine. To that end, the two elements ground milling machine and milling unit usually need to be positioned relative to one another in a relatively precise manner. Typically, the milling unit is pre-positioned under the machine frame of the ground milling machine and then the desired final position of the milling unit relative to the ground milling machine is achieved in a highly elaborate manner by time-consuming maneuvering work until a final position is reached in which the milling unit can be fastened to the ground milling machine via the provided fastening elements. Now, one aspect of the present invention is to divide the alignment process by means of two alignment devices into a “pre-alignment phase” and a “fine alignment phase” and to thereby facilitate the whole process. The first alignment device is used for rough alignment, and the second alignment device is used for fine alignment. Accordingly, the essential steps of the method according to one embodiment of the present invention are:
[0007] a) rough alignment of the milling unit relative to the machine frame with a first alignment device; and subsequently
[0008] b) fine alignment of the milling unit relative to the machine frame with a second alignment device.
[0009] As used herein, rough alignment relates to alignment movements by means of which the milling unit can be aligned relative to the machine frame of the ground milling machine by at most a few decimeters, in particular, a few centimeters relative to one another, and fine alignment particularly relates to alignment movements by means of which the milling unit can be aligned relative to the machine frame of the ground milling machine by at most a few centimeters, in particular, at most in the low single-digit range, and, in particular, by a few millimeters relative to one another. Here, rough alignment particularly includes compensation of transverse offset, i.e., an offset of the milling unit relative to the ground milling machine in the horizontal plane and perpendicular or transverse to the forward direction of advance or the longitudinal extension of the ground milling machine in the range of +/−150 mm max, in particular, +/−100 mm and more particular in the range of +/−50 mm with respect to the final position. Furthermore, rotational position deviations, i.e., rotations of the milling unit in the horizontal plane relative to the final position by at most +/−10°, in particular, +/−7°, and more particularly +/−4°, are also corrected by the alignment device for rough alignment. In contrast, the alignment device for fine alignment compensates deviations in the horizontal plane of at most +/−30 mm, in particular, +/−20 mm, and more particularly +/−10 mm, with respect to the final position, and thus concerns final alignment. A gradation of the alignment steps via individual alignment devices is advantageous in that a particularly efficient and reliable guiding of the two elements—milling unit and ground milling machine—toward their desired final relative position is possible, so that damage and wear to the fastening devices, for example, holding pins, lever elements, etc., can be reduced. Furthermore, it is possible to start with only a very imprecise placing of the milling unit relative to the ground milling machine at the beginning of the mounting process, so that time-consuming maneuvering works, in particular, with the transport unit, can be avoided since the milling unit is guided to the final fastening position by means of the first and the second alignment devices step by step. Then, the milling unit is fastened by means of a suitable fastening device and the functional connections are established. Functional connections are preferably achieved via a quick connector for corresponding line connections. Fastening is preferably effected via a quick coupling system driven via at least one actuator, such as driven in particular electrically, hydraulically and/or pneumatically. In particular, for establishing the support connection, the fastening system of the same Applicant disclosed in DE 10 2014 011 856.8 may be used to that end. Reference is hereby made to the disclosure of said application.
[0010] The first and/or the second alignment device are preferably designed such that when moving one element (e.g., the ground milling machine without the milling unit), said devices guide the relative position of the two elements (ground milling machine without milling unit and milling unit) towards one another or to a desired relative position. Through the movement of one element, the other element can thus also be moved, or movement of one element causes movement, in particular, partially different movement, of the respective other element. Generally, for driving a movement of an element, an external drive such as an external vehicle, e.g., a forklift, etc., may be considered, although the use of the drive propulsion of the ground milling machine and/or the height adjustment drive of the lifting columns is preferred. Thus, rough alignment and/or fine alignment are preferably effected by moving the ground milling machine relative to the ground. In this regard, it is particularly preferred when rough alignment is effected by means of a forward and/or backward travelling movement or a lift adjustment of the ground milling machine and fine alignment is effected by lowering the ground milling machine or the machine frame.
[0011] Ideally, rough alignment and fine alignment are effected by means of elements via which the ground milling machine and the milling unit abut one another.
[0012] In step a), the ground milling machine is moved in a guided manner relative to the milling unit in and against the forward direction of advance, in particular, along wedge surfaces extending horizontally and inclined to the longitudinal axis of the ground milling machine or to the forward and/or backward direction of advance. Thus, the wedge surfaces achieve a guide surface along which a counter-element of the milling unit slides in the direction of the desired final position of the milling unit relative to the ground milling machine. Such a sliding guide operates in a particularly reliable manner and is relatively robust. Since the ground milling machine per se already has drive propulsion, additional driven special machinery for rough alignment between the two above mentioned elements are not required.
[0013] As an alternative, rough alignment according to step a) can be effected via swinging the milling unit, which is suspended from the machine frame. One aspect of the alternative configuration of the method according to the present invention is to use the gravitational force as a driving force for the rough alignment movement. Thus, said embodiment requires to initially suspend the milling unit from the machine frame of the ground milling machine. Appropriately, this is effected by means of flexible connections, as will be described in greater detail below. If the machine frame is lifted by the extension of the lifting columns, the milling unit is freely suspended from under the machine frame. If defined suspension conditions are met, the suspended milling unit always assumes the same position relative to the machine frame. Defined suspension conditions are in this case essentially characterized in that the suspension points on the milling unit and on the machine frame as well as the suspension elements, in particular, their length, are set. Ideally, suspension conditions are selected such that the milling unit already has its final position in terms of its horizontal alignment when reaching the final swing position, and thus the machine frame only needs to be lowered onto the milling unit yet.
[0014] Said swing process thus comprises the following steps. After placing the milling unit roughly under the machine frame of the ground milling machine, first a flexible suspension connection is established between the milling unit and the ground milling machine, in particular, the machine frame of the ground milling machine. To that end, at least three and, in particular, four individual suspension points are used which are spaced from one another and which, in particular, are located in the region of the upper four corners of the milling unit. As used herein, the term “flexible” is to be understood such that the suspension connection has at least one degree of freedom. In the end, the suspension connection is to achieve a swing-type suspension of the milling unit from the machine frame. For example, the flexible suspension connection may comprise holding points on the milling unit and on the machine frame as well as a connection structure such as a connecting rod, connecting members, connecting chains, etc. What is important is that the achieved suspension connection enables a certain movability of the milling unit when in the state suspended from the machine frame. Once the flexible suspension connection is established, the ground milling machine, respectively the machine frame, is lifted by extension of the lifting columns until the milling unit is lifted from the ground via the suspension connection. Once the milling unit does not have contact to the ground, it is suspended only via the suspension connection from the machine frame and then swings into the desired final position, in particular, of the rough alignment. If the ground milling machine or the machine frame is lowered by means of the retraction of the lifting columns, the milling unit touches the ground again, however this time in the desired horizontal position relative to the machine frame. After that, the ground milling machine is lowered further until it sits on the milling unit via the connection points for fastening the milling unit. Generally, if the aforesaid process occurs in a particularly precise manner, it is possible to omit a further step of fine alignment. However, due to existing unevenness and other imponderabilities, it turned out that a subsequent fine alignment yet to be described below in greater detail further simplifies the mounting process and makes it more reliable.
[0015] In step b) the ground milling machine is vertically displaced relative to the milling unit, in particular, the machine frame of the ground milling machine is lowered onto the milling unit, in particular, by retraction of the lifting columns. It is also in this case that the use of a sliding guide for fine alignment, specifically between the milling unit and the machine frame of the ground milling machine, is particularly preferred, in particular, along inclined slide surfaces extending vertically. Conical wedge surfaces having vertically extending longitudinal axes are particularly preferred.
[0016] Preferably, each of the alignment steps “rough alignment” and “fine alignment” is assigned a distinct drive. This allows a particularly reliable separation of said two steps and at the same time allows a particularly efficient mounting of the milling unit, since reaching the desired relative final positions of the milling unit relative to the ground milling machine is enabled in a reliable manner.
[0017] Another aspect of the present invention relates to a ground milling machine, in particular, for performing the method according to the present invention. Therefore, reference is made to the explanations of the method according to the present invention for the description of this aspect.
[0018] A generic ground milling machine comprises a machine frame, a drive engine, travelling devices driven by the drive engine and connected to the machine frame via height-adjustable lifting columns, and a milling unit with a milling drum for milling off ground material and a milling drum box for covering the milling drum toward the sides and upwards, and the milling unit is fastened or can be fastened in a detachable manner to the machine frame of the ground milling machine via a fastening device. In order to improve the mounting process of the milling unit, it is provided according to the present invention that a first and a second alignment device are present, which are designed for alignment of the released milling unit relative to the machine frame for fastening the milling unit to the machine frame, the first and second alignment devices being configured differently. Thus, the two alignment devices are devices that influence the relative position of the milling unit to be fastened on the ground milling machine and of the ground milling machine and, in particular, of its machine frame, and which, in particular, direct it to a final position in which the milling unit can be fastened to the ground milling machine via a suitable fastening device. According to the present invention, the two alignment devices preferably act functionally independently of one another. The two alignment devices thus each preferably comprise different means which act, in particular, between the milling unit and the ground milling machine, and which, in particular, successively, cause the alignment of the milling unit relative to the ground milling unit without milling unit. As a result, this enables designing the achieved extent of alignment, or the possible scope of alignment, in a graduated manner, which, in particular, reduces wear of fastening means and also the time required for the mounting process.
[0019] Reference is made to the above descriptions, in particular, with respect to the meaning of the terms “rough alignment” and “fine alignment”.
[0020] It is ideal if the first and the second alignment device have means each at the milling unit and at the machine frame which are designed such that they get into contact or abutment with one another during the alignment process. Such means may, on the one hand, be elements protruding in the vertical direction, such as abutment blocks, bolts, pins, etc., and receiving elements such as depressions, boreholes, slide devices, such as inclined slide surfaces, etc. Generally, even a rail system can be applied.
[0021] Alignment is effected in a particularly reliable manner when the first and/or the second alignment device are form fit devices, in particular, having slide surfaces, in particular, shaped as cone and/or wedge surfaces. A wedge surface relates to a surface which in a vertical or horizontal reference plane extends inclined, i.e., in particular, at an angle relative to the forward/backward direction of advance of the ground milling machine or to a vertical axis. A counter-element (for example, on the side of the machine frame) abuts against said surface (e.g., on the side of the machine frame). If the wedge surface is moved relative to the counter-element in the forward/backward direction of advance or in the vertical direction, some kind of wedge drive mechanism results, by means of which the other element is also moved.
[0022] Devices of this type are particularly robust, simple in structure and deliver reliable results. Here, the first alignment device (rough alignment) may have wedge surfaces essentially acting in the horizontal direction and thus serve essentially for compensation of a transverse offset and/or rotations, as already described above. The wedge surfaces thus extend along the longitudinal extension of the ground milling machine preferably toward the center of the machine. Reference is made to the above explanations for details in this regard.
[0023] Specifically, for example, the first alignment device may comprise form fit elements, in particular, wedge wall elements, protruding in the vertical direction, and counter-elements may be provided, in particular, for abutment against the wedge wall elements, in particular, on the inner surfaces thereof, the form fit elements being arranged on the machine frame and the counter-elements being arranged on the milling unit, or vice versa.
[0024] Preferably, the wedge wall elements are arranged in opposing pairs on the longitudinal sides of the ground milling machine. The wedge surfaces extend appropriately in or against the forward direction of advance of the ground milling machine toward one another (in particular, in the horizontal plane) so that the horizontal distance of the wedge surfaces tapers in or against the forward direction of advance of the ground milling machine. This achieves an overall structure horizontally acting in a funnel-like manner, via which transverse offsets and/or rotations of the milling unit relative to the machine frame can be compensated to a comparatively large extent. The wedge surfaces may extend toward one another in a curved, stepped or even straight manner.
[0025] Additionally or alternatively, the first alignment device may also comprise a flexible suspension connection between the milling unit and the ground milling machine, in particular, the machine frame, in particular, in the form of ropes, chains or straps. For rough alignment of the milling unit, in particular, relative to the machine frame, the suspension connection is provided, via which the milling unit can be suspended from the ground milling machine and particularly from under or below the machine frame temporarily. If the milling unit is suspended from the machine frame without contact to the ground, it swings into a defined position. This requires that the suspension points of the suspension connection as well as at least the length of the suspension elements are defined. If the milling unit is placed on the ground by the retraction of the lifting columns after reaching said defined swing position, it thus has a defined relative position with respect to the horizontal plane relative to the machine frame of the ground milling machine. If the machine frame is further lowered to the ground until reaching the milling unit, often times the fastening connection may already be established or, preferably, the second alignment device acts at this point or ideally already during the lowering process.
[0026] It is thus preferred if the first alignment device is a suspension swing via which the milling unit can be suspended from the machine frame of the ground milling machine. The suspension swing may have the aforementioned basic structure. It is preferred when parts of the suspension swing can be demounted and are only mounted for the mounting process between the milling unit and the machine frame. As an alternative, there may be a storage chamber on the machine frame, into which the connection elements of the suspension swing, when released from the milling unit, can be sunk, for example, pivoted. The advantage of this variant with a suspension swing is that the drive for rough alignment is achieved via the gravitational force. As a result, there is no need for a separate drive for alignment of the milling unit relative to the machine frame of the ground milling machine.
[0027] The second alignment device (fine alignment) preferably comprises wedge surfaces extending essentially in the vertical direction, such as conical surfaces protruding upward or downward. Said vertical wedge surface thus are at an angle to a vertical reference axis. Thus, if the wedge surface engages with counter-elements (as already described with respect to the first alignment device) and if the machine frame of the ground milling machine is lowered by a retraction of the lifting columns, the counter-elements thus move along the wedge surfaces, so that the relative position of the machine frame to the milling unit changes. The counter-elements and the wedge surfaces are correspondingly placed and designed in such a way that the milling unit and the ground milling machine get into the final position desired for fastening the milling unit by means of the fastening device. Using the height adjustability of the ground milling machine for fine alignment is advantageous also because said movement can be controlled in a very precise manner.
[0028] Specifically, the second alignment device preferably comprises trunnions or teeth standing vertically with their longitudinal axes, preferably conical trunnions, and receptacle bores or receptacle recesses as counter-elements, the trunnions or teeth being arranged on the machine frame and the receptacle bores and receptacle recesses being arranged on the milling unit, or vice versa. In this regard, reference is, in particular, made to DE 10 2014 011 856.8 and to the basic structure described in said specification.
[0029] According to one embodiment of the present invention, the first alignment device and the second alignment device are functionally arranged in series. This means that, for the overall mounting process, first a rough alignment using the first alignment device is effected. The second alignment device may have no function at this point. If a desired final position of the milling unit relative to the ground milling machine has been reached with the first alignment device, the second alignment device takes effect, for example, by starting another movement of the ground milling machine relative to the milling unit, while, to that end, the respectively acting elements of the first alignment device may optionally remain engaged or may get disengaged. The advantage is that the two alignment devices can be designed in a graduated manner in terms of their maximum tolerance limits and, as a result, a very fast and also very precise alignment of the milling unit relative to the ground milling machine is possible.
[0030] In order to achieve a functional arrangement in series, it is preferred if the vertical height of the vertically protruding form fit elements of the first alignment device is greater than the vertical height of the trunnions or teeth of the second alignment device. This makes it possible to selectively only engage the first alignment device by means of a height adjustment of the lifting columns and only subsequently, by a further retraction of the lifting columns, additionally or alternatively, the second alignment device.
[0031] Finally, according to the present invention, it is preferred if the milling drum box is connected to the machine frame via a quick coupling system, particularly a lockable and unlockable quick coupling system, which can be operated from the operator platform and/or if a connection block for simultaneously connecting multiple fluid and/or supply connections between the milling unit and the remaining ground milling machine is provided. As a result, the time required for mounting and dismounting of the milling unit can be reduced even further. A corresponding quick coupling system for fastening the milling unit to the ground milling machine (corresponding to the fastening device) is disclosed in DE 10 2014 011 856.8, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The present invention will be explained in more detail below with reference to the exemplary embodiments shown in the figures. In the schematic figures:
[0033] FIG. 1 shows a side view of a ground milling machine;
[0034] FIG. 2 shows a partial sectional view through the ground milling machine with separate milling unit;
[0035] FIGS. 3 a to 3 k show the sequence of an exchanging process in a side view;
[0036] FIGS. 4 a to 4 c show detailed views concerning rough alignment with a first alignment device in a view from below to the milling unit and the bottom side of the ground milling machine;
[0037] FIGS. 5 a and 5 b show detailed views concerning fine alignment with a second alignment device in a perspective view of the milling unit and the left side of the ground milling machine (detail) obliquely from the front;
[0038] FIG. 6 a shows a cross-sectional view of FIG. 2 with a milling unit pre-positioned relative to the machine part;
[0039] FIG. 6 b shows an enlarged detailed view of region A of FIG. 6 a;
[0040] FIG. 7 a shows a cross-sectional view of FIG. 2 with the fastening device in the locking position;
[0041] FIG. 7 b shows an enlarged detailed view of region A of FIG. 7 a ; and
[0042] FIGS. 8 a to 8 f show the sequence of a mounting process with a suspension swing.
[0043] Like components are indicated with like reference numerals throughout the figures, wherein not each and every component necessarily is repeatedly indicated in each of the figures.
DETAILED DESCRIPTION OF THE INVENTION
[0044] FIG. 1 shows a generic ground milling machine 1 , in the present case a road cold milling machine. In this case, said machine specifically is a large-scale milling machine of the center rotor type. Essential elements of the ground milling machine are a machine part 2 and a milling unit 3 . The machine part 2 includes a machine frame 6 supported by travelling devices 4 via lifting columns 5 , with a drive engine 7 , an operator platform 8 and a milled material conveyor device 9 . The lifting columns 5 enable height adjustment of the machine frame 6 in the vertical direction relative to the ground. The drive engine 7 delivers the drive energy required for the drive propulsion and the drive of the milling device as described below. During working operation, operation of the ground milling machine 1 is effected from the operator platform 8 by an operator. During working operation, the ground milling machine 1 travels over the ground to be processed in the working direction and mills off milling material. This is specifically effected with the milling unit 3 , comprising a milling drum box 10 as well as a milling drum 11 , which is arranged inside the milling drum box 10 . The milling drum box 10 all in all comprises a front wall, a rear wall, an upward cover located above the milling drum as well as covers to the sides to the right and to the left. The milling drum box 10 is designed to be open toward the ground, so that the milling drum 11 positioned within the milling drum box 10 can engage the ground. For the milling operation, the milling drum 11 rotates about a horizontal rotation axis R extending transversely to the working direction a.
[0045] The milling unit 3 is designed to be demountable as a modular unit relative to the machine part 2 of the ground milling machine 1 , for example, for transport and exchange purposes. To that end, a fastening device 12 for connecting the milling unit 3 to the machine part 2 is provided, which is merely schematically shown in FIG. 1 . The structure and functionality of said fastening device 12 will be explained in the following figures in greater detail by way of example. In the simplest case, these may be threaded bolts and corresponding nuts. It will be readily appreciated that for mounting/dismounting the milling unit 3 the drive train (functional connection), which in the present embodiment is partially designed as a belt drive, must be separated and re-established after installation of the milling unit 3 . As an alternative, a drive connection to a hydraulic system is possible as well.
[0046] FIG. 2 shows the state prior to the installation of the demounted milling unit 3 , with the milled material conveyor device demounted, prior to the installation of the milling unit 3 at the machine part 2 in view direction of the arrows to section line I-I of FIG. 1 . In the present exemplary embodiment, the milling unit 3 is slid via a special transport unit 13 in the direction b from a position laterally next to the machine part 2 transversely to the working direction a underneath the machine part 2 between the front and rear travelling devices 4 . The machine frame 6 of machine part 2 is adjusted via lifting columns 5 in the vertical direction upward into an exchange adjustment position so that sufficient space is available underneath machine frame 6 of machine part 2 . Machine part 2 and milling unit 3 are very roughly aligned to one another.
[0047] The transport unit 13 includes, for example, a base plate T 1 , on which a support device T 2 is mounted for reception and positional stabilization of the milling unit 3 . In particular, vertically protruding support walls are provided to that end, which stabilize the milling unit 3 to the face side. Furthermore, an upward projecting transport arm T 3 is present, which has a corresponding counter-part T 4 for engagement with a load arm of a swap body truck. On the face side of the base plate T 1 opposite the transport arm T 3 , rolls T 5 are present, which can roll on the ground U and thus enable easier movement of the transport unit 13 . The transport unit 13 further comprises a wall vertically projecting toward the transport arm T 3 , said wall serving as an insertion limit T 6 or stop. The wall extends in the vertical direction thus far that the wall does not fit into the region underneath the machine frame of the ground milling machine even when the lifting columns are in the exchange adjustment position. However, within the scope of the present invention, the important factor is that the milling unit is initially positioned under or underneath the ground milling machine 1 in any manner. Thus, transport unit 13 is to be understood as being optional.
[0048] FIGS. 3 a to 3 k emphasize further details of the present example of a method according to the present invention for dismounting and mounting or exchanging the milling unit 3 , and reference is also made to the individual steps indicated in the general part of the description. Furthermore, a prior dismounting of the milling unit 3 is shown for a better understanding.
[0049] FIG. 3 a is the starting point. The ground milling machine 1 here is in the transport adjustment position with respect to the height position of the lifting columns. In this state, the ground milling machine can be moved to a place of operation, for example. The milling machine does not engage the ground. Here, the machine frame is at height HT in the vertical direction above the essentially planar and horizontally extending ground U. If now the dismounting of the milling unit is initiated, first the lifting columns are optionally extended further in the arrow direction until reaching the exchange adjustment position according to FIG. 3 b and the machine frame has a distance HW to the ground U. Said distance HW is larger than the distance HT. In this state, the center of mass of the ground milling machine is higher than in the transport adjustment position. Furthermore, a control unit S 1 may be provided, which, when exceeding the height adjustment beyond the transport adjustment position or when reaching the exchange adjustment position, only allows a limited travelling operation, in particular, with respect to the maximum permitted travelling speed and/or distance. Here, the term “limited” is to be understood in that the maximum possible travelling speed is substantially less than in transport operation. Alternatively or additionally, even the maximum permitted travelling distance in this state may be limited by the control unit S 1 . For the sake of clarity, the control unit is indicated as an example only in FIG. 3 b , but relates to the entire process of FIGS. 3 a to 3 k . This “over-lift” of the height adjustment relative to the transport height HT is optional, however.
[0050] The ground clearance achieved below the milling unit is sufficiently great that the transport unit can be brought under the milling unit, for example, from the side transversely to the longitudinal direction of the ground milling machine ( FIG. 3 c ). Now, the lifting columns are retracted in the arrow direction in said relative position of the transport unit 13 and the ground milling machine 1 , thereby reducing the distance of the machine frame to the ground to become the distance HB, until the milling unit, as indicated in FIG. 3 d , rests on the transport unit. Usually, the distance HB is between the distances HT and HW. In this state, existing connection fastenings of the milling unit to the remaining ground milling machine, usually to the machine frame thereof, are released. Furthermore, functional connections such as connections of the hydraulic system of the ground milling machine, electric connections and drive connections, are released, for example, by removing the drive belts or corresponding hydraulic connections.
[0051] For reaching distance HW, the lifting columns can be extended in the arrow direction again, with the milling unit, separated from the ground milling machine, remaining on the transport unit 13 ( FIG. 3 e ). The transport unit will subsequently be pulled away from below the ground milling machine together with the milling unit 13 and may be loaded onto a truck, for example. FIG. 3 f shows the state of the ground milling machine directly after removing the transport unit 13 . On the one hand, it is now possible to lower the ground milling machine again to the height HT and to also load it onto a transport vehicle, for example, if merely dismounting and mounting the milling unit 13 is required. Mounting the same or a different milling unit is effected based upon the situation illustrated in FIG. 3 f , i.e., ground milling machine 1 without milling unit 3 is brought into the exchange adjustment position HW according to FIG. 3 f on a most horizontal and planar ground U, be it at the same location or at another location. However, the method according to the present invention also covers variants in which the milling machine is extended into its transport height HT or is jacked up via blocks on the ground for increasing ground clearance.
[0052] When the exchange adjustment position with ground clearance HW is reached (be it by means of an “over-lift”, by jacking up onto blocks on the ground or, if sufficient, by extending the machine frame “only” in the transport position), the transport unit 13 may be moved under the ground milling machine 1 in the region between the front and rear travelling devices, as illustrated in FIG. 3 g . An essential factor for connecting the milling unit 3 to the ground milling machine is that a correct and precise alignment of the milling unit 3 relative to the ground milling machine 1 is effected, so that the provided fastening devices between the milling unit 3 and the ground milling machine 1 can be used in an optimum manner and, to the extent possible, without wear. To that end, a two-stage alignment device is provided to be explained in greater detail below. FIG. 3 g illustrates in this context already that a first rough alignment after a first slight lowering is effected by a forward and/or backward movement of the ground milling machine in and/or against the arrow direction, whereby respective guide elements at the milling unit 3 and at the ground milling machine 1 of a first alignment device get in a horizontal overlapping, whereby the milling unit 3 is roughly positioned relative to the ground milling machine. By a subsequent further lowering, the guide elements at the milling unit 3 and the ground milling machine 1 of a second alignment device get into a horizontal and vertical overlapping, resulting in fine alignment of the milling unit 3 relative to the ground milling machine 1 . Here, the lifting columns are retracted until the ground milling machine almost or in fact rests on the milling unit ( FIG. 3 h , height HB). In this position, support and functional connections are established between the milling unit 3 and the ground milling machine 1 , comprising, for example, the connection of hydraulic supply lines, electric connections and/or drive connections, such as, in particular, a belt connection for a drive belt transmission for driving the rotation of the milling drum of the milling unit. As an alternative, it is also possible to only establish the support connections or the fastening of the milling unit 3 to the ground milling machine 1 , so that the milling unit can be lifted by the ground milling machine 1 , and to close further connections later.
[0053] Subsequently, according to FIG. 3 i , the ground milling machine 1 , now including the milling unit 3 , is lifted by extending the lifting columns until reaching height HW. Subsequently, removal of the transport unit 13 (if present) is effected under the ground milling machine ( FIG. 3 j ) as well as lowering or retracting the lifting columns to a height HT (if an “over-lift” position had been assumed), so that a regular travelling operation of the ground milling machine is possible again.
[0054] The process shown in FIGS. 3 a to 3 k is merely to be understood as an explanation. An advantageous aspect with regard to the overall method shown in FIGS. 3 a to 3 k is that adjusting the height of the transport unit 13 is not required for dismounting and mounting the milling unit on the one hand, and, on the other hand, the ground milling machine 1 per se reaches a sufficient ground clearance by extending the lifting columns to the exchange adjustment position, so that the transport unit 13 can be placed under the machine, thus also enabling a fastening of the milling unit to the ground milling machine.
[0055] One variant also covered by the present invention lies with using longer lifting columns or lifting columns that enable a greater lift adjustment than lifting columns known so far. However, due to the construction-related tilt tendency of the machine when the lift columns are extended, it is also in this case that the height HW is reserved for the mounting and dismounting process and is not suitable for the regular travelling operation with the maximum height HT of the ground milling machine. For example, this may be ensured by the above mentioned control unit S 1 . The present invention also includes variants, in which ground clearance of the machine frame of the ground milling machine is improved in that the ground milling machine jacks itself up, i.e., raises itself by moving onto blocks on the ground or comparable devices.
[0056] FIGS. 4 a to 4 c illustrate the effects of the first alignment device A 1 for rough alignment. FIGS. 4 a to 4 c show the region between the front and the rear travelling devices in a view from below, i.e., ground U. Here, FIG. 4 a corresponds to FIG. 3 g . For the sake of clarity, the forward direction or the working direction a of the center rotor type milling machine is also indicated in FIGS. 4 a to 4 c.
[0057] Essential elements of the first alignment device A 1 are wedge surfaces A 1 . 1 arranged at the machine frame and wedge surfaces A 1 . 2 arranged at the milling unit, said surfaces forming a form fit device, wherein in each case one pair with wedge surfaces A 1 . 1 and A 1 . 2 is arranged at the right side and at the left side. The wedge surfaces A 1 . 1 protrude from the machine frame downward in the vertical direction and the wedge surfaces A 1 . 2 protrude from the milling unit 3 , specifically from the milling drum box, upward in the vertical direction. If the machine frame of the ground milling machine 1 is lowered, the wedge surfaces A 1 . 1 and A 1 . 2 come to overlap one another with respect to a virtual horizontal plane. An essential factor is that the elements of the second alignment device A 2 , which will be explained in greater detail below, are still “free of overlap”, i.e., do not yet overlap one another in a virtual horizontal plane at this point. In FIGS. 4 a to 4 c , the milling unit 3 rests on the transport device. If now the ground milling machine 1 moves against the arrow direction a, i.e., moves backward in this specific case, the wedge surfaces A 1 . 1 and A 1 . 2 further approach one another. Each of the wedge surfaces extends in the horizontal plane essentially in a straight line obliquely toward the center in the working direction a or in the forward direction of advance. The wedge surfaces A 1 . 1 and A 1 . 2 of a pair are further designed complementary to one another.
[0058] In FIG. 4 b , the wedge surface A 1 . 1 and A 1 . 2 have approached sufficiently close enough that the pair located at the right side (with respect to the view in FIGS. 4 a to 4 c ) abuts one another already. This is not the case for the left pair yet. Thus, in the position shown in FIG. 4 b , the milling unit 3 has a transverse offset to the right. If the ground milling machine is moved further, the milling unit is forced to the left by the effect of the wedge surfaces so that the transverse offset is compensated step by step.
[0059] The final position of this rough centering is shown in FIG. 4 c . The pairs of the wedge surfaces A 1 . 1 and A 1 . 2 abut one another in a form fitting manner both on the right and the left side. If the ground milling machine would be further moved backward, it would carry with it the milling unit 3 via the contacting wedge surfaces, not least by the stop surfaces adjoining the wedge surfaces A 1 . 1 and A 1 . 2 and extending horizontally and transversely to the direction a.
[0060] FIGS. 5 a and 5 b show the function of the second alignment device A 2 , and reference is made to FIGS. 6 a to 7 b in this respect. Essential elements of the second alignment device A 2 are centering cones 30 protruding from the milling unit in the vertical direction, with said cones also being arranged spaced from one another transversely to the longitudinal direction of the ground milling machine. Receptacle bores are present at the machine frame for receiving the centering cones 30 , although said bores are not visible in FIGS. 5 a and 5 b . FIGS. 5 a and 5 b illustrate the milling unit still in the state resting on the transport unit 13 , said unit not being illustrated in these figures for the sake of clarity. Once the pre-centering by means of the alignment device A 1 is finished, the tips of the centering cones rest reliably within the circumference of the receptacle bores at the machine frame viewed in the vertical direction. If the lifting columns are further lowered, the centering cones engage the receptacle bores so that the bores can slide-off with their edges on the centering cones. This achieves that the relative position of the milling unit 3 and the ground milling machine 1 are exactly aligned so that the milling unit 3 can be fastened to the ground milling machine, for example, by means of the fastening device described below. During fine alignment, the slide surfaces of the first alignment device A 1 slide past one another in the vertical direction. Thus, it is important that the wedge surfaces of the first alignment device are constructed in such a way that they permit said movement. This is achieved in that they are designed in a straight fashion in the vertical direction, for example.
[0061] For further illustration, FIG. 6 a shows the milling unit 3 in the position pre-positioned by the first alignment device A 1 underneath the machine part 2 , with the transport unit 13 as well as the lifting columns 5 and the travelling device 4 being omitted in this case for the sake of clarity. Furthermore, FIG. 6 b illustrates region A of FIG. 6 a in an enlarged view. FIG. 6 a shows the arrangement viewed in the working direction a.
[0062] An essential factor for fastening the milling unit 3 to the machine part 2 or the machine frame 6 lies with the fastening device 12 , essential details of which are particularly indicated in FIG. 6 b . The fastening device 12 with its individual elements is partially supported on the milling unit 3 and partially supported on the machine part 2 in a fixed or movable manner. A complete dismounting of parts of the fastening device 12 from the milling unit 3 and from the machine part 2 is not provided so that the elements of the fastening device 12 are all in all arranged at the parts 2 and 3 in a fixed manner.
[0063] In the present exemplary embodiment, the fastening device 12 specifically includes a locking element 14 and a counter element 15 . The locking element 14 is designed as a single-arm pivot lever pivotally mounted at the machine frame, which lever is movable, in this case pivotable, about a pivot axis R 1 extending horizontally and in the working direction a between the release position indicated in FIG. 6 b and the locking position, which is shown, for example, in FIG. 7 b to be explained in greater detail below. At the end opposite the rotation axis R 1 , a locking protrusion 17 is present at the locking lever 16 , which protrudes from the adjacent surface of the lever element toward the observer from the image plane in FIG. 6 b . It may also be provided that said locking protrusion is arranged between two similarly designed locking levers 16 in the form of a support bracket.
[0064] Adjustment of the locking lever 16 , or of the locking element 14 , from the release position illustrated in FIG. 6 b into the locking position illustrated in FIG. 7 b is effected automatically, driven by a pressure spring 19 arranged inside a drive element 18 . The pressure spring 19 thus pushes the locking lever toward the locking position, and, in other words, acts in the direction of the locking position. For displacing the locking element 14 into the release position according to FIG. 6 b , a hydraulic pressure application of the drive element 18 designed as a cylinder-piston unit is effected via a hydraulic circuitry 20 indicated in FIG. 6 a by means of a corresponding valve 21 . Thus, the overall arrangement ensures that in the case of a missing pressure application, the locking lever 16 automatically takes the locking position according to FIG. 4 b driven by the pressure spring 19 . Here, the hydraulic cylinder is articulated at the machine frame 2 at the side of the cylinder and at the locking lever 16 at the side of the piston, in each case in a joint-like manner. In the present exemplary embodiment, the drive device is thus entirely arranged at the side of the machine part 2 of the ground milling machine 1 .
[0065] The fastening device 12 further includes the counter-element 15 which is designed as a fixed holding hook protruding from an upper wall 22 of the milling drum box with a web 23 projecting in the vertical direction and a locking protrusion 24 projecting vertically in a head region of the web 23 . Here, the locking protrusion 24 is engaged behind by the locking protrusion 17 of the locking lever 16 for fastening the milling unit 3 to the machine part 2 , viewed from the machine part 2 , as particularly indicated in FIG. 7 b . The stop surface 24 ′ at the locking protrusion 24 for the locking protrusion 17 of the locking lever 16 extends at an angle α inclined to the horizontal plane and declines in the pivoting direction of the locking lever 16 in the direction of the locking position in the vertical direction downward. This ensures that the milling unit 3 is pressed against the machine part 2 in the vertical direction upward, so that the special design of the contact surface 25 with inclination in cooperation with the locking protrusion 17 acts as a clamping device 51 between the milling unit 3 and the machine part 2 .
[0066] FIGS. 6 a and 7 a further illustrate that the fastening device 12 overall has two locking elements 14 and counter elements 15 each having one drive element 18 according to the previous explanations. The engagement or stop positions between the respective locking element 14 and the respective counter element 15 are arranged to be spaced apart from one another as far as possible transversely to the working direction toward the outer sides of the ground milling machine 1 . An essential factor is that both drive elements 18 are connected to one another in parallel via the hydraulic circuit 20 and both are actuated via valve 21 simultaneously and at the same effect. The pressure application in the position illustrated in FIG. 6 a thus causes a pivoting-in of the two locking levers 16 toward one another. Operation of the fastening device is effected via a suitable switch (not shown in the Figures), for example, in the operator platform 8 and/or laterally at the ground milling machine 1 close to the milling unit 3 .
[0067] Separately and spaced apart from the fastening device 12 , the second alignment device A 2 is provided. Said device comprises a hollow-cylindrical receptacle opening 27 or trunnion receptacle at the side of the machine part 2 , and, as a counter element at the side of the milling unit 3 , the mandrel 28 or trunnion protruding in the direction of the machine part 2 , i.e., in the vertical direction, said mandrel or trunnion including a cylindrical base part 29 and a centering cone 30 resting on the base part and tapering upward to become a tip. If, for fastening the milling unit 3 to the machine part 2 , the milling unit 3 and the machine part 2 are moved toward one another from the position shown in FIG. 6 b into the position shown in FIG. 7 b , first the centering cone 30 with its tip gets into the region of the receptacle opening 27 . In case of a slight imprecise alignment of the milling unit 3 relative to the machine part 2 , the centering cone 30 may slide with its outer surface onto the edge of the receptacle opening 27 and thus cause exact positioning of the milling unit 3 relative to the machine part 2 . Thus, in the region of the centering cone 30 , there is a clearance for the mandrel 28 in the receptacle opening 27 , the clearance becoming smaller along with an increasing alignment movement of the machine part 2 in the direction of the milling unit 3 . If now also the cylindrically shaped base part 29 slides into the receptacle opening 27 upon continued insertion movement, a form fit between the outer surface shell of the base part 29 and the inner surface shell of the receptacle opening 27 is achieved, so that a form fit is achieved in the horizontal plane. In the direction of the horizontal plane, the milling unit 3 is positioned relative to the machine part 2 practically without any clearance. This effect is of particular importance since the form fit established by the centering and form fit device 26 of the second alignment device A 2 in the direction of the horizontal plane causes a relief of the fastening device 12 in that the latter does not have to ensure a positional securing between the milling unit 3 and the machine part 2 . Thus, the fastening device 12 exclusively needs to apply clamping forces in the vertical direction for securing the milling unit 3 . The fastening forces to be applied by the fastening device 12 are comparatively low due to this functional separation of the vertical fixation and the horizontal fixation, so that there is no need to configure it in a particularly massive manner and also traction forces to be achieved may be comparatively low. FIGS. 6 a and 7 a illustrate that the centering and form fit device 26 is also provided multiple times between the milling unit 3 and machine part 2 , in the present case two times in the Figures. Furthermore, it is essential that the centering and form fit device 26 in the horizontal plane is spaced apart further outward than the fastening device 12 with respect to the longitudinal center axis in the working direction a. As a result of the largest possible spacing from the outer sides, and thus the largest possible spacing from one another, of the centering and form fit device 26 , optimum securing is achieved in the direction of the horizontal plane.
[0068] A synopsis of the figures illustrates that a very fast and moreover reliable dismounting and mounting of a milling unit 3 at a ground milling machine 1 will be possible. It is obvious that the specific design and arrangement of, in particular, the alignment devices A 1 and A 2 may vary, as long as the above mentioned effects are achieved. For example, the arrangement of individual elements of the respective alignment devices A 1 and/or A 2 at the machine frame and at the milling unit 3 can be effected vice versa. It may be provided as well that the wedge surfaces are designed as extending toward one another against the forward direction of advance of the machine. Furthermore, the specific design of the fastening device may vary. Thus, such variants are, in particular, also comprised by the present invention in which the milling unit is connected to the machine frame via known screw bolt connections. However, in particular, with regard to the operational comfort and in view of the shortened exchange time, an automatically actuatable fastening device is preferred.
[0069] FIGS. 8 a to 8 f illustrate an alternative embodiment of a first alignment device. One aspect of the present invention of the shown embodiment is to suspend the milling unit 3 temporarily from the machine frame of the ground milling machine 1 in the type of a suspension swing. To this end, the first alignment device A 1 comprises multiple fastening points A 1 . 3 on the milling unit 3 and multiple fastening points A 1 . 4 on the machine frame of the ground milling machine. The fastening points A 1 . 3 and A 1 . 4 serve for connecting a connection element A 1 . 5 . Preferably, in each case one fastening point A 1 . 3 is connected to a fastening point A 1 . 4 via in each case one connection element A 1 . 5 (although in FIGS. 8 a to 8 f only the connection elements A 1 . 5 present on the right side viewed in the working direction can be seen; in the present exemplary embodiment, a corresponding pair of connection devices A 1 . 5 is provided on the left side as well). Thus, the entire alignment device comprises in the present exemplary embodiment a total of four such individual connections so that the milling unit 3 can be suspended from the machine frame of the ground milling machine 1 via four connection elements A 1 . 5 . The essential factor is that the connection elements A 1 . 5 are connected to the fastening points A 1 . 3 and/or A 1 . 4 in such a way and/or are designed in such a way that they enable movement about at least one degree of freedom, respectively represent an at least partially flexible connection. This makes it possible that the milling unit swings relative to the machine frame in the arrow direction c (toward the observer in FIG. 8 c ) when the machine frame is lifted from the position shown in FIG. 8 b by the extension of the lifting columns into the position shown in FIG. 8 c , and thus takes a defined relative position relative to the machine frame of the ground milling machine 1 . It will be readily understood that to this end the connection elements A 1 . 5 have a defined length.
[0070] Once the swing movement is finished, the machine frame is lowered by the retraction of the lifting columns until the milling unit 3 rests on the ground (or optionally on a transport device still positioned thereunder), for example. This relieves the connection elements A 1 . 5 , enabling them to be dismounted and stored away, for example. If the machine frame is lowered even further by the retraction of the lifting columns, it comes to rest on the milling unit 3 from the top according to FIG. 8 a or approximates the milling unit close enough for the milling unit 3 to be fastenable to the machine frame via the fastening device 12 . Once this process is completed, the ground milling machine 1 may re-assume a transport height by the extension of the lifting columns and be moved to the place of operation.
[0071] In this alternative of the first alignment device A 1 , fine alignment can be achieved by means of the above described second alignment device A 2 , for example. The fastening device 12 can be realized in the above described ways and manners, for example.
[0072] While the present invention has been illustrated by description of various embodiments and while those embodiments have been described in considerable detail, it is not the intention of Applicant to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. The present invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicant's invention. | The present invention relates to methods for mounting a milling unit of a ground milling machine and to a ground milling machine comprising a mountable and dismountable milling unit. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a fuel-air ratio control apparatus for overriding an engine governor means to preclude an increase of fuel to the engine during a reduction of air pressure in the engine intake manifold. Engines equipped with superchargers smoke badly under lug. Lug is encountered when resistance or load on the engine is increased to the extent that engine speed is reduced below that which is indicated by the governor setting. Under these conditions, the engine governor attempts to regain the engine speed indicated by the governor setting by automatically advancing the engine fuel rack to supply more fuel. However, due to the reduction in supercharger speed caused by the reduced engine speed, insufficient air is supplied to the engine to support complete combustion of the additional fuel being injected. The patent to Crews, et al, U.S. Pat. No. 3,795,233, of common assignment herewith teaches a fuel-air control apparatus for resolving the problems as described above. However, it was found that even with this control apparatus, excessive amounts of secondary exhaust plumes were still being generated during engine lug.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming one or more of the problems as set forth above. According to the present invention, an improved fuel-air ratio control apparatus is disclosed for supercharged engines having a governor connected to a fuel control member and a supercharger supplying air through an intake manifold to the engine. The present invention includes an integral servo piston and valve unit placed in a restraining relationship with respect to the fuel control member. The servo piston is activated by a fluid force controlled by movement of a valve spool. This spool slides in an opening and closing manner relative to ports in a portion of the servo piston. The valve spool is secured to a pressure responsive mechanism which communicates with the engine intake manifold. The improvement comprises using resilient means including an adjustable stop means to control the amount of restraint imposed on the fuel adjusting member during engine lug.
In operation, during engine start-up the valve spool and ports of the servo piston are in an open position to render the servo unit inoperative and to permit unrestricted operation of the fuel adjusting member. The servo unit is subsequently activated when a predetermined increase in manifold air pressure shifts the valve spool relative to the servo piston ports and blocks and meters a flow of hydraulic fluid to the servo piston. During subsequent reductions in manifold air pressure, the servo unit is effective to restrain the fuel adjusting member against movement towards an increased fuel position. The restraint of the fuel adjusting member precludes any disproportionate increases in fuel to the engine when the air available in the intake manifold is insufficient to support proper fuel combustion. The resilient means comprises a plurality of springs whose spring rate additively determines the torque rise reduction enabled through limitation of the increasing fuel flow to the engine during engine lug. The adjustment means provides means for enabling variation of the point at which one of the torque reduction springs is engaged. This torque reduction spring is preloaded so as to prevent rattling of the spring when not engaged.
Therefore, it is an object of the present invention to provide an improved fuel-air ratio control apparatus wherein secondary exhaust emissions during engine lug are minimized.
Another object of the present invention is to provide an improved fuel-air ratio control apparatus for overriding the governor and control the injection of fuel to a supercharged engine as a function of a plurality of torque reduction springs, including a means for adjusting when a second torque reduction spring is to take effect.
A further object of the present invention is to provide an improved governor overriding fuel-air ratio control apparatus which is responsive to intake manifold air pressure with the control apparatus automatically permitting unrestricted movement of the fuel adjusting member during start-up to insure sufficient fuel for dependable starting, but thereafter automatically restricting the injection of fuel to the engine.
Other objects and advantages of the present invention will become more readily apparent upon reference to the accompanying drawings and the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal vertical section through the fuel-air ratio control apparatus of the present invention also schematically illustrating a supercharged engine intake manifold, a governor, and a fuel pump mechanism with the control apparatus being shown in an engine start condition.
FIG. 2 is a longitudinal vertical section through the fuel-air ratio control apparatus of the present invention similar to FIG. 1, but omitting the governor and showing the fuel air ratio control device in the control operative position.
FIG. 3 illustrates a longitudinal vertical section through the fuel air ratio control apparatus of the present invention similar to FIG. 2, but showing the control device in the full engine load power position.
FIG. 4 illustrates the torque reduction available during engine lugging with the present apparatus as compared with the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to FIG. 1, a fuel pump 10 has a plunger 12 which is vertically reciprocal during engine operation to supply fuel through a fuel injection line 11 to one of the cylinders of the engine, there being one pump for each engine cylinder. Longitudinal movement of a fuel adjusting member 17 having rack teeth 15 moves a gear 14 secured to plunger 12. The pump is of the metering type in which angular adjustment of the plunger 12 results in a variation of the quantity of fuel injected upon each stroke.
The fuel adjusting member 17 is secured to a riser 18 having an extended link 19 with a stop member 20 attached at its distal end. A pair of flyweights 22 carried upon a yoke 23 are driven by a gear 24 which is rotated by the engine's timing gear (not shown) at a speed proportional to engine speed. Radially outward movement of the flyweights due to centrifugal force causes portions of the flyweights to act leftwardly upon the riser 18. A spring 26, disposed between the riser and a collar 27, opposes the biasing action of the flyweights. A movable lever 28 is positioned to provide a predetermined selectable preload force for the spring 26 to act against the force of the flyweights 22.
An engine air intake manifold 30 is supplied with air pressure by an engine driven supercharger 31. A conduit, shown schematically at 32, communicates the intake manifold with a chamber 35. Chamber 35 is formed in part by an adaptor 33 secured by bolts 37 to a control housing 39, and a shaft housing 34 secured by bolts 38 to the adaptor 33. A further cover 36, described in more detail below, is secured over the shaft housing 34.
Control housing 39 has an inlet 40 connected to a source of pressurized fluid, such as engine lubrication oil. An orifice 43 communicates inlet 40 with a bore 44 formed in the housing 39. A servo unit 46 has a piston portion 47 slidable within bore 44 and a valve portion 48 integral with the piston portion 47 and slidable within a bore 50 formed in the housing. A valve means is provided by said valve portion 48 in combination with a valve spool 63. The valve portion 48 also includes an extending portion 49 with a shoulder 49a thereon which is positioned to engage the stop member 20 under conditions to be explained hereinafter. An expansable chamber 53 is formed by a face 51 of the piston 47, a surface 52 of housing 39, and bore 44. Orifice 43 is positioned such that fluid from inlet 40 is permitted to enter chamber 53. Shoulders 54 on the servo unit 46 provide the means for enabling the fluid from orifice 43 to be communicated to the chamber 53 when the piston portion 47 is in its rightmost position within bore 44.
A first set of passages 56 in the valve portion 48 communicate the chamber 53 with a bore 62 in the servo unit. A second set of passages 57 in the valve portion 48 communicate the bore 62 with an annular groove 58 formed in the bore 50. This annular groove, in turn, is intersected by drain passages 60 in housing 39. Another passage 91 is provided to communicate to the drain any fluid which might leak through the servo unit.
The valve spool 63, slidable in the bore 62, has an annulus 66 formed between a pair of lands 64 and 65. When the land 64 is disposed as shown in FIG. 1, the passages 56 are open. Land 65 is similarly disposed so that the passages 57 are open and chamber 53 is in communication with the drain passages 60.
The valve spool 63 is secured to an annular cup member 68 by means of a cylindrical member 69. A first spring member 72 having a first spring rate, is disposed between the piston 47 and the cup member 68. A second spring member 73, having a second spring rate, is disposed between the cup member 68 and an annular seat member 74. The seat member 74 is positioned on an annular shoulder 75 defined within the housing 39. A diaphragm 76 is secured between the adapter 33 and the housing 39 and is supported by the cup member 68. A washer 77 disposed adjacent to and rearwardly of the diaphragm 76 acts as a seat for a third spring member 78 which resides between the adapter 33 and the washer 77. The rates of the three above described spring members are such that forces on the diaphragm are balanced when no air pressure is extant in the chamber 35 to provide sensitivity in the servo unit.
The cylindrical member 69 includes a bore 100 defined therein. Fourth and fifth spring members 102 and 104 are positioned within the bore 100, with a spacer 106 defined on a rod or shaft 108 separating the two springs 102 and 104. The base of cylindrical member 69 provides a seat for the valve spool 63 which thereby provides the opposite seat for the spring 104. A seat 110 is formed in the bore 100 to provide a seat for spring 102. The rod 108 extends through a shoulder opening 111 in the shaft housing 34. At its end, the rod 108 defines a threaded portion 112. Two jam nuts 114 and 116 are disposed on the threaded portion 112. The shoulder opening 111 is shaped such that it provides a stop means for the rod 108 after the rod has shifted to the right a predetermined distance. The cover 36, when secured by bolts 118 to housing 34, covers the rod portion extending through opening 111 and the jam nuts 114 and 116 threaded thereon. The jam nuts 114, 106 to provide means for adjusting the point at which the rod 108 is caused to be stopped by the shoulder opening 111, thus defining the predeterminable shifting distance for the rod 108, as described above. Therefore, only after the rod 108 and jam nuts 114, 116 have engaged the shoulder opening 111 stop, will the springs 102 and 104 have an affect on the operation of the control apparatus. At this point springs 102 and 104 will have an additive influence on the spring rate of spring 73. Note that spring 102 is preloaded by spring 104 so that both of these springs are loaded in all conditions to maintain a constant rate. More on the operative effect of springs 102 and 104 is given hereinbelow.
OPERATION
Prior to engine start-up, the fuel-air ratio control of the present invention assumes an inoperative position in the following manner. Spring member 72 urges the servo unit 46 towards the right, as shown in FIG. 1, and removes the shoulder 49a from engagement with stop 20. Any movement of the lever 28 in a counterclockwise direction compresses the spring 26 and moves the fuel adjusting member 17 rightwardly toward an over-fueling position. During engine cranking or upon initial startup of the engine, the valve spool 63 is maintained in the position as shown. This enables communication between passages 56 and 57 through annulus 66 by means of the balanced condition of the spring members 73 and 78 acting upon the diaphragm 76. Fluid under pressure which enters chamber 53 from the inlet orifice 43 is drained off through passages 56 and 57, and 60 thus preventing exertion of a fluid force on the piston 47 and consequently leftward movement thereof.
After the engine has been started and its speed has increased a predetermined amount, pressure in intake mainfold 30 builds up, generating a corresponding pressure build up in chamber 35. Consequently, the diaphragm 76 is acted upon as a function of the increasing air pressure in chamber 35. This tends to compress spring members 72 and 73 and to move the valve spool 63 towards the right. Such movement eventually causes the land 64 to cover passages 56. Fluid is thus prevented from draining from the chamber 53 and fluid pressure begins to build therein to force the piston 47 towards the left into a control operative position. During this leftward movement, the shoulder 49a may engage stop member 20 and move the fuel adjusting member 17 to a decreased fuel position. FIG. 2 illustrates the fuel air control apparatus in this control operative position.
Note that although the valve spool 63 has shifted to the right to a certain extent due to the air pressure in chamber 35 acting on the diaphragm 76, the jam nuts 114, 116 do not yet abut against the shoulder 111. As the air pressure in chamber 35 continues to increase, however, the jam nuts 114, 116 will abut the shoulder 111 which will act as a stop means to restrain further rightward movement of the shaft 108. Further discussion of the effect of this structure is given hereinbelow.
When the engine is operating at idle, as shown in FIG. 2, the air pressure in the intake manifold and in chamber 35 together with the bias of spring member 78, are not sufficient to completely overcome the bias of spring members 72 and 73 acting upon the diaphragm 76. So long as the jam nuts 114, 116 do not abut shoulder 111, springs 102 and 104 have no effect on the position of the valve spool 63. Thus, the valve spool 63 is restrained in a leftward position, since its position is controlled by the position of the diaphragm member 76. Further, the piston 47 is in the operative position wherein land 64 effectively restricts the passages 56 permit only a predetermined amount of fluid to be metered from chamber 53, to thereby maintain the piston 47 in the position shown in FIG. 2. The passages 57, as seen in FIG. 2, are out of alignment with annular groove 58 and the drain passages 60 to prevent fluid drainage therethrough.
As previously described, when the lever 28 is moved counterclockwise, the spring 25 is compressed to cause loading and movement of the fuel adjusting member 17 rightwardly toward an increased fuel position. However, with the fuel-air ratio control device operative, the spring member 73 and 78 would tend to position the valve spool 63 toward the left. Therefore, the servo unit 46 and the shoulder 49a would permit only a slight movement of the fuel control member toward the increased fuel position.
As engine speed is increased from the low idle position indicated in FIG. 2, the air pressure in chamber 35 increases slightly to move the diaphragm 76 and thereby the valve spool 63 to the right. This causes the land 64 to move and slightly uncover the passages 56 to permit fluid to be metered out the opening, to drain through the outlet 120 via passages 122 in the seat member 74. Fuel adjusting member 17 would then be permitted to pull the servo unit to the right so long as the air pressure in chamber 35 was increasing and the valve spool 63 was moving rightwardly allowing thereby the valve means 48 to operate as above described.
FIG. 3 illustrates the fuel air ratio control apparatus of the present invention with the control apparatus in a state corresponding to the engine operating at its rated full power condition. As the control apparatus approaches this state, with increasing engine speed and consequent increasing air pressure, the jam nuts 114, 116 abut the shoulder 111 such that the rightward movement of the valve spool 63 causes spring 102 and 104 to be deflected. This deflection is enabled by the spacer 106, coupled to the jam nuts via shaft 108, which acts as a seat for the springs 102 and 104. The rightward movement of the valve spool 63 is coupled to the spring 102 and 104 by means of the seat 110 which is operatively connected to the valve spool 63 by means of the cylindrical member 69. Therefore, with the control apparatus in its full power position as seen in FIG. 3, the rates of springs 102 and 104 have become an additive influence on valve spool 63 movement, i.e., to move to the right, the diaphragm and valve spool 63 must overcome the spring rates of springs 102 and 104 in conjunction with the spring rates of springs 73, 72 and 78.
During normal operation of the engine, within a predetermined load and speed range as determined by the governor flyweights 22, sufficient air will be available within the chamber 35 to maintain the fuel-air ratio control apparatus in a position which does not restrict the slight movements encountered by the governor in maintaining that speed. However, as mentioned above, when an increased load on the engine occurs, engine speed goes down, creating an engine lug condition. The governor then attempts to return the engine to its rated speed by advancing the fuel adjusting member 17. To prevent any disproportionate amount of fuel from entering the engine due to the insufficient air available at the lower engine speed to support full combustion of the fuel, the fuel-air ratio control apparatus restrains the fuel adjusting member 17 until the air pressure is sufficient to allow full fuel combustion.
The improved apparatus provides resilient means comprising two additional spring 102 and 104 which, in conjunction with springs 78, 72, and 73 restrain the fuel adjusting member 17 during this critical engine lugging period. As mentioned above, all of these springs interact at this engine speed range, so that as the air pressure in chamber 35 drops due to the reducing engine speed, these springs allow leftward motion of spool valve 63 and thus the servo unit 46 and associated shoulder 49a to cause a lesser amount of fuel to be supplied via the operation of the fuel adjusting member then in prior art fuel-air control devices. The position of the servo unit 46 is changed as a function of valve spool 63, since land 64 is caused to restrict the passages 56 as valve spool 63 moves to the left, thereby allowing fluid forces in chamber 53 to build up and cause piston 47 of the servo unit 46 to also move leftwardly.
To put the above description in different terminology, normally when the engine speed goes down into a lugging state due to an increased load, the torque supplied by the engine goes up. The rate of this torque rise during engine lug is a function of the amount of fuel supplied to the engine. That is, the less fuel supplied, the less the resultant rate of torque rise. The springs 102 and 104 act as torque limiter springs. FIG. 4 illustrates the torque reduction available from the combined springs 102 and 104 as compared with prior are fuel-air ratio control devices. The dotted line curve illustrates the prior art operation. Note that the maximum torque attainable from an engine is also reduced with the combined springs of the present invention. Note also that jam, nuts 114 and 116 enable the adjustment of the duration of the increased torque limiting effect caused by springs 102 and 104. | An improved fuel-air ratio control apparatus for a supercharged engine having a governor means connected to a fuel adjusting member and a supercharger for supplying air through an intake manifold is disclosed. The control apparatus is directly engageable with the fuel adjusting member and is responsive to intake manifold air pressure and engine oil pressure. The apparatus is inoperative to restrain the adjusting member during start-up of the engine and remains so until such time as a predetermined intake manifold pressure is attained, at which time the control apparatus moves to a position which permits the metering of engine oil therethrough to permit normal governor operation and proportional increases of fuel with air pressure increased. The control apparatus thereafter automatically limits the fuel supplied to the engine, and therefore engine torque rise, during a decrease in engine speed caused by loading on the engine to thereby limit any undesired exhaust smoke. The improvement relates to the amount of torque reduction available from two torque reducer springs, and to the new means for adjustment of the rate of torque reduction using jam nuts. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
There are many occasions when a mixture of particles of different types must be separated; for example in the recovery of ore and in the sorting of trash. The different magnetic properties of the materials may permit a separation to be accomplished by passing the particles through a magnetic field, but, when the materials are not magnetically attractive, other separation techniques are necessary. Many materials, particularly plastic materials are electrically neutral and are not affected by magnetic charging, and thus separation depending on magnetic effects is not feasible. Separation based on differences in specific gravities is also widely used where possible, but in the case of plastic materials the specific gravities of different materials are frequently too similar to form a basis for such separation. It has now been found that such electrically neutral materials may be given a temporary surface charge that is sufficiently strong and persistent to permit a separation based on the different charges received by different materials.
It is an object of this invention to provide a process and apparatus for separating mixtures of two or more types of particles of electrically neutral materials. It is another object of this invention to provide a process and an apparatus for subjecting a feed mixture of electrically neutral particles of synthetic plastic material to a series of directional changes and interparticle contacts while in turbulent flow to produce particles with temporary surface charges, and separating those particles based on their surface charges. Still other objects will become apparent from the more detailed description which follows.
SUMMARY OF THE INVENTION
This invention relates to a process and an apparatus for causing electrically neutral particles to assume a surface electrical charge and separating the surface-charged particles according to their respective charges to recover particles of like charges. The process of this invention involves causing the electrically neutral particles to assume a surface electrical charge by subjecting the particles to turbulent flow involving interparticle physical contact and sudden directional changes, subjecting the resulting surface-charged particles to an electrical field to effect a separation between particles according to their charges.
The apparatus of this invention involves a particle separator such as that of U.S. Pat. No. 5,251,762 to Taylor and Jackson wherein electrically charged particles are passed vertically between rotating cylindrical electrodes to effect a separation at the exit of the separator between particles of different charges (i.e., negative or positive charges). For purposes of this invention, the apparatus of the patent is modified to receive a feed stream of electrically neutral particles and subject them to triboelectrification sometimes called "frictional charging", to cause the particles to become temporarily frictionally charged on the surfaces of the particles, and then to be subjected to the separation process of such patent so as to produce a separation between positively and negatively charged particles.
A particularly useful apparatus for imparting surfaces charges to the electrically neutral particles is a chamber that includes turns or changes in cross section along its length. When particles are caused to flow through the pipe under turbulent flow conditions, there are numerous high speed collisions between particles which, in turn, produce surface charges on the colliding particles, and it is these charges which are sufficient to permit a separation to be made in an apparatus such as that of the aforesaid U.S. Pat. No. 5,251,762. Where practical, the chamber preferably will have a chemical structure the same as the chemical structure of one of the constituents of the colliding particles. If that is impractical, the ratio of constituents in the mixture of colliding particles may be altered by "seeding" or adding solid particles used as a catalyst to further influence charging of the particle stream. The catalyst may be removed, prior to the physical separation of the electrically neutral particles, allowing it to be reused. The power to produce the turbulent flow in the particle stream may be produced by positive pressure behind the particle stream or by inducing a vacuum ahead of the particle stream.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The novel features believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a front elevational view of a particle separator fitted with blower means to produce turbulent flow within a stream of electrically neutral particles so as to produce surface electrical charges on the particles just prior to subjecting the particles to an electrostatic separation to separate charged particles of one type from charged particles of another type, in accord with a first embodiment of this invention;
FIG. 2 is a front elevational view of a particle separator fitted with a vacuum means to produce turbulent flow within a stream of electrically neutral particles so as to produce surface electrical charges on the particles just prior to subjecting the particles to an electrostatic separation to separate charged particles of one type from charged particles of another type, in accord with a second embodiment of this invention;
FIG. 3 is a side elevational view of the separator of FIG. 2;
FIG. 4 is a side elevational view of a pre-charging apparatus similar to that depicted in FIG. 1;
FIG. 5 is a side elevational view of a pre-charging apparatus surrounding a vacuum, in accord with a third embodiment of this invention;
FIG. 6 is a top plan view of the apparatus of FIG. 5;
FIG. 7 is a side elevational view of a baffled pre-charging apparatus in accord with a fourth embodiment of this invention;
FIG. 8 is an end elevational view of the apparatus of FIG. 7; and
FIG. 9 is a front elevational view of a particle separator similar to FIG. 1 and having a catalyst being added to "seed" the particle stream of electrically neutral particles, in accord with a fifth embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
This invention is shown in detail in the accompanying drawings. In FIG. 1 there is shown storage hopper 10 movable so as to be able to deposit particles of electrically neutral material, e.g., plastic sheeting broken into particles, carpet material, etc., onto moving table or belt 11, which, in turn, directs those particles into feed hopper 12. Blower 13 directs pressurized air through chamber or conduit 14 in the direction of arrow 15 carrying along the particles dropped into conduit 14 from feed hopper 12. Conduit 14 passes through a series of generally right angle turns 16 A-H before emptying into a centrifugal separator 17 which discharges the charged electrically neutral particles into hopper 30 at the top of an electrostatic separator similar to that of U.S. Pat. No. 5,251,762 and recovers at the lower end thereof a separation between the charged particles and the uncharged particles. The flow of particles and air through conduit 14 must be turbulent and there must be sufficient right hand turns 16 in conduit 15 to produce temporary surface charging of such particles. Turbulent flow conditions generally exist when the flow is not streamlined and frequently is measured by reference to a Reynolds Number, well known in fluid flow calculations.
The size of the chamber or conduit 14 and the number of turns or cross sectional changes are not critical except to the extent that the particles exiting from the chamber must exhibit electrical charges on the particle surfaces. These charges are temporary in that the charges do not persist when the material is at rest. The charges are developed by collisions with other particles in a fluid flow system, particularly when that flow is in a form known as "turbulent flow" to engineers proficient in fluid flow mechanics. When such a condition exists the particles in the turbulent flow system assume surface electrical charges that can be used to separate charged particles from uncharged particles.
In FIGS. 2 and 3 there are shown features of a system similar to that described above except that the particles are not motivated by the pressure of a blower but are motivated by being subjected suddenly to an evacuated chamber. In FIGS. 2 and 3 a vacuum chamber 20 is connected by pipe 21 to a dehumidifying chamber 22. The particulate feed enters from hopper 23 to belt 24 and passes under heat lamps 25 to a receiver 26 until ready for loading into chamber 20. When it is time to feed particles into chamber 20 it is done by suction through line 27. Suction pump 28 maintains a vacuum in chamber 20 through line 29 and to connections thereto. When surface charging has been completed the particles are fed through hopper 30 into the top of an electrostatic separator such as that of U.S. Pat. No. 5,251,762, which separated particles being recovered from the discharge end of that separator.
FIG. 4 depicts the most common and preferred apparatus for charging the particles. The conduit 35 is similar to conduit 14 of FIG. 1 that is bent in several places along its length to produce a number of generally right angle turns. The size of the pipe and the number of turns are not critical except to the extent that the particles exiting from the pipe must exhibit electrical charges on their surfaces.
FIGS. 5 and 6 depict another pre-charging apparatus in which a conduit 36 that is bent in several places along its length to produce a number of turns. The size of the pipe and the number of turns are not critical except to the extent that the material exiting from the pipe must exhibit electrical charges on its surface. This apparatus may be used where frequent cleaning of the apparatus is required and disassembly is impractical. This conduit 36 may be required when, for example, the mixture of electrically neutral particles also contains a conductive contaminant. While providing sufficient, though not necessarily optimal pre-charging, this configuration facilitates cleaning to remove conductive coating of the interior of conduit 36. Some electrically neutral streams may contain conductive contaminants which over a period of time may coat the pre-charging apparatus, thus diminishing its effectiveness. The conduit 36 will provide turbulent flow regimes at the same time the shallow angle turns allow for manual cleaning without disassembly.
FIGS. 7 and 8 depict an elongated conduit 37 that has several internal baffles 38, 39 spaced along the length thereof. The baffles provide flow interruptions and abrupt changes of direction and enhance contact charging of the particles. The size of the pipe, number of baffles and baffle spacing is not critical except to the extent that the particles exiting from the conduit must exhibit electrical charges on their surfaces. The baffles 38, 39 require the particles to repeatedly and rapidly change both direction and velocity in a short distance. These baffles 38, 39 significantly increase drag in the conveying system and would likely be advantageous only in applications where space is limited.
FIG. 9 depicts an enhancement to that described in FIG. 1 except that the pellets 40 are added to the particle stream. Pellets 40 are added to the particulate feed in hopper 1. The particulate feed and pellets are blended as it moves through the conveying system 2 and 3. When surface charging has been completed the mixture of pellets and particles are separated by a screen 41. The pellets 40 are, for example, screened at 41 for reuse through the return pipe 5 to feed hopper 1. The charged particles are fed through hopper 6 into the top of an electrostatic separator such as that of U.S. Pat. No. 5,251,762 which separated particles being recovered from the discharge end of that separator. The pellets 40 are of the same chemical composition as one of the particle stream's constituents. The particle size within the stream of electrically neutral particles is by design different than the size of the pellets 40. The size differential facilitates separation, as by screen 41, of the pellets 40 from the stream once a surface charge has been induced on the particles to be separated.
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention. | A process and apparatus for subjecting a mixture of two types of electrically charged particles to intense physical contact through a pneumatic transfer modified by turbulent flow and path interruptions to produce surface electrical charges on the particles, and separating the charged particles to recover particles having the same charge. Seeding with a recoverable catalyst may be used as well as forming the path of the mixture from one of the two types of electrically neutral particles. The path interruptions may be sudden directional changes, circuitous paths, baffles, induced vortices and other mechanical apparatus. | 1 |
This application is a continuation of application Ser. No. 08/591,217 filed on Jan. 17, 1996 (now abandoned), which is a is a continuation of application Ser. No. 08,291,611 filed Aug. 17, 1994 (now U.S. Pat. No. 5,496,507), which is a continuation-in-part of application Ser. No. 08/107,517 filed Aug. 17, 1993 (now abandoned). Issued U.S. Pat. No. 6,119,691 is also related to this case.
FIELD OF THE INVENTION
The invention concerns electret-enhanced filter media (more simply called “electret filters”) made of fibers such as melt-blown microfibers. The invention concerns an improved method for making fibrous electret filters for removing particulate matter from air. The invention is especially concerned with respirators and improving the level of filtration-enhancing electrostatic charges on the filter media.
DESCRIPTION OF THE RELATED ART
For many years nonwoven fibrous filter webs have been made from polypropylene using melt-blowing apparatus of the type described in Report No. 4364 of the Naval Research Laboratories, published May 25, 1954, entitled “Manufacture of Super Fine Organic Fibers” by Van A. Wente et al. Such melt-blown microfiber webs continue to be in widespread use for filtering particulate contaminants, e.g., as face masks and as water filters, and for other purposes, e.g., as a sorbent web to remove oil from water, acoustic insulation and thermal insulation.
The filtration quality of a melt-blown microfiber web can be improved by a factor of two or more when the melt-blown fibers are bombarded as they issue from the die orifices with electrically charged particles such as electrons or ions, thus making the fibrous web an electret. Similarly, the web can be made an electret by exposure to a corona after it is collected. Melt-blown polypropylene microfibers are especially useful, while other polymers may also be used such as polycarbonates and polyhalocarbons that may be melt-blown and have appropriate volume-resistivities under expected environmental conditions.
Fibrous filters for removing particulate contaminants from the air are also made from fibrillated polypropylene films. Electret filtration enhancement can be provided by electrostatically charging the film before it is fibrillated.
Common polymers such as polyesters, polycarbonates, etc. can be treated to produce highly charged electrets but these charges are usually short-lived especially under humid conditions. The electret structures may be films or sheets which find applications as the electrostatic element in electro-acoustic devices such as microphones, headphones and speakers, in dust particle control, high voltage electrostatic generators, electrostatic recorders and other applications.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a method of charging a nonwoven web of thermoplastic microfibers to provide electret filter media comprising impinging on a nonwoven web of thermoplastic nonconductive microfibers capable of having a high quantity of trapped charge jets of water or a stream of water droplets at a pressure sufficient to provide the web with filtration enhancing electric charge and drying said web. Surprisingly, it has been found that merely by impinging these jets of water or stream of water droplets onto the nonwoven microfiber web, the web develops filtration enhancing electret charge. The charging can be further enhanced by subjecting the web to corona discharge treatment prior to impingement by the water. Preferably, the web is formed from melt blown polypropylene microfibers, poly(4-methyl-1-pentene) microfibers or blends thereof. The term “hydrocharging” will be used herein to describe this method.
The webs appear to be charged after impingement by jets of water or a stream of water droplets because when a hydrocharged web is exposed to unfiltered x-ray radiation, the filtration efficiency is markedly reduced.
The fibrous electret filter produced by the method of the present invention is especially useful as an air filter element of a respirator such as a face mask or for such purposes as home and industrial air-conditioners, air cleaners, vacuum cleaners, medical air line filters, and air conditioning systems for vehicles and common equipment such as computers, computer disk drives and electronic equipment. In respirator uses, the electret filters may be in the form of molded or folded half-face masks, replaceable cartridges or canisters, or prefilters. In such uses, an air filter element produced by the method of the invention is surprisingly effective for removing particulate aerosols. When used as an air filter, such as in a respirator, the electret filter media has surprisingly better filtration performance than does a comparable electret filter charged by known methods.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an apparatus useful in making the nonwoven microfiber web used in the method of the present invention.
FIG. 2 is a perspective view of a water jet spray apparatus useful in the present invention.
FIG. 3 is a perspective view of a nebulizer useful in the present invention.
FIG. 4 is a perspective view of a pump action sprayer useful in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The melt blown microfibers useful in the present invention can be prepared as described in Van A. Wente, “Superfine Thermoplastic Fibers,” Industrial Engineering Chemistry , vol. 48, pp. 1342-1346 and in Report No. 4364 of the Naval Research Laboratories, published May 25, 1954, entitled “Manufacture of Super Fine Organic Fibers” by Van A. Wente et al.
The resin used to form the melt blown microfibers is a thermoplastic nonconductive, i.e., having a resistivity greater than 10 14 ohm·cm, resin capable of having a high quantity of trapped charge. Preferred resins include polypropylene, poly(4-methyl-1-pentene) and blends thereof. The resin should be substantially free from materials such as antistatic agents which could increase the electrical conductivity or otherwise interfere with the ability of the fibers to accept and hold electrostatic charges. The melt blown microfibers can be of a single resin, formed of a resin blend, e.g., polypropylene and poly(4-methyl-1-pentene, or formed of two resins in layered or core/sheath configurations. When polypropylene and poly(4-methyl-1-pentene) are used in layered or core/sheath configurations, the poly(4-methyl-1-pentene) is preferably on the outer surface.
Blown microfibers for fibrous electret filters of the invention typically have an effective fiber diameter of from about 3 to 30 micrometers preferably from about 7 to 15 micrometers, as calculated according to the method set forth in Davies, C. N., “The Separation of Airborne Dust and Particles,” Institution of Mechanical Engineers, London, Proceedings 1B, 1952.
Staple fibers may also be present in the web. The presence of staple fibers generally provides a more lofty, less dense web than a web of only blown microfibers. Preferably, no more than about 90 weight percent staple fibers are present, more preferably no more than about 70 weight percent. Such webs containing staple fiber are disclosed in U.S. Pat. No. 4,118,531 (Hauser) which is incorporated herein by reference.
Sorbent particulate material such as activated carbon or alumina may also be included in the web. Such particles may be present in amounts up to about 80 volume percent of the contents of the web. Such particle-loaded webs are described, for example, in U.S. Pat. No. 3,971,373 (Braun), U.S. Pat. No. 4,100,324 (Anderson) and U.S. Pat. No. 4,429,001 (Kolpin et al.), which are incorporated herein by reference.
The electret filter media prepared according to the method of the present invention preferably has a basis weight in the range of about 10 to 500 g/m 2 , more preferably about 10 to 100 g/m 2 . In making melt-blown microfiber webs, the basis weight can be controlled, for example, by changing either the collector speed or the die throughput. The thickness of the filter media is preferably about 0.25 to 20 mm, more preferably about 0.5 to 2 mm. The electret filter media and the polypropylene resin from which it is produced should not be subjected to any unnecessary treatment which might increase its electrical conductivity, e.g., exposure to gamma rays, ultraviolet irradiation, pyrolysis, oxidation, etc.
Nonwoven microfiber webs useful in the present invention may be prepared using an apparatus as shown in FIG. 1 . Such an apparatus includes a die 20 which has an extrusion chamber 21 through which liquified fiber-forming material is advanced; die orifices 22 arranged in line across the forward end of the die and through which the fiber-forming material is extruded; and cooperating gas orifices 23 through which a gas, typically heated air, is forced at high velocity. The high velocity gaseous stream draws out and attenuates the extruded fiber-forming material, whereupon the fiber-forming material solidifies as microfibers during travel to a collector 24 to form web 25 .
When staple fibers are present in the web, they may be introduced through use of a lickerin roll 32 disposed above the microfiber blowing apparatus as shown in FIG. 1. A web 27 of staple fibers, typically a loose, nonwoven web such as prepared on a garnet or RANDO-WEBBER apparatus, is propelled along table 28 under drive roll 29 where the leading edge engages against the lickerin roll 32 . The lickerin roll 32 picks off fibers from the leading edge of web 27 separating the fibers from one another. The picked fibers are conveyed in an air stream through an inclined trough or duct 30 and into the stream of blown microfibers where they become mixed with the blown microfibers.
When particulate matter is to be introduced into the web it may be added using a loading mechanism similar to duct 30 .
Hydrocharging of the web is carried out by impinging jets of water or a stream of water droplets onto the web at a pressure sufficient to provide the web with filtration enhancing electret charge. The pressure necessary to achieve optimum results will vary depending on the type of sprayer used, the type of polymer from which the web is formed, the thickness and density of the web and whether pretreatment such as corona charging was carried out prior to hydrocharging. Generally, pressures in the range of about 10 to 500 psi (69 to 3450 kPa) are suitable. Preferably the water used to provide the water droplets is relatively pure. Distilled or deionized water is preferable to tap water.
The jets of water or stream of water droplets can be provided by any suitable spray means. Those apparatus useful for hydraulically entangling fibers are generally useful in the method of the present invention, although operation is carried out at lower pressures in hydrocharging than generally used in hydroentangling.
An example of a suitable spray means is shown in FIG. 2 where fibrous web 10 is transported on support means 11 . The transport means may be in the form of a belt, preferably porous, such as a mesh screen or fabric. Water jets 12 in water jet head 13 provide the water spray with a pump (not shown) providing the water pressure. Water jets 12 impinge on web 10 at impingement points 12 ′. Preferably, a vacuum is provided beneath a porous support to aid in passage of the spray through the web and to reduce drying energy requirements.
Further examples of spray means suitable for use in the method of the present invention include nebulizers such as that shown in FIG. 3 wherein water provided through water line 14 and pressurized air provided through air line 15 are supplied to a nozzle 16 to provide a spray mist to impact web 10 and pump action sprayers such as that shown in FIG. 4 where a pump handle 17 forces water provided by water supply means 18 through nozzle 19 to provide a spray mist.
In the following examples, all percentages and parts are by weight unless otherwise noted. The following test method was used to evaluate the 5 examples.
DOP Penetration and Pressure Drop
Dioctyl phthalate (DOP) 0.3 micrometer diameter particles at a concentration of between 70 and 110 mg/m 3 are generated using a TSI No. 212 sprayer with four orifices and 30 psi (207 kPa) clean air. The particles are forced through a sample of filter media which is 11.45 cm in diameter at a rate of 42.5 L/min, which is a face velocity of 6.9 centimeters per second. The sample was exposed to the aerosol for 30 seconds. The penetration is measured with an optical scattering chamber, Percent Penetration Meter Model TPA-8F available from Air Techniques Inc. The DOP penetration is preferably less than about 70%, more preferably less than about 40%. The pressure drop is measured at a flow rate of 42.5 L/min and a face velocity of 6.9 cm/sec using an electronic manometer. Pressure drop is reported as ΔP in mm of water. Preferably the pressure drop is less than about 4 mm of water, more preferably less than about 3 mm of water for a single layer of web.
The penetration and pressure drop are used to calculate a quality factor “QF value” from the natural log (On) of the DOP penetration by the following formula: QF [ 1 / mm H 2 O ] = - Ln [ DOP Penetration ( % ) 100 ] Pressure Drop [ mm H 2 O ]
A higher initial QF value indicates better initial filtration performance. Decreased QF values effectively correlate with decreased filtration performance. Generally a QF value of at least about 0.25 is preferred, a value of at least about 0.5 is more preferred and a value of at least about 1 is most preferred.
Cigarette Smoke Adsorption Test
The cigarette smoke adsorption test was performed in a test chamber having rectangular dimensions with a volume of 1 m 3 which contained an aspirator (CAM 770 Room Air Cleaner, Norelco Company) fitted with a flat filter sample (14 cm×14 cm). A smoker device capable of smoking a predetermined number of cigarettes (1-10) emitted smoke within the test chamber during a controlled burn time of 4 to 5 minutes. A fan provided uniform mixing of the cigarette smoke generated within the test chamber. A laser particle counter (Model PMS LAS-X from Particle Measurement System, Colorado) having a sampling flow rate of 5 cc/sec and a detection range of 0.1 to 7.5 micrometer particle size monitored the particle concentration per count within the test chamber environment. The particle trapping efficiency and the pressure drop of the filter samples were measured before and after the adsorption of the cigarette smoke.
The particle trapping efficiency of the filter media was measured using a TSI AFT-8110 automated filter tester (TSI, St. Paul, Minn.) with NaCl particles and a face velocity of air passing through the sample of 26.7 cm/sec. The concentration of the NaCl particles, C in and C out , at positions upstream and downstream, respectively, of the filter samples were measured using the photometer in the TSI AFT-8110 and the particle trapping efficiency, E, of the filter was calculated using the formula:
E=(1−[C out /C in ]× 100%.
Ambient Air Particle Loading Test
Filter samples were subjected to ambient air at a flow rate of 149 ft 3 /min (250 m 3 /hr) for extended periods of time using samples 300 mm×116 mm and then challenged with particles of 0.3 micrometers and 1.0 micrometers in size. The resultant particle trapping efficiencies were measured as described in the cigarette smoke adsorption test both prior to the challenge and after designated ambient air loading times.
EXAMPLES 1-7 AND COMPARATIVE EXAMPLES C1-C2
A polypropylene (ESCORENE 3505G, available from Exxon Corp.) microfiber web was prepared as described in Wente, Van A., “Superfine Thermoplastic Fibers,” Industrial Engineering Chemistry , vol. 48, pp. 1342-1346. The web had a basis weight of 55 g/m 2 and a thickness of 0.1 cm. The effective fiber diameter of the fibers was 7.6 μm. Samples of the web were subjected to impingement of water jets provided by a hydroentangler (Laboratory Model, serial no. 101, available from Honeycomb Systems Corp.), similar to that shown in FIG. 1, which had a spray bar width of 24 in (0.6 m) with 40 spray orifices, each 0.005 in (0.13 mm) in diameter, per inch (2.5 cm) width at various water pressures as set forth in Table 1. Each sample passed beneath the spray bar at a rate of 3.5 m/min, and was treated once on each face, vacuum extracted and dried at 70° C. for one hour. The treated samples were tested for DOP penetration and pressure drop and the quality factor was calculated. The penetration (Pen) and quality factor (QF) are reported in Table 1.
TABLE 1
Pressure
Pen
Example
(kPa)
(%)
QF
C1
34.5
78
0.09
C2
69
72
0.11
1
172
39
0.31
2
345
32
0.37
3
690
35
0.34
4
1380
39
0.34
5
2070
43
0.34
6
2760
46
0.31
7
3450
46
0.34
As can be seen from the data in Table 1, hydrocharging (at pressures of at least about 170 kPa) develops useful levels of electret enhanced filtration characteristics in this web.
EXAMPLES 8-15 AND COMPARATIVE EXAMPLES C3-C4
A web was prepared as in Examples 1-7 and subjected to corona treatment by passing the web, in contact with an aluminum ground plane, under a positive DC corona twice at a rate of 1.2 m/min with the current maintained at about 0.01 mA/cm corona source and the corona source was about 4 cm from the ground plate. Samples of this web were then subjected to impingement of water jets as in Examples 1-7 at various pressures as set forth in Table 2. The treated samples were tested for DOP penetration and pressure drop and the quality factor was calculated. The penetration (Pen) and quality factor (QF) are reported in Table 2.
TABLE 2
Pressure
Pen
Example
(kPa)
(%)
QF
C3
0
27
0.38
C4
69
21
0.46
8
172
16
0.55
9
345
15
0.57
10
690
15
0.61
11
1380
15
0.66
12
2070
13
0.80
13
2760
14
0.79
14
3450
18
0.75
15
4140
25
0.61
As can be seen from the data in Table 2, hydrocharging (at pressures greater than about 170 kPa) increased the electret filtration characteristics of this web.
EXAMPLES 16-21 AND COMPARATIVE EXAMPLE C5
A web was prepared as in Examples 1-7 except the polymer used was poly4-methyl-1-pentene (TPX MX-007, available from Mitsui Chemical Co. The web was subjected to corona treatment as in Examples 8-15. In Examples 16-21, samples of this web were then subjected to impingement of water droplets as in Examples 1-7 at various pressures as set forth in Table 3. The treated samples were tested for DOP penetration and pressure drop and the quality factor was calculated. The penetration (Pen) and quality factor (QF) are reported in Table 3.
TABLE 3
Pressure
Pen
Example
(kPa)
(%)
QF
C5
0
19
0.85
16
69
11
1.31
17
172
2.1
2.06
18
345
2.0
2.06
19
1035
2.9
1.97
20
1380
3.1
1.75
21
2760
11
1.12
As can be seen from the data in Table 3, hydrocharging poly-4-methyl-1-pentene webs at pressures of about 69 kPa and greater produced webs having excellent electret enhanced filtration characteristics.
EXAMPLES 22-24 AND COMPARATIVE EXAMPLES C6-C8
In Examples 22-24 and Comparative Examples C6-C8, polypropylene (ESCORENE 3505G) microfiber webs containing 50 weight percent staple fiber were prepared as described in U.S. Pat. No. 4,118,531 (Hauser). Each web weighed about 50 g/m 2 . In Example 22 and Comparative Example C6, the staple fiber was 17 denier, 5.1 cm long polypropylene, natural, available from Synthetic Industries (17d PP); in Example 23 and Comparative Example C7, the staple fiber was 15 denier, 3.1 cm polyester, KODEL K-431 available from Eastman Chemical Company (15d PET); and in Example 24 and Comparative Example C8, the staple fiber was 6 denier, 5.1 cm polyester, KODEL K-211 available from Eastman Chemical Company (6d PET). Prior to use, the polyester staple fibers were washed to remove surface finish using about 2 weight percent LIQUINOX (available from Alconox, Inc.) in hot water (about 140° F., 60° C.) with agitation for about 5 minutes, rinsed and dried.
Samples of each web were subjected to corona treatment as described in Examples 8-15. In Examples 22-24, the webs were subsequently subjected to impingement of water spray as in Examples 1-7 at a rate of 3.5 m/min with a hydrostatic pressure of 690 kPa. The treated samples were tested for DOP penetration and pressure drop and the quality factor was calculated. The penetration (Pen) and quality factor (QF) are reported in Table 4.
TABLE 4
Pen
Example
Fiber Type
(%)
QF
22
17d
PP
49
1.67
23
15d
PET
44
2.24
24
6d
PET
47
1.82
C6
17d
PP
68
0.95
C7
15d
PET
72
0.97
C8
6d
PET
76
0.82
As can be seen from the data in Table 4, hydrocharging webs of mixtures of melt blown microfibers and staple fibers after corona treatment increases the Quality Factor when compared to webs treated only with corona charging. The most significant increase was seen in the web containing 50 percent 15 denier polyester staple fiber.
EXAMPLES 25-26 AND COMPARATIVE EXAMPLE C9
A polypropylene web was prepared as in Examples 1-7. The web had a basis weight of 54 g/m 2 and a thickness of 1.04 mm. The effective fiber diameter was 7.5 μm. In Comparative Example C9, a sample of the web was corona charged as in Examples 8-15. In Example 25, a sample was hydrocharged using a nebulizer (Model SCD 052H, available from Sonic Development Corp., resonator cap removed) with an air pressure of 380 to 414 kPa and water at atmospheric pressure at a distance of about 7 to 12 cm on each side. In Example 26, a sample was corona charged as in Comparative Example C9 and then hydrocharged as in Example 25. The treated samples were tested for DOP penetration and pressure drop and the quality factor was calculated. The penetration (Pen) and quality factor (QF) are reported in Table 5.
TABLE 5
Pen
Example
(%)
QF
C9
25
0.56
25
45.5
0.36
26
21
0.67
As can be seen from the data in Table 5, hydrocharging this web with the nebulizer (Example 25) provided enhanced filtration characteristics although the Quality Factor was not as high as that charged only with corona charging (Comparative Example C9). Hydrocharging with the nebulizer after corona treatment provided the highest Quality Factor in the examples in Table 5.
EXAMPLE 27 AND COMPARATIVE EXAMPLE C10
A web was prepared as in Examples 1-7 except the polymer used was a pellet blend of 75% polypropylene (FINA 3860X, available from Fina Oil & Chemical Co.) and 25% poly(4-methyl-1-pentene) (TPX MX-007, available from Mitsui Chemical Co.). The web was 1.0 mm thick and had a basis weight of 55 g/m 2 . The effective fiber diameter was 8.1 μm. In Example 27, a sample of the web was subjected to corona treatment and then to impingement of jets of water as in Examples 8-15 using water pressure of 345 kPa (50 psi). In Comparative Example C10, a sample was subjected to only corona treatment. The treated samples were tested for DOP penetration and pressure drop and the quality factor was calculated. The penetration (Pen) and quality factor (QF) are reported in Table 6.
TABLE 6
Pen
Example
(%)
QF
27
6.8
1.16
C10
29
0.51
As can be seen from the data in Table 6, hydrocharging significantly enhanced the filtration characteristics of the web of Example 27 over that of the web of Comparative Example C10 which was only corona charged.
EXAMPLE 28
A polypropylene/poly(4-methyl-1-pentene) multilayer microfiber was prepared as in Examples 1-7 except the apparatus utilized two extruders and a three-layer feedblock (splitter assembly) following the method for forming microfiber webs having layered fibers as described in U.S. Pat. No. 5,207,970 (Joseph et al.) which is incorporated herein by reference. The first extruder delivered a melt stream of a 50 melt flow rate polypropylene resin, available from FINA Oil and Chemical Co., to the feedblock assembly which heated the resin to about 320° C. The second extruder, which heated the resin to about 343° C., delivered a melt stream of poly(4-methyl-1-pentene) supplied as TPX™ grade MX-007 by Mitsui Petrochemical Industries, Ltd. to the feedblock. The feedblock split the two polymer streams. The polymer melt streams were merged in an alternating fashion into a three-layer melt stream on exiting the feedblock, with the outer layers being the poly(4-methyl-1-pentene) resin. The gear pumps were adjusted so that a 75:25 pump ratio of polypropylene:poly(4-methyl-1-pentene) polymer melt was delivered to the feedblock assembly. Webs were collected at a collector to die distance of 28 cm (11 in.). The resulting web of three-layer microfibers had an effective fiber diameter of less than about 8 micrometers and a basis weight of 55 g/m 2 . The web was subjected to corona treatment as described in Examples 8-15, then, to impingement of water as described in Examples 1-7 using a water pressure of 345 kPa. The web was then subjected to vacuum extraction and dried at 70° C. for one hour. The pressure drop and penetration were measured on the web before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 7.
EXAMPLE 29
A web having a basis weight of 55 g/m 2 and comprising three-layer microfibers having an effective fiber diameter less than about 8 micrometers was prepared as in Example 28, except the polypropylene and the poly(4-methyl-1-pentene) melt streams were delivered to the three-layer feedblock at a 50:50 ratio and the collector to die distance was 23 cm (9 inches). The resulting web was corona treated and subsequently subjected to impingement of water jets and dried as in Example 28. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 7.
EXAMPLE 30
A web having a basis weight of 55 g/m 2 and comprising three-layer microfibers having an effective fiber diameter less than about 8 micrometers was prepared as in Example 28, except the polypropylene and poly(4-methyl-1-pentene) melt streams were delivered to the three-layer feedblock in a 25:75 ratio and the collector to die distance was 7.5 inches (19 cm). The resulting web was corona treated and subsequently subjected to impingement of water jets and dried as in Example 28. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 7.
EXAMPLE 31
A web of the poly(4-methyl-1-pentene) was prepared as in Example 28, except only one extruder, which heated the resin to 343° C., was used. The extruder was connected directly to the die through a gear pump. The collector distance from the die was 19 cm (7.5 inches). The resulting web having an effective fiber diameter of 8.5 micrometers and a basis weight of 55 g/m 2 was corona treated and subsequently subjected to impingement of water jets and dried as in Example 28. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 7.
EXAMPLE 32
A web having a basis weight of 55 g/m 2 and comprising three-layer microfibers having an effective fiber diameter less than about 8 micrometers was prepared as in Example 28, except the second extruder delivered a melt stream of a pellet blend of 50 melt flow polypropylene resin, available from FINA, and poly(4-methyl-1-pentene) resin (Mitsui “TPX” grade MX-007) to the feedblock. The polymer melt streams were merged in an alternating fashion into a three layer melt stream, with the outer layers being pellet blend (75 weight percent polypropylene:25 weight percent poly(4-methyl-1-pentene). The gear pumps were adjusted to deliver a 50:50 weight ratio of polypropylene:pellet blend polymer melt to the feed block assembly. The collector distance from the die was 19 cm (7.5 in). The resulting web was corona treated and subsequently subjected to impingement of water jets and dried as per Example 28 treatment. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 7.
TABLE 7
Pen %
QF
Corona +
Corona +
Pen %
QF
Water Jet
Water Jet
Example
Corona Only
Corona Only
Impingement
Impingement
28
19.7
0.75
3.7
1.45
29
15.4
0.8
6.3
1.30
30
15.6
0.9
4.8
1.49
31
19.4
0.73
2.5
1.52
32
39.0
0.42
9.1
1.2
As can be seen from the data in Table 7, the webs containing fibers having outer layers of, or containing poly(4-methyl-1-pentene), showed excellent levels of enhanced filtration characteristics when subjected to both corona treatment and impingement of water jets.
EXAMPLE 33
A web having a basis weight of 63 g/m 2 and comprising five-layer microfibers having an effective fiber diameter of less than about 10 micrometers was prepared as in Example 28 except that the polypropylene and poly(4-methyl-1-pentene) melt streams were delivered to the five-layer feedblock in a 50:50 weight ratio. The polymer melt streams were merged in an alternating fashion into a five-layer melt stream on exiting the feedblock, with the outer layers being the poly(4-methyl-1-pentene) resin. The resultant web was subjected to corona treatment by passing the web, in contact with an aluminum ground plate, under six positive DC corona sources, sequentially at a rate of 7 m/min with the current maintained at about 0.05 mA/cm and the corona source was about 7 cm from the ground plate. The corona treated web was then subjected to impingement of water jets as in Example 28 except the water pressure was 690 kPa. The web was vacuum extracted and dried in a through-air drier at 82° C. for about 45 seconds. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 8.
EXAMPLE 34
A web having a basis weight of 62 g/m 2 and comprising five-layer microfibers having an effective fiber diameter less than about 10 micrometers was prepared as in Example 28, except only one extruder, which heated the resin to 340°C. was used. The extruder delivered a melt stream of a pellet blend containing 50 weight percent 50 melt flow polypropylene resin and 50 weight percent poly(4-methyl-1-pentene) (Mitsui “TPX” grade MX-007) to the feedblock. The resulting web was corona treated and also subsequently subjected to impingement of water jets and dried as in Example 33. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 8.
EXAMPLE 35
A web having a basis weight of 62 g/m 2 and comprising five-layer microfibers having an effective fiber diameter of less than about 10 micrometers was prepared as in Example 33 except the second extruder delivered a melt stream of a poly(4-methyl-1-pentene) supplied as “TPX” grade DX820 by Mitsui Petrochemical Industries, Ltd., to the feedblock. The polymer melt streams were merged in an alternating fashion into a five layer melt stream, with the outer layers being poly(4-methyl-1-pentene). The gear pumps were adjusted to deliver a 50:50 weight ratio of the polypropylene:poly(4-methyl-1-pentene) polymer melt to the feed block assembly. The resulting web was corona treated and also subsequently subjected to impingement of water jets and dried as in Example 33. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 8.
EXAMPLE 36
A web having a basis weight of 59 g/m 2 and comprising five-layer microfibers having an effective fiber diameter of less than about 10 micrometers was prepared as in Example 28 except the second extruder delivered a melt stream of a pellet blend of 80 weight percent 50 melt flow polypropylene resin and 20 weight percent poly(4-methyl-1-pentene) (Mitsui “TPX” grade MX-007) to the feedblock. The polymer melt streams were merged in an alternating fashion into a five layer melt stream, with the outer layers being the pellet blend. The gear pumps were adjusted to deliver a 50:50 weight ratio of the polypropylene:pellet blend polymer melt to the feed block assembly. The resulting web was corona treated and also subsequently subjected to impingement of water jets and dried as in Example 33. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 8.
EXAMPLE 37
A web of poly(4-methyl-1-pentene) (Mitsui “TPX” grade MX-007) was prepared utilizing a five layer melt stream as in Example 28, except only one extruder which heated the resin to 343° C., was used. The extruder was connected directly to the die through a gear pump. The resulting web was corona treated subsequently subjected to impingement of water jets and dried as in Example 33. The basis weight was 65 g/m3 and the effective fiber diameter was less than 10 micrometers. The pressure drop and penetration were measured on webs before impingement of water jets (corona treatment only) and after both corona treatment and impingement with water jets and the quality factor was calculated. The penetration and quality factor are reported in Table 8.
TABLE 8
Pen %
QF
Corona +
Corona +
Pen %
QF
Water Jet
Water Jet
Example
Corona Only
Corona Only
Impingement
Impingement
33
26.7
0.66
7.8
1.31
34
28.7
0.49
11.8
0.94
35
25.8
0.55
9.3
1.01
36
26.4
0.56
13.7
0.9
37
25.2
0.51
7.1
1.24
EXAMPLES 38a-d, 39a-d AND 40a-d
Circular filter layers 10.16 cm in diameter and 1.3 mm thick were prepared from web materials prepared as described in Example 35 for Examples 38a-d, Example 36 for Examples 39a-d and Example 37 for Examples 40a-d. Circular filter elements were assembled of various numbers of layers, as indicated in Table 9, of charged electret filter media as in U.S. Pat, No. 4,886,058 (Brostrom et al.) for the front and rear walls of the filter elements. Each assembled filter element had a singular, circular polypropylene breather tube having an inner diameter of 1.91 cm. The filter elements were subjected to the DOP penetration and pressure drop test. The results are reported in Table 9.
EXAMPLES 41a-e
A web of 50 melt flow polypropylene resin was prepared as in Example 33, except that only one extruder, which heated the resin to 320° C. was used, and it was connected directly to the die though a gear pump. The resulting web had a basis weight of 55 g/m 2 and an effective fiber diameter of less than about 8 micrometers. The resulting web was corona treated and also subsequently subjected to impingement of water jets and dried as in Example 33.
Filter elements containing various numbers of layers of the electret web were prepared and tested as in Examples 38-40. The results are set forth in Table 9
COMPARATIVE EXAMPLE C11
A web of 50 melt flow polypropylene resin was prepared as in Example 41 except the resultant web was only corona treated. A filter element using six layers of electret filter media was assembled and tested as in Examples 38-40. The results are set forth in Table 9.
TABLE 9
Layers
Initial
Loaded
of Filter
Initial
Pressure
Loaded
Pressure
Media
Penetration
Drop
Penetration
Drop
Ex.
per wall
(%)
(mm H 2 O)
(%)
(mm H 2 O)
38a
5
0.001
18.5
0.001
18.9
b
4
0.001
15.4
0.003
15.9
c
3
0.007
12.4
0.018
12.8
d
2
0.161
9.6
0.529
9.8
39a
5
0.002
17.6
0.006
18.0
b
4
0.013
13.8
0.032
14.1
c
3
0.114
11.9
0.294
12.4
d
2
0.840
8.9
2.15
9.3
40a
5
0.001
23.3
0.001
23.8
b
4
0.001
18.4
0.001
18.9
c
3
0.080
14.5
0.017
14.9
d
2
0.167
10.8
0.311
11.1
41a
6
0.001
21.4
0.001
21.8
b
5
0.001
16.7
0.002
17.0
c
4
0.001
15.0
0.021
15.3
d
3
0.007
12.0
0.237
12.4
e
2
0.177
9.1
3.37
9.4
C11
6
0.015
17.7
0.127
17.4
The data demonstrates that water jet impingement upon a corona treated microfiber filter media of either polypropylene fiber, multilayer fiber construction of polypropylene with poly4-methyl-1-pentene, and fibers of poly-4-methyl-i-pentene permits less penetration of DOP both initially and at final loading compared with polypropylene microfiber 6-layer construction subjected only to corona treatment. Therefore, filter elements utilizing the water impingement treated microfiber media can be made with fewer layers of media and lower pressure drop across the filter element can result while the filter element still offers comparable or superior performance levels to corona treated electret filter media having a greater number of layers.
EXAMPLE 42
A filter sample was prepared as in Example 31 except the collector to die distance was 40 cm (16 in), the resin was heated to 372° C., the effective fiber diameter was 14 micrometers, the basis weight was 50 g/m 2 , and the web was dried at 80° C. for about 25 min. The pressure drop was measured. The sample was subjected to the cigarette smoke test and filter efficiency was determined. The results are shown in Table 10.
EXAMPLE 43
A filter was prepared as in Example 42 except TPX™ grade MX-02 poly(4-methyl-1-pentene) was used. The pressure drop was measured. The sample was subjected to the cigarette smoke test and filter efficiency was determined. The results are shown in Table 10.
TABLE 10
Pressure
drop
Filter
Filter
Filter
(mm
Uncharged
Initial
Efficiency
Efficiency
Efficiency
H 2 O)
Filter
Filter
After 1
After 5
After 10
at 26.7
Efficiency
Efficiency
Cigarette
Cigarettes
Cigarettes
Ex.
cm/sec
E max (%)
E 1 (%)
E t (%)
E t (%)
E t (%)
42
2.8
16.5
80.5
—
48.8
17.9
43
3.4
18.6
67.1
60.3
53.9
34.4
The data in Table 10 illustrates the superior filtration performance of the filters made from poly(4-methyl-1-pentene) and treated by the combination of corona and water impingement.
EXAMPLES 44a and 44b
A filter sample was prepared as in Example 31 except the collector to die distance was 11 inches (28 cm) and the effective fiber diameter was 14 micrometers. The web had a basis weight of 40 g/m 2 and a thickness of 1.2 mm (0.049 in). A pleated filter element was prepared from the filter web and a scrim of Colback™ (80 g/m 2 , available from BASF Corp.) which had been adhesively adhered to the filter web using about 1 g/m 2 adhesive. The filter element was 29 cm long, 10 cm wide and had 52 pleats in its 29 cm length with the pleats having a height of 28 mm. The web was tested for initial efficiency and pressure drop values as well as for the filter efficiency after ambient air particle loading at particle sizes of 0.3 micrometer diameter (Example 44a) and 1 micrometer diameter (Example 44b). The results are shown in Table 11.
TABLE 11
133 Hour
290 Hour
Initial
133 Hour
exposure
290 Hour
exposure
Particle
Initial
Pressure
exposure
Pressure
exposure
Pressure
Size
Efficiency
Drop
Efficiency
Drop
Efficiency
Drop
Ex.
(um)
(%)
(mm H 2 O)
(%)
(mm H 2 O)
(%)
(mm H 2 O)
44a
0.3
70.5
10.8
53.8
13.8
47
15.5
44b
1.0
86.8
10.8
79.0
13.8
75
15.5
The data in Table 11 demonstrates that the particle trapping efficiency can be sustained for long periods even under conditions of continuous use with a range of particle sizes.
The various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention and this invention should not be restricted to that set forth herein for illustrative purposes. | Electret filter media comprising a nonwoven web of thermoplastic nonconductive microfibers having trapped charge, said charge provided by (1) subjecting the nonwoven web to a corona treatment, followed by (2) impingement of jets of water or a stream of water droplets on the web at a pressure sufficient to provide the web with filtration enhancing electret charge and (3) drying the web. This electret filter media may be used in a respiratory mask to provide extraordinarily good filtration properties. | 3 |
FIELD OF THE INVENTION
This invention relates to mechanical locks for securing two flaps together to form a panel of a carton. More particularly, it relates to the mechanical locks employed in a wrap-around carton.
BACKGROUND OF THE INVENTION
Wrap-around carriers or cartons are commonly used to package beverage containers as well as other types of articles. To form a package the centrally located top panel section of a carrier blank is normally positioned on a group of articles to be packaged and the side panel sections are folded down. Bottom panel flaps at opposite ends of the blank are then folded into place, with one of the flaps partially overlapping the other. Primary locking tabs on one of the flaps are connected to an edge of a primary opening in the other flap, and secondary locking tabs are secured so as to prevent the primary locks from separating. Prior to securing the locks the blank must be tightly drawn about the articles to prevent movement by the articles in the package. This requires the bottom panel flaps to be pulled into final position before the locking tabs can be set into place. Often, the design of the locking mechanism requires this to be accomplished through the use of fingers on the packaging machine which grip and pull the flaps into their final position.
A problem with the type of forming procedure described is that the packaging machines have to be timed and pitched according to the style of carton being run. In other words, the carton tightening fingers must be operated at distance between the center line of adjacent packages, and the speed at which the packages are moving through the machine. Therefore the packaging machine locking device must be reset each time a package is run for articles of different size or configuration.
It would be highly advantageous to be able to run different types of wrap-around cartons on the same packaging machine without having to change the pitch and timing of the locking device on the machine each time. Preferably, the design of the carton panel flaps and the locks themselves should be such that primary and secondary locks are provided.
BRIEF SUMMARY OF THE INVENTION
The invention is directed to a carton formed from a blank having flaps at either end, where one of the flaps partially overlaps and is mechanically attached to the other flap. The mechanical attachment is made by a locking tab on the outer or overlapping flap in cooperation with a locking opening in the inner flap. The locking tab has a base portion which underlies the inner flap of the carton adjacent an edge of the locking opening and an opposite outer portion which extends through a secondary opening in the inner flap. In addition, a flap connected to an edge of the locking opening opposite the first edge at least partially covers the locking opening.
This design allows the locking tab and the locking opening flap to be folded back prior to performing the locking operation. By exerting a force against the folded back locking tab and an oppositely directed force against the folded back locking opening flap the inner and outer panel flaps can be tightly drawn about the articles being packaged and moved into partially overlapping condition. The locking tab can then be inserted into place.
In a preferred arrangement the locking opening flap incorporates a smaller tab, which has a first edge connected by fold line to the locking opening flap and a second edge which contacts the outer portion of the locking tab.
The invention makes it possible to tightly draw a wrap-around carrier blank around the articles to be packaged without having to employ timed finger elements, while at the same time providing effective primary and secondary locks for securely holding the panel flaps in place. These and other aspects and benefits of the invention will readily be apparent from the more detailed description of the preferred embodiment of the invention which follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a pictorial view of a wrap-around carrier of the type incorporating the locking means of the invention;
FIG. 2 is a plan view of a blank for forming the carrier of FIG. 1;
FIG. 3 is an end view of an initial stage during the forming of a carrier from the blank of FIG. 2;
FIG. 4 is an enlarged plan view of the underside of the carrier of FIG. 3, omitting the articles being packaged for the sake of clarity, as the partially formed carrier is moving through a packaging machine at a slightly later stage of carrier formation;
FIG. 5 is a transverse sectional view taken along line 5--5 of FIG. 4, omitting details of the packaging machine except for the-tightening chains described below;
FIG. 6 is a partial pictorial view of the bottom panel flaps of the carrier at an initial stage during the forming of one of the bottom panel locks;
FIG. 7 is a partial pictorial view similar to that of FIG. 6, but showing the locking tabs at a later stage of lock formation;
FIG. 8 is a partial pictorial view similar to that of FIG. 7, but showing the locking tabs at a still later stage of lock formation;
FIG. 9;is an enlarged transverse sectional view taken on line 9--9 of FIG. 8;
FIG. 10 is a partial plan view of the exterior of the bottom panel of a carrier showing the finished lock; and
FIG. 11 is a partial plan view of the interior of the bottom panel of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a wrap-around carrier incorporating the invention and designed to contain six articles is indicated at 10. The carrier is of basic wrap-around design, including a top panel 12 connected by fold lines 14 to side panels 16, which in turn are connected by fold lines 18 to a bottom panel 20. As described in more detail below, the bottom panel is formed from two partially overlapping flaps 22 and 24 which are connected to each other by the mechanical locking means of the invention. The packaged articles are shown for purpose of illustration as comprising two adjacent rows of three beverage cans C, although they could just as well have been represented by any article capable of being contained in a wrap-around carrier.
A blank for forming the carrier is shown in FIG. 2 as comprising a generally rectangular sheet of flexible material possessing sufficient stiffness and strength to make it capable of withstanding the stresses to which the carrier is subjected during packaging and use. Paperboard of the type normally associated with the carrier industry is preferred. The top panel section 12, which includes finger holes 26, is centrally located in the sheet between the side panel sections 16, and the bottom panel flaps 22 and 24 are connected to opposite side panel sections.
The bottom panel flap 22, which is the outer flap in a carrier formed from the blank, is connected by fold line 28 to three locking tabs 30. The fold line 28 is substantially parallel to the fold line 18, and is interrupted at each locking tab by spaced transverse slits 32. A slit 34, substantially parallel to the fold lines 18 and 28, extends between the ends of the transverse slits 32 and forms with the slits 32 a primary locking tab 36. Each tab 30 functions as a secondary locking tab and includes a fold line 38 substantially parallel to the fold lines 18 and 28 which allows the end portion 39 of the tab 30 to be folded down as explained below.
At the opposite end of the blank the inner bottom panel flap 24 includes three locking openings defined at their outer boundary by cutout edges 40, at their inner boundary by fold lines 42 and at their sides by transverse slits 44 and cutout edges 46. The slits 44 are extensions of the cutout edges 46 and intersect with the ends of the fold line 42. Interrupting the fold line 42 is a slit 48 which is connected by short transverse slits 50 to a fold line 52. The slits 48 and 50 and the fold line 52 form a tab 54. Another edge 56 extends between the ends of the transverse slits 44, forming a cutout 58 defined by the edges 40, 46 and 56. This arrangement creates a flap or tab 60 defined by the fold line 42, the slits 44 and the edge 56. The edge 40 functions as a primary locking edge and the slit 48 functions as a secondary locking slot.
To form a package, the articles are segregated into the desired final arrangement, in this case into two rows of cans of three in each row, and the blank is positioned on top of the cans so that the top panel section rests on top of the cans. The side panel sections and the bottom panel flaps are then folded in as is conventional. A typical point in this folding process is illustrated in FIG. 3. As the inward folding of the bottom panel flaps continues the secondary locking tabs 30 and the flaps 60 are folded back in the reverse direction as illustrated in FIGS. 4 and 5. As previously noted, the cans have been omitted in FIGS. 4 and 5 for the sake of clarity. The folded tabs 30 and flaps 60 provide grips which are used to pull the flaps toward each other to draw the carrier blank more tightly about the articles.
Although the various folding steps and the tightening step can be performed by hand, it is preferred to carry them out by conventional elements of a packaging machine, which are well known in the industry and need no further explanation or illustration. As to the pulling of the bottom panel flaps toward each other, continuous chains 62 of the packaging machine have been shown in FIGS. 4 and 5 to better illustrate a particular benefit of the carton locks. It can be seen that the folded tabs 30 and flaps 60 can now function as pockets or hooks which receive the continuously moving chains 62. These chains are arranged so as to converge slightly, giving them a transverse component of movement, as indicated by the arrows 64, as well as their main component of movement in the machine direction, indicated by the arrows 66. The inward movement of the chains therefore pushes against the folds of the tabs 30 and flaps 60, pulling them and the connected bottom panel flaps 22 and 24 toward each other. Because the movement of the chains is continuous, they need not be timed or adjusted to the particular pitch of the carriers being run in the machine, thereby requiring no adjustment or changeover if it is desired to run a different style of package in the machine.
When the bottom panel flaps have been pulled tightly about the articles the relative positions of a tab 30 and its associated flap 60 are as illustrated in FIG. 6. Both the tab 30 and the flap 60 are still folded back, but the outer bottom panel flap 22 now slightly overlaps the inner bottom panel flap 24, with the primary locking tab 36 being poised over the primary locking edge 40 of the associated opening. The tab 30 is then pivoted up toward its original position to a point where the primary locking tab 36 engages the locking edge 40. The simultaneous folding of the three tabs 30 of the blank is enough to hold the bottom panel flaps together in this position.
As illustrated in FIG. 7, the flap 60 is then folded back to its original position substantially in the same plane as the bottom panel flap 24. There is adequate room for this to take place since the tab 30 remains folded up to a point which allows this folding action of the flap 60. The final step in the locking process is to pivot the locking tab 30 down while also folding the outer tab portion 39 down about the fold line 38, and then pushing the outer tab portion 39 through the slit 48. A typical position of these elements during this phase of the folding process is illustrated in FIG. 8. As more clearly shown in FIG. 9, because the outer tab portion 39 does not move into the slit 48 at a right angle to the flap 60, the tab portion 39 contacts the small tab 54 of the flap 60 and pivots it slightly down into the interior of the carton. Although in the finished package the tab 54 may move back to a substantially parallel relationship with respect to the flap 60, the fold line 52 continuously biases the tab 54 against the outer tab portion 39 of the locking tab 30, thereby acting to prevent withdrawal of the tab portion 30 from the slit 48. By maintaining the secondary locking tab 30 securely in place, the engagement of the primary locking tab 36 beneath the primary locking edge 40 is also maintained, thereby locking the bottom panel flaps together. The final arrangement of the locks as they appear from the exterior of the carton is shown in FIG. 10. The final arrangement of the locks as they appear from the interior of the carton is shown in FIG. 11.
Although the panel locking process has been described in connection with the formation of an upright carton, it will be understood that the same principles would apply if the panel were formed with the carton inverted.
As previously stated, the invention makes it possible to tightly draw a wrap-around carrier blank around the articles to be packaged without having to employ timed finger elements, while at the same time providing effective primary and secondary locks for securely holding the panel flaps in place. Although continuous chains have been illustrated as representing a desirable method for pulling the flaps together in a packaging machine, it should be understood that other mechanical means may be designed for carrying out the same function.
It should also be understood that the invention is not limited to all the specific details described in connection with the preferred embodiment and that changes to certain features of the preferred embodiment which do not alter the overall basic function and concept of the invention may be made without departing from the spirit and scope of the invention defined in the appended claims. | A wrap-around carrier capable of being tightly drawn about the packaged articles. Locking tabs on the outer bottom panel flap and locking opening flaps on the inner bottom panel flap are folded back to provide surfaces against which oppositely directed forces can push to move the bottom panel flaps into final partially overlapped condition. The locking tabs include a base locking portion which engages an edge of the locking openings and an outer secondary locking portion which extends through an opening in the inner bottom panel flap. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
None.
BACKGROUND OF INVENTION
The dispensing of viscous condiments, e.g., mustard, ketchup, mayonnaise, sandwich spreads and the like, is commonly done in restaurants. In order to handle the volume throughput requirements in restaurant kitchens, devices have been constructed for dispensing such condiments from tubes (packages) with the assistance of mechanical pump-type devices. Such devices are similar in construction to caulking guns. An example of such a device may be found in U.S. Pat. No. 4,830,231. While such devices have been effective, they do have some shortcomings.
It is desirable to eliminate material from the tubes that is not necessary. Even a small amount of material savings in a container can result in significant cost savings because of the large quantity required by restaurants, particularly in the fast food industry. However, to eliminate material, new assembly techniques may be needed necessitating new manufacturing equipment which adds again to the expense of the containers. Additionally, when viscous materials are contained in a container it is highly desirable to impede the migration of liquids such as water and lipids (fats) into the container material when such container material includes paperboard which can absorb and transfer such liquids by wicking. The absorption of such liquids can cause a detrimental appearance to the package and may even cause its unnecessary disposal. Typically, a condiment dispenser, such as that shown in the above-identified patent, was assembled using hot melt adhesives to join various container portions at the discharge end thereof. It would be desirable to reduce or eliminate this use of hot melt adhesive as a major element providing structural integrity to the package. Hot melt can cause detrimental generation of steam from moisture contained in various packaging components, particularly paperboard during assembly. The steam can cause problems such as forming tiny bubbles and/or holes through the hot melt thereby permitting oil and moisture to pass into raw edges of the paperboard tube. Thus, the tube (package) may become saturated, soften and begin to fall apart.
It is therefore desirable to provide an improved condiment dispenser. It is also desirable to provide an improved dispenser that has a reduction in the materials used and a reduction in the cost to manufacture.
SUMMARY OF INVENTION
The present invention relates to a container usable as a dispenser for use with viscous flowable condiments. The container includes a sidewall that is generally tubular forming a storage compartment for a viscous condiment. The sidewall has opposite ends, one of which is preferably open for receipt of a piston therein. The piston can be used to apply force to the condiment within the container to induce dispensing. The other end of the container is a normally closed end having a dispensing valve assembly. The dispensing valves are located on a valve plate secured to a mount plate which is secured to an inturned flange formed as part of the sidewall. The sidewall may be a convolute formed tube with a longitudinal seam. A removable membrane cover may be secured over the dispensing valve assembly which will provide a tamper-evident seal. The membrane cover is attached to the dispensing valve assembly before the valve assembly is attached to the sidewall. A die may be used to cut the perimeter shape of the membrane cover so that it precisely fits within an opening formed by the inturned flange. A portion of the membrane cover may be reverse bent to provide for gripping and subsequent removal of the cover. The dispensing valve assembly may be secured to the inturned generally flat flange and have an outer exposed edge portion engaging a hot melt material to cover all or substantially all of the exposed edge. Preferred materials for the sidewall and a portion of the dispensing valve assembly are paperboard and can have a polymer coating thereon to help effect resistance to penetration by liquids, and to help effect the joining of various components to one another as by heat sealing.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side elevation view of a condiment dispenser shown partially in section and held by a dispensing gun in accordance with one embodiment of the present invention;
FIG. 2 is a fragmentary perspective view of the dispensing end of the condiment dispenser in accordance with one embodiment of the present invention;
FIG. 3 is a view similar to FIG. 2 but with a peel-off closure member covering the dispensing openings; and
FIG. 4 is an enlarged fragmentary sectional view of the dispensing end of FIG. 3 in accordance with one embodiment of the present invention; and
FIG. 5 is a fragmentary top view of a web of covers that are partially die cut and interconnected together via their ears prior to their securement to a valve assembly in accordance with one embodiment of the present invention.
The same numbers used throughout the various figures designate like or similar parts and/or structure as described herein.
DETAILED DESCRIPTION
The reference numeral 1 designates generally a condiment dispenser for use in the storage and dispensing of viscous condiments 2 such as ketchup, mustard, mayonnaise, sandwich spread and the like. Such condiments 2 can be water and/or lipid based. In a preferred embodiment, the condiment dispenser 1 includes a feed device 3 that may be in the form of a trigger gun for use in applying force to a piston 4 which will in turn pressurize the condiment 2 for dispensing through a dispenser valve assembly 5 having one or more dispensing openings 6 . During dispensing, the piston 4 moves toward the valve assembly 5 . The feed device 3 can be manually operated for example by having a trigger or may be power operated for example by having an electric motor-driver actuator. Preferably, the feed device 3 is easily sanitized as by washing without detriment to the feed device.
The condiment dispenser 1 includes a sidewall 10 that may be formed of a polymeric-coated paperboard having a longitudinal seam 11 formed by overlapping edge margin portions 12 which may be secured together as by heat sealing of the polymeric coating. Preferably, the paperboard of the sidewall 10 has a thickness suitable to contain the condiment in storage and under dispensing pressure. The polymeric coating may be polyethylene or the like as are known in the art. Seam 11 may be formed as by heat sealing edge margins 12 as is also known in the art. The sidewall 10 has an inturned flange portion 14 which has a significant portion thereof generally perpendicular to the sidewall 10 and relatively flat. The flange 14 has an outer face 15 and an opening 16 which is defined by an internal edge 17 . The outer face 15 of the flange 14 is flush to slightly below flush with the free end 13 of the sidewall 10 , e.g. about 3/16 inch or less. Preferably the opening 16 is generally round as best seen in FIGS. 2 , 3 . When the flange 14 is formed, a plurality of pleats 18 may occur which can be easily accommodated by subsequent assembly steps as described below. The pleats 18 add rigidity to the flange 14 . Flange 14 may be formed by a roll forming process and may be held in its formed position by attachment to the valve assembly 5 .
The valve assembly 5 closes one end of the chamber 19 formed by sidewall 10 and is adapted for the selective release of condiment 2 from the chamber 19 . In the illustrated structure, the valve assembly 5 is secured in covering relation to the opening 16 and is preferably secured to an inside face 20 of the flange 14 . As shown in FIG. 4 , the valve assembly 5 includes a mount plate 21 in the form of an annular ring or disk having opposite side faces 22 , 23 , an outer perimeter edge 24 and an inner edge 25 defining a through opening 26 . Preferably, the opening 26 is in axial alignment with the opening 16 providing communication between the chamber 19 and the exterior of the dispenser 1 .
A slitted valve plate 31 is attached to the mount plate 21 preferably by securement to the face 22 . The valve plate 31 is preferably located on the interior side of the plate 21 . In a preferred embodiment, the valve plate 31 is in the form of a polymeric sheet, for example, low density polyethylene, having a plurality of the dispensing openings 6 in the form of die cut slits which can be in the form of an X for each opening. When the condiment 2 is pressurized by force applied to the piston 4 , flaps 32 formed by the X die cut slit will resiliently move outwardly allowing openings 6 to be exposed in the plate 31 for the condiment to flow through. During dispensing, the piston 4 moves along the chamber 19 toward the valve assembly 5 . When pressure is relieved, the flaps 32 move back to a closed or partially closed position. As shown, the plate 31 is secured to the face 22 as by heat bonding. In a preferred embodiment, the plate 21 is polymeric-coated paperboard element allowing heat bonding of the plate 21 to the flange 14 and to the valve plate 31 . The openings 6 are positioned inside or inwardly of the edge 25 . One or more openings 6 may be provided albeit four are shown in FIG. 2 .
As seen in FIG. 4 , the edge 24 of the plate 21 is sealed by a bead of hot melt 35 . Typically, during assembly of paperboard items, the paperboard will contain a certain amount of moisture. When the paperboard is heated, for example, during the application of hot melt or via the heat sealing process to join parts or areas together, the water in the paperboard will turn to steam and migrate out of the paperboard when possible. In the present invention, the openings 6 may be used as a steam vent should same be produced in the plate 21 during the application of hot melt as a caulking agent.
It should be pointed out that since plates 21 and 31 along with sidewall 10 , flange 14 and valve plate 31 all have polyethylene (or the like) coated surfaces, they can be heat welded together thereby eliminating the need for a hot melt to act as a structural component. Typically, when the paperboard elements are formed, they are die cut leaving “rough” edges that are uncoated. Such edges provide a means for ingress and egress of liquid vapor into the paperboard matrix. As best seen in FIG. 4 , a bead of hot melt 35 is applied proximate the edge 24 of plate 21 , the sidewall 10 , and flange 14 . It has been found that this hot melt functions primarily to seal the package and since the structural integrity is accomplished via the heat welding of the poly coated surfaces, rather than via hot melt, less hot melt is required and it may be of a less complex nature. Thus, the package is inherently stronger and less expensive to construct.
A cover 45 in the form of a membrane may be provided to selectively close the openings 6 for storage and shipping of the dispenser 1 . The cover 45 may be adhesively secured the outer surface 23 of plate 21 in overlying relation to the openings 6 . The cover 45 may be in the form of a polymeric-coated paper element or may be a polymeric material. It is preferred that the cover 45 be resistant to penetration by liquids. With the construction of the package as described above, when the hot melt is applied as shown and described with respect to FIG. 4 , the air tight seal between plate 21 and cover 45 closes off the escape route of steam to the outside. But for the construction of the present invention, the pressure of the steam would be high enough that it would pass through the hot melt rendering the hot melt caulking ineffective because oil and moisture then could pass into the raw edge 24 and saturate the paper and damage the integrity of the package. It is preferred that there be an air gap 26 a between at least a portion of the cover membrane 45 and the outer surface 46 of the valve disk 31 to provide for the release of steam should any be generated in the plate 21 during and shortly after the application of the hot melt 35 . This gap 26 a would allow for steam, if steam is generated, to move in the direction of the arrows 26 b and be discharged through the opening 6 into the chamber 19 . FIG. 4 shows the steam's path 26 b as it exits plate 21 . Steam can exit plate 21 through edge 25 . Upon exiting edge 25 of plate 21 , the steam enters air gap 26 a . Once the steam is in air gap 26 a , it can then exit into chamber 19 and the atmosphere through openings 6 .
As shown in FIG. 3 , the cover 45 has a plurality of circumferentially spaced ears 47 projecting from an outer perimeter 48 thereof. The cover 45 also includes a tab portion 50 having an ear 47 . FIG. 4 is a sectional view of FIG. 3 taken about line 4 - 4 . Therefore, neither the ears 47 nor the tab 50 are depicted in FIG. 4 . However, both the ears 47 and the tab 50 can be seen in FIG. 3 .
Preferably, during the manufacturing of valve assembly 5 , a plurality of covers 45 are included in a web made from a single piece of material. In the web, the covers 45 are partially die cut and interconnected together via their ears 47 . The valve assembly 5 may be appropriately aligned with a respective cover 45 in the web. Once the dispenser 1 is aligned with a cover 45 , the cover 45 may be bonded to the plate 21 . As shown, the bonding of the cover 45 to the plate 21 can take place in the annular ring area on surface 23 defined edges 17 and edge 25 . It will be appreciated by one skilled in the art that one bonding method includes heat bonding cover 45 to plate 21 . After the cover is bonded to the plate 21 , the final die cutting of the cover from the web can be accomplished by cutting the ears 47 . Once the ears 47 are cut, the cover 45 is completely detached from the web.
As mentioned above, the cover 45 has a tab portion 50 . Tab portion 50 provides the user a place to grip the cover 45 to assist in its removal from the valve assembly 5 . After the cover 45 is bonded to the valve assembly 5 , but before the valve assembly 5 is secured to sidewall 10 , tab portion 50 may be folded back toward the outer surface of cover 45 . The folding of tab portion 50 allows surface 23 of plate 21 to be directly mated to the inner face 20 of flange 14 without the tab portion 50 interfering. If tab portion 50 were not folded, it could extend into the seal created between surface 23 and face 20 . This could prevent the proper sealing of plate 21 to sidewall 10 . Additionally, it would prevent the cover 45 from being removed from the dispenser 1 because the tab portion 50 of cover 45 would be permanently sealed between surface 23 and face 20 . It will be appreciated by one skilled in the art that a tab portion 50 that is ¾″ long by ⅜″ wide is sufficient.
Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required.” Many changes, modifications, variations and other uses and applications of the present invention will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. | A dispenser is provided for viscous condiments. The dispenser includes a tubular sidewall having opposite ends. One opposite end is open and can receive a plunger or piston therein for applying force to condiment contained within a compartment inside of the sidewall. The other end of the sidewall includes a dispenser valve assembly comprising a member secured to an inturned flange portion of the sidewall with the flange portion being generally normal to the sidewall. The dispenser valve assembly is suitably secured to the flange portion as by heat sealing to form a composite laminated structure that is resistant to the penetration of liquids from the condiments. A bead of hot melt can be provided to seal an exposed outer edge of the dispenser valve assembly and to seal the dispenser valve assembly to the sidewall. The dispenser valve assembly includes a valve plate having one or more selectively openable discharge openings formed therein that will open and close under the influence of pressure applied to the condiment within the dispenser. | 1 |
This application is a Rule 60 Continuation Application of application Ser. No. 07/305,173, filed Feb. 2, 1989, now U.S. Pat. No. 4,968,659.
BACKGROUND OF THE INVENTION
This invention relates to a heat transfer sheet, more particularly, a heat transfer sheet which is useful in a heat transfer system by use of a sublimable dye (heat migratable dye), excellent in releasability between the dye carrying layer (the dye carrying layer is a layer comprising a dye and a binder; hereinafter called merely as dye layer) and the image-receiving material, and can give a mono-color or full-color image with excellent image density.
As the method capable of giving excellent mono-color or full-color image simply and at high speed in place of general letter printing method or printing method of the prior art, the ink jet system or the heat transfer system have been developed. Among them, as the system capable of giving a full-color image comparable with color photography having excellent continuous tone gradation, the so called sublimation heat transfer system by use of a sublimable dye is superior.
As the heat transfer sheet to be used in the above sublimation type heat transfer system, one having a dye layer containing a sublimable dye formed on one surface of a substrate film such as polyester film, while on the other hand, having a heat-resistant layer provided on the other surface of the substrate film for prevention of sticking of the thermal head, has been generally used.
By superposing the dye layer surface of a heat transfer sheet on an image-receiving material having an image-receiving layer comprising a polyester resin, etc. and heating imagewise the heat transfer sheet from the back surface thereof with a thermal head, the dye in the dye layer is migrated onto the image-receiving material to form a desired image.
In the heat transfer system as described above, since a very high speed heat transfer is demanded, heating with a thermal head is effected for a very short time (msec unit), whereby a high temperature is required for the thermal head.
As the result, when the temperature of the thermal head is elevated, the binder forming the dye layer is softened and sticks to the image-receiving material, whereby there occurs the inconvenience that the heat transfer sheet and the image-receiving material are adhered together, further causing in an extreme case a problem that the dye layer is peeled off during peeling of them to be transferred as such onto the image-receiving material surface.
In the prior art, for avoiding the above problem, there has been proposed a technique to form a curable silicone film separately on the surface of the dye layer (for example, Japanese Laid-open Patent Publication No. 209195/1986). However, in this method, when a curable silicone composition is coated on the dye layer, the solvent component in said composition attacks the dye layer, whereby the problem occurs that the dye is liable to be precipitated on the surface. Also, it is technically difficult to form a curable silicone film with a uniform thickness on the dye layer surface, and coating irregularity is liable to occur inevitably, which may consequently be a factor to cause sensitivity irregularity or formation irregularity of the image.
On the other hand, in the prior art, it has been also proposed to incorporate various release agents such as silicone polymers comprising perfluoroalkylated ester straight or branched alkyl or aryl siloxane units of straight alkyl or polyethyleneoxides or waxes (for example Japanese Laid-open Patent Publication No. 208994/1987). However, according to the knowledge of the present inventor, these release agents are not also necessarily satisfactory in improving releasability during heat transfer.
Accordingly, an object of the present invention is to provide a heat transfer sheet which can give an image of excellent quality without causing such problems as mentioned above.
SUMMARY OF THE INVENTION
The above object can be accomplished by the present invention as described below.
That is, the present invention is a heat transfer sheet comprising a dye carrying layer containing a dye which is migrated by heating to be transferred onto an image-receiving material laminated on a substrate film, characterized in that a specific dye-permeative release agent is contained in the dye carrying layer.
By incorporating a specific release agent as described below in the dye layer of the heat transfer sheet, releasability between the dye layer and the image-receiving material during heat transfer is improved, and an image having excellent image density, light resistance, and contamination resistance can be provided.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the preferred embodiments, the present invention is described in more detail.
The heat transfer sheet of the present invention comprises basically a dye layer formed on a substrate film similarly as in the prior art technique, but it is characterized by including a dye-permeative release agent in said dye layer.
As the substrate film for the heat transfer sheet of the present invention as described above, any material known in the art having heat resistance and strength to some extent may be employed, such as paper, various converted papers, polyester films, polystyrene films, polypropylene films, polysulfone films, Aramide films, polycarbonate films, polyvinyl alcohol films, Cellophane, etc., having a thickness of 0.5 to 50 μm, preferably 3 to 10 μm, particularly preferably polyester films. These substrate films may be in the form of sheets or continuous films, which are not particularly limited.
The dye layer to be formed on the above substrate film is a layer having a dye carried on any desired binder resin.
As the dye to be employed, any dye which has been used in the heat transfer sheet known in the art can be effectively used in the present invention without any particular limitation. For example, some preferable dyes may include red dyes such as MS Red G, Macrolex Red Violet R, Ceres Red 7B, Samaron Red HBSL or Resolin Red F3BS, yellow dyes such as Holon Brilliant Yellow 6GL, PTY-52 or Macrolex Yellow 6G, and blue dyes such as Kayaset Blue 714, Wacsoline Blue AP-FW, Holon Brilliant Blue S-R or MS Blue 100.
As the binder resin for carrying the dye as described above, any one binder resin known in the art can be used, and preferable examples may include cellulosic resins such as ethyl cellulose, hydroxyethyl cellulose, ethylhydroxy cellulose, hydroxypropyl cellulose, methyl cellulose, cellulose acetate, cellulose acetate butyrate, etc.; vinyl resins such as polyvinyl alcohol, polyvinyl acetate, polyvinyl butyral, polyvinylacetoacetal, polyvinyl pyrrolidone, polyacrylamide, etc.; polyesters; and others. Among them, cellulose type, polyvinyl acetoacetal type, polyvinyl butyral type and polyester type resins are preferred with respect to migratability of the dye, etc., and further polyvinyl acetoacetal type, polyvinyl butyral type resins are particularly preferred.
The dye layer of the heat transfer sheet of the present invention can be formed basically from the above materials, but the specific feature of the present invention resides in incorporating a dye-permeative release agent in the dye layer thus formed.
As such release agent, all of known release agents used in the release paper, etc. in the prior art, which will not interfere with heat migration of the dye in the dye layer, can be used. The release agent which does not interfere with heat transfer of the dye in the dye layer can be easily chosen and used by preparing heat transfer sheets by use of various release agents and carrying out heat transfer tests.
Preferred in the present invention are silicone type compounds and phosphoric acid ester type surfactants. For example, as silicone compounds, there may be included silicone alkyd, silicone grafted polymer, alkyl modified silicone, fluorine fatty acid modified silicone, phenyl group containing silicone, fatty acid modified silicone, polyether modified silicone, silicone for release, surface bleed type silicone, etc., and among them, particularly preferred is fluorine fatty acid modified silicone. As phosphoric ester type compounds, for example, phosphoric acid ester sodium salts, etc. may be included.
Of these release agents, examples of the structures of particularly preferred silicone compounds may include the following. ##STR1##
The content of the above release agent may be 0.1% by weight to 30% by weight based on the dye layer (dye and binder), preferably 0.1% by weight to 20% by weight. If it is added in excess of 30% by weight, the dye is liable to be agglomerated in the dye, whereby storability becomes undesirably bad. Most preferred among the combinations of the binder and the mold release agent is the combination of polyvinyl acetoacetal or polyvinyl butyral resin with fluorine fatty acid modified silicone.
Further, in the dye layer, other various additives similarly as known in the prior art can be included, if necessary.
Such a dye layer is formed preferably by adding the sublimable dye, the binder resin, the release agent and other optional components as described above in an appropriate solvent to have the respective components dissolved or dispersed therein, thus forming a coating material or ink for formation of dye layer, and then coating and drying this on the above substrate film.
The dye layer thus formed has a thickness of about 0.2 to 5.0 μm, preferably 0.4 to 2.0 μm, and the sublimable dye in the dye layer should be suitably present in an amount of 5 to 90% by weight, preferably 10 to 70% by weight, of the dye layer.
The dye layer formed may be formed by selecting one color from among the above dyes when the desired image is a mono-color, or when the desired image is a full-color image, for example, appropriate cyan, magenta and yellow (further black, if necessary) are selected to form a dye layer of yellow, magenta and cyan (further black, if necessary) as shown in FIG. 1.
The image-receiving material to be used for formation of image by use of the heat transfer sheet as described above may be any material of which the surface has dye receptivity for the above dye, and also in the case of paper, metal, glass, synthetic resin, etc. having no dye receptivity, a dye receiving layer may be formed on at least one surface thereof.
As the image-receiving material on which no dye receiving layer is required to be formed, there may be included, for example, fibers, fabrics, films, sheets, moldings, etc. comprising polyolefinic resins such as polypropylene, etc., halogenated polymers such as polyvinyl chloride, polyvinylidene chloride, etc., vinyl polymers such as polyvinyl acetate, polyacryl ester, etc., polyester type resins such as polyethylene terephthalate, polybutylene terephthalate, etc., polystyrene type resins, polyamide type resins, copolymer type resins of olefins such as ethylene, propylene, etc. with other vinyl monomers, ionomers, cellulosic resins such as cellulose diacetate, etc., polycarbonate, etc. Particularly preferred is a sheet or film comprising a polyester or a converted paper having a polyester layer provided thereon.
Also, in the present invention, even a non-dyeable image-receiving material such as paper, metal, glass and others can be made an image-receiving material by coating and drying a solution or dispersion of the dyeable resin as described above on its recording surface, or by laminating those resin films thereon. Further, even the above image-receiving material having dyeability may also form a dye-receiving layer from a resin with further better dyeability on its surface as in the case of the above paper.
The dye-receiving layer thus formed may be formed from a single material or a plurality of materials, and further various additives may be included therein within the range which does not interfere with the object of the present invention.
Such a dye-receiving layer may have any desired thickness, but generally a thickness of 2 to 50 μm. Also, such a dye-receiving layer may be preferably a continuous coating, but it may be also formed as non-continuous coating by use of a resin emulsion or a resin dispersion.
The means for imparting heat energy to be used in carrying out heat transfer by use of the above heat transfer sheet and the recording medium as described above, any imparting means known in the art can be used. For example, by means of a recording device such as thermal printer (e.g. Video Printer VY-100, manufactured by Hitachi K.K.), etc., by imparting a heat energy of about 5 to 100 mJ/mm 2 , by controlling the recording time, a desired image can be formed.
According to the present invention as described above, the following effects can be exhibited by incorporating a mold release agent in the dye layer on the substrate film.
(1) The releasability between the dye layer and the image-receiving material becomes good during transfer, whereby the problem of transfer of the dye layer onto the image-receiving layer can be cancelled.
(2) Also, lowering in efficiency of heat utilization from the thermal head is minimal, whereby there ensues the advantage that an image having excellent image density, light resistance, and contamination resistance can be obtained.
The present invention is described in more detail below by referring to Examples and Comparative Examples. In the sentences, parts or % are based on weight unless otherwise particularly noted.
EXAMPLES AND COMPARATIVE EXAMPLES
As the substrate film, on the surface of a polyethylene-terephthalate film with a thickness of 6 μm applied with heat-resistant treatment on the back surface opposite to the surface where a dye layer is to be formed, the ink compositions for forming the dye layers of the three colors shown below were successively coated and dried by gravure coating to a coated amount on drying of 1.0 g/m 2 to prepare heat transfer sheets of the present invention and Comparative examples shaped in continuous films. The ink compositions used in Examples were completely uniform, and even when stored for one month under the temperature condition of 10° C., the inks became uniform without any precipitate or agglomerate being observed.
______________________________________Yellow colorPTY-52 (manufactured by Mitsubishi Kasei, 5.50 partsJapan, C.I. Disperse Yellow 141)Polyvinyl butyral resin (manufactured by 4.80 partsSekisui Kagaku Kogyo, Japan, Ethlec BX-1)Methyl ethyl ketone 55.0 partsToluene 34.70 partsRelease agent (Table 1 shown below) 1.03 partsMagenta colorMS Red G (manufactured by Mitsui Toatsu, 2.60 partsJapan, C.I. Disperse Red 60)Macrolex Red Violet R (manufactured by 1.40 partsBayer, C.I. Disperse Violet 26)Polyvinyl butyral resin (Ethlec BX-1) 3.92 partsMethyl ethyl ketone 43.34 partsToluene 43.34 partsRelease agent (Table 1 shown below) 0.79 partsCyan colorKayaset Blue 714 (manufactured by Nippon 5.50 partsKayaku, Japan, C.I. Solvent Blue 63)Polyvinyl butyral resin (Ethlec BX-1) 3.92 partsMethyl ethyl ketone 22.54 partsToluene 68.18 partsRelease agent (Table 1 shown below) 0.94 parts______________________________________
Next, by use of a synthetic paper (manufactured by Oji Yuka, Japan, Yupo FPG150) as the substrate film, on one surface thereof was coated a coating solution with a composition shown below to a ratio of 4.5 g/m 2 on drying and dried at 130° C. for 3 minutes to obtain an image-receiving material to be used in the present invention and Comparative examples.
______________________________________Polyester resin (manufactured by Toyobo, 6.0 partsJapan, Vylon 600)Vinyl chloride-vinyl acetate copolymer 14.0 parts(UCC, VAGH)Amino-modified silicone oil (manufactured 0.4 partsby Shinetsu Kagaku Kogyo, Japan,X-22-3050C)Epoxy-modified silicone oil (manufactured 0.4 partsby Shinetsu Kagaku Kogyo, Japan,X-22-3000E)Methyl ethyl ketone 20.0 partsToluene 20.0 parts______________________________________
HEAT TRANSFER TEST
The heat transfer sheets of the above Examples and Comparative Examples were superposed on the above image-receiving material with the dye layer and the image-receiving layer opposed to each other, and thermal head recording was performed from the back surface of the heat transfer sheet by use of a thermal head (KMT-85-6, MPD2) under the conditions of a head application voltage of 12.0 V, an application pulse width in a step pattern which is successively reduced every 1 msec. from 16.0 msec./line, and a sub-scanning direction of 6 line/mm (33.3 msec./line).
As the result, as shown below in Table 1, in all the cases of Examples, the dye layer will not be migrated as such onto the image-receiving layer, and also releasability between the heat transfer sheet and the image-receiving material after recording was good. Also, the recorded image obtained exhibited sharp color formation.
TABLE 1______________________________________Silicone Manufacturer, Moldcompound Product No. releasability______________________________________ExamplesSilicone alkyd Shinetsu Kagaku ◯ KP-5206Silicone graft Toa Gosei Kagaku ◯polymer GS-30Silicone graft Toa Gosei Kagaku ◯polymer US-3000Phosphoric Toho Kagaku Kogyo ◯acid ester Na Gafak RE410saltPhosphoric Ajinomoto Lecithin ◯acid esterAlkyl modified Shinetsu Kagaku ◯silicone KF412Fluorine fatty Shinetsu Kagaku ⊚acid modified SO-50450SsiliconeFluorine fatty Shinetsu Kagaku ⊚acid modified SO-11250SsiliconeFluorine fatty Shinetsu Kagaku ⊚acid modified TA-4230siliconeFluorine fatty Shinetsu Kagaku ⊚acid modified TA-88siliconeFluorine fatty Shinetsu Kagaku ⊚acid modified TA-30730siliconeFluorine fatty Shinetsu Kagaku ⊚acid modified X-24-3525siliconePhenyl group Shinetsu Kagaku ◯containing KP-328siliconeFatty acid Shinetsu Kagaku ◯modified TA-6830siliconePolyether Shinetsu Kagaku ◯modified KF-352siliconeSilicone for Shinetsu Kagaku ◯mold release X-62-2087Surface bleed Shinetsu Kagaku ◯type silicone X-62-1215Comparative examplesPolyethylene Microfine ××wax MF8FNo addition ××Aluminum Ajinomoto ALM ×chelating agentTitanium Nippon Soda TTS ×chelating agent______________________________________ (Note) ⊚ ; excellent ◯; good ×; bad
From the results as described above, in all the cases of the heat transfer sheets of Examples, the dye layer was not migrated as such onto the image-receiving surface during printing, and also releasability between the heat transfer sheet and the image-receiving material during printing was good. Also, the recorded image was found to be good in all of printing density, light resistance and contamination resistance.
In contrast, in the case of Comparative Examples, the dye layer was peeled off to be migrated onto the image-receiving material at a considerable ratio, and also releasability between the transfer sheet and the image-receiving material during printing was not good. | A heat transfer sheet including a dye carrying layer containing a dye which is migrated by heating to be transferred onto an image-receiving material laminated on a substrate film. The dye carrying layer containing a dye-permeative release agent including a modified silicon type compound and/or a phophoric acid ester type surfactant. | 8 |
FIELD OF THE INVENTION
The present invention generally relates to special ketones that function as photolabile pro-fragrances. The present invention also relates to washing or cleaning agents containing such ketones. It also relates to a method for the lasting fragrancing of surfaces.
BACKGROUND OF THE INVENTION
Washing or cleaning agents mostly contain fragrances which impart a pleasant odor to the agents. The fragrances mostly mask the odor of the other ingredients, creating a pleasant odor impression for the user.
In the washing agents sector in particular, fragrances (referred to synonymously also as perfumes) are important constituents of the composition, since in both the wet and the dry state the laundry should have a pleasant and where possible also a fresh scent. The fundamental problem underlying the use of fragrances is that they are more or less highly volatile compounds, yet a lasting fragrance effect is desired. In the case in particular of fragrances which provide the fresh and light notes of the perfume and which because of their high vapor pressure evaporate particularly quickly, the desired persistence of the fragrance impression is very difficult to achieve.
A delayed fragrance release can occur through for example the carrier-bound use of fragrances. A carrier-bound precursor form of a fragrance is also known as a pro-fragrance or fragrance storage substance. In this context international patent application WO2007/087977 discloses the use of 1-aza-3,7-dioxabicyclo[3.3.0]octane compounds as pro-fragrances for the delayed release of fragrance aldehydes and fragrance ketones by hydrolysis. An alternative possibility for the delayed release of fragrances is the use of photoactivatable substances as pro-fragrances. Exposure to sunlight or to another electromagnetic radiation source of a certain wavelength induces the breakage of a covalent bond in the pro-fragrance molecule, causing a fragrance to be released.
U.S. Pat. No. 6,949,680 discloses the use of certain phenyl or pyridyl ketones as photoactivatable substances which in the presence of light in a photochemical fragmentation release a terminal alkene as an active substance. Said active substance has for example a fragrance-imparting or antimicrobial activity, which is first delayed by the photochemically induced decomposition and is released over an extended period on a specific surface.
WO2009/118219 A1 describes certain ketones as photoactivatable substances which allow the delayed release of cyclic compounds having at least one cyclic double bond, in particular cyclic terpenes or cyclic terpenoids having at least one cyclic double bond.
WO2010/066486 A2 describes certain beta-hydroxyketones as photoactivatable substances which in the presence of light allow for a release of fragrance aldehydes (perfume aldehydes) and fragrance ketones (perfume ketones).
The object of the present invention was to provide further photoactivatable substances as pro-fragrances which allow for the delayed release of perfume ketones, in particular of damascone.
Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
BRIEF SUMMARY OF THE INVENTION
A compound of the general formula (I),
wherein at least two of the residues R in formula (I) denote the residue a shown in square brackets,
and wherein the remaining residues R in formula (I), independently of one another, each denote hydrogen, a halogen atom, —NO 2 , a linear or branched, substituted or unsubstituted alkoxy group having 1 to 15 C atoms, a linear or branched, substituted or unsubstituted alkyl group having 1 to 15 C atoms, an aryl residue, a cycloalkyl residue, acyl residue, —OH, —NH alkyl, —NH 2 or —N(alkyl) 2 , and wherein for each residue a set in square brackets, independently of one another; R2 denotes a substituted hydrocarbon residue having at least one C═O group; R1 and R3, independently of one another, each denote hydrogen, a halogen atom, —NO 2 , a linear or branched, substituted or unsubstituted alkoxy group having 1 to 15 C atoms, a linear or branched, substituted or unsubstituted alkyl group having 1 to 15 C atoms, an aryl residue, a cycloalkyl residue, acyl residue, —OH, —NH alkyl, —NH 2 or —N(alkyl) 2 .
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention.
The object of the present invention was achieved by a compound of the general formula (I),
wherein at least two of the residues R in formula (I) denote the residue a shown in square brackets,
and wherein the remaining residues R in formula (I), independently of one another, each denote hydrogen, a halogen atom, —NO 2 , a linear or branched, substituted or unsubstituted alkoxy group having 1 to 15 C atoms, a linear or branched, substituted or unsubstituted alkyl group having 1 to 15 C atoms, an aryl residue, a cycloalkyl residue, acyl residue, —OH, —NH alkyl, —NH 2 or —N(alkyl) 2 ,
and wherein for each residue a set in square brackets, independently of one another, R2 denotes a substituted hydrocarbon residue having at least one C═O group, R1 and R3, independently of one another, each denote hydrogen, a halogen atom, —NO 2 , a linear or branched, substituted or unsubstituted alkoxy group having 1 to 15 C atoms, a linear or branched, substituted or unsubstituted alkyl group having 1 to 15 C atoms, an aryl residue, a cycloalkyl residue, acyl residue, —OH, —NH alkyl, —NH 2 or —N(alkyl) 2 .
The residue R2, which denotes a substituted hydrocarbon residue having at least one C═O group, can be linear or branched and in particular it can also encompass at least one ring system.
The compounds according to the invention of the general formula (I) are ketones, so they are also referred to below as ketones according to the invention or as ketones according to the invention of formula (I). Surprisingly it has been found that the ketones according to the invention are particularly effective pro-fragrances, which allow for the delayed release of perfume ketones, in particular of damascone. The use of the ketones according to the invention in washing, cleaning or care agents led to an improved long-term fragrance effect in the use thereof, in particular in connection with the treatment of textiles. When, for example, ketones according to the invention were used in a laundry treatment agent such as for example a washing agent or fabric softener, an improved long-term fragrance effect in the treated laundry was found. Corresponding products also have a particularly good storage stability. The agents according to the invention also enable the total amount of perfume contained in the agent to be reduced while nevertheless achieving olfactory benefits in the laundered textiles, in particular with regard to the perception of freshness. The favorable ratio of releasable perfumes to anchor molecule is also particularly advantageous. At least two molecules of perfume are released per carrier molecule. This allows for a particularly effective use for fragrancing purposes. The excellent long-term fragrance effect appears to be explainable by the fact that when the stored perfumes are released on the target substrate the process proceeds successively, in other words one (or more) bound perfume molecule still acts as an anchor while another perfume molecule has already been released.
It is also possible that individual residues R of the ketone of the general formula (I) are bridged between one another to form cyclic compounds, for example via C, O, N or S atoms.
According to the invention it is particularly preferable that in the residue a R1 denotes hydrogen or a linear or branched, substituted or unsubstituted alkyl group having 1 to 6 C atoms, in particular a methyl group. It is likewise preferable that in the residue a R3 denotes hydrogen or a linear or branched, substituted or unsubstituted alkyl group having 1 to 6 C atoms, in particular a methyl group.
The residues a with which the benzene ring in formula (I) is substituted can in each case be identical or different. In a preferred embodiment said residues a are identical. This embodiment is particularly advantageous if a particularly intensive odor of a certain perfume is to be produced. The embodiment in which different residues a are used is particularly advantageous when mixed odors are desired.
Two of the residues R in formula (I) preferably denote the residue a set in square brackets, but that number can also be higher, for example three or four of the residues R in formula (I) can denote the residue a set in square brackets.
If there are two residues R in formula (I) according to the residue a set in square brackets, they are preferably in the 1,4-position on the benzene ring in respect of one another. If there are three residues R in formula (I) according to the residue a set in square brackets, they are preferably in the 1,3,5-position on the benzene ring in respect of one another.
In a preferred embodiment of the invention all other residues R on the benzene ring in formula (I) that do not correspond to the residue a set in square brackets denote hydrogen.
The ketone according to the invention of the general formula (I) is suitable as a pro-fragrance for all conventional fragrance ketones, selected in particular from Buccoxime; isojasmone; methyl-beta-naphthyl ketone; musk indanone; Tonalide/Musk plus; alpha-damascone, beta-damascone, delta-damas cone, gamma-damascone, damascenone, damarose, methyl dihydrojasmonate, menthone, carvone, camphor, fenchone, alpha-ionone, beta-ionone, gamma-methyl ionone, fleuramone, dihydrojasmone, cis-jasmone, iso-E-Super®, methyl cedrenyl ketone or methyl cedrylone, acetophenone, methyl acetophenone, para-methoxyacetophenone, methyl-beta-naphthyl ketone, benzyl acetone, benzophenone, para-hydroxyphenyl butanone, celery ketone or livescone, 6-isopropyl decahydro-2-naphthone, dimethyl octenone, frescomenthe, 4-(1-ethoxyvinyl)-3,3,5,5-tetramethylcyclohexanone, methyl heptenone, 2-(2-(4-methyl-3-cyclohexen-1-yl)propyl)cyclopentanone, 1-(p-menthen-6(2)yl)-1-propanone, 4-(4-hydroxy-3-methoxyphenyl)-2-butanone, 2-acetyl-3,3-dimethyl norbornane, 6,7-dihydro-1,1,2,3,3-pentamethyl-4(5H)indanone, 4-damascol, dulcinyl or cassione, gelsone, hexylon, isocyclemone E, methyl cyclocitrone, methyl lavender ketone, orivone, para-tert-butyl cyclohexanone, Verdon, Delphone, muscone, neobutenone, plicatone, Veloutone, 2,4,4,7-tetramethyl oct-6-en-3-one, tetrameran or mixtures thereof. The ketones can preferably be selected from the damascones, carvone, gamma-methyl ionone, iso-E-Super, 2,4,4,7-tetramethyl oct-6-en-3-one, benzyl acetone, damascenone, methyl dihydrojasmonate, methyl cedrylone, hedione and mixtures thereof. All damascones and damascenones are most preferred.
The stored ketones can be released from the compound according to the invention of formula (I) under exposure to electromagnetic radiation, in particular encompassing wavelengths from 200 to 400 nm.
According to a particularly preferred embodiment the ketone according to the invention of formula (I) is a compound in which two of the residues R correspond to the specified residue a set in square brackets and are in the 1,4-position in respect of one another, wherein they are the same residue a, and wherein the other four residues R denote hydrogen, and wherein the residues a are preferably chosen such that under exposure to light, in particular encompassing wavelengths from 200 to 400 nm, the ketone according to the invention releases one of the fragrance ketones listed by name above, in particular fragrance ketones of the damascone type.
According to a preferred embodiment the residue a set in square brackets corresponds to the following residue b:
wherein the residue R4 denotes an optionally substituted hydrocarbon residue having at least 5 C atoms, which encompasses in particular a cyclic hydrocarbon residue.
Particularly preferred residues b correspond to the following residues b1 to b5:
Preferred ketones according to the invention of formula (I) encompass 2 or 3 of the residues b1 to b5, the other residues R denoting hydrogen. Particularly preferred ketones according to the invention of formula (I) encompass 2 identical residues selected from b1 to b5, said residues preferably being in the 1,4-position in respect of one another, the other residues R denoting hydrogen.
Correspondingly, an example of a particularly preferred ketone according to the invention is shown below:
The ketones according to the invention of the aforementioned formulae can be incorporated very stably into the conventional washing or cleaning agent matrices, into cosmetics and into existing perfume compositions. They allow for a delayed release of the stored fragrances, namely in particular of damascone in the α, β, γ or δ form and of damascenone, in particular β-damascenone. Said ketones impart a particularly long-lasting freshness impression to conventional washing or cleaning agents and to cosmetics. The dried, laundered textile in particular benefits from the good long-term fresh fragrance effect. The slow release of the stored perfume takes place following exposure to light (electromagnetic radiation), in particular encompassing wavelengths from 200 to 400 nm, as illustrated in simplified terms in the reaction equation below:
The present invention also provides a washing or cleaning agent, preferably a washing agent, fabric softener or washing auxiliary agent, containing at least one ketone according to the invention of formula (I), wherein said ketone is preferably contained in amounts of between 0.0001 and 5 wt. %, advantageously between 0.001 and 4 wt. %, more advantageously between 0.01 and 3 wt. %, in particular between 0.1 and 2 wt. %, relative in each case to the total agent. Suitable cleaning agents are for example cleaning agents for hard surfaces, such as preferably dishwashing agents. They can likewise be cleaning agents such as for example household cleaners, general purpose cleaners, window cleaners, floor cleaners, etc. They can preferably be a product for cleaning lavatory pans and urinals, advantageously a toilet freshener to hang in the lavatory pan, in particular a toilet rim block.
According to a preferred embodiment of the invention the washing or cleaning agent according to the invention contains at least one surfactant selected from anionic, cationic, non-ionic, zwitterionic, amphoteric surfactants or mixtures thereof.
According to a further preferred embodiment of the invention the agent according to the invention is in solid or liquid form.
The invention also provides a cosmetic agent containing at least one ketone of formula (I), which cosmetic agent preferably contains said ketone in amounts of between 0.0001 and 5 wt. %, advantageously between 0.001 and 4 wt. %, more advantageously between 0.01 and 3 wt. %, in particular between 0.1 and 2 wt. %, relative in each case to the total agent.
The invention also provides an air care agent (e.g. room air freshener, room deodorizer, room spray, etc.) containing at least one ketone of formula (I), wherein said ketone is preferably contained in amounts of between 0.0001 and 50 wt. %, advantageously between 0.001 and 5 wt. %, more advantageously between 0.1 and 3 wt. %, in particular between 0.1 and 2 wt. %, relative in each case to the total agent.
According to a further preferred embodiment of the invention an agent according to the invention (i.e. washing or cleaning agent, cosmetic agent or air care agent), in particular washing or cleaning agent, contains additional fragrances, preferably in amounts from 0.00001 to 5 wt. %, selected in particular from the group encompassing fragrances of natural or synthetic origin, preferably more highly volatile fragrances, higher-boiling fragrances, solid fragrances and/or fixative fragrances.
Fixative perfumes, which can advantageously be used in the context of the present invention, are for example essential oils such as angelica root oil, aniseed oil, arnica flower oil, basil oil, bay oil, bergamot oil, champaca flower oil, noble fir oil, noble fir cone oil, elemi oil, eucalyptus oil, fennel oil, spruce needle oil, galbanum oil, geranium oil, gingergrass oil, guaiac wood oil, gurjun balsam oil, helichrysum oil, hon-sho oil, ginger oil, iris oil, cajeput oil, calamus oil, chamomile oil, camphor oil, cananga oil, cardamom oil, cassia oil, pine needle oil, copaiba balsam oil, coriander oil, spearmint oil, caraway oil, cumin oil, lavender oil, lemongrass oil, lime oil, mandarin oil, melissa oil, musk seed oil, myrrh oil, clove oil, neroli oil, niaouli oil, olibanum oil, orange oil, origanum oil, palmarosa oil, patchouli oil, Peru balsam oil, petitgrain oil, pepper oil, peppermint oil, pimento oil, pine oil, rose oil, rosemary oil, sandalwood oil, celery oil, spike lavender oil, star anise oil, turpentine oil, thuja oil, thyme oil, verbena oil, vetiver oil, juniper berry oil, wormwood oil, wintergreen oil, ylang-ylang oil, hyssop oil, cinnamon oil, cinnamon leaf oil, citronella oil, lemon oil and cypress oil.
However, higher-boiling or solid perfumes of natural or synthetic origin can also be used in the context of the present invention as fixative perfumes or perfume blends, i.e. as fragrances. These compounds include the compounds listed below and mixtures thereof: ambrettolide, α-amylcinnamaldehyde, anethol, anisaldehyde, anisic alcohol, anisol, methyl anthranilate, acetophenone, benzyl acetone, benzaldehyde, ethyl benzoate, benzophenone, benzyl alcohol, benzyl acetate, benzyl benzoate, benzyl formate, benzyl valerianate, borneol, bornyl acetate, α-bromostyrene, n-decyl aldehyde, n-dodecyl aldehyde, eugenol, eugenol methyl ether, eucalyptol, farnesol, fenchone, fenchyl acetate, geranyl acetate, geranyl formate, heliotropin, methyl heptine carboxylate, heptaldehyde, hydroquinone dimethyl ether, hydroxycinnamaldehyde, hydroxycinnamic alcohol, indole, irone, isoeugenol, isoeugenol methyl ether, isosafrole, jasmone, camphor, carvacrol, carvone, p-cresol methyl ether, coumarin, p-methoxyacetophenone, methyl-n-amyl ketone, methyl methyl anthranilate, p-methyl acetophenone, methyl chavicol, p-methyl quinoline, methyl-β-naphthyl ketone, methyl-n-nonyl acetaldehyde, methyl-n-nonyl ketone, muscone, β-naphthol ethyl ether, β-naphthol methyl ether, nerol, nitrobenzene, n-nonyl aldehyde, nonyl alcohol, n-octyl aldehyde, p-oxyacetophenone, pentadecanolide, β-phenyl ethyl alcohol, phenyl acetaldehyde dimethyl acetal, phenyl acetic acid, pulegone, safrole, isoamyl salicylate, methyl salicylate, hexyl salicylate, cyclohexyl salicylate, santalol, skatole, terpineol, thymene, thymol, γ-undelactone, vanillin, veratrum aldehyde, cinnamaldehyde, cinnamyl alcohol, cinnamic acid, ethyl cinnamate, benzyl cinnamate. The more highly volatile fragrances include in particular the lower-boiling perfumes of natural or synthetic origin, which can be used alone or in mixtures. Examples of more highly volatile fragrances are alkyl isothiocyanates (alkyl mustard oils), butanedione, limonene, linalool, linalyl acetate and propionate, menthol, menthone, methyl-n-heptenone, phellandrene, phenylacetaldehyde, terpinyl acetate, citral, citronellal.
According to a further preferred embodiment the agent according to the invention (i.e. washing or cleaning agent, cosmetic agent or air care agent), in particular washing or cleaning agent, has at least one, preferably a plurality of, active components, in particular active washing components, active care components, active cleaning components and/or cosmetic components, advantageously selected from the group encompassing anionic surfactants, cationic surfactants, amphoteric surfactants, non-ionic surfactants, acidifying agents, alkalizing agents, anti-crease compounds, antibacterial substances, antioxidants, anti-redeposition agents, antistatics, builder substances, bleaching agents, bleach activators, bleach stabilizers, bleach catalysts, ironing aids, cobuilders, fragrances, anti-shrink agents, electrolytes, enzymes, color protecting agents, coloring agents, dyes, dye transfer inhibitors, fluorescent agents, fungicides, germicides, odor-complexing substances, auxiliary agents, hydrotropes, rinse aids, complexing agents, preservatives, corrosion inhibitors, water-miscible organic solvents, optical brighteners, perfumes, perfume carriers, pearling agents, pH adjusters, phobing and impregnating agents, polymers, non-swelling agents, anti-slip agents, foam inhibitors, layered silicates, dirt-repellent substances, silver protection agents, silicone oils, soil release active agents, UV protective substances, viscosity regulators, thickening agents, discoloration inhibitors, graying inhibitors, vitamins and/or fabric softeners. Within the meaning of this invention, stated amounts for the agent according to the invention in wt. %, unless otherwise specified, relate to the total weight of the agent according to the invention.
The amounts of individual ingredients in the agents according to the invention (i.e. washing or cleaning agent, cosmetic agent or air care agent), in particular washing or cleaning agent, are guided in each case by the intended use of the agents in question, and the person skilled in the art is familiar in principle with the orders of magnitude of the amounts of ingredients to use or can obtain them from the associated specialist literature. Depending on the intended use of the agents according to the invention, a higher or lower surfactant content, for example, will be chosen. For example, the surfactant content of washing agents, for example, can conventionally be between 10 and 50 wt. %, preferably between 12.5 and 30 wt. % and in particular between 15 and 25 wt. %, whereas cleaning agents for automatic dishwashing, for example, can contain between 0.1 and 10 wt. %, preferably between 0.5 and 7.5 wt. % and in particular between 1 and 5 wt. % of surfactants.
The agents according to the invention (i.e. washing or cleaning agent, cosmetic agent or air care agent), in particular washing or cleaning agent, can contain surfactants, with anionic surfactants, non-ionic surfactants and mixtures thereof, but also cationic surfactants, being preferably suitable. Suitable non-ionic surfactants are in particular ethoxylation and/or propoxylation products of alkyl glycosides and/or linear or branched alcohols each having 12 to 18 C atoms in the alkyl part and 3 to 20, preferably 4 to 10, alkyl ether groups. Corresponding ethoxylation and/or propoxylation products of N-alkylamines, vicinal diols, fatty acid esters and fatty acid amides, which in terms of the alkyl part correspond to the cited long-chain alcohol derivatives, and of alkyl phenols having 5 to 12 C atoms in the alkyl residue can also be used.
Suitable anionic surfactants are in particular soaps and examples containing sulfate or sulfonate groups, with preferably alkali ions as cations. Soaps which can be used are preferably the alkali salts of saturated or unsaturated fatty acids having 12 to 18 C atoms. Such fatty acids can also be used in not completely neutralized form. Suitable surfactants of the sulfate type include the salts of sulfuric acid semi-esters of fatty alcohols having 12 to 18 C atoms and the sulfation products of said non-ionic surfactants with a low degree of ethoxylation. Suitable surfactants of the sulfonate type include linear alkylbenzene sulfonates having 9 to 14 C atoms in the alkyl part, alkane sulfonates having 12 to 18 C atoms, and olefin sulfonates having 12 to 18 C atoms which are formed in the reaction of corresponding monoolefins with sulfur trioxide, as well as alpha-sulfo fatty acid esters which are formed in the sulfonation of fatty acid methyl or ethyl esters.
Cationic surfactants are preferably selected from the esterquats and/or the quaternary ammonium compounds according to the general formula (R I )(R II )(R III )(R IV )N + X − , in which R I to R IV denote identical or different C 1-22 alkyl residues, C 7-28 arylalkyl residues or heterocyclic residues, wherein two or in the case of an aromatic bonding as in pyridine even three residues together with the nitrogen atom form the heterocycle, for example a pyridinium or imidazolinium compound, and X − denotes halide ions, sulfate ions, hydroxide ions or similar anions. Quaternary ammonium compounds can be produced by reacting tertiary amines with alkylating agents, such as for example methyl chloride, benzyl chloride, dimethyl sulfate, dodecyl bromide, but also ethylene oxide. The alkylation of tertiary amines having one long alkyl residue and two methyl groups is achieved particularly easily; in addition, the quaternization of tertiary amines having two long residues and one methyl group can be performed under gentle conditions with the aid of methyl chloride. Amines having three long alkyl residues or hydroxy-substituted alkyl residues are not very reactive and are quaternized with dimethyl sulfate, for example. Suitable quaternary ammonium compounds are for example benzalkonium chloride (N-alkyl-N,N-dimethyl benzylammonium chloride), benzalkon B (m,p-dichlorobenzyldimethyl-C 12 -alkylammonium chloride, benzoxonium chloride (benzyldodecyl bis-(2-hydroxyethyl)ammonium chloride), cetrimonium bromide (N-hexadecyl-N,N-trimethylammonium bromide), benzetonium chloride (N,N-dimethyl-N-[2-[2-[p-(1,1,3,3-tetramethylbutyl)phenoxy]ethoxy]ethyl]benzylammonium chloride), dialkyldimethylammonium chlorides such as di-n-decyldimethylammonium chloride, didecyldimethylammonium bromide, dioctyldimethylammonium chloride, 1-cetylpyridinium chloride and thiazoline iodide and mixtures thereof. Preferred quaternary ammonium compounds are benzalkonium chlorides having C 8 -C 22 alkyl residues, in particular C 12 -C 14 alkylbenzyldimethylammonium chloride.
Preferred esterquats are methyl-N-(2-hydroxyethyl)-N,N-di(tallow acyloxyethyl)ammonium methosulfate, bis-(palmitoyl)ethyl hydroxyethyl methylammonium methosulfate or methyl-N,N-bis(acyloxyethyl)-N-(2-hydroxyethyl)ammonium methosulfate.
Surfactants are contained in the agents according to the invention (i.e. washing or cleaning agent, cosmetic agent or air care agent), in particular washing or cleaning agent, in quantitative proportions of preferably 5 wt. % to 50 wt. %, in particular 8 wt. % to 30 wt. %. In laundry post-treatment agents in particular, up to 30 wt. % of surfactants are preferably used, in particular 5 wt. % to 15 wt. %, preferably including at least a proportion of cationic surfactants.
An agent according to the invention, in particular washing or cleaning agent, preferably contains at least one water-soluble and/or water-insoluble, organic and/or inorganic builder. The water-soluble organic builder substances include polycarboxylic acids, in particular citric acid and sugar acids, monomeric and polymeric aminopolycarboxylic acids, in particular methylglycine diacetic acid, nitrilotriacetic acid and ethylenediamine tetraacetic acid as well as polyaspartic acid, polyphosphonic acids, in particular amino tris(methylene phosphonic acid), ethylenediamine tetrakis(methylene phosphonic acid) and 1 hydroxyethane-1,1-diphosphonic acid, polymeric hydroxy compounds such as dextrin as well as polymeric (poly)carboxylic acids, polymeric acrylic acids, methacrylic acids, maleic acids and mixed polymers thereof, which can also contain small amounts of polymerizable substances without carboxylic acid functionality incorporated by polymerization. For the production of liquid agents in particular, the organic builder substances can be used in the form of aqueous solutions, preferably in the form of 30 to 50 wt. % aqueous solutions. All the cited acids are generally used in the form of their water-soluble salts, in particular their alkali salts.
Organic builder substances can be included if desired in amounts of up to 40 wt. %, in particular up to 25 wt. % and preferably from 1 wt. % to 8 wt. %. Amounts close to the cited upper limit are preferably used in paste-form or liquid, in particular water-containing, agents according to the invention. Laundry post-treatment agents according to the invention, such as fabric softeners for example, can optionally also be free from organic builders.
Suitable water-soluble inorganic builder materials include in particular alkali silicates and polyphosphates, preferably sodium triphosphate. Crystalline or amorphous alkali aluminosilicates in particular can be used as water-insoluble, water-dispersible inorganic builder materials, if desired in amounts of up to 50 wt. %, preferably not over 40 wt. % and in liquid agents in particular in amounts of 1 wt. % to 5 wt. %. Of these the crystalline sodium aluminosilicates in washing agent grade, in particular Zeolite A, P and optionally X, are preferred. Amounts close to the cited upper limit are preferably used in solid, particulate agents. Suitable aluminosilicates have in particular no particles with a particle size of more than 30 μm and preferably consist of at least 80 wt. % of particles with a size of less than 10 μm. It is, however, particularly preferable to avoid the use of water-insoluble builder materials, to a very great extent at least, such that they are preferably used, if at all, in only small amounts, for example in amounts of <5 wt. % or <1 wt. %, relative to the total agent.
Suitable substitutes or partial substitutes for said aluminosilicate are crystalline alkali silicates, which can be present alone or mixed with amorphous silicates. The alkali silicates that can be used as builders in the agents according to the invention preferably have a molar ratio of alkali oxide to SiO 2 of less than 0.95, in particular from 1:1.1 to 1:12, and can be amorphous or crystalline. Preferred alkali silicates are the sodium silicates, in particular the amorphous sodium silicates, with a molar ratio of Na 2 O:SiO 2 of 1:2 to 1:2.8. Crystalline layered silicates of the general formula Na 2 Si x O 2x+1 .y H 2 O are preferably used as crystalline silicates, which can be present alone or mixed with amorphous silicates, in which x, the modulus, is a number from 1.9 to 4 and y is a number from 0 to 20, and preferred values for x are 2, 3 or 4. Preferred crystalline layered silicates are those in which x assumes the values 2 or 3 in the cited general formula. In particular both β- and δ-sodium disilicates (Na 2 Si 2 O 5 .y H 2 O) are preferred. Virtually anhydrous crystalline alkali silicates of the aforementioned general formula prepared from amorphous alkali silicates, in which x denotes a number from 1.9 to 2.1, can also be used in agents according to the invention. In a further preferred embodiment of agents according to the invention a crystalline sodium layered silicate with a modulus of 2 to 3 is used, such as can be prepared from sand and soda. Crystalline sodium silicates with a modulus in the range from 1.9 to 3.5 are used in a further preferred embodiment of agents according to the invention. If alkali aluminosilicate, in particular zeolite, is also present as an additional builder substance, the weight ratio of aluminosilicate to silicate, relative in each case to anhydrous active substances, is preferably 1:10 to 10:1. In agents containing both amorphous and crystalline alkali silicates, the weight ratio of amorphous alkali silicate to crystalline alkali silicate is preferably 1:2 to 2:1 and in particular 1:1 to 2:1.
If desired, builder substances are preferably contained in the agents according to the invention, in particular washing or cleaning agents, in amounts of up to 60 wt. %, in particular 5 wt. % to 40 wt. %. Laundry post-treatment agents according to the invention, such as fabric softeners for example, are preferably free from inorganic builders.
Suitable peroxygen compounds are in particular organic peracids or peracid salts of organic acids, such as phthalimidoperhexanoic acid, perbenzoic acid or salts of diperdodecanedioic acid, hydrogen peroxide and inorganic salts which give off hydrogen peroxide under the application conditions, such as perborate, percarbonate and/or persilicate. If solid peroxygen compounds are to be used, they can be used in the form of powders or granules, which can also be coated in a manner known in principle. Alkali percarbonate, alkali perborate monohydrate or, in liquid agents in particular, hydrogen peroxide in the form of aqueous solutions containing 3 wt. % to 10 wt. % of hydrogen peroxide are particularly preferably optionally used. If an agent according to the invention contains bleaching agents, such as preferably peroxygen compounds, these are present in amounts of preferably up to 50 wt. %, in particular from 5 wt. % to 30 wt. %. The addition of small amounts of known bleaching agent stabilizers such as for example phosphonates, borates or metaborates and metasilicates as well as magnesium salts such as magnesium sulfate can be useful.
Compounds which under perhydrolysis conditions yield aliphatic peroxocarboxylic acids having preferably 1 to 10 C atoms, in particular 2 to 4 C atoms, and/or optionally substituted perbenzoic acid can be used as bleach activators. Substances bearing O and/or N acyl groups of the cited C atomic number and/or optionally substituted benzoyl groups are suitable. Polyacylated alkylene diamines, in particular tetraacetyl ethylenediamine (TAED), acylated triazine derivatives, in particular 1,5-diacetyl-2,4-dioxohexahydro-1,3,5-triazine (DADHT), acylated glycolurils, in particular tetraacetyl glycoluril (TAGU), N-acylimides, in particular N-nonanoyl succinimide (NOSI), acylated phenol sulfonates, in particular n-nonanoyl or isononanoyl oxybenzene sulfonate (n- or iso-NOBS), carboxylic anhydrides, in particular phthalic anhydride, acylated polyhydric alcohols, in particular triacetin, ethylene glycol diacetate, 2,5-diacetoxy-2,5-dihydrofuran and enol esters, as well as acetylated sorbitol and mannitol or mixtures thereof (SORMAN), acylated sugar derivatives, in particular pentaacetyl glucose (PAG), pentaacetyl fructose, tetraacetyl xylose and octaacetyl lactose, as well as acetylated, optionally N-alkylated glucamine and gluconolactone, and/or N-acylated lactams, for example N-benzoyl caprolactam, are preferred.
Hydrophilically substituted acyl acetals and acyl lactams are likewise preferably used. Combinations of conventional bleach activators can also be used. Such bleach activators can be included in the conventional range of amounts, preferably in amounts from 1 wt. % to 10 wt. %, in particular 2 wt. % to 8 wt. %, relative to the total agent.
Sulfonimines and/or bleach-reinforcing transition metal salts or transition metal complexes can also be included as so-called bleach catalysts in addition to the aforementioned conventional bleach activators or in their place.
Suitable enzymes for use in the agents include those from the class of proteases, cutinases, amylases, pullulanases, hemicellulases, cellulases, lipases, oxidases and peroxidases as well as mixtures thereof. Enzymatic active ingredients obtained from fungi or bacteria, such as Bacillus subtilis, Bacillus licheniformis, Streptomyces griseus, Humicola lanuginosa, Humicola insolens, Pseudomonas pseudoalcaligenes or Pseudomonas cepacia , are particularly suitable. The optionally used enzymes can be adsorbed on supporting materials and/or embedded in coating substances to protect them against premature inactivation. If desired, they are preferably contained in the agents according to the invention in amounts not exceeding 5 wt. %, in particular 0.2 wt. % to 2 wt. %.
As optical brighteners the agents can optionally contain for example derivatives of diaminostilbene disulfonic acid or alkali metal salts thereof. Salts of 4,4′-bis(2-anilino-4-morpholino-1,3,5-triazinyl-6-amino)stilbene-2,2′-disulfonic acid or similarly structured compounds bearing a diethanolamino group, a methylamino group, an anilino group or a 2-methoxyethylamino group in place of the morpholino group, are suitable for example.
Suitable foam inhibitors include for example organopolysiloxanes and mixtures thereof with microfine, optionally silanized silicic acid and paraffin waxes and mixtures thereof with silanized silicic acid or bis-fatty acid alkylene diamides. Mixtures of various foam inhibitors are also used to advantage, for example those comprising silicones, paraffins or waxes. The foam inhibitors, in particular silicone- and/or paraffin-containing foam inhibitors, are preferably bound to a granular, water-soluble or water-dispersible carrier substance. Mixtures of paraffin waxes and bistearyl ethylenediamides are preferred in particular.
In addition, the agents can also contain components known as soil release agents, which positively influence the ability to wash oils and fats out of textiles. This effect becomes particularly apparent if a textile that has previously been washed multiple times with an agent according to the invention containing said oil and fat releasing component is soiled. The preferred oil and fat releasing components include for example non-ionic cellulose ethers such as methyl cellulose and methyl hydroxypropyl cellulose containing from 15 to 30 wt. % of methoxyl groups and from 1 to 15 wt. % of hydroxypropoxyl groups, relative in each case to the non-ionic cellulose ether, and the polymers of phthalic acid and/or terephthalic acid or derivatives thereof with monomeric and/or polymeric diols, in particular polymers of ethylene terephthalates and/or polyethylene glycol terephthalates or anionically and/or non-ionically modified derivatives thereof, known from the prior art.
The agents can also contain dye transfer inhibitors, preferably in amounts from 0.1 wt. % to 2 wt. %, in particular 0.1 wt. % to 1 wt. %, which in a preferred embodiment of the invention are polymers of vinyl pyrrolidone, vinyl imidazole, vinyl pyridine-N-oxide or copolymers thereof.
Graying inhibitors have the task of holding the dirt released from the textile fibers suspended in the liquor. Water-soluble colloids, mostly of an organic nature, are suitable for this purpose, for example starch, glue, gelatin, salts of ether carboxylic acids or ether sulfonic acids of starch or cellulose or salts of acid sulfuric acid esters of cellulose or starch. Water-soluble polyamides containing acid groups are also suitable for this purpose. Starch derivatives other than those mentioned above can also be used, for example aldehyde starches. Cellulose ethers such as carboxymethyl cellulose (Na salt), methyl cellulose, hydroxyalkyl cellulose and mixed ethers, such as methylhydroxyethyl cellulose, methylhydroxypropyl cellulose, methylcarboxymethyl cellulose and mixtures thereof can preferably be used, for example in amounts of 0.1 to 5 wt. %, relative to the agents.
The organic solvents that can be used in the agents according to the invention, particularly if they are in liquid or paste form, include alcohols having 1 to 4 C atoms, in particular methanol, ethanol, isopropanol and tert-butanol, diols having 2 to 4 C atoms, in particular ethylene glycol and propylene glycol, and mixtures thereof and the ethers derivable from said classes of compounds. Such water-miscible solvents are preferably present in the agents according to the invention in amounts not exceeding 30 wt. %, in particular 6 wt. % to 20 wt. %.
To set a desired pH that is not established automatically by mixing the other components, the agents according to the invention can contain system-compatible and environmentally compatible acids, in particular citric acid, acetic acid, tartaric acid, malic acid, lactic acid, glycolic acid, succinic acid, glutaric acid and/or adipic acid, but also mineral acids, in particular sulfuric acid, or bases, in particular ammonium or alkali hydroxides. Such pH adjusters are optionally included in the agents according to the invention in amounts preferably not exceeding 20 wt. %, in particular 1.2 wt. % to 17 wt. %.
The production of solid agents according to the invention (i.e. in particular washing or cleaning agents) presents no difficulties and can be performed in principle in a known manner, for example by spray drying or granulation, with optional peroxygen compound and optional bleach catalyst optionally being added at a later stage. A method involving an extrusion step is preferred for the production of agents according to the invention having an elevated bulk density, in particular in the range from 650 g/l to 950 g/l. The production of liquid agents according to the invention likewise presents no difficulties and can likewise be performed in a known manner.
The production of the ketones according to the invention is described in the example section by way of example by reference to the production of a pro-fragrance containing δ-damascone. The other ketones of the general formula (I) are also obtainable via this standard synthesis route.
According to a preferred embodiment the teaching according to the invention can be used to significantly reduce the perfume content in washing, cleaning and personal care agents. In this way it is possible also to offer perfumed products for particularly sensitive consumers who because of specific intolerances and irritations can use normally perfumed products only to a limited extent if at all.
In addition to the ketone according to the invention, a preferred solid, in particular powdered, washing agent according to the invention can also contain in particular components selected for example from the following:
Anionic surfactants, such as preferably alkyl benzene sulfonate, alkyl sulfate, for example in amounts of preferably 5 to 30 wt. %, Non-ionic surfactants, such as preferably fatty alcohol polyglycol ethers, alkyl polyglucoside, fatty acid glucamide, for example in amounts of preferably 0.5 to 15 wt. %, Builders, such as for example zeolite, polycarboxylate, sodium citrate, in amounts of for example 0 to 70 wt. %, advantageously 5 to 60 wt. %, preferably 10 to 55 wt. %, in particular 15 to 40 wt. %, Alkalis, such as for example sodium carbonate, in amounts of for example 0 to 35 wt. %, advantageously 1 to 30 wt. %, preferably 2 to 25 wt. %, in particular 5 to 20 wt. %, Bleaching agents, such as for example sodium perborate, sodium percarbonate, in amounts of for example 0 to 30 wt. %, advantageously 5 to 25 wt. %, preferably 10 to 20 wt. %, Corrosion inhibitors, for example sodium silicate, in amounts of for example 0 to 10 wt. %, advantageously 1 to 6 wt. %, preferably 2 to 5 wt. %, in particular 3 to 4 wt. %, Stabilizers, for example phosphonates, advantageously 0 to 1 wt. %, Foam inhibitor, for example soap, silicone oils, paraffins, advantageously 0 to 4 wt. %, preferably 0.1 to 3 wt. %, in particular 0.2 to 1 wt. %, Enzymes, for example proteases, amylases, cellulases, lipases, advantageously 0 to 2 wt. %, preferably 0.2 to 1 wt. %, in particular 0.3 to 0.8 wt. %, Graying inhibitor, for example carboxymethyl cellulose, advantageously 0 to 1 wt. %, Discoloration inhibitor, for example polyvinyl pyrrolidone derivatives, preferably 0 to 2 wt. %, Adjusters, for example sodium sulfate, advantageously 0 to 20 wt. %, Optical brighteners, for example stilbene derivative, biphenyl derivative, advantageously 0 to 0.4 wt. %, in particular 0.1 to 0.3 wt. %, Optionally further fragrances, Optionally water, Optionally soap, Optionally bleach activators, Optionally cellulose derivatives, Optionally dirt repellents,
percentages by weight relative in each case to the total agent.
In another preferred embodiment of the invention the agent is in liquid form, preferably in gel form. Preferred liquid washing or cleaning agents and cosmetics have water contents of for example 10 to 95 wt. %, preferably 20 to 80 wt. % and in particular 30 to 70 wt. %, relative to the total agent. In the case of liquid concentrates the water content can also be particularly low, for example <30 wt. %, preferably <20 wt. %, in particular <15 wt. %, percentages by weight relative in each case to the total agent. The liquid agents can also contain non-aqueous solvents.
In addition to the ketone according to the invention, a preferred liquid, in particular gel-form, washing agent according to the invention can also contain in particular components selected for example from the following:
Anionic surfactants, such as preferably alkyl benzene sulfonate, alkyl sulfate, for example in amounts of preferably 5 to 40 wt. %, Non-ionic surfactants, such as preferably fatty alcohol polyglycol ethers, alkyl polyglucoside, fatty acid glucamide, for example in amounts of preferably 0.5 to 25 wt. %, Builders, such as for example zeolite, polycarboxylate, sodium citrate, advantageously 0 to 15 wt. %, preferably 0.01 to 10 wt. %, in particular 0.1 to 5 wt. %, Foam inhibitor, for example soap, silicone oils, paraffins, in amounts of for example 0 to 10 wt. %, advantageously 0.1 to 4 wt. %, preferably 0.2 to 2 wt. %, in particular 1 to 3 wt. %, Enzymes, for example proteases, amylases, cellulases, lipases, in amounts of for example 0 to 3 wt. %, advantageously 0.1 to 2 wt. %, preferably 0.2 to 1 wt. %, in particular 0.3 to 0.8 wt. %, Optical brighteners, for example stilbene derivative, biphenyl derivative, in amounts of for example 0 to 1 wt. %, advantageously 0.1 to 0.3 wt. %, in particular 0.1 to 0.4 wt. %, Optionally further fragrances, Optionally stabilizers, Water Optionally soap, in amounts of for example 0 to 25 wt. %, advantageously 1 to 20 wt. %, preferably 2 to 15 wt. %, in particular 5 to 10 wt. %, Optionally solvents (preferably alcohols), advantageously 0 to 25 wt. %, preferably 1 to 20 wt. %, in particular 2 to 15 wt. %, percentages by weight relative in each case to the total agent.
In addition to the ketone according to the invention, a preferred liquid fabric softener according to the invention can also contain in particular components selected from the following:
Cationic surfactants, such as in particular esterquats, for example in amounts of 5 to 30 wt. %, Co-surfactants, such as for example glycerol monostearate, stearic acid, fatty alcohols, fatty alcohol ethoxylates, for example in amounts of 0 to 5 wt. %, preferably 0.1 to 4 wt. %, Emulsifiers, such as for example fatty amine ethoxylates, for example in amounts of 0 to 4 wt. %, preferably 0.1 to 3 wt. %, Optionally further fragrances, Dyes, preferably in the ppm range, Stabilizers, preferably in the ppm range, Solvents such as for example water, in amounts of preferably 60 to 90 wt. %, percentages by weight relative in each case to the total agent.
The invention also provides a method for the lasting fragrancing of surfaces, wherein a ketone according to formula (I) or a washing or cleaning agent according to the invention is applied to the surface to be fragranced (e.g. textile, crockery, floor) and said surface is then exposed to electromagnetic radiation, in particular encompassing wavelengths from 200 to 400 nm.
The invention also provides a method for lasting room fragrancing, wherein an air care agent according to the invention is exposed to electromagnetic radiation, in particular encompassing wavelengths from 200 to 400 nm.
EXAMPLE
Representation of a ketone of general formula (I):
The dilithium enolate of 0.43 g (2.3 mmol) of 1,1′-benzyl-1,4-diyl dipropan-1-one was produced by reaction in 10 ml of anhydrous tetrahydrofuran with 5.1 mmol LDA (comprising 5.1 mmol of diisopropylamine and 6 mmol of a 1.6 M n-BuLi solution in n-hexane, stirred for 1 hour at −78° C. in 15 ml THF) by dropwise addition at −78° C. over a period of 1 hour. At the same temperature the bis-enolate was then mixed with 5.52 mmol of cerium(III) chloride (2.05 g, dried under vacuum) in 15 ml of THF and stirred for 30 min at −78° C. Then 0.96 g of damascone were added dropwise within 30 min while stirring, and the batch was heated to room temperature within 5 hours. The reaction solution was mixed with 40 ml of saturated aqueous ammonium chloride solution and extracted twice with 50 ml of ether. The organic phase was washed with water and saturated NaCl solution and dried over MgSO 4 . The raw material remaining after drawing off the solvent was purified by washing with pentane. A colorless oil was obtained, which was further purified by column chromatography (mobile solvent petroleum ether:ethyl acetate=95:5). The mono-substituted and di-substituted products were obtained as a mixture in the ratio 1:5 in the form of a colorless oil.
The di-substituted product produced in this way had a very good fragrancing effect when used in washing agents and fabric softeners in textile treatment. In particular, the fragrance impression on the laundry washed therewith and then dried was found to have a better persistence as compared with washing agents and fabric softeners containing an equivalent amount of δ-damascone but of an otherwise identical composition. The fresh fragrance impression of the textiles lasted significantly longer, both after line drying and in particular after drying in an automatic dryer.
While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents. | Fragrances having a fresh character are usually very volatile and therefore not very economical in typical applications such as washing or cleaning processes for example. For that reason they have to be used in relatively large amounts in order to bring about appropriate effects. The present invention describes photolabile pro-fragrances that allow for a greatly improved persistence of the fragrance impression, in particular one having a fresh character, in typical applications. A more economical use of the fragrances in question can be ensured in this way. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-In-Part of application Ser. No. 07/566,159, filed Aug. 9, 1990.
BACKGROUND OF THE INVENTION
This invention relates generally to the art of packaging and more particularly to an apparatus and process for the assembly of a package having a bayonet carrying handle.
The bayonet handle package, described in pending U.S. patent application, Ser. No. 07/566,159, filed Aug. 9, 1990 and incorporated herein by reference, is a recent development which is superior to prior art handled packages in virtually every respect. One of the primary advantages of the bayonet handle package is the suitability of the bayonet handle itself to high speed mating with a carton blank.
Prior art handles, which are still seen in the marketplace, are generally attached to the carton blank by riveting. The riveting process, however, is slow and prone to frequent failure. This greatly increases the cost of the package to the eventual consumer.
The bayonet handle, on the other hand, is folded and inserted into apertures on the carton blank such that barbs on the ends of the handle are ensnared on the aperture lip. Attachment is therefore accomplished by the combination of the aperture and the shape of the handle. Since the need for a rivet and its concomitant attachment process is eliminated, the bayonet handle inherently lends itself to increased attachment speeds. The machinery, however, necessary to fully exploit the advantages of the bayonet handle design has not appeared in the prior art.
SUMMARY OF THE INVENTION
It is thus an object of this invention to provide an apparatus to facilitate the attachment of an elongated bayonet handle to a carton blank.
It is a further object of the invention to provide a continuous motion apparatus for the attachment of an elongated bayonet handle to a carton blank.
It is a further and more particular object of the invention to provide a high-speed continuous motion apparatus for the assembly of a package having a bayonet carrying handle.
It is also an object of the invention to provide a novel process for the insertion of an elongated bayonet handle having barb heads defining respective ends thereof to a carton blank having a pair of handle insertion apertures.
Some of these, as well as other, objects are accomplished by an apparatus for releasably gripping and bending an elongated bayonet handle having a barb head on each end. The gripping and bending of the handle facilitates insertion of the barb heads into handle insertion apertures defined by the carton blank. Attachment of the handle to the blank is thereby accomplished.
The apparatus comprises a handle gripping and insertion wheel mounted on a horizontal rotatable shaft and further comprises means for driving the shaft. The wheel carries a plurality of evenly-spaced, circumferentially mounted handle clamping and insertion assemblages. The assemblages operate cyclically--that is, depending upon the assemblage position in the 360 degree rotational cycle of the wheel--to grip, bend and release the handles.
The process of the invention contemplates first providing an apparatus as described. Second, the wheel begins continuous rotation to effectuate the cyclical operation of the gripping and bending assemblages. A handle is then positioned at a first location near the wheel where it is gripped by one of the rotating assemblages. The further rotation of the wheel operates the rotating assemblage to bend the handle such that the barb heads are inserted into the handle insertion apertures of an appropriately placed carton blank. Attachment of the handle to the carton blank is thereby accomplished.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective schematic illustration in simplified form of the assembly of various component parts into a bayonet handle package which is ready to enter a folder/gluer device.
FIG. 2 is a side elevation view of the continuous motion apparatus of the invention wherein some of the more significant internal components are illustrated in phantom.
FIG. 3 is a partial plan view of the continuous motion apparatus of the invention.
FIG. 4 is an enlarged partial elevation illustrating in detail the handle bending and tripping apparatus of the invention as well a other components facilitating high speed bayonet handle attachment.
FIGS. 5 through 11 are sectional perspective views, partially in phantom, of a handle gripper constructed in accordance with the invention sequentially illustrating the gripper's cyclical operation.
DETAILED DESCRIPTION
In accordance with this invention, it has ben found that a novel apparatus and method may be provided to facilitate the attachment of an elongated bayonet handle to a carton blank. The apparatus functions to automatically grip and bend an appropriately positioned handle whereby barb heads defining each end of the handle may be inserted into handle insertion apertures formed in the carton blank. Thus, handle attachment is accomplished at speeds and with efficiency heretofore unattainable.
The bayonet handle package generally comprises there separate components: the carton blank, the liner and the bayonet handle. Once these components have been assembled, well known machines are available to fold and glue the package into its final boxlike form. These folder/gluers can operate at considerable speeds--over four hundred packages per minute. Prior to this invention, means have not been available to assemble the packages at rates comparable to the folder/gluers.
FIG. 1 illustrates in simplified form the component assembly function of the invention. Component assembly is largely effectuated by the rotating action of handle gripping and insertion apparatus 10. As shown by the directional arrows, the three components are singularly and continuously conveyed to different locations near apparatus 10 as it rotates. Apparatus 10 facilitates assembly of the components s that the assembled package may be received by a folder/gluer (not shown).
Specifically, handles 12, individually sheared from the bottom of handle cartridge 14, are delivered in seriatim to a first location 16, which is proximate and tangent to apparatus 10. Similarly, carton blanks 18 are delivered in seriatim from carton blank source 20 to a second location 22, also proximate and tangent to apparatus 10. The formation of handle insertion apertures, such as 24 and 26, is typically completed at a point during delivery from source 20 to location 22. The apertures are partially formed at the time of blank manufacture by perforating a small disc in the blank material. Thus, aperture formation may be completed at this stage by simply removing the disc, or "slug."
Handles, such as shown at 28, that have been received by apparatus 10, are carried to location 22 to arrive in tandem with the blanks. Subsequently, barb heads, illustrated at 30 and 32 of handle 28, are inserted through the handle insertion apertures, thus attaching a handle to a blank, such as blank 34.
As the apparatus 10 continues to rotate, it carries the handle and attached blank to a third location 36. Simultaneously, container liners 38 are conveyed in seriatim from liner source 40. At location 36, a liner 42 converges upon the blank and is attached thereto by hot glue or other adhesive. The barb heads are thus retained and the package assembly is complete. Assembled packages are then carried to the folder/gluer. During this time, the glue will "set."
As seen in FIG. 2, apparatus 10 comprises at least one wheel maintained on rotatable shaft 46. Shaft 46, in turn, is horizontally mounted on frame 48, supported by subframe 50, which rests on floor 52. Operator 54, who is depicted as being six feet in height, is shown for purposes of reference.
Handle cartridges 14 (FIG. 1) are carried to handle dispenser 56 via lateral conveyor 58. Handle dispenser 56 shears the handles from the bottom of cartridge 14. Thereafter, handle conveyor 60 singularly carries the handles 12 (FIG. 1) to location 16. U.S. Pat. Nos. 4,946,536; 4,854,931; 4,832,537; 4,811,861; and 4,662,974 illustrate means for dispensing and conveying thermoplastic articles, such as bayonet handles, from a fused cartridge. The above listed U.S. Patents are hereby incorporated by reference into this disclosure.
Carton blank source 20 comprises carton feeder 62, which is generally automatically loaded by a prefeeder, such as that shown at 64. Similarly, liner source 40 comprises liner feeder 66. Liner feeder 66, like carton feeder 62, is also automatically loaded. This loading is accomplished by prefeeder 68 and lateral liner conveyor 70.
Carton blanks 18 (FIG. 1) are carried from carton feeder 62 to location 22 by a carton blank conveyor 72. In the preferred embodiment of the invention, conveyor 72 may comprise a carton blank delivery belt 74 or the like above a guide track, such as track 76. Belt 74 is wrapped continuously around guide wheel 78 and idler wheel 80. Guide wheel 78 is the drive wheel. Track 76 supports the blanks as they are held and moved by lugs, such as lug 77, on belt 74. Track 76 is adapted such that it can be lowered away from belt 74. In this way, blanks which may occasionally become jammed can be easily removed.
In a similar manner, liners 38 (FIG. 1) are singularly and continuously transported to location 36 by a liner conveyor 82. Conveyor 82 may comprise a lugged liner delivery belt, such as 84, above a liner guide track 85 (FIG. 4). Belt 84 is wrapped continuously around drive wheel 86 and idler wheel 88. Glue-pressing wheel 90, which is above apparatus 10 and near location 36, firmly presses the liners onto the carton blanks. This facilitates the spreading and setting of the glue (which has been applied by means such as a glue gun at a location intermediate locations 22 and 36). The glue further sets as the assembled package is transported to the folder/gluer by package conveyor 92. In the preferred embodiment, conveyor 92 is similar to conveyor 82, having a lugged belt 94 above a cooperating package guide track 95 (FIG. 4). Belt 94 is wrapped around drive wheel 96 and idler wheel 98. Conveyors 82 and 92 and glue-pressing wheel 90 are raisable as a unit for jam clearing.
As has been shown, the system requires the delivery of three separate components to apparatus 10 with precision timing. It can be expected that occasionally one or more of the components will not arrive as desired. To prevent partially assembled packages from proceeding to the folder/gluer, it is desirable that, should proper delivery of one component fail, all three components be rejected and carried away. Thus, handle reject conveyor 117, liner reject conveyor 118 (FIG. 2), and carton blank reject conveyor 119 (FIG. 2) are provided.
Referring to FIG. 3, it can be seen that apparatus 10 typically comprises a pair of parallel wheels 100 and 102. The wheels 100 and 102 are spaced appropriately for the length of a particular handle. Typically, this spacing will be adjustable such that a wide variety of handle lengths may be accommodated. FIG. 3 also illustrates the apparatus main drive motor 104. Motor 104 is in mechanical communication with and thereby drives all of the movements within the apparatus. This linkage is provided by drive shafts, such as 106, and gear boxes, such as 108. Proper timing is accomplished through a combination of gear ratios, machine dimensions and control circuitry.
Apparatus 10 has circumferentially mounted and evenly spaced thereon a series of handle clamping and insertion assemblages. Best results have been obtained with six such assemblages. Each such assemblage comprises a pair of parallel handle grippers which grip the handles at an interior section inward of the barb heads. One gripper of each pair is located, respectively, on one of the parallel wheels 100 and 102. Wheels 100 and 102 have therein cams which actuate the grippers as the wheels rotate via shaft 46. Thus, the gripping, bending and insertion occurs in a continuous motion.
One gripper of each pair corresponds, respectively, to a single handle barb head. Each gripper is identical, except, of course, being in mirror image. As such, the function of a complete assemblage may be readily understood with reference to one gripper.
FIG. 4 illustrates the function of such a gripper 110, which is mounted on wheel 102. As shown, gripper 110 emerges from a recessed position to grip a handle arriving at location 16. Between location 16 and 22 the gripper again recesses. This action bends the barb head such that it projects axially away from the wheel. At location 22, gripper 110 begins to push the barb head through a properly aligned handle insertion aperture, which has previously been formed by rotary aperture punch mechanism 112. Punch peg pairs 114 and 116, mounted on mechanism 112, are timed to rotate into the carton blanks as they pass underneath, thereby removing the aperture "slug."
Referring to FIGS. 5 through 11, it can be seen that gripper 110 comprises clamping base 120, clamping arm 122, blade-rail 124, and crimping member 126. Of these four components, only blade-rail 124 is stationary relative to the wheel 102. FIGS. 5 and 6 illustrate the arrival of a handle 128 at location 16. Here, an interior section of handle 128 inward of barb head 130 is received into clamping base 120 and clamping arm 122. Barb head 130 is thereby simultaneously positioned between blade-rail 124 and the crimping member 126, which is in its outward, extended position. This aligns barb head score 132 with upper edge 134 of blade-rail 124. Thereafter, as shown in FIG. 7, the rotation of wheel 102 operates the interior cams to bring clamping base 120 and clamping arm 122 together to form clamping unit 123. In this way, handle 128 is securely gripped. Subsequently, crimping member 126 begins to retract axially. As member 126 descends through a plane marked by blade-rail upper edge 134, fingers 136 and 138 of crimping member 126 apply pressure to "break" score 132. Barb head 130 is thereby crimped.
Next, as shown in FIG. 8, the continued rotation of wheel 102 causes clamping unit 123 to axially retract. This movement draws barb head 130 onto blade-rail axial edge 140. Thus, barb head 130 is bent to be perpendicular to the remainder of handle 128 and projecting axially away from the center of wheel 102.
Referring to FIGS. 9 and 10, wheel 102 continues to rotate past location 22 where carton blank 142 has been received. Subsequently, clamping unit 123 begins to extend axially, thereby pushing barb head 130 through handle insertion aperture 144. The crimp in barb head 130 assists insertion by allowing for slightly less precision in alignment. Higher insertion rates are thereby attainable.
Finally, as shown in FIG. 11, wheel 102 rotates into position 36. Base 120 and arm 122 open and, further, arm 122 pivots such that the two components are no longer contiguous. Handle 128 is thereby released. Simultaneously, the other barb head (not shown) of handle 128 is similarly inserted by the gripper (not shown) parallel to gripper 110. Thus, handle attachment is effectuated.
The invention provides a continuous, virtually trouble-free production rate of at least 200 packages per minute. Furthermore, a rate of nearly 700 packages per minute may be maintained for shorter periods of time. This is in contrast with prior art riveting machines which have had difficulty maintaining a production rate of 100 packages per minute. Thus, it can be seen that a novel and useful apparatus and process for the assembly of a bayonet handle package have been provided. Many variations will become apparent to one of skill in the art from a reading of the above description. Such modifications are within the spirit and scope of this invention as defined by the following appended claims. | An apparatus and process for the assembly of a bayonet handle package are provided. The apparatus comprises at least one handle gripping and insertion wheel mounted on a horizontal rotatable shaft and further comprises means for driving the shaft. The wheel carries a plurality of evenly-spaced, circumferentially mounted handle clamping and insertion assemblages. The assemblages operate cyclically--that is, depending upon the assemblage position in the 360 degree rotational cycle of the wheel--to grip, bend and release the handles.
The process of the invention contemplates first providing an apparatus as described. Second, the wheel begins continuous rotation to effectuate the cyclical operation of the gripping and bending assemblages. A handle is then positioned at a first location near the wheel where it is gripped by one of the rotating assemblages. The further rotation of the wheel operates the rotating assemblage to bend the handle such that the barb heads are inserted into handle insertion apertures formed in an appropriately placed carton blank. Attachment of the handle to the carton blank is thereby accomplished, facilitating package assembly. | 8 |
This application claims the benefits of provisional application Ser. No. 60/256,361 filed Dec. 19, 2000.
BACKGROUND OF THE INVENTION
This invention relates to modules for matrix transformers and similar applications wherein a metal foil secondary winding is bonded to the inside surface of one or more magnetic cores with terminations being extensions of the metal foil brought to the end or side of the magnetic core. Reference is made to U.S. Pat. No. 4,942,353 “High Frequency Matrix Transformer Power Converter Module” (Herbert, Repp and Cebry). A number of design improvements have been made to this Power Converter Module while bringing it to production, in particular, the use of square cores having a square hole therein.
Until the present invention, all of the modules have used a two turn secondary winding which was usually used as a push-pull winding having one turn on each side of a center-tap termination. If it was necessary to generate more output voltage than this single winding could produce, then more cores were added in series.
In all embodiments of the modules made to the present, the foil windings have been bonded to the inside of the core in a 180 degree helix. The 180 degree helix is not necessary for the electrical or magnetic properties, but it allows a very simple and neat termination of the module, as may be seen in the drawings of the referenced patent and the drawings herein showing prior art. It was not thought to be possible to install more windings and terminate them neatly.
SCOPE OF THE INVENTION
This invention teaches that four metal foil windings can be bonded to the inside of the core, each in a 90 degree helix. Very simple direct connections and straight connections can connect the windings with no crossovers or overlaps and so that the center-tap and output terminations are located similarly to the two turn version yet make a module with four turns. This may be used as a push-pull winding having two turns on each side of the center-tap, or it may be used as a four turn winding, as, for instance, with a full bridge rectifier in a power converter.
Because the terminations are very similar, it can be introduced into present manufacturing with no modifications to the rest of the mechanical parts. Component values may change, though, because the output voltage and current may be different.
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BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a magnetic core subassembly having four windings installed therein.
FIG. 2 shows a pair of magnetic cores with windings and terminations.
FIG. 3 shows a phantom view of the magnetic core with two of the windings installed.
FIG. 4 shows a phantom view of the magnetic core with all four windings installed.
FIG. 5 shows a phantom view of two magnetic cores with their windings and the external interconnections to make a four turn secondary winding.
FIG. 6 shows a possible flat stamping for the windings.
FIGS. 7 a , 7 b and 7 c show an end view, side view and top view respectively of the winding of FIG. 6 after it has been formed.
FIG. 8 shows a phantom view of a prior art winding.
FIG. 9 shows a prior art two turn winding on two cores.
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DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a single core module 1 of the present invention. A magnetic core 3 has installed therein four metal foil windings 5 , 7 , 9 and 11 which pass through the hole in the magnetic core 3 as a 90 degree helix. The magnetic core 3 is preferably made of ferrite and preferably has no gap; however, magnetic cores made of other materials such as sintered metal, laminations, wound tape or whatever as well as cores having two or more parts assembled with one or more gaps certainly may be used and are equivalent for the teachings of this invention.
The metal foil windings 5 , 7 , 9 and 11 are preferably made of soft copper, as an illustration, not a limitation. They may be identical, as they are shown, and any apparent difference in appearance in FIG. 1 is attributable to the direction from which each is inserted, as will be further explained below. The exact configuration of the terminations of the metal foil windings is a trade off of each specific application, and the configuration shown is as an illustration, not a limitation.
Usually, the metal foil windings 5 , 7 , 9 and 11 will be used as secondary windings in a matrix transformer, but that is as an illustration, not a limitation. Transformers are reciprocal, so in different applications the metal foil windings could be a primary winding, or they could be one of several secondary windings.
Usually, the matrix transformer modules are assembled without a primary winding, and the through holes therein will receive a primary winding to be added later. The through holes may be lined, as with a Teflon® sleeve.
FIG. 2 shows a matrix transformer module 21 having two magnetic cores 3 each with four metal foil windings 5 , 7 , 9 and 11 there in, comprising the module 1 of FIG. 1, and another module 2 which is identical to the module 1 of FIG. 1 .
As a first step in assembling the module 21 of FIG. 2, the two modules 1 and 2 may be soldered together, side by side such that the winding 9 of module 1 is connected to winding 5 of module 2 . On the side that cannot be seen, winding 7 of module 1 is similarly soldered to winding 11 of module 2 , as will be further discussed and illustrated below.
As a second step in assembling the module 21 of FIG. 2, a metal strap 29 may be soldered between windings 5 and 11 of module 1 as shown, and this common connection may be the center-tap of a push-pull winding when the rest of the connections are done.
As a third step in assembling the module 21 of FIG. 2, four connecting strap 23 , 25 , 27 and (hidden, but shown in FIG. 5) 29 may be soldered connecting respective windings 7 and 7 , 11 and 11 , 9 and 9 and 5 and 5 of modules 1 and 2 . This will be further discussed and illustrated below.
The order of assembly suggested is for illustration only, not a limitation. The assembly may be made in any order or simultaneously, and the resulting assembly 21 is the same. The exposed ends of the metal foil windings 9 and 7 of module 2 may be the output terminations of the module 21 , and may, as an illustration, not a limitation, be soldered to leads of a rectifier package in a power converter.
FIG. 3 shows the module 1 of FIG. 1 partially assembled. The magnetic core 3 is shown in phantom so that the internal configuration of the metal foil windings 5 and 7 may be seen. Each is a 90 degree helix, and each has its respective ends bent to conform to the outside of the magnetic core 3 to be terminations of the respective metal foil windings.
The metal foil winding 5 may be made from copper foil, as shown in FIG. 6 . In FIG. 6, the dashed lines indicate bends, as is further illustrated in FIGS. 7 a-c.
FIGS. 7 a-c show a metal foil winding 7 which is the same as the metal foil winding 5 of FIG. 6; however, the orientation of the formed winding 7 corresponds in position to the metal foil winding 7 of the other drawings. All of the windings in this example are the same except for orientation. That is for illustration, not as a limitation, but it is advantageous for manufacturing because one part can be used in all four locations.
FIG. 7 a shows an end view of the formed metal foil winding 7 .
FIG. 7 b shows a side view of the formed metal foil winding 7 .
FIG. 7 c shows a top view of the formed metal foil winding 7 . In all three views, and in the other drawings, the metal foil winding 7 is bent twice into a “J” shape on one end, and is bent once into an “L” shape on the other end. A lengthwise bend gives the center of the metal foil winding 7 an “L” shaped section.
Although strictly speaking a helix has a circular path, the form of the metal foil windings may be called a “90 degree helix” even when used in a core having a square hole to represent that it has a twist through 90 degrees so that while it enters the hole on a particular side, it exits the hole on the opposite end on a side that is displaced 90 degrees from the entrance side. The helix may be clockwise or counterclockwise. It would be equivalent to use a magnetic core with a round hole or any other shaped hole. It would be more difficult to form the bends for a hole that did not have flat edges, but using the extended ends of the foil as terminations is an illustration, not a limitation, and other means of attaching electrical conductors to the metal foil windings at the ends of the hole would be equivalent under this invention.
It is preferred that the lengthwise bend be made before the metal foil winding 7 is inserted into the magnetic core 3 . The radius of the lengthwise bend should conform to the corner of the square hole in the magnetic core 3 . One or more of the other bends may also be made before insertion. One or more of the bends on the ends of the metal foil winding 7 may be made after insertion, and this may be preferred if there is dimensional variance in the magnetic cores 3 . This is entirely arbitrary, and is a trade off for each application.
It is contemplated, however, that at least the first bend of the “J” end of the metal foil winding may be made before insertion so as to be a mechanical stop controlling the depth of insertion.
With further reference to FIG. 3, it can be seen that if this is done, the metal foil winding 5 would be inserted from the front side of the core 3 as drawn, and the metal foil winding 7 would be inserted from the back side of the core 3 .
FIG. 4 shows all of the metal foil windings 5 , 7 , 9 and 11 installed in a magnetic core 3 (shown in phantom). While the shape of the ends of the metal foil windings 5 , 7 , 9 and 11 are arbitrary, and may vary from application to application, in the present instance it can be seen that the ends that extend vertically are trimmed so they would not touch a top or bottom metal mounting plate if either or both is used. By contrast, the ends that extend horizontally are extended and wrap around to the sides of the cores, to facilitate connections to be made later.
FIG. 5 shows the module 21 of FIG. 2 with the magnetic cores 3 , shown in phantom so that the internal configuration and the rear connections of the several metal foil windings and connecting straps can be seen.
FIGS. 8 and 9 show prior art two winding modules 81 and 91 . Two metal foil windings 85 and 87 comprising 180 degree helices are bonded into a magnetic core 83 (shown in phantom in FIG. 8 ). FIG. 9 shows a two core assembly 91 .
“Bonding” may mean assembling together using an adhesive, and usually it is preferred to bond the metal foil windings into the magnetic cores with an adhesive such as epoxy, as an illustration, not a limitation. However, “bonding” may also include any means that retains the metal foil windings in their respective correct positions. Many magnetic materials are conductive, or somewhat conductive. If such a magnetic material is used, it is preferred that there be at least an insulating film on the magnetic core or on the winding to prevent short circuiting, as would be well understood by one skilled in the art of matrix transformers.
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\ \ \ | Four metal foil windings can be bonded to the inside of a magnetic core, each in a 90 degree helix. Very simple direct and straight connections can connect the windings to the windings of another similar core in a flat transformer module with no crossovers or overlaps. The center-tap and output terminations are located similarly to the two turn version of the flat transformer module, but make a module with four turns. This may be used as a push-pull winding having two turns on each side of the center-tap, or it may be used as a four turn winding, as, for instance, with a full bridge rectifier in a power converter. | 7 |
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